Komatsu wb97s руководство по эксплуатации

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  WEBM007500 SHOP MANUAL WB97S BACKHOE-LOADER SERIAL NUMBER F00003 WB97S-5 and up…
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  CONTENTS CONTENTS Page 10. STRUCTURE AND FUNCTION…………….10-1 20. TESTING AND ADJUSTING ………………. 20-1 30. DISASSEMBLY AND ASSEMBLY …………….. 30-1 40. STANDARD MAINTENANCE …………….. 40-1 90. OTHER……………………90-1 00-1 WB97S-5…
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  PAGE INTENTIONALLY LEFT BLANK…
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  10-22 10-76 20-11 20-65 30-47 10-23 10-77 20-12 20-66 30-48 10-24 10-78 20-13 20-67 30-49 10-25 10-79 20-14 20-68 30-50 10-26 10-80 20-15 20-69 30-51 10-27 10-81 20-16 20-70 30-52 10-28 10-82 20-17 30-53 10-29 10-83 20-18 30-54 00-3 WB97S-5…
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  30-282 40-6 30-125 30-204 30-283 40-7 30-126 30-205 30-284 40-8 30-127 30-206 30-285 40-9 30-128 30-207 30-286 40-10 30-129 30-208 30-287 40-11 30-130 30-209 30-288 40-12 30-131 30-210 30-289 40-13 30-132 30-211 30-290 40-14 30-133 30-212 30-291 40-15 00-4 WB97S-5…
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  Smoke only in the areas provided for smoking. Never 13. Before starting work, remove the leads from the bat- smoke while working. tery. Always remove the lead from the negative ( – ) terminal first. 00-5 WB97S-5…
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  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. 00-6 WB97S-5…
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  This section gives the judgement standards when inspecting disassembled parts. NOTE The specifications contained in this shop manual are subject to change at any time and without any no- tice. Contact your Komatsu distributor for the latest information. 00-7 WB97S-5…
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  REVISED EDITION MARK When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown on the LIST OF REVISED PAGES between the title page and SAFETY page. 00-8 WB97S-5…
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  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. 00-9 WB97S-5…
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  ± 330 ± 45 ± 450 —- 2900 4050 This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer. a Nm (newton meter): 1 Nm = 0.102 kgm 00-10 WB97S-5…
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  9/16” — 18 2.3–2.5 23–25 11/16” — 16 3.4–3.9 33–38 13/16” — 16 5.2–5.8 51–57 1” — 14 8.2–9.2 80–90 1.3/16 — 12 12.2–13.3 120–130 1.7/16 — 12 15.3–17.3 150–170 1.11/16 — 12 18.4–20.4 180–200 2” — 12 20.4–24.4 200–240 00-11 WB97S-5…
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  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 00-12 WB97S-5…
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  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 00-13 WB97S-5…

• Page 16: Table Of Contents

  WEIGHT TABLE WEIGHT TABLE k This weight table is a guide for use when transporting or handling components. Unit: kg Machine model WB97S-5 Engine assembly — Muffler — Exhaust pipe Radiator — exchanger Hydraulic oil tank (empty) Fuel tank (empty)

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  General Motors Cor- system poration) Fuel DIESEL OIL – tank ASTM D975 N. 2 Engine PERMANENT cooling COOLANT – (aa) system a ASTM D975 N. 1 Special red permanent antifreeze suitable for aluminium radiators. If pure, dilute with water (50%). 00-15 WB97S-5…
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  (3) Use engine oil with CD classification; if oil with CC 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. 00-16 WB97S-5…
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  2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 00-17 WB97S-5…
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  136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26 00-18 WB97S-5…
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  13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777 00-19 WB97S-5…
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  119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663 00-20 WB97S-5…
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  16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298 00-21 WB97S-5…
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  1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4 00-22 WB97S-5…
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  3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2 00-23 WB97S-5…
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  167.0 65.6 302.0 –14.4 42.8 105.8 24.4 168.8 68.3 311.0 –13.9 44.6 107.6 25.0 170.6 71.1 320.0 –13.3 46.4 109.4 25.6 172.4 73.9 329.0 –12.8 48.2 111.2 26.1 174.2 76.7 338.0 –12.2 50.0 113.0 26.7 176.0 79.4 347.0 00-24 WB97S-5…

• Page 27: Table Of Contents

  WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)………… 117 STEERING UNIT …………72 PPC VALVES…………..73 SOLENOID VALVE GROUP (EV1)…….90 SOLENOID VALVE GROUP (EV2)…….92 SAFETY VALVES …………93 SHOVEL CYLINDERS ……….97 BACKHOE CYLINDERS ……….99 AIR-CONDITIONING UNIT ………103 OPERATION OF THE AIR CONDITIONING UNIT..104 10-1 WB97S-5…

• Page 28: Structure And Function

  (4). differential shafts. • The transmission (3) is electro-hydraulic in all its functions (power shuttle); direction and speed can be selected manually from a dedicated control unit and is managed by solenoid valves. 10-2 WB97S-5…

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  4th gear 0.810 16.31 0.810 13.83 RKZ13480 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 10-3 WB97S-5…

• Page 30: Transmission (4Wd)

  STRUCTURE AND FUNCTION TRANSMISSION (4WD) TRANSMISSION (4WD) Hydraulic convertor-transmission circuit diagram 10-4 WB97S-5…

• Page 31: Wb97S

  18. Drive engagement pressure check 19. 1st gear engagement 20. 2nd gear engagement 21. 3rd gear engagement 22. 4th gear engagement 23. Main shaft lubrication (B shaft) 24. Output shaft lubrication (C/E shafts) 25. Oil temperature thermostat port from oil cooler 10-5 WB97S-5…

• Page 32: Transmission

  3. Oil filter 9. Converter input pressure check port 4. Oil refilling port 10. Reverse engagement pressure check port 5. Oil drain plug 11. Forward engagement pressure check port 6. Oil temperature sensor 12. PPC valve feed pressure check port 10-6 WB97S-5…

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  STRUCTURE AND FUNCTION TRANSMISSION Kinematics diagram RKZ11140 10-7 WB97S-5…

• Page 34: Control Valve Block

  3. C26 – 4th gear solenoid valve (ED2) 4. C21 — Reverse gears command solenoid valve (ED4) 5. C22 – Forward gear solenoid valve (ED3) 6 — C25 – 3rd gear solenoid valve (ED7) 7. C23 – 1st gear solenoid valve (ED1) 10-8 WB97S-5…

• Page 35: Drive Shafts

  4. Forward clutch piston 5. Shoulder ring 6. Driven shaft Drive shaft RKZ11170 a. 2nd gear port 3. 4th drive gear (Z=58) 4. 1st drive gear (Z=17) 1. 3rd drive gear (Z=45) 5. 2nd gear piston 2. 2nd drive gear (Z=28) 10-9 WB97S-5…

• Page 36
  8. 4th gear piston 3. 4th gear driven gear (Z=30) 9. 3rd gear piston 4WD driven shaft RKZ11190 4WD disengagement command port 3. 4WD gear driven (Z=41) 1. Front output shaft 4. Piston (n°3). 2. 4WD disengagement piston 5. Spring 10-10 WB97S-5…

• Page 37: Front Axle

  9. Bearing 2. Ring gear 10. Sealing ring 3. Planetary gear 11. Flange 4. Ring nut 12. Ring nut 5. Half-axle 13. Bearing 6. Pin 14. Bevel pinion 7. Differential housing 15. Pin 8. Spacer 16. Oil refilling plug 10-11 WB97S-5…

• Page 38
  4. Crown wheel holder 15. Pin 5. Wheel hub 16. Protection 6. Sealing ring 17. Sealing ring 7. Pin 18. Bearing 8. Shim 19. Snap ring 9. Protection 20. Centering pin 10. Bushing 21. Stud bolt 11. Sealing ring 22. Plug 10-12 WB97S-5…
• Page 39
  1. Steering cylinder Port a — From the steering unit (L Port) 2. Oil refilling plug Port b — From the steering unit (R Port) 3. Oil drain plug 4. Nut 5. Adjusting screw 6. Nut 7. Bushing 8. Bushing 10-13 WB97S-5…

• Page 40: Rear Axle

  11. Sealing ring 2. Planetary gear 12. Flange 3. Planetary gear 13. Spacer 4. Ring gear 14. Bevel pinion 5. Differential housing 15. Differential housing 6. Ring nut 16. Disk 7. Half-axle 17. Steel disk 8. Pin 9. Bearing 10-14 WB97S-5…

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  4. Crown wheel holder 15. Pin 5. Wheel hub 16. Protection 6. Gasket 17. Gasket 7. Pin 18. Bearing 8. Shim 19. Snap ring 9. Protection 20. Centering pin 10. Bushing 21. Stud bolt 11. Gasket 22. Plug 10-15 WB97S-5…
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  7. Brake disk 2. Bushing 8. Bushing 3. Parking brake control shaft 9. Working brake control piston 4. Bleed screw 10. Pressure disk 5. Parking brake control lever 11. Intermediate disk 6. Parking brake control cam 12. Spacer 10-16 WB97S-5…
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  Check item A 1. Steering cylinder 2. Nut 3. Adjusting screw 4. Nut Port c — From solenoid valve group ST2 (Port A) Port d — From solenoid valve group ST2 (Port B) Port e — From brake pump 10-17 WB97S-5…

• Page 44: Steering System (4Ws)

  Steering condition in which rear axle steering is activated and the direction of the rear wheels agrees with that of the front wheels. • The hydraulic power supplied by the pump (2) is transferred to cylinders (9) and (10) and transformed into mechanical steering power. 10-18 WB97S-5…

• Page 45
  (5) (port R); from the control valve the oil passes (port L); from the control valve the oil passes out of Port out of Port T and drains into the tank (3). T and drains into the tank (3). 10-19 WB97S-5…
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  (port R), (port L) from which it passes (port T) to drain into the tank from which it passes (port T) to drain into the tank (3). (3). 10-20 WB97S-5…
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  (5) which the oil passes (port T) to drain into the tank (3). (port L) from which it passes (port T) to drain into the tank (3). 10-21 WB97S-5…
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  PAGE INTENTIONALLY LEFT BLANK…

• Page 49: Hydraulic Circuit

  STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT 80 l/min 160 bar PRIORITY VALVE CLAMP CYLINDERS 10-23 WB97S-5…

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  PAGE INTENTIONALLY LEFT BLANK…

• Page 51: Hydraulic Pump

  Port PLS — Load Sensing signal input Port P1L — From control valve (Port Pp) Port PM — Operating mode control signal input Port PLS — From control valve (Port LS) Port PM — From EV1 solenoid valve group (Port PM) 10-25 WB97S-5…

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  HYDRAULIC PUMP 1. MAIN PUMP View X View Z RKZ09420 PORT FUNCTIONS Port Pa — Delivery control group feed Port Pe — Delivery control signal Port Pd4 — Drain Port Pd5 — Drain Port PM2 — Operating mode signal 10-26 WB97S-5…
• Page 53
  Section B — B 1. Bearing 8. Swash plate 2. Input shaft 9. Cover 3. Hydraulic pump 10. Shoe guide 4. Swash plate 11. Control piston 5. Shoe 12. Spring 6. Piston 13. Sealing ring 7. Cylinder block 14. Ball 10-27 WB97S-5…
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  (10). The surface of the swash plate (10) is so designed that the oil pressure always remains within acceptable limits. The oil in each chamber is drawn in and discharged through holes in the valve plate (10). 10-28 WB97S-5…

• Page 55: Other

  E’ and F’ within the cylinder block (1) becomes 0 and the pump does not take in or deliver any oil. 4 — In brief, the angle of the swash plate a is proportional to pump delivery. 10-29 WB97S-5…

• Page 56
  PC and LS valves. The linear motion is transmitted to the swash plate (7). The swash plate is supported by the pump body (8) through the ball (9), and this is the reason why the swash plate (7) moves in a semicircular alternate motion. 10-30 WB97S-5…
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  HYDRAULIC PUMP 2. DELIVERY CONTROL VALVE RKZ09430 PORT FUNCTIONS T port — Drain P1 port — Delivery control group feed Pd4 port — Drain PE port — Delivery control signal output PM port — Operating mode signal input 10-31 WB97S-5…
• Page 58
  T port — Drain 2. Spring PA Port — Pump delivery pressure 3. Retainer PM port — Operating mode signal input 4. Seat PPL port — Delivery control signal output 5. Spool 6. Sleeve 7. Piston 8. Gasket 9. Piston 10-32 WB97S-5…
• Page 59
  PA Port — Pump delivery pressure 3. Seat PE port — Delivery control signal 4. Spring PLS port — LS signal input 5. Nut PPL port — Delivery control signal input 6. Plug PPLS port — LS pump signal input 10-33 WB97S-5…
• Page 60
  Pump pressure PPLS (pump pressure at control valve input) and pressure PLS (Load Sensing pressure) are introduced into the LS valve. The relation between differential pressure DPLS and pump delivery varies as shown in the diagram on the right. 10-34 WB97S-5…
• Page 61
  In other words, when the force applied by pressure PC is added to the force applied by the pump’s delivery pressure against the spool (5), the relation between pump delivery pressure and delivery is switched from «1» to «2» in accordance with increment «X». 10-35 WB97S-5…
• Page 62
  As a result of that, the pressure in C increases, and interconnected: pressure at passage J is sent for the control piston (2) stops. relief (PT), and the control piston (2) shifts to the left. • Pump delivery increases as a result. 10-36 WB97S-5…
• Page 63
  As a result of that, the pressure in C decreases, and equivalent to the pump’s delivery pressure (PA), and the control piston (2) stops. the control piston (2) shifts to the right. • Pump delivery decreases as a result. 10-37 WB97S-5…
• Page 64
  • The equilibrium between the force applied by pressure PA against spool (4) and the force applied by spring (1) against spool (5) is what determines the position at which the control piston (2) (hence pump delivery) stops. 10-38 WB97S-5…
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  PAGE INTENTIONALLY LEFT BLANK…

• Page 66: Spool Control Valve

  STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE 8-SPOOL CONTROL VALVE 10-40 WB97S-5…

• Page 67
  To the steering unit (P Port) PB7 — From the outriggers PPC valve (P2 port) DLS — From the steering unit (LS Port) PB8 — From the outriggers PPC valve (P4 port) PP — To the hydraulic pump (P1L port) 10-41 WB97S-5…
• Page 68
  18. Spool (arm control) 6. Safety valve 19. Spool (priority valve) 7. Anticavitation valve (arm in) 20. Unloading valve 8. Anti-shock/anticavitation valve (RH swing) 9. Anti-shock/anticavitation valve (shovel curl) 10. Anticavitation valve (boom lower) 11. Anticavitation valve (backhoe bucket dump) 10-42 WB97S-5…
• Page 69
  17. Check valve 6. Arm 18. Check valve DELIVERY CONTROL VALVE 19. Check valve 20. Check valve 7. Arm 21. Check valve 8. Boom swing 22. LS, DLS pressure check valve 9. Front bucket 23. LS by-pass plug 10. Boom 10-43 WB97S-5…
• Page 70
  2. Spool (left outrigger control) 3. Backhoe plate lock solenoid valve 4. Backhoe plate lock valve 5. Spool (shovel arm control) 6. Spool (backhoe bucket control) 7. Spool (Boom control) 8. Spool (front bucket control) 9. Spool (boom swing control) 10-44 WB97S-5…
• Page 71
  STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE 1. Servocontrol max. pressure valve 2. Max. pressure valve spool 3. Sequential reducing valve 4. Blow out plug 5. Unloading valve 6. LS by-pass plug 7. Spool (Arm control) 10-45 WB97S-5…
• Page 72
  STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE 10-SPOOL CONTROL VALVE 10-46 WB97S-5…
• Page 73
  STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE 10-47 WB97S-5…
• Page 74
  PB6 — From solenoid valve group EV1 (B1 Port) PB7 — From solenoid valve group EV2 (B2 Port) PB8 — From the shovel PPC valve (P4 port) PB9 — From the outriggers PPC valve (P2 port) PB10 -From the outriggers PPC valve (P4 port) 10-48 WB97S-5…
• Page 75
  21. Spool (boom swing control) 9. Anti-shock/anticavitation valve (RH swing) 22. Spool (arm control) 10. Anti-shock/anticavitation valve (shovel curl) 23. Spool (priority valve) 11. Anticavitation valve (boom lower) 24. Unloading valve 12. Anticavitation valve (backhoe bucket dump) 25. LS by-pass plug 10-49 WB97S-5…
• Page 76
  14. 4 in 1 bucket 26. Check valve 6. Front bucket 15. Jig arm 27. LS, DLS pressure check 7. Boom swing valve 16. Shovel arm 8. Arm 28. LS by-pass plug 17. Max. pressure valve 18. Check valve 10-50 WB97S-5…
• Page 77
  2. Spool (left outrigger control) 3. Backhoe plate lock solenoid valve 4. Backhoe plate lock valve 5. Spool (shovel arm control) 6. Spool (backhoe bucket control) 7. Spool (Boom control) 8. Spool (front bucket control) 9. Spool (boom swing control) 10-51 WB97S-5…
• Page 78
  STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE 1. Servocontrol max. pressure valve 2. Max. pressure valve spool 3. Sequential reducing valve 4. Blow out plug 5. Unloading valve 6. LS by-pass plug 7. Spool (Arm control) 10-52 WB97S-5…

• Page 79: Clss

  The CLSS system includes the variable flow pump, the control valve and the working equipment. • The pump includes the main pump, the TCC valve and the LS. valve. Actuator Control valve TCC valve LS valve Servo piston RKP00661 10-53 WB97S-5…

• Page 80
  Min. Pump passage LS passage LS differential pressure ∆P Set differential pressure of LS valve Main pump RKP02931 Min. Max. Servo piston ∆ LS valve Differential Differential pressure high pressure PC valve Pump pressure Pump pressure high RKP02921 10-54 WB97S-5…
• Page 81
  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 ∆ P ∆ P Pressure Pressure compensation compensation valve valve LS valve RKP02941 10-55 WB97S-5…
• Page 82
  3. Safety valve: 270 bar 4. Check valve 5. Anti-shock/anticavitation valve: 215 bar 6. Anti-shock/anticavitation valve: 220 bar 7. Anti-shock/anticavitation valve: 350 bar 8. Pressure compensation valves 9. Priority valve 10. Servocontrols reducing valve 11. Backhoe plate lock valve RKZ09170 10-56 WB97S-5…
• Page 83
  3. Safety valve: 270 bar 4. Check valve 5. Anti-shock/anticavitation valve: 215 bar 6. Anti-shock/anticavitation valve: 220 bar 7. Anti-shock/anticavitation valve: 350 bar 8. Pressure compensation valves 9. Priority valve 10. Servocontrols reducing valve 11. Backhoe plate lock valve RKZ09180 10-57 WB97S-5…
• Page 84
  The pump’s delivery circuit PP is then connected to the tank circuit T by means of the holes in spool (1). • This ensures that the pump delivery pressure PP stays regulated at 27.5 bar (28 kg/cm 10-58 WB97S-5…
• Page 85
  The pump’s delivery pressure PP is regulated by the combination of the pressure from the spring (27.5 bar (28 kg/cm )) and the pressure PLS of the LS, i.e. when the differential pressure DPLS reaches a value of 27.5 bar (28 kg/cm 10-59 WB97S-5…
• Page 86
  PP and the pressure PLS of the LS fails to reach the spring loading pressure value of spring (2) (27.5 bar (28 kg/ ), the spool (1) is pushed to the left by the spring (2). 10-60 WB97S-5…
• Page 87
  LS and into the chamber of spring PLSS. • At this point, the PLS circuit of the LS is connected to the tank circuit T by means of the by-pass plug (4). (See the description of the LS by-pass plug). 10-61 WB97S-5…
• Page 88
  A is introduced directly into the PLS circuit of starts flowing into the circuit of actuator A through the the LS. duct a. • At the same time, pressurised oil is introduced into the PLS circuit of the LS through holes b. 10-62 WB97S-5…
• Page 89
  LS. Functioning PP = Pump circuit PLS = Load Sensing circuit • Pressurised oil in the Load Sensing PLS circuit flows T = Drain circuit through filter a, through orifice b and into the tank circuit T. 10-63 WB97S-5…
• Page 90
  This bottleneck generates a pressure loss between that are responsible for opening the notches of each circuits PP and PPA. spool. 10-64 WB97S-5…
• Page 91
  Delivery distribution is lower than the proportion of the opening surfaces of the spool. • When the ratio is lower than 1.00: PP – PPA < PLS – PA (= A) Delivery distribution is higher than the proportion of the opening surfaces of the spool. 10-65 WB97S-5…
• Page 92
  The position of the spool (1) is determined in such a way as to ensure that the oil delivered to the steering unit matches the delivery needs at any time. 1= Priority valve spool PP = Pump circuit D = Steering unit feed circuit DLS = Steering unit LS signal 10-66 WB97S-5…
• Page 93
  The spool (1) of the unloading valve moves, and delivery pressure is regulated at 29 bar (30 kg/cm (For details, see 3.2 UNLOADING VALVE). • The spool (2) and valve (3) reduce the pump’s delivery pressure PP to 29 bar (30 kg/cm Pressure is then sent to the servocontrols via port PC. 10-67 WB97S-5…
• Page 94
  If the pump’s delivery pressure PP exceeds 29 bar (30 kg/cm ), valves (2) and (3) reduce pressure PP to 29 bar (30 kg/cm The reduced pressure is then sent to the servocontrols via port PC. • When this occurs, the sequential reducing valve (4) stays open. 10-68 WB97S-5…
• Page 95
  This generates a pressure gap between PP pressure and actuator pressure. PP pressure is incremented in excess of 29 bar (30 kg/cm ) and is then reduced to 29 bar (30 kg/cm ) by valves (2) and (3) to guarantee pressure feed to the servocontrols. 10-69 WB97S-5…
• Page 96
  SS circuit of the plate lock cylinders. • When the entire circuit reaches pump delivery pressure PP, the check valve (3) lowers, thereby dividing the circuit, which is therefore kept at the maximum pressure reached by the delivery circuit. 10-70 WB97S-5…
• Page 97
  When the solenoid valve is energized, pressurised oil in the SS circuit is sent to the tank circuit through spool (4). • As a result, the SS circuit pressure decreases, and the plate is released, so it can be shifted. 10-71 WB97S-5…

• Page 98: Steering Unit

  The rotating dispenser ensures that the volume of oil supplied to the cylinder is proportionate to the angle of rotation of the steering wheel. • In the event of malfunction, the oil dispenser will function automatically as a hand-pump, thus guaranteeing emergency steering. 10-72 WB97S-5…

• Page 99: Ppc Valves

  P2 port — To control valve (PA3 port) P3 port — To control valve (PA8 port) P4 port — To control valve (PB8 port) P port — From EV1 solenoid valve group (VL port) Port T — To hydraulic tank 10-73 WB97S-5…

• Page 100
  STRUCTURE AND FUNCTION PPC VALVES 1. Spool 6. Nut 2. Adjusting screw (inner) 7. Joint 3. Adjusting screw (outer) 8. Cover 4. Piston 9. Retainer 5. Disk 10. Body 10-74 WB97S-5…
• Page 101
  A-P1 – i.e. the pressure acting on stem (1) – is enough to counteract the force of the spring (2). This ensures proportionality between control lever position, A-P1 circuit pressure, and main control valve stem displacement. 10-75 WB97S-5…
• Page 102
  This causes the main control valve to send the oil contained in chamber B towards input P2, through calibrated hole f’ and into f’ discharge chamber D. RKZ09460 10-76 WB97S-5…
• Page 103
  P2 port — To control valve (PA3 port) P3 port — To control valve (PA8 port) P4 port — To control valve (PB8 port) P port — From EV1 solenoid valve group (VL port) Port T — To hydraulic tank 10-77 WB97S-5…
• Page 104
  STRUCTURE AND FUNCTION PPC VALVES RKZ08980 1. Spool 7. Joint 2. Adjusting screw (inner) 8. Cover 3. Adjusting screw (outer) 9. Retainer 4. Piston 10. Piston 5. Disk 11. Body 6. Disk 10-78 WB97S-5…
• Page 105
  Control valve ducts A and B and PPC valve ducts P3 and P2 are connected to discharge chamber D by and P4 are connected to discharge chamber D by means of the calibrated hole f in spool (1). means of the calibrated hole f in spool (1). RKZ08990 10-79 WB97S-5…
• Page 106
  B-P1 – i.e. the pressure acting on stem (1) – is enough to counteract the force of the spring (2). This ensures proportionality between control lever position, B-P1 circuit pressure, and main control valve stem displacement. 10-80 WB97S-5…
• Page 107
  This causes the main control valve to send the oil contained in chamber AB towards input P2, through calibrated hole f’ and into relief chamber D. p’ RKZ09020 10-81 WB97S-5…
• Page 108
  , denergizing the solenoid. RKZ09021 10-82 WB97S-5…
• Page 109
  To control valve (10 spools) (PA10 port) P4 port — To control valve (8 spools) (PB7 port) To control valve (10 spools) (PB10 port) P port — To EV1 solenoid valve group (P2 port) Port T — To hydraulic tank 10-83 WB97S-5…
• Page 110
  STRUCTURE AND FUNCTION PPC VALVES 1. knob 2. Nut 3. Lever 4. Boot 5. Plate 6. LH PPC valve body 7. RH PPC valve body 10-84 WB97S-5…
• Page 111
  OPERATION 1. Control lever in neutral position RKZ09380 • Ports A and B of control valve and ports P1 and P2 of PPC valves are connected to the tank circuit. • Hence, the spool is in neutral position. 10-85 WB97S-5…
• Page 112
  P1, while port P2 remains conected to the tank circuit. • Pressure at port P1 increases as the travel of lever (1) increases. Consequently, the spool of the control valve moves to the left by a distance that is proportional to the travel of the lever (1). 10-86 WB97S-5…
• Page 113
  When lever (1) is moved fully to the left, the valves (2) are fully rotated. • Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only, and the spool of the control valve performs its full travel. 10-87 WB97S-5…
• Page 114
  To backhoe control valve (Port PA2) (LH swing boom) 3 port — To backhoe control valve (Port PA1) (In arm) P port — To EV1 solenoid valve group (VBH port) 2 port — To backhoe control valve (Port PB2) (swing boom) 10-88 WB97S-5…
• Page 115
  Port 4 — To control valve (Port PA5) (dump bucket) Port 3 — To backhoe control valve (Port PA4) (lower boom) Port P — To solenoid valve group (VBH port) Port 2 — To control valve (Port PB5) (curl bucket) 10-89 WB97S-5…

• Page 116: Solenoid Valve Group (Ev1)

  Port UBH — To backhoe PPC valves (Port P) Port UL — To shovel PPC valve (Port P) Port PM — To hydraulic pump (Port PM) Port P — From control valve (Port PPPC) Port T — To hydraulic tank 10-90 WB97S-5…

• Page 117
  Port A1 — To control valve (Port PA6) Port B1 — To control valve (Port PB6) Port PM — To hydraulic pump (Port PM) Port P — From control valve (Port PPPC) Port T — To hydraulic tank 10-91 WB97S-5…

• Page 118: Solenoid Valve Group (Ev2)

  Y203 — Phase coincidence steering solenoid valve Port F1 — To outriggers PPC valve (Port P) Y202 — Crab steering solenoid valve Port R2 — To boom unlock cylinder Y400 — Safety lock solenoid valve Y401 — Safety lock solenoid valve Port block 10-92 WB97S-5…

• Page 119: Safety Valves

  (Port A6) 2 — Adjusting screw From control valve (10-spool) 3 — Spring (Port A8) 4 — Spool Port C2 — To the raise cylinders (Bottom side) 5 — Unlock screw CHARACTERISTICS Safety valve calibration: 220 10 bar 10-93 WB97S-5…

• Page 120
  Flow Q ( min) RKZ08070 Port PiL — To the dump cylinder (Bottom side) CHARACTERISTICS Safety valve calibration: 220 10 bar Port C2 — To the dump cylinder (Head side) Port V2 — From control valve (8-spool) (B3 port) 10-94 WB97S-5…
• Page 121
  — To the boom cylinder (bottom side) CHARACTERISTICS Safety valve calibration 1: 250 15 bar V2 port — From control valve (B4 port) Safety valve calibration 2: 200 20 bar C2 port — To the boom cylinder (Head side) 10-95 WB97S-5…
• Page 122
  Flow Q ( min) RKZ08110 CHARACTERISTICS PiL port — To the arm cylinder (bottom side) Safety valve calibration 1: 300 10 bar V2 port — From control valve (A1 port) C2 port — To the arm cylinder (Head side) 10-96 WB97S-5…

• Page 123: Shovel Cylinders

  1. Bottom bushing 4. Gasket 7. Head 2. Cylinder 5. Piston 8. Head bushing 3. Nut 6. Stem DUMPING CYLINDER 707-00-0y920 1. Bottom bushing 4. Gasket 7. Head 2. Cylinder 5. Piston 8. Head bushing 3. Nut 6. Stem 10-97 WB97S-5…

• Page 124
  2. Nut 5. Stem 3. Gasket 6. Head CHARACTERISTICS Cylinder Lifting Dump 4 in 1 bucket Piston rod diameter Internal cylinder diameter Piston stroke Max. cylinder length 1740 2145 Min. cylinder length 1170 Key size for piston safety nut 10-98 WB97S-5…

• Page 125: Backhoe Cylinders

  3. Head 7. Guide ring 11. Ball-bearings (no. 10) 4. Cylinder 8. Cushion plunger 707-00-0y871 1. Bottom bushing 5. Brake bushing 9. Nut 2. Stem 6. Gasket 10. Bottom bushing 3. Head 7. Guide ring 4. Cylinder 8. Piston 10-99 WB97S-5…

• Page 126
  1. Bottom bushing 4. Cylinder 7. Guide ring 2. Stem 5. Piston 8. Nut 3. Head 6. Gasket 9. Bottom bushing OUTRIGGER CYLINDER 707-00-0Y0910 1. Stem 4. Gasket 7. Nut 2. Head 5. Guide ring 3. Cylinder 6. Piston 10-100 WB97S-5…
• Page 127
  2. Restriction ring 6. Head 10. Piston seal 3. Stem 7. Bottom bushing 11. Spacer 4. Cylinder 8. Piston 12. Cushion plunger JIG ARM CYLINDER 42N-6C-13301 1. Stem 3. Cylinder 5. Gasket 2. Head 4. Piston 6. Guide ring 10-101 WB97S-5…
• Page 128
  Key size for piston safety nut – CHARACTERISTICS Cylinder Outriggers Boom swing Jig arm Piston rod diameter Internal cylinder diameter Piston stroke 1140 Max. cylinder length 1690 319.5 2590 Min. cylinder length 1055 89.5 1450 Key size for piston safety 10-102 WB97S-5…

• Page 129: Air-Conditioning Unit

  5. Expansion valve • Safe pressures: 6. Evaporator High pressure: 26 bar 7. Clutch thermostat sensor Low pressure: 2.5 bar 8. Cab air circulation fans • Coolant fluid: R134a 9. Air feeder • Coolant quantity: 2250 ±150 g 10-103 WB97S-5…

• Page 130: Operation Of The Air Conditioning Unit

  ( 6 ) a t a m b i e n t temperature is considerably warmer than — 8°C. For this reason it yields heat to the coolant fluid, bringing it up to boiling point and complete evaporation. 10-104 WB97S-5…

• Page 131: Fuse And Relay Centre

  STRUCTURE AND FUNCTION FUSE AND RELAY CENTRE FUSE AND RELAY CENTRE 10-105 WB97S-5…

• Page 132: Driver Seat Wiring

  STRUCTURE AND FUNCTION DRIVER SEAT WIRING DRIVER SEAT WIRING 10-106 WB97S-5…

• Page 133: Switch Panel Wiring

  STRUCTURE AND FUNCTION SWITCH PANEL WIRING SWITCH PANEL WIRING 10-107 WB97S-5…

• Page 134: Front Dash Wiring

  STRUCTURE AND FUNCTION FRONT DASH WIRING FRONT DASH WIRING 10-108 WB97S-5…

• Page 135: Lateral Dash Wiring

  STRUCTURE AND FUNCTION LATERAL DASH WIRING LATERAL DASH WIRING 10-109 WB97S-5…

• Page 136: Roof Wiring

  STRUCTURE AND FUNCTION ROOF WIRING ROOF WIRING 10-110 WB97S-5…

• Page 137: Engine Wiring

  STRUCTURE AND FUNCTION ENGINE WIRING ENGINE WIRING 10-111 WB97S-5…

• Page 138: Speed Selector Wiring

  STRUCTURE AND FUNCTION SPEED SELECTOR WIRING SPEED SELECTOR WIRING 10-112 WB97S-5…

• Page 139: Backhoe Wiring

  STRUCTURE AND FUNCTION BACKHOE WIRING BACKHOE WIRING 10-113 WB97S-5…

• Page 140: Jig Arm Wiring

  STRUCTURE AND FUNCTION JIG ARM WIRING JIG ARM WIRING 10-114 WB97S-5…

• Page 141: Ws Push-Buttons Panel Wiring

  STRUCTURE AND FUNCTION 4WS PUSH-BUTTONS PANEL WIRING 4WS PUSH-BUTTONS PANEL WIRING 10-115 WB97S-5…

• Page 142: Wd Solenoid Valves Wiring

  STRUCTURE AND FUNCTION 4WD SOLENOID VALVES WIRING 4WD SOLENOID VALVES WIRING 10-116 WB97S-5…

• Page 143: Wiring Diagram (Standard Version See Also Group 90)

  WIRING DIAGRAM (STANDARD VERSION) (see also Group 90) WIRING DIAGRAM (STANDARD VERSION) (see also Group 90) Out1 Out2 L R 31b 15 53c WASHER LAVACRISTALLO I I I HORN CLAXON 7,5A 7,5A 7,5A 7,5A 7,5A 15A 15A Sal2 Sal1 12 13 13 14 12Vcc 10-117 WB97S-5…

• Page 144
  PAGE INTENTIONALLY LEFT BLANK…
• Page 145
  • Introduction…………..33 TESTING THE AIR-CONDITIONING UNIT ….55 • 8-spool control valve + Hammer……34 • 10-spool control valve + Hammer……34 EMPTYING THE AIR-CONDITIONING UNIT ….57 CHECKING THE SETTING OF MAIN RELIEF AND TROUBLESHOOTING ……….58 SECONDARY VALVES……….35 20-1 WB97S-5…
• Page 147
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA NORMAL OR STANDARD TECHNICAL DATA Machine model WB97S-5 Unit: Standard Normal Check item Test conditions value value High idling 2400±50 2350–2450 Engine speed 1050±50 Low idling 1000–1100 (without load): – – Calibration speed Sudden acceleration –…
• Page 148
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Machine model WB97S-5 Standard Normal Classifi Check item Test conditions Unit cation value value • Hydraulic oil temperature: 45–55 °C Max. 2400±50 2350–2450 • Converter oil temperature: 80 °C • Engine oil temperature cooling circuit:…
• Page 149
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Machine model WB97S-5 Standard Normal Classifi Check item Test conditions Unit cation value value • Engine stopped • Knob lever: at the center Accelerator pedal Min. Max. 65–95 and at 90° from the lever •…
• Page 150
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Machine model WB97S-5 Standard Normal Classifi Check item Test conditions Unit cation value value • Engine speed: 2200 rpm • Oil temperature: 45–55 °C • Move arm cylinder to end of stroke and measure Control valve 235–260…
• Page 151
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Machine model WB97S-5 Standard Normal Classifi Check item Test conditions Unit cation value value • Engine speed (without load): 2400±50 • Hydraulic oil temperature: 45–55 °C With converter 2175±50 2125–2225 • Machine in 3rd gear •…
• Page 152
  NORMAL OR STANDARD TECHNICAL DATA The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe bucket and standard arm (or jig arm) closed. Machine model WB97S-5 Standard Normal Classifi…
• Page 153
  NORMAL OR STANDARD TECHNICAL DATA The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe bucket and standard arm (or jig arm) closed. Machine model WB97S-5 Standard Normal Classific…
• Page 154
  NORMAL OR STANDARD TECHNICAL DATA The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe bucket and standard arm (or jig arm) closed. Machine model WB97S-5 Standard Normal Classific…
• Page 155
  NORMAL OR STANDARD TECHNICAL DATA The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe bucket and standard arm (or jig arm) closed. Machine model WB97S-5 Standard Normal Classific…
• Page 156
  NORMAL OR STANDARD TECHNICAL DATA The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe bucket and standard arm (or jig arm) closed. Machine model WB97S-5 Standard Normal Classific…
• Page 157
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Fig. A Fig. B RKZ10860 Fig. C Fig. D RKZ10680 RKZ10690 20-13 WB97S-5…
• Page 158
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Fig. E Fig. F RKZ10830 Fig. G Fig. H RKZ10730 RKZ10720 20-14 WB97S-5…
• Page 159
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Fig. J Fig. K RKZ10740 RKZ10750 Fig. L Fig. M RKZ10780 20-15 WB97S-5…
• Page 160
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Fig. N Fig. P RKZ10800 RKZ10790 Fig. Q Fig. R RKZ10820 RKZ10810 20-16 WB97S-5…
• Page 161
  TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA Fig. S RKZ10830 20-17 WB97S-5…
• Page 162
  Differential digital 0–1000 bar pressure gauge ATR800200 Flow-meter Delivery 0–300 /min. Pipe fitting kit – Commercially Maintenance station For coolant R134a available Air-conditioning Commercially Sampling every 15 Thermometer-hygrometer unit available seconds Commercially Leak detector For coolant R134a available 20-18 WB97S-5…
• Page 163
  4 -Adjust valve clearance according to the instructions p r o v i d e d i n t h e e n g i n e s h o p m a n u a l ( c o d e WHBMNEF000). 20-19 WB97S-5…
• Page 164
  Maximum speed: 2400±50 rpm a 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 «ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER»). 20-20 WB97S-5…
• Page 165
  15 sec one from the other. • ANALYSIS 1 -If readings are not within the required interval, check the engine according to the instructions provided in manual code WHBMNEF000. 2 -If the engine has no conditions, adjust the pump’s power absorption (PC valve). 20-21 WB97S-5…
• Page 166
  Check belt tension again after 15 minutes of operation. 6 -Once proper tension is reached, retain the position of the adjustment bolt (5) with the nut (4). 7 -Retain the adjustment bracket (9) with the screw (3)and the compressor with the screws (1). 20-22 WB97S-5…
• Page 167
  3- Push brake pedal to bottom and, while keeping it pushed, loosen the bleeding screw (2) of the braking unit that is being bled until the pedal reaches the end of its stroke. 4 -Keeping pedal at the end stroke, tighten bleeding screw (2). 20-23 WB97S-5…
• Page 168
  After air bleeding apply on screws (2) safety plugs. • 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 fully release cylinder and servocontrol circuit residual pressure. 20-24 WB97S-5…
• Page 169
  3- Push accelerator pedal until accelerator lever (3) contacts the injection pump high idling adjusting screw. 4 -Adjust the end travel stopper (6) of accelerator pedal (1) in this position and lock it with nut (7). 5 -Release the accelerator pedal (1). RKZC3210 20-25 WB97S-5…
• Page 170
  Engine idling speed: 1900±50 rpm RKZC3240 7 -Return to engine low idling speed and retain the position of the nut (5) with the locking nut (4). 8 -Check MAX speed once more by pushing the hand accelerator to end of travel. 20-26 WB97S-5…
• Page 171
  5 -Loosen nuts (3) and adjust slack using stoppers (4). 6 -When adjustment is complete, secure the stoppers (4). a When stoppers are secured, double check to ensure that slack “G” is within range and that the pedals touch the stoppers simultaneously. RKZC3460 20-27 WB97S-5…
• Page 172
  To confirm whether this is the case, check the oil. If a leak condition exists, the oil will be stirred. 20-28 WB97S-5…
• Page 173
  Connect a pressure gauge E2 (250 bar) to the pump during the inspection. 6 -Apply the brake pedal corresponding to the pump and pressurize the circuit to approx. 120 bar. a Do not exceed maximum permitted pressure ± 5 bar). (150 RKZC6100 20-29 WB97S-5…
• Page 174
  When checks and repair (if any) are complete, bleed the air from the braking groups (See » B L E E D I N G A I R F R O M C I R C U I T S — ELIMINATING RESIDUAL PRESSURE»). 20-30 WB97S-5…
• Page 175
  (4) get in contact with pin (3) of lever (6). Lock nuts (5) position. 3 -Apply a dynamometer in the middle of the handle (1) and verify that the handle lock the position happens when a pull force “F” of 40 2 kg. 20-31 WB97S-5…
• Page 176
  If a normal braking condition is not achieved after two attempts to adjust the lever, check control cable for slackness and braking discs for wear and replace components as necessary. (See «30 REMOVAL AND INSTALLATION» for details). 20-32 WB97S-5…
• Page 177
  1 -The machine is equipped with a single control valve with hydraulically controlled spools. The control valve is protected against overpressure by a single upper valve (or main valve, referred to as «LS safety valve») with adjustable pressure setting. 20-33 WB97S-5…
• Page 178
  Curl Lowering Boom Lifting Komatsu Ltd. Dump – Backhoe bucket Curl Closes 4 in 1 bucket Opens – Jig arm – Lifting – Shovel arm Lowering – Down – Right outrigger – Down – Left outrigger RKZ11110 – 20-34 WB97S-5…
• Page 179
  (For details, see «SETTING THE MAIN R E L I E F V A L V E S A N D T H E R E D U C I N G VALVES»). 20-35 WB97S-5…
• Page 180
  Move piston to the end of stroke to check the pressure. a Normal pressure values: Cylinder and movement (bar) Hammer 180–210 Right 225–250 Boom swing Left 225–250 Shovel Dump 235–260 20-36 WB97S-5…
• Page 181
  5 -Start the engine, connect a weight of approx. 1500 kg to the bucket, and fully lower the outriggers. RKZ10910 6 -Slowly extend the arm and boom and take the pressure when the boom lowers. a Normal pressure: 320–360 bar RKZ10920 20-37 WB97S-5…
• Page 182
  If one movement fails to reach the setting pressure, then the malfunction is in the tested element. a If all movements fail to reach the setting pressure, then you need to pressure set or replace the secondary valve. 20-38 WB97S-5…
• Page 183
  • To DECREASE pressure turn in COUNTERCLOCKWISE direction. 3 -Lock the nut (1). 3 Nut: 29.4– 39.2 Nm a When adjustment is complete, check the setting of the main relief valve using the procedures used for measurements. RKZ10930 20-39 WB97S-5…
• Page 184
  2 -Adjust the pressure using the nut (2). • To INCREASE pressure turn in CLOCKWISE direction. • DECREASE pressure turn COUNTERCLOCKWISE direction. 3 -Tighten nut (1) while holding nut (2). 3 Nut (1): 39 – 49 Nm RKZ10960 20-40 WB97S-5…
• Page 185
  4 -Simultaneously perform a boom raise and a backhoe bucket curl movement to end of travel and then read the RKZC3320 DP pressure. a Normal value: 27.5±1.5 bar a If the DPLS value is not within the permissible range, set the unloading valve. 20-41 WB97S-5…
• Page 186
  Each turn of the adjustment screw (2) will change RKZC3330 the pressure by approx. 13 bar. 2 -Lock the nut (3). 3 Nut: 27.4- 34.3 Nm 3 -When adjustment is complete, check the setting of the LS valve (1) using the procedures used for checking. RKZ10970 20-42 WB97S-5…
• Page 187
  To INCREASE pressure rotate in CLOCKWISE direction. • DECREASE pressure rotate COUNTERCLOCKWISE direction. a Each turn of the screw (3) will change the pressure RKZC3350 by _____ bar. 2 -Lock the nut (2). 3 Nut: 22 ± 2.5 Nm RKZ10980 20-43 WB97S-5…
• Page 188
  RKZ10990 a Turn the adjustment screw by not more than 180° in relation to the 0° line, in both directions a Adjustment screw position on first installation shown 2 -Lock the nut (1). 3 Nut: 27.4–34.4 Nm RKZ11000 20-44 WB97S-5…
• Page 189
  • To INCREASE pressure rotate in CLOCKWISE direction. • DECREASE pressure rotate COUNTERCLOCKWISE direction. 3 -Stop the engine and replace the plug (3); ensure that the RKPB1360 seal (5) is in its proper position. 3 Plug: 50±10 Nm 20-45 WB97S-5…
• Page 190
  STANDARD TECHNICAL DATA). a Test cylinder on one side only, as there is only one gasket separating the two chambers. 9 -Restore the hydraulic connection, steer the wheel several times in both directions to remove any air from the circuit. 20-46 WB97S-5…
• Page 191
  5 -Bring the engine back to MIN and compare the pressure with the normal value. a Min. pressure: 3 bar a If the pressure value drops to below the permissible lower limit, the power train pump needs an replacement. 3 Plug: 30 Nm 20-47 WB97S-5…
• Page 192
  Normal pressure: 14-17 bar 4 -Gradually increase engine speed to 2.200 rpm; take a new reading on pressure gauge E6. a Min. pressure: 14 bar a If reading drops below minimum, the transmission pump needs replacing. 3 Plug: 30 Nm RKZC6160 20-48 WB97S-5…
• Page 193
  (See «CHECKING ENGINE WITH LOAD»). 5 -Repeat this test in REVERSE gear. a If the revs are high than the permissible limits, the clutches are worn, and must be replaced. 20-49 WB97S-5…
• Page 194
  10 -Stop the engine and check the shovel position for 5 minutes. • If shovel link has a lowering movement, drift is due to gaskets of plugged cylinder. 11 -Repeat operation from stage 8 to stage 10 to check the other cylinder. RKZC3450 20-50 WB97S-5…
• Page 195
  9 -Stop the engine and check the position of the shovel teeth for 5 minutes. • If the shovel teeth turn, the drift is due to the gasket seals of the plugged cylinder. 10 -Repeat operation from stage 6 to stage 9 to check the other cylinder. 20-51 WB97S-5…
• Page 196
  If boom has no lowering movement, drift is due to control valve. RKZ11030 • Arm testing 1 -Set the machine with arm fully extended and with bucket teeth on ground. 2 -Stop the engine and release residual hydraulic pressures. RKZ11040 20-52 WB97S-5…
• Page 197
  3 -Disconnect bucket cylinders (3) pipes (1) and (2) and plug them to avoid impurity inlet. 4 -Plug bucket cylinder hole on base side and fit a temporary pipe on head side to catch possible oil leakage. RKZC3420 20-53 WB97S-5…
• Page 198
  9 -Check the outriggers position for 5 minutes. • If one or both outriggers have a lowering movement, drift is due to single or both cylinders. • If there is no lowering, drift is due to control valve. RKZ11090 20-54 WB97S-5…
• Page 199
  Ambient temperature (°C) Outgoing air temperature (°C) 9 -f the average value of the temperature measured does not fall within the values given in the table, it will be necessary to thoroughly check the unit. 20-55 WB97S-5…
• Page 200
  Obstruction in the H.P. line between the compressor and the condenser- filter tube, before the measurement point of the H.P. • Compressor damaged • Compressor belt missing • Electromagnetic pulley that slips or does not engage L.P. roughly equal to H.P. • Compressor damaged 20-56 WB97S-5…
• Page 201
  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- conditioning unit is refilled. 20-57 WB97S-5…
• Page 202
  Overloading/ incorrect weight distribution related to the vehicle Incorrect wheel adjustment Verify group integrity and wheel side bearings. Contamination in the axle box or Look for foreign particles. Check assembly of the incorrect assemblyof parts various parts of the axle. 20-58 WB97S-5…
• Page 203
  Replace the differential in case it does not survive any one of the Defective axle test phases Remove excessive weight and redistribute load, following Bent halfshaft instructions related to the vehicle Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre 20-59 WB97S-5…
• Page 204
  Replace Pinion spline worn out Replace Bent halfshaft Replace Noise while steering CAUSES REMEDY Worn out differential gears Replace Worn out differential box Replace or spider Differential thrust washers worn out Replace Half shaft spline worn out Replace 20-60 WB97S-5…
• Page 205
  Load bump Worn out or pitted bearings CAUSES REMEDY Insufficient lubrication; contaminated oil Replace bearings. Excessive use axial pinion Use correct lubrication, fill up to the right level and substitute Normal wear out at recommended intervals Pinion nut loosened 20-61 WB97S-5…
• Page 206
  Bent or broken halfshaft or halfshaft broken at wheel side CAUSES REMEDY Vehicle intensively operated or overloaded Replace the axle shaft Wheel support loosened Check beam body distortion. Check wheel bearing and replace if necessary. Beam body bent 20-62 WB97S-5…
• Page 207
  Overloading/ incorrect weight distribution related to the vehicle Incorrect wheel adjustment Verify group integrity and wheel side bearings. Contamination in the axle box or Look for foreign particles. Check assembly of the incorrect assemblyof parts various parts of the axle. 20-63 WB97S-5…
• Page 208
  Overloading/ incorrect weight distribution related to the vehicle Remove excessive weight and redistribute load, following Bent halfshaft instructions related to the vehicle Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre 20-64 WB97S-5…
• Page 209
  Replace Pinion spline worn out Replace Bent halfshaft Replace Noise while steering CAUSES REMEDY Worn out differential gears Replace Worn out differential box Replace or spider Differential thrust washers worn out Replace Half shaft spline worn out Replace 20-65 WB97S-5…
• Page 210
  Load bump Worn out or pitted bearings CAUSES REMEDY Insufficient lubrication; contaminated oil Replace bearings. Excessive use axial pinion Use correct lubrication, fill up to the right level and substitute Normal wear out at recommended intervals Pinion nut loosened 20-66 WB97S-5…
• Page 211
  Bent or broken halfshaft or halfshaft broken at wheel side CAUSES REMEDY Vehicle intensively operated or overloaded Replace the axle shaft Wheel support loosened Check beam body distortion. Check wheel bearing and replace if necessary. Beam body bent 20-67 WB97S-5…
• Page 212
  Incorrect oil level Top up Worn clutch unit Replace/Repair 4WD clutch failure Repair/Replace 4WD shaft group Overheated solenoids/solenoid valves Replace Damaged wiring connections between Repair/Replace transmission and vehicle Damage to shift electronic control logic Replace Damaged sensors Replace 20-68 WB97S-5…
• Page 213
  Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test) Overheating See «overheating» Gear selector or direction of movement selector Replace malfunction Control module malfunction Replace Shift electronic control malfunction Replace Damaged hydraulic system Repair/Replace 20-69 WB97S-5…
• Page 214
  Gear shift won’t engage CAUSES REMEDY Damage to clutch engagement assembly Repair/Replace Damaged hydraulic system Repair/Replace Damaged control valve Replace Damage to pressure sensors Check/Replace Electrical system fault Repair/Replace Selector malfunction Replace Control module malfunction Replace Shift electronic control malfunction Replace 20-70 WB97S-5…

• Page 215: Disassembly And Assembly

  Installation…………. 187 BATTERY …………..34 • Disassembly and assembly ……..189 • Removal …………..34 REAR AXLE…………… 233 • Installation ……………35 • Removal…………..233 FUEL TANK…………..36 • Installation…………. 235 • Removal …………..36 • Disassembly and assembly ……..236 • Installation ……………37 30-1 WB97S-5…

• Page 216
  OUTRIGGER CYLINDER ………. 321 BACKFRAME LOCK PISTONS………352 • Removal…………..321 • Removal …………..352 • Installation…………. 322 • Installation ………….353 BACKHOE SWING CYLINDERS ……323 • Removal…………..323 • Installation…………. 325 BACKHOE BUCKET CYLINDER ……326 • Removal…………..326 • Installation…………. 327 30-2 WB97S-5…
• Page 217
  «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICATION», «LUBRICATING GREASE». NOTE If no symbol is indicated, the values to be used are those given in the introductory sections of this manual. 30-5 WB97S-5…
• Page 218
  For details, see «20. TESTING AND ADJUSTMENTS». • After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly. 30-6 WB97S-5…
• Page 219
  Plunger CA119228 False differential box CA715004 Plunger CA715022 CA715026 Plunger Disassembly — assembly CA715027 Plunger front axle CA715039 Plunger CA715042 Plunger CA715064 Plunger CA715108 Plunger CA715265 CA715505 Plunger CA715506 Plunger CA715543 Plunger CA715742 Plunger CA722521 Sensor test system 30-7 WB97S-5…
• Page 220
  CA715128 False pinion rear axle CA715172 Plunger CA715265 CA715380 Bearing assembly kit CA715388 False differential box CA715391 Plunger CA715456 Backlash meas. tool CA715505 Plunger CA715506 Plunger CA715541 Plunger CA715706 Preloading meas. tool CA715742 Plunger CA715521 Sensor test system 30-8 WB97S-5…
• Page 221
  Disassembly — assembly transmission CA715746 Plunger CA715745 Calibrator CA715732 Lifting of B, C, and E shafts CA715149 Plunger CA715744 Protection + shims CA715747 Calibrator CA715748 Plunger CA716009 Calibrator CA716010 Protection CA716018 Protection + shims CA716019 Plunger CA716020 Calibrator CA716021 Extractor 30-9 WB97S-5…
• Page 222
  01010-50816 . Screw 790-201-1590 . Driver for boom cylinder 790-201-1580 . Driver for bucket cylinder . Driver for swing and shovel arm 790-201-1570 cylinder 790-201-1560 . Driver for shovel cylinder 790-201-1550 . Driver for outrigger cylinder 790-102-4300 790-102-4310 30-10 WB97S-5…
• Page 223
  (4) and disconnect the gas springs (5) from the chassis. RKZC0750 3 -Remove the snap rings (6) and washers (7). RKZC0760 4 -Attach lifting equipment to engine hood (3); pull out fulcrum pins (8) and remove hood (3). 4 Engine hood: 32 kg RKZC0770 30-11 WB97S-5…
• Page 224
  REMOVAL AND INSTALLATION ENGINE HOOD Installation • To install, reverse removal procedure. a Check catch (9) for proper centring. RKZC0780 30-12 WB97S-5…
• Page 225
  3 -Connect the guard (4) to the lifting equipment and slightly tension the rope. 4 -Take out the screws (1) and remove the protection (4). RKZC0800 Installation • To install, reverse removal procedure. [*1] 2 Screw: Loctite 242 3 Screw: 300 Nm 30-13 WB97S-5…
• Page 226
  4- Drain the air conditioning unit. (For details see «20 TESTING AND ADJUSTMENTS»). [*2] 5 -Disconnect the connector (4) and remove the horn (5). RKZC0810 6 -Disconnect hose (7) from radiator (6) and remove surge tank (8). RKZC0820 30-14 WB97S-5…
• Page 227
  Mark the hoses and their respective positions for connection. [*4] RKZC0850 For machines equipped with an air-conditioning unit. 10 -Disconnect the tubes (17) and (18). a Immediately plug the tubes and the orifices to prevent to prevent moisture from entering into the circuit. RKZC0860 30-15 WB97S-5…
• Page 228
  14 -Move the radiator group (6) to the front of the machine so as to disengage it from the cooling fan. [*5] 15 -Attach lifting equipment to the group (6) and remove the group. 4 Radiator group: 37 kg RKZC0900 30-16 WB97S-5…
• Page 229
  After about one minute, stop the engine and top up all levels. [*5] ± a Align radiator (6) with fan (26), making sure the fan protrudes from fan shroud by 25±2 mm. RKZ10741 30-17 WB97S-5…
• Page 230
  4 -Disconnect the connector (3) and remove the horn (4). 5 -Loosen and remove four screws (5) and washers, and remove condenser (6) together with dehydrating filter. RKZC0910 Installation • To install, reverse removal procedure. 1 -Refill the air-conditioning unit. (For details, see «20 TESTING AND ADJUSTMENTS»). 30-18 WB97S-5…
• Page 231
  RKZC0930 3 -Loosen the tie strap (6) retaining the muffler pipe to the turbocharger. RKZC0940 4 -Loosen and remove the four screws (7) and washers. 5 -Remove the muffler (5). Installation • To install, reverse removal procedure. RKZC0950 30-19 WB97S-5…
• Page 232
  (3) and (4). RKZC0960 3 -Disconnect connector (6) from filter clogging sensor (5). RKZC0970 4 -Loosen and remove the screws (7) and remove the filter (8) together with the filter holder. RKZC0980 Installation • To install, reverse removal procedure. 30-20 WB97S-5…
• Page 233
  3 -Disconnect the connector (4) from the filter clogging lamp. RKZC0971 4 -Loosen and remove the screws (5) and the air filter (6). RKZC0981 5 -Loosen and remove screw (7) and nut (8), and remove heat guard (9). RKZC0990 30-21 WB97S-5…
• Page 234
  REMOVAL AND INSTALLATION TURBOCHARGER 6 -Remove the muffler (10) (For details see «MUFFLER»). RKZC1000 7 -Remove the turbocharger (3) according to the instructions provided in the engine manual (manual code WHBMNEF000). RKZC0962 Installation • To install, reverse removal procedure. 30-22 WB97S-5…
• Page 235
  (For details see «20 TESTING AND ADJUSTMENTS»). 2 -Release the tie strap and disconnect the connector (3). RKZC3000 3 -Disconnect fluid delivery and return pipes (5), (6) from compressor (4). [*1] a Collect the O-rings. RKZC3010 4 -Remove the air filter (8). RKZC0982 30-23 WB97S-5…
• Page 236
  ( F o r d e t a i l s s e e » A I R — C O N D I T I O N I N G U N I T COMPRESSOR BELT»). 2 -Connect the unit to the maintenance station and refill it. (For details see «20 TESTING AND ADJUSTMENTS»). 30-24 WB97S-5…
• Page 237
  2 -Remove the air filter (2). RKZC0983 3 -Loosen the screw (3) retaining the tensioner bracket (4). 4 -Loosen nut (5) and screw (6) for belt tension. 5 -Loosen the screws (7) retaining the compressor (8) and remove the belt (9). 30-25 WB97S-5…
• Page 238
  AIR-CONDITIONING UNIT COMPRESSOR BELT Installation • To install, reverse removal procedure. [*1] 3 Bracket lock nut: 117.6 Nm [*2] 3 Fan fastening nuts: 42 Nm 1 -Carry out the belt tensioning procedure. (For details see «20 TESTING AND ADJUSTMENTS»). 30-26 WB97S-5…
• Page 239
  RKZC1010 3 -Remove the screw (5) and washer from the upper vibration damper. 4 -Remove the second screw (4) and remove the exhaust pipe (6). RKZC1020 Installation • To install, reverse removal procedure. 30-27 WB97S-5…
• Page 240
  4 -Remove four screw covers and screws (8). 5 -Remove the lower side instrument board (9). a Cut the wiring harness strap and position the instrument board (9) inside the RH case (10). • To install, reverse removal procedure. RKZC6530 30-28 WB97S-5…
• Page 241
  9 -Disconnect connectors (14) and (15) from the lighter. RKZC1080 10 -Extract screws (16) and remove the hand accelerator handle (17). 11 -Remove screws (18) from the accelerator lever assembly. RKZC1090 12 -Loosen and remove the screws (19) and (20). RKZC1100 30-29 WB97S-5…
• Page 242
  15 -Extract screws (23) and remove contact carrier plate (24) for rear wiper. RKZC1120 16 -Extract the lower screws (25) retaining the right hand case (10). RKZC6520 17 -Extract three screw covers (26) and screws retaining the right hand case (10) at the rear. RKZC1140 30-30 WB97S-5…
• Page 243
  20 -Move the rear of the right hand case (10) towards the middle of the cab, remove pin (30), and disconnect hand accelerator cable (31). 21 -Loosen nut and disconnect sheath (32). RKZC1170 22 -Disconnect the contact carrier plate connector (33). RKZC2990 30-31 WB97S-5…
• Page 244
  27 — Remove screw (35), then rotate fan group (36) counterclockwise. RKZC1190 28 -Extract the fan group (36). RKZC1200 29 -Remove the clamp (37). 30 -Disconnect connectors (38) and (39); slide off and move to one side the fuse and relay group (40). RKZC1210 30-32 WB97S-5…
• Page 245
  Quantity of fluid (R134a): 2250 ±150 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. 4 -Complete installation by reversing the removal procedure. 30-33 WB97S-5…
• Page 246
  4 -Take out the screws and remove the platform (5) and door. RKZC1260 5 -Disengage battery negative (–) terminal (6) from shield and disconnect from battery (7). 6 -Use the same procedure as above to disconnect the battery positive terminal (8). [*1] RKZC1270 30-34 WB97S-5…
• Page 247
  7 -Loosen wing nut (9) and remove tie rod (10) and bracket (11). 8 -Remove the battery (8). RKZC1280 Installation • To install, reverse removal procedure. [*1] k Connect the battery positive (+) cable first, and then the battery negative (–) cable. 30-35 WB97S-5…
• Page 248
  3 -Remove the lower left-hand guard (4) of the cab. RKZC1300 4 -Disconnect the connector (5) from the level gauge (6). 5 -Mark and disconnect the fuel inlet and return hoses (7), (8). a Plug all pipes/hoses to prevent contamination. RKZC1310 30-36 WB97S-5…
• Page 249
  4 Fuel tank: 68 kg RKZC1320 Installation • To install, reverse removal procedure. [*1] 3 Tank retaining screws: 120 Nm 1 -Refill the fuel tank. Fuel: max. 150 2 -Bleed the air from the fuel circuit. 3 -Start the engine. 30-37 WB97S-5…
• Page 250
  (3). RKZC1340 3 -Remove four screw covers (4) and loosen four screws (5) retaining the instrument panel. RKZC1350 4 -Slide off instrument panel (6) from steering column; disconnect connectors (7) and (8), and remove instrument panel. RKZC1360 30-38 WB97S-5…
• Page 251
  6 -Disconnect connectors (13) and (14) and remove groups (11) and (12). [*1] RKZC1380 Installation • To install, reverse removal procedure. [*1] a Before attempting to tighten the screws, check the antirotation stake (15) for proper engagement into the steering column (16). RKZC1390 30-39 WB97S-5…
• Page 252
  3 -Remove the front mat (3). RKZC1031 4 -Loosen and remove the upper screws (4) retaining the instrument panel holder (5). RKZC1400 5 -Remove the guards (6) and extract the upper screws (7) retaining the front trim cover (8). RKZC1410 30-40 WB97S-5…
• Page 253
  (5). 10 -Remove the plug and (12) and draw oil from the tank (13). 11 -Reinstall the plug and disconnect connectors (14) and pressure switch connectors (15) and (16). 12 -Remove the tank (13). RKZC1450 30-41 WB97S-5…
• Page 254
  Make sure that the push-rods (21) center the seating of the pistons. a When installation is complete, inspect for proper brake pedal pre-travel and alignment. (For details, see «20 TESTING AND ADJUSTMENTS»). [*3] 3 Union: 20 Nm RKZ10750 30-42 WB97S-5…
• Page 255
  RKZC1381 4 -Loosen and remove the upper screws (4) retaining the instrument panel holder (5). RKZC1400 5 -Remove the steering column lock knob (6). 6 -Remove the screws (7) retaining the side of the instrument panel holder. RKZC6210 30-43 WB97S-5…
• Page 256
  (9); remove the steering unit. Installation • To install, reverse removal procedure. [*1] a Start the engine and perform several complete steering manoeuvres in both directions, to bleed the air out of the steering system. RKZC1500 30-44 WB97S-5…
• Page 257
  (For details see «EXHAUST PIPE»). 2 -Disconnect the injection pump control rod (2) from the pitman arm (1). 3 -Remove the front mat, remove screws (3) and loosen screw (4). 4 -Remove the steering unit guard (5). RKZC3040 30-45 WB97S-5…
• Page 258
  7 -Disconnect the tubes (10) and (3). [*3] a Plug the pipes and pipe-fittings to prevent entry of impurities. 8 -Take out the screws (11) and remove the hood (12). RKZC6231 9 -Disconnect lower frame harness connectors (14) from fuse block (13). RKZC6240 30-46 WB97S-5…
• Page 259
  Check that all the hoses are marked and note down the bends and routing patterns. a Cap pipes, hoses holes prevent contamination. a Lay the hoses inside the cab to gain access to the feed and exhaust hoses. RKZC1992 30-47 WB97S-5…
• Page 260
  RKZC2322 15 -Disconnect parking brake cable (25) from brake caliper. [*5] 16 -Take out the screws (26) and remove the protection (27). RKZC1302 17 -Remove nuts (28) as well as front and rear screws. [*6] RKZC3061 30-48 WB97S-5…
• Page 261
  19 -Take out the screws (31) and remove the protection (32). RKZC0743 20 -Disconnect hose (34) from condenser (33). [*8] a Cap the hose and hole to ward off humidity. a Release the hose and route it under the cab. RKZC3071 30-49 WB97S-5…
• Page 262
  25 -Loosen straps (40) and disconnect heating hoses (41). a Mark the pipes to avoid exchanging them during installation. a Cap pipes, hoses holes prevent contamination. 26 -Ensure that all hoses, harnesses and wires are free, and remove the cab. RKZC3101 30-50 WB97S-5…
• Page 263
  Adjust the stroke of the parking brake lever. (For details, see «20 TESTING AND ADJUSTMENTS»). [*6] 3 Cab retaining screws: 200 Nm [*7] 3 Suction pipe union: _________ Nm [*8] 3 Union (34): 16 Nm 1 — Refill the coolant liquid. Coolant liquid: approx. 15 30-51 WB97S-5…
• Page 264
  PAGE INTENTIONALLY LEFT BLANK…
• Page 265
  T R A N S M I S S I O N — R E V E R S E , D I R E C T I O N INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP»). RKZC1382 30-53 WB97S-5…
• Page 266
  RKZC1411 7 -Loosen and remove the lower screws (12) retaining the front trim cover (11). 8 -Fully lower the steering column; extract the knob (13). RKZC1421 9 -Slide the front trim cover (11) up to remove it. RKZC1431 30-54 WB97S-5…
• Page 267
  12 -Disconnect oil level and pressure switch connectors (15) and (16). RKZC1451 13 -Disconnect the brake fluid delivery tubes (17). [*1] a Plug all pipes/hoses to prevent contamination. RKZC1461 14 -Loosen mounting bolt (18). 15 -Pull out the screws (19) and remove the protection (20). 30-55 WB97S-5…
• Page 268
  19 -Disconnect the strap (27) holding the steering unit and working brake hoses. 20 -Loosen and remove nut (28) and washer. 21 -Disconnect the washer hoses (29) and remove the complete wiper arm (30). RKZC1540 22 -Disconnect connector (32) from washer pump (31). RKZC1550 30-56 WB97S-5…
• Page 269
  RKZC6260 25 -Take out the screws (37) and remove the conveyor (38). RKZC1580 26 -Lift the rubber bulkhead and disconnect the discharge hose (40) from the tank (39). a Plug the pipe to prevent contamination. RKZC1590 30-57 WB97S-5…
• Page 270
  29 -Disconnect the vent hose (44) and filter and remove. 30 -Remove the screws and remove the fill sleeve (45). a Collect the O-ring. RKZC1620 31 -Remove screws (46) and washers and remove the tank’s front holder (47). RKZC1630 30-58 WB97S-5…
• Page 271
  2 -Start the engine and check for leaks. 3 -Bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). 4 -Stop the engine, check the oil level in the tank and, if necessary, top it up. 30-59 WB97S-5…
• Page 272
  (6) and (7) from the pump (4). a Cap pipes, hoses holes prevent contamination. 4 -Disconnect the suction pipe (8) and the draining hose (9) from the pump. a Cap pipes, hoses holes prevent contamination. 30-60 WB97S-5…
• Page 273
  3 Pump screws: 220 Nm 1 -Refill the hydraulic oil. Hydraulic oil: approx. 40 2 -Start the engine and run it at MIN. to bleed any air. 3 -Stop the engine and check the oil level in the tank. 30-61 WB97S-5…
• Page 274
  1 -Remove the piston pump (1). (For details see «PISTON PUMP»). [*2] 2 -Remove the front mat and remove the metal sheet (2) closing off the cab floor. RKZC1521 3 -Disconnect rear cardan shaft (4) from transmission (3). [*4] 30-62 WB97S-5…
• Page 275
  6 -Take out the screws (8) and remove the harness holder (9). RKZC6290 7 -Disconnect the connector (10) from the rev sensor (11). RKZC6310 8 -Disconnect delivery hose (12) to oil cooler and return hose (13) from gearbox (3). 9 -Remove the clamp (14). RKZC6300 30-63 WB97S-5…
• Page 276
  13 -Disconnect the gearbox oil load and oil level control pipe (18), remove the screw (19) and remove the complete pipe (18). RKZC6320 14 -Remove the nuts (20) on the vibration dampers (21), the screws (22) and remove the gearbox supports (23). [*6] [*7] RKZC6330 30-64 WB97S-5…
• Page 277
  16 -Loosen and remove the two screws (24) retaining the gearbox (3) to the engine (17). [*8] RKZC6350 17 -Move the gearbox group (3) towards the rear of the machine and extract the group. 4 Transmission: 254 kg RKZC6360 30-65 WB97S-5…
• Page 278
  1 -Start the engine to circulate the oil. Check that there are no leaks. 2 -Bleed the air from the working equipment circuits. (For details see «20 TESTING AND ADJUSTMENTS»). 3 -Stop the engine, check the levels and, if necessary, top them up. 30-66 WB97S-5…
• Page 279
  Disassembly and assembly 1. Plugs and filters 1.1 Disassembly RKZ11200 1 -Remove the drain plug (1) and drain the oil from the transmission. RKZC3490 2 -Remove the two cap screws (2) which fasten the cover for the oil screen. RKZC3500 30-67 WB97S-5…
• Page 280
  If necessary, remove the connector (7) for the oil filter (6). RKZC3520 5 -Unscrew and remove the oil filter protection valve (8). RKZC3530 6 -Check the valve (8) condition. a Clean with care the valve and replace the O-ring (9) and (10) if necessary. RKZC3540 30-68 WB97S-5…
• Page 281
  RKZC3550 8 -To check the FORWARD clutch pressure, remove the plug (12). RKZC3560 9 -To check the REVERSE clutch pressure, remove the plug (13). RKZC3570 10 -To check the lubrication pressure, remove the plug (14). RKZC3580 30-69 WB97S-5…
• Page 282
  12 -Rimuovere il termostato olio (16). RKZC3600 1.2 Assembly 1 -Assemble the speed sensor (15) to the prescribed torque 3 Sensor: 50 Nm RKZC3590 2 -Assemble the thermostat (16) to the prescribed torque. 3 Thermostat: 30 Nm RKZC3600 30-70 WB97S-5…
• Page 283
  5 -Clean with care the oil filter protection valve (8). Assemble the new O-ring (9) and (10). RKZC3540 6 -Assemble the oil filter protection valves (8). Tighten the valve (8) to the prescribed torque 3 Valve: 23 Nm RKZC3530 30-71 WB97S-5…
• Page 284
  9 -Assemble new O-ring (5) to the filter (4). Insert the filter (4) with O-ring (5) and assemble the cover (3). RKZC3620 10 -Assemble the two cap screws (2) at prescribed torque to fasten the cover (3). 3 Screw: 23 Nm RKZC3501 30-72 WB97S-5…
• Page 285
  REMOVAL AND INSTALLATION TRANSMISSION 11 -Assemble the drain plug (1) to the prescribed torque. 3 Plug: 80 Nm RKZC3490 30-73 WB97S-5…
• Page 286
  2. Torque converter and oil pump 2.1 Disassembly RKZ11210 1 -Remove torque converter (1). (For details see «CONVERTOR»). RKZC3630 2 -Remove screws (2). a Make reference mark on the pump and bell housing before untightening the screws. RKZC3640 30-74 WB97S-5…
• Page 287
  Do not disassemble the oil pump (3) RKZC3660 5 -Remove O-ring (4). a Replace the O-ring at each disassembly. RKZC3670 6 -If replacement is necessary, remove the seal ring (5). a This is a destructive operation for the seal ring. RKZC3680 30-75 WB97S-5…
• Page 288
  RKZC3700 3 -Grease the ring (5) to keep it centred/coaxial with respect to the shaft slot centre line and to make the introduction onto the pump easier. RKZC3710 30-76 WB97S-5…
• Page 289
  The two teeth on the converter that are responsible for driving the pump can cut the lip of the sealing ring. 7 -Couple transmission and converter to the engine flywheel with the screws of the bell converter drive plate. RKZC3630 30-77 WB97S-5…
• Page 290
  REMOVAL AND INSTALLATION TRANSMISSION 3. Hydraulic control valve 3.1 Disassembly RKZ11220 1 -Drain oil from transmission hydraulic circuit, disconnect all electrical connections. Remove screws (1). RKZC3730 2 -Lift control valve (2). RKZC3740 30-78 WB97S-5…
• Page 291
  4 -Place the control valve unit on a clean workbench. Remove fastening screws (4) from the valves (5) and (6). RKZC3760 5 -Extract with care the valves (5) and (6) with a screwdriver. RKZC3770 6 -Remove the valves (5) and (6). RKZC3780 30-79 WB97S-5…
• Page 292
  REMOVAL AND INSTALLATION TRANSMISSION 7 -Check the valves (5) and (6) condition. RKZC3790 8 -Unscrew and remove the valve (7). RKZC3800 9 -Check the valve (7) condition. RKZC3810 10 -Unscrew and remove the oil filter protection valve (8). RKZC3530 30-80 WB97S-5…
• Page 293
  2 -Assemble the oil filter protection valves (8). Tighten the valve (8) to the prescribed torque 3 Valve: 23 Nm RKZC3530 3 -Assemble the ON/OFF (6) and proportional (5) valves using the locations shown on the side. RKZ11230 30-81 WB97S-5…
• Page 294
  4 -Assemble the valve mounting screws (4). RKZC3761 6 -Assemble the new gasket (3). RKZC3750 7 -Assemble the control valve unit (2) to the transmission (11). RKZC3820 8 -Tighten the bolts (1) to the prescribed torque. 3 Screws: 23 Nm RKZC3830 30-82 WB97S-5…
• Page 295
  4. Hydraulic system lines 4.1 Disassembly RKZ11240 1 -Drain oil from transmission hydraulic circuit. Unscrew the connections of pipe (1) (shaft lubrication) and remove the pipe (1). RKZC3840 2 -Remove the pipe (2) (2nd speed) unscrewing related connections. RKZC3850 30-83 WB97S-5…
• Page 296
  RKZC3870 4.1 Assembly 1 -Assemble the pipe (1) tightening the connections to the prescribed torque. 3 Unions: 30 Nm RKZC3840 2 -Assemble the pipe (2) tightening torques the connections to the prescribed torque. 3 Unions: 30 Nm RKZC3850 30-84 WB97S-5…
• Page 297
  3 -Assemble the pipes (3), (4), (5) and (6) then tighten related connections to the prescribed torque. 3 Unions: 30 Nm RKZC3860 4 -Assemble the pipe (7) tightening torques the connections to the prescribed torque. 3 Unions: 30 Nm RKZC3870 30-85 WB97S-5…
• Page 298
  REMOVAL AND INSTALLATION TRANSMISSION 5. Transmission housing 5.1 Disassembly RKZ11250 1 -Drain oil from transmission. Unscrew flange (2) fastening bolt (1). RKZC3880 30-86 WB97S-5…
• Page 299
  RKZC3900 3 -Collect the washer (3). RKZC3910 4 -Remove flange (2) and O-ring (4). a Replace the O-ring at each disassembly. RKZC3920 5 -Remove seal ring (5). a This is a destructive operation for the seal ring. RKZC3930 30-87 WB97S-5…
• Page 300
  6 -Remove the fastening screws (6) from the flange (7). RKZC3940 7 -Remove flange (7). RKZC3950 8 -Extract transmission shaft PTO (8). RKZC3960 9 -If to be replaced, remove teflon seal ring (9) by cutting it. a This is a destructive operation for the seal ring. RKZC3970 30-88 WB97S-5…
• Page 301
  10 -Remove snap ring (10). RKZC3980 11 -Extract bearing (11) with tool F2. RKZC3990 12 -Unscrew flange (13) fastening bolt (12). Use a screwdriver and two screws to stop flange rotation. RKZC3901 13 -Remove the bolt (12) and washer (14). RKZC3911 30-89 WB97S-5…
• Page 302
  This is a destructive operation for the seal ring. RKZC4010 16 -Remove fastening bolts (17) from the rear (18) and front (19) half housings. RKZC4020 17 -Insert a lever in the special slot to detach the cover. RKZC4030 30-90 WB97S-5…
• Page 303
  Accurately remove from mating surfaces any residual of sealant and clean them with a detergent. RKZC4050 2 -Assemble all the transmission internal parts. Apply a thin film of prescribed sealant on the edge of the rear half-housing. 2 Loctite 510 RKZC4060 30-91 WB97S-5…
• Page 304
  (19) half housings. Tighten the bolts to the prescribed torque. 3 Screws: 50 Nm RKZC4070 5 -Assemble seal ring (5) on front shaft output. Use tool F8. RKZC4080 6 -Assemble flange (2) and a new O-ring (4). RKZC3920 30-92 WB97S-5…
• Page 305
  8 -Tighten the bolt (1) to the prescribed torque. Use screwdriver and two screws to stop flange rotation. 3 Screws: 139 Nm RKZC4090 9 -Assemble seal ring (16) on rear shaft output. Use tool F8. RKZC4100 10 -Assemble flange (13) and a new O-ring (15). RKZC3921 30-93 WB97S-5…
• Page 306
  12 -Tighten the bolt (12) to the prescribed torque. Use screwdriver and two screws to stop flange rotation. 3 Screws: 139 Nm RKZC4090 13 -Assemble bearing (11) on transmission shaft PTO (8). RKZC4110 14 -Assemble snap ring (10). RKZC4120 30-94 WB97S-5…
• Page 307
  17 -Apply a thin film of sealant to the flange (7). 2 Loctite 510 a Verify that the two holes for oil passage (A) match. RKZC4140 18 -Assemble the screws (6) to prescribed torque. 3 Screw: 50 Nm RKZC3940 30-95 WB97S-5…
• Page 308
  6. Shafts A — D 6.1 Disassembly 17 18 RKZ11260 1 -Grasp with pliers the input shaft assembly A . Remove with shaft assembly D and lift. RKZC4150 2 -If to be replaced, remove the teflon seal ring (1). RKZC4160 30-96 WB97S-5…
• Page 309
  Pulling any farther can damage the parts. k Do not install the separator between gear and bearing. RKZC4180 5 -Remove bearing (3). RKZC4190 6 -Remove spacer (4). RKZC4200 30-97 WB97S-5…
• Page 310
  REMOVAL AND INSTALLATION TRANSMISSION 7 -Remove gear (6). RKZC4210 8 -Remove needle cage (7). RKZC4220 9 -Remove spacer (8). RKZC4230 10 -Remove split pin (9). RKZC4240 30-98 WB97S-5…
• Page 311
  12 -Use prybars to lift and to remove the thrust plate lock ring (11) evenly. RKZC4260 13 -Remove the clutch plates (18) and the clutch drive plates (17). RKZC4270 14 -Place a mark below the groove on the friction bell. RKZC4280 30-99 WB97S-5…
• Page 312
  Lower the spring (15) lock washer (13). Use tool F9. RKZC4300 17 -Remove snap ring (14). RKZC4310 18 -Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool. RKZC4301 30-100 WB97S-5…
• Page 313
  22 -If to be replaced, remove teflon seal ring (20) and relevant inner O-ring (20) from outer seat of piston and teflon seal rings (21) and relevant inner O-ring (21) from inner of piston. To remove the rings it is necessary to cut them. RKZC4350 30-101 WB97S-5…
• Page 314
  If Teflon seal rings (22) are to be replaced, remove the rings by cutting them. RKZC4360 24 -Remove snap ring (23). RKZC4370 25 -Remove bearing (24) by means of an extractor. RKZC4380 26 -Remove bearing (24) and thrust washer (25). RKZC4390 30-102 WB97S-5…
• Page 315
  Number clutch steel plate (each side) Nominal clutch plate thickness 2.40±0.05 mm Nominal clutch kit thickness * 29.0–29.2 mm RKZC4420 Maximum clutch plate wear (each side) 0.25 mm Maximum clutch kit wear 1.5 mm * Under load of 163 kg RKZC4430 30-103 WB97S-5…
• Page 316
  2 -Remove bearing (37) of shaft D by means of an extractor. RKZC4460 6.2 Assembly SHAFT A 1 — Assemble new teflon ring (20) and relevant inner O- rings (20),new teflon ring (21) and relevant inner O-rings (21) respectively into the piston outer and inner seats. RKZC4350 30-104 WB97S-5…
• Page 317
  2 — Apply a thin film of grease on the sealing rings just inserted. RKZC4470 3 -Insert clutch piston (19) with special tool F10 as protection of seal rings (21). RKZC4480 4 -Assemble sleeve (5). RKZC4330 5 -Assemble spring (15) and washer (13). RKZC4320 30-105 WB97S-5…
• Page 318
  Ensure that the snap ring (14) is well fitted. RKZC4310 8 -Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool. RKZC4301 9 -Remove tool F9 and assemble split pin (9). RKZC4490 30-106 WB97S-5…
• Page 319
  RKZC4510 13 -Assemble clutch plates (18) and clutch drive plates (17) on the gear (6). The assembled clutch pack must contain seven clutch drive plates and six clutch plates. RKZC4520 30-107 WB97S-5…
• Page 320
  14 -Locate the pack assembly by means of two screwdrivers. RKZC4530 15 -Assemble snap ring (10). RKZC4540 16 -Assemble washer (4). RKZC4200 17 -Heat the bearing (3) to 80÷100 °C (176° to 212 °F). Assemble bearing (3). Use tool F2. RKZC4550 30-108 WB97S-5…
• Page 321
  20 -Install the F5a spacer onto the input shaft with the chamfered end facing in. RKZC4570 21 -Slide the F5b expander/protector onto the input shaft and on the spacer. The expander/protector will stop in the correct position to install the seal ring in the groove. RKZC4580 30-109 WB97S-5…
• Page 322
  Leave the seal compressor in place for 15 minutes until the sealing ring has cooled and is properly sized and seated in the groove. After the seal ring has cooled, remove the seal compressor from the shaft. RKZC4620 30-110 WB97S-5…
• Page 323
  27 -Heat the bearing (24) to 80÷100 °C (176° to 212 °F) Use driver F11 to drive the bearing (24) onto the input shaft until the bearing makes contact with the thrust washer. RKZC4650 28 -Assemble snap ring (23). RKZC4660 30-111 WB97S-5…
• Page 324
  Install the teflon seal ring onto the expander/protector. RKZC4690 32 -Install the F13 pusher over the expander/protector and slide the seal ring until it reaches the groove in the shaft. Remove the pusher, expander/protector, and spacer from the shaft. RKZC4700 30-112 WB97S-5…
• Page 325
  Once the sealing ring has cooled, remove the seal compressor from the shaft. To install the three Teflon rings remaining, carry out steps 29 to 33 in this section using the other spacers of tool F12. RKZC4720 30-113 WB97S-5…
• Page 326
  If the gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble the clutches do not work correctly, disassemble the clutches to find the problem. clutches to find the problem. 30-114 WB97S-5…
• Page 327
  Use tool F3. RKZC4740 40 -Lubricate with oil the shaft seat A.A. RKZC4750 41 -Fit shaft assembly D and shaft assembly A. The operation is correct only if the two shafts are fitted at the same time. RKZC4760 30-115 WB97S-5…
• Page 328
  REMOVAL AND INSTALLATION TRANSMISSION 7. AXIS B 7.1 Disassembly RKZ11280 1 -Remove screws (28) and protection (29). RKZC4770 2 -Lift the three shafts B-C-E, at the same time B-C-E. Use tool F15. RKZC4780 30-116 WB97S-5…
• Page 329
  This is a destructive operation for the seal rings. RKZC4790 4 -By means of an extractor remove bearing (3) and gear (4). RKZC4800 5 -Remove The bearing (3) and the gear (4). RKZC4810 6 -Remove snap ring (5). RKZC4820 30-117 WB97S-5…
• Page 330
  REMOVAL AND INSTALLATION TRANSMISSION 7 -Remove spacer (6). RKZC4830 8 -Remove the spring pin (23). RKZC4840 9 -Remove gear (8). RKZC4850 10 -Remove roller retainers (7) and washer (13). RKZC4860 30-118 WB97S-5…
• Page 331
  REMOVAL AND INSTALLATION TRANSMISSION 11 -Remove spring pin (24) and spacer (14). RKZC4870 12 -Slightly press thrust plate (10). RKZC4880 13 -Remove snap ring (9). RKZC4890 14 -Remove thrust plate (10) by means of two screwdrivers. RKZC4900 30-119 WB97S-5…
• Page 332
  16 -Lower the spring (17) retaining washer (16). Use tool F9. RKZC4920 17 -Remove snap ring (15). RKZC4930 18 -Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool. RKZC4920 30-120 WB97S-5…
• Page 333
  22 -If to be replaced, remove teflon seal ring (20) and relevant inner O-ring from outer seat of piston and teflon seal rings (21) and relevant inner O-ring from inner of piston. To remove the rings it is necessary to cut them. RKZC4350 30-121 WB97S-5…
• Page 334
  Use new parts as required. 26 -If the clutch discs are to be used again, keep the clutch packs in the same previous assembly order separate and record which clutch pack goes with each clutch. RKZC4420 30-122 WB97S-5…
• Page 335
  Check the slots in the side of the input shaft housing for damage from the tangs on the steel discs. Use new parts as required during assembly. 7.2 Assembly 1 -Assemble bearing (25). Use tool F2. RKZC4990 30-123 WB97S-5…
• Page 336
  RKZC4350 4 -Apply a thin film of grease on the sealing rings just inserted. RKZC4470 5 -Insert clutch piston (19) with special tool F10 as protection of seal rings (21). RKZC4480 30-124 WB97S-5…
• Page 337
  6 -Assemble sleeve (18). RKZC4950 7 -Assemble spring (17) and washer (16). RKZC4940 8 -Lower the spring (16) lock washer (17). Use tool F9. RKZC4302 9 -Insert snap ring (15). a Ensure that the snap ring (15) is well fitted. RKZC4311 30-125 WB97S-5…
• Page 338
  Remove the top piece of the F9 special tool. RKZC4301 11 -Assemble clutch pack to shaft (22). RKZC4911 12 -Assemble spacer (14) and spring pin (24). RKZC5010 13 -Insert washer (13) and roller bearing (7). RKZC5020 30-126 WB97S-5…
• Page 339
  16 -Apply compressed air at low pressure in hole in order to push the thrust plate (10) against the retaining ring (9), then align the clutch plate (11) spline. RKZC5050 17 -Assemble gear (8) paying attention it completely fit in its seat. RKZC5060 30-127 WB97S-5…
• Page 340
  Distance: 2.20–3.05 mm. a If the distance is not within specification, the clutch is probably assembled wrong. RKZC4631 21 -Assemble gear (4) taking care to orientate the shelf facing the clutch and bearing (3). Use tool F16. RKZC5090 30-128 WB97S-5…
• Page 341
  Hear the 2nd speed gear piston moving to lock the 2nd speed gear clutch pack. Try to move the 2nd speed gear. The 2nd speed gear must not turn on the input shaft. If the clutch does not work correctly, disassemble the clutch to find the problem. 30-129 WB97S-5…
• Page 342
  F17. RKZC5100 24 -Lift the three shafts B-C-E at the same time and insert into the half-housing. Use tool F15. RKZC4780 25 -Assemble protection (29) and tighten screws (28) to the prescribed torque. 3 Screw: 50 Nm RKZC4770 30-130 WB97S-5…
• Page 343
  REMOVAL AND INSTALLATION TRANSMISSION 8. AXIS C 8.1 Disassembly RKZ11300 1 -Remove screws (59) and protection (60). RKZC4771 2 -Lift the three shafts B-C-E, at the same time B-C-E. Use tool F15. RKZC4780 30-131 WB97S-5…
• Page 344
  TRANSMISSION 3 -By means of an extractor remove bearing (58). RKZC5110 4 -Remove the spacer (57). RKZC5120 5 -Remove the gear (54) with its inner parts. RKZC5130 6 -Overturn the group. Push down the thrust plate (39). RKZC5140 30-132 WB97S-5…
• Page 345
  RKZC5150 8 -Remove the thrust plate (39) by means of two screwdrivers. RKZC5160 9 -Remove clutch kit (40). RKZC5170 10 -Push down the thrust washer (42) to allow lock ring removal (41). Use the special tool F9. RKZC5180 30-133 WB97S-5…
• Page 346
  (43). RKZC5800 13 -Remove clutch piston (44) by blowing in compressed air through the delivery hole. RKZC5210 14 -If to be replaced, remove teflon seal ring (45) and relevantimer O-ring from outer seat of piston (44). RKZC5220 30-134 WB97S-5…
• Page 347
  Remove bushing (47) and (56), roller bearing (46) and (55) and spacer (50). RKZC5240 17 -Chech the condition of removed parts (46), (47), (50), (55) and (56). RKZC5250 18 -Remove the O-rings (48) and (52) from the bush (50). destructive operation for the seal rings RKZC5260 30-135 WB97S-5…
• Page 348
  If replacement is necessary, cut the teflon seal rings (49) and (51) to remove they from the bush (50). destructive operation for the seal rings RKZC5270 20 -Remove gear (35). RKZC5280 21 -Remove roller retainer (36). RKZC5290 22 -Remove spacer (31). RKZC5300 30-136 WB97S-5…
• Page 349
  23 -Push down the counterdisk (33) to set free the lock ring (34). RKZC5310 24 -Remove snap ring (34). RKZC5320 25 -Remove the thrust plate (33) by means of two screwdrivers. RKZC5330 26 -Remove clutch kit (32). RKZC5340 30-137 WB97S-5…
• Page 350
  28 -Lower the spring (28) lock washer (29). Use tool F9. RKZC4303 29 -Remove snap ring (30). RKZC4312 30 -Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool. RKZC4301 30-138 WB97S-5…
• Page 351
  34 -If to be replaced, remove teflon seal ring (25) and relevant inner O-ring from outer seat of piston and teflon seal rings (24) and relevant inner O-ring from inner of piston. To remove the rings it is necessary to cut them. RKZC4351 30-139 WB97S-5…
• Page 352
  TRANSMISSION 35 -Overturn the shaft (23). Cut and remove the seal rings (16), (17), (18) and (19). RKZC5390 36 -By means of an extractor remove bearing (1). RKZC5400 37 -Remove spacer (2). RKZC5410 38 -Remove gear (3). RKZC5420 30-140 WB97S-5…
• Page 353
  TRANSMISSION 39 -Remove roller retainers (7) and washer (8). RKZC5430 40 -Remove the spring pin (21). RKZC5440 41 -Push down the thrust plate (5) to set free the lock ring (4). RKZC5311 42 -Remove snap ring (4). RKZC5321 30-141 WB97S-5…
• Page 354
  REMOVAL AND INSTALLATION TRANSMISSION 43 -Remove the thrust plate (5) by means of two screwdrivers. RKZC5331 44 -Remove clutch kit (6). RKZC5341 45 -Lower the spring (11) lock washer (10). Use tool F9. RKZC4304 46 -Remove snap ring (9). RKZC4313 30-142 WB97S-5…
• Page 355
  48 -Remove the lock ring (9), the thrust washer (10) and spring (11). RKZC5361 49 -Extract clutch piston (13) from its seat by blowing in compressed air through the delivery hole. RKZC5370 50 -Remove the bush (12) and clutch piston (13). RKZC5381 30-143 WB97S-5…
• Page 356
  If using a new clutch kit soak the clutch plates (B) in clean transmission oil for at least an hour before assembly. In any case lubricate the contact surfaces of clutch drive plates with clean transmission oil before RKZC4432 assembly. RKZC4442 30-144 WB97S-5…
• Page 357
  55 -Inspect the bore of the shaft in the input shaft housing for damage that will cause leakage when the clucth is assembled. Check the slots in the side of the input shaft housing for damage from the tangs on the steel discs. Use new parts as required during assembly. 30-145 WB97S-5…
• Page 358
  3 -Assemble new teflon ring (45) with relative O-ring on clutch piston (44). RKZC5480 4 -Apply a thin film of grease on the outer edge and in the inner part of clutch piston (44) and assemble in gear (54). RKZC5490 30-146 WB97S-5…
• Page 359
  7 -Insert snap ring (41). a Ensure that the snap ring (41) is well fitted. RKZC5180 8 -Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool. RKZC5510 30-147 WB97S-5…
• Page 360
  If the distance is not within specification, the clutch is probably assembled wrong. RKZC5530 12 -Assemble new teflon ring (25) and relevant inner O-ring, new teflon ring (24) and relevant inner O-rings respectively into the piston (26) outer and inner seats. RKZC4352 30-148 WB97S-5…
• Page 361
  13 -Apply a thin film of grease on the sealing rings just inserted. RKZC4470 14 -Insert clutch piston (26) with special tool F10 as protection of seal rings (24). RKZC4481 15 -Assemble sleeve (27). RKZC4951 16 -Assemble spring (28) and retainer washer (29). RKZC5540 30-149 WB97S-5…
• Page 362
  Ensure that the snap ring (30) is well fitted. RKZC4312 19 -Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool. RKZC4301 20 -Remove tool F9 and assemble spring pin (22). RKZC5550 30-150 WB97S-5…
• Page 363
  Apply a thin film of grease under washer (31) to avoid its falling when overturning the shaft. RKZC5560 22 -Assemble the washer (31) on the pin (22). RKZC5590 23 -Insert clutch kit (32) on main shaft (23). RKZC4912 24 -Insert the roller bearing (36) and thrust plate (33). RKZC5600 30-151 WB97S-5…
• Page 364
  (32). a Distance: 1.50–1.95 mm. a If the distance is not within specification, the clutch is probably assembled wrong. RKZC4632 28 -Insert gear (35) paying attention it completely fit in its seat. RKZC5280 30-152 WB97S-5…
• Page 365
  30 -Assemble the gear assembly (54) on main shaft (23). RKZC5640 31 -Assemble the bush (47) and needle bearing (46) with special tool F2. RKZC5650 32 -Assemble the new O-rings (48) and (52) to the bush (50). RKZC5260 30-153 WB97S-5…
• Page 366
  35 -Assemble the bush (50) on main shaft (23) with special tool F2. k The reference mark must be on the top surface RKZC5660 36 -Assemble the bush (56) and needle bearing (55) with special tool F2. RKZC5670 36 -Assemble the spacer (57). RKZC5120 30-154 WB97S-5…
• Page 367
  (13) inner seat. RKZC4353 39 -Apply a thin film of grease on the sealing rings just inserted. RKZC4470 40 -Inseryt the clutch piston (13) with the special tool F10 as protection of seal rings (15). RKZC4482 30-155 WB97S-5…
• Page 368
  41 -Assemble sleeve (12). RKZC4331 42 -Assemble spring (11) and washer (10). RKZC4321 43 -Lower the spring (11) lock washer (10). Use tool F9. RKZC4304 44 -Insert snap ring (9). a Ensure that the snap ring (9) is well fitted. RKZC4313 30-156 WB97S-5…
• Page 369
  45 -Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool. RKZC4301 46 -Assemble spring pin (21). RKZC5580 47 -Insert clutch kit (6) on main shaft (23). RKZC4913 48 -Assemble thrust plate (5). RKZC5570 30-157 WB97S-5…
• Page 370
  (6). a Distance: 2.20–3.05 mm. a If the distance is not within specification, the clutch is probably assembled wrong. RKZC4633 52 -Assemble the thrust washer (8) and roller bearing (7). RKZC5430 30-158 WB97S-5…
• Page 371
  55 -Assemble bearing (1) with the special tool F2. RKZC5720 56 -Install Teflon sealing rings (16), (17), (18) and (19). Use special tool F5 and carry out steps 29 to 34 in section «6.2 Assembly» to install. RKZC4681 30-159 WB97S-5…
• Page 372
  Apply compressed air of approximately 6 bar to the input shaft. 3rd speed gear clutch passage. If the clutch does not work correctly, disassemble Hear the 3rd speed gear piston moving to lock the the clutch to find the problem. 30-160 WB97S-5…
• Page 373
  58 -Hook the three shafts B-C-E using the special tool F15. Lift the shafts B-C-E at the same time and insert the unit into the half-housing. Use tool F15. RKZC4780 59 -Assemble protection (60) and tighten screws (59) to the prescribed torque. 3 Screw: 50 Nm RKZC4771 30-161 WB97S-5…
• Page 374
  REMOVAL AND INSTALLATION TRANSMISSION 9. AXIS E 9.1 Disassembly RKZ11340 1 — Remove screws (24) and protection (25). RKZC4772 2 — Lift the three shafts B-C-E at the same time. Use tool F15. RKZC4780 30-162 WB97S-5…
• Page 375
  This is a destructive operation for the seal rings. RKZC5730 4 -By neans of an extractor, remove bearings (21) and (1). Remove spacer (20). RKZC5740 5 -Assemble the gear (18). RKZC5750 6 -Remove roller bearing (19). RKZC5760 30-163 WB97S-5…
• Page 376
  Press the Belleville washers (5) and remove retaining ring (2). Use tool F25. RKZC5770 8 -Remove the shim (3) and washers (4). RKZC5780 9 -Remove the Belleville washers (5) and spacer (6). RKZC5790 10 -Remove snap ring (17). RKZC5800 30-164 WB97S-5…
• Page 377
  11 -Remove the thrust plate (16) and clutch kit (15). RKZC5810 12 -Remove brake counter disk (14). RKZC5820 13 -Estract piston (8) using pins (10) as pusher. RKZC5830 14 -Remove the O-rings, inner (7) and outer (9). a Replace the O-rings at each disassembly. RKZC5840 30-165 WB97S-5…
• Page 378
  Number clutch steel plate Nominal clutch plate thickness 2.00±0.05 mm Nominal clutch kit thickness * 33.8–34.0 mm Maximum clutch plate wear (each side) 0.15 mm Maximum clutch kit wear 1.35 mm * Under load of 163 kg RKZC4441 30-166 WB97S-5…
• Page 379
  2 -Insert O-rings (11) on the relative pins (10). RKZC5850 3 -Insert pins (10) on clutch piston (8). RKZC5860 4 -Apply a thin film of grease on O-Rings and position the pins on clutch piston (8) in correspondence with the holes on output shaft. RKZC5870 30-167 WB97S-5…
• Page 380
  6 -Insert brake counter disk (14) on shaft (12) with with tapered edge facing down. RKZC5890 7 -Mount the clutch kit (15) starting with a drive plate (A) followed by a clutch plate (B). RKZC5900 8 -Mount thrust plate (16) on shaft (12). RKZC5910 30-168 WB97S-5…
• Page 381
  REMOVAL AND INSTALLATION TRANSMISSION 9 -Assemble retaining ring (17). RKZC5920 10 -Assemble gear (18). RKZC5930 11 -Assemble roller bearing (19) and spacer (20). RKZC5940 12 -Assemble bearing (21) using special tool F2. RKZC5950 30-169 WB97S-5…
• Page 382
  (4) and locking (2). S=X-S1=X-1.80mm RKZ11350 16 -Pick the (S) shim (3) from the range of shims available. a Choose a shim that will provide a piston travel of 1.70-1.90 mm. SHIM RANGE Shim (mm) RKZ11360 30-170 WB97S-5…
• Page 383
  18 -Insert Belleville washer (5). a Check the Belleville washer (5) orientation. RKZC6000 19 -Mount washer (4) and shims (3) with thickness S defined at sequence 14. RKZC6010 20 -Lower Belleville washers (5) and assemble retaining ring (2). Use tool F25. RKZC5771 30-171 WB97S-5…
• Page 384
  24 -In order to verify the seal of rings (7) and (9) feed the piston chamber with oil at 10 bar and check with a dial gauge located as shown in the photo if the real stroke is included between 1.7 and 1.9 mm. RKZC6040 30-172 WB97S-5…
• Page 385
  Listen to hear the piston moving to unlock the clutch pack. The belleville washers compressing. Try to move the 4WD gear. The 4WD gear must turn freely on the 4WD shaft. If the clutches do not work correctly, disassemble the clutches to find the problem. 30-173 WB97S-5…
• Page 386
  REMOVAL AND INSTALLATION TRANSMISSION 26 -Lift the three shafts B-C-E at the same time and insert into the half-housing. Use tool F15. RKZC4780 26 -Assemble protection (25) and tighten screws (24) to the prescribed torque. 3 Screw: 50 Nm RKZC4772 30-174 WB97S-5…
• Page 387
  Ensure that the mating surfaces are clean and free of dents. [*1] a To aid in mating flywheel and joint, before mating engine and transmission, tighten a threaded shank “A” as guide to the joint: 2 Screw: Loctite 262 3 Screw: 39 Nm RKZC1850 30-175 WB97S-5…

• Page 388: Front Counterweight

  3 -Remove the screws and release the straps (1) and (2) retaining the heating system hoses. RKZC2870 4 -Disconnect the heating system hoses (3) and (4) and remove the tie strap (5) retaining the gearbox oil hoses. a Cap pipes, hoses holes prevent contamination. RKZC2880 30-176 WB97S-5…

• Page 389
  Only if equipped 7 -Release the wiring harness (12) to the compressor (9) from the tie straps and disconnect. RKZC2910 8 -Disconnect wiring harness (13) from thermal starter and disconnect connector (14) from the coolant liquid temperature sensor. RKZC2930 30-177 WB97S-5…
• Page 390
  (18) from the oil pressure sensor. RKTA0811 11 -Disconnect wiring harness (20) and ground wire (21) from generator (19). RKZC2940 12 -Disconnect heating system connector and fuel temperature sensor connector (22) and (23) from the filter holder. RKTA0801 30-178 WB97S-5…
• Page 391
  (24), and apply a slight tension to the chains or cables. RKZC2970 17 -Loosen and remove nuts (25), screws (26) and vibration dampers (27) from front engine mounts. [*1] 18 -Remove the engine (28). 4 Engine: approx. 370 kg 30-179 WB97S-5…
• Page 392
  Check transmission oil level before starting the engine. a Thoroughly check the connectors to ensure that they are properly connected. 1 -Start the engine and let it idle for a couple of minutes. 2 -Stop the engine and check all levels. 30-180 WB97S-5…
• Page 393
  4 -Lift rear window (1) to the top and remove the rear mat. RKZC1870 5 -Take out the screws (2) and remove the platform (3). RKZC1970 6 -Loosen the clamp (4) on the control valve support frame (5) (4 screws). RKZC8090 30-181 WB97S-5…
• Page 394
  9 -Turn the tubes (10) that provide direct connection away fro m control valve and retain their position by temporarily tightening clamp (4) on frame (5). RKZC8091 10 -Disconnect connector (11) from backhoe plate lockout solenoid valve (12). RKZC1951 30-182 WB97S-5…
• Page 395
  1 -Start the machine to circulate the oil; check to ensure that there are no leaks. 2 -Bleed the air from the working equipment circuits. (For details see «20 TESTING AND ADJUSTMENTS»). 3 -Stop the engine, check the hydraulic oil level and top up as necessary. 30-183 WB97S-5…
• Page 396
  (1). Installation • To install, reverse removal procedure. 1 -Run the engine and and steer few times in both direction, using alternatively the 2 wheel steering mode and one of the 4 wheel steering mode. 30-184 WB97S-5…
• Page 397
  4 Wheel: _________ kg 9 -Remove the mud guard (3). [*3] 10 -Disconnect the cardan shaft (5) from the axle (4). [*4] 11 -Disconnect from rear axle support (6) the lubrication hose (7). a Plug the pipe to prevent contamination. 30-185 WB97S-5…
• Page 398
  It should be possible to lower the jack 10 cm in order to disengage the axle from the fulcrum supports. 17 -Remove the screws (6), (9) with washers. 18 -Lower the jack until the axle is disengaged. 19 -Extract the entire axle (4). 4 Front axle: 525 kg 30-186 WB97S-5…
• Page 399
  3 Support screws: 550±55 Nm 2 Screw: Loctite 242 1 -Check the oil level in the tank and start the engine. 2 -Perform a few complete steering manoeuvres in both directions to bleed the air from the steering circuit. 30-187 WB97S-5…
• Page 400
  PAGE INTENTIONALLY LEFT BLANK…
• Page 401
  FRONT AXLE FRONT AXLE Disassembly and assembly 1. Flange group 1.1 Disassembly RKZ11690 1 -Remove the lock ring (1) and flange (2). RKZ11700 2 -Remove seal ring (3). a This is a destructive operation for the seal ring. RKZ11720 30-189 WB97S-5…
• Page 402
  2 O-ring: oil RKZ11710 2 -Assemble the seal ring (3) into the central body with the special tool D19 and a hammer. RKZ11720 3 -Install the flange (2) on the pinion end. Assemble the lock ring (1). RKZ11700 30-190 WB97S-5…
• Page 403
  2.1 Disassembly RKZ11730 1 -Loosen the special screw (1). Remove the rear support (2) from the differential support (8). RKZ11811 2 -Remove the O-Ring (4) from the rear support (2). a Replace the O-ring at each disassembly. RKZ11761 30-191 WB97S-5…
• Page 404
  (8) only if necessary. a Cut the bush (6) with a chisel. a Replace the bush at each disassembly. RKZ11780 6 -Loosen the special screw (15). Remove the front support (13) from the axle housing (9). RKZ11750 30-192 WB97S-5…
• Page 405
  1 -Insert the washer (7) onto the differential support. Heat the bush (6) at 110–120 °C than assemble it to the differential support. a If necessary use a pad and a hammer to assemble the bush (6). RKZ11780 30-193 WB97S-5…
• Page 406
  Insert the O-ring into the seat on the shown side. RKZ11760 7 -Insert the rear support (2) on the differential support (8). a Be careful to avoid damaging the O-ring (4). 8 -Tighten the screw (1). 3 Screw: 200 Nm RKZ11810 30-194 WB97S-5…
• Page 407
  Set the bush (12) with the screw hole aligned with the screw hole in the support (13). 14 -Assemble the screw (15). RKZ11840 15 -Insert the front support (13) on the axle beam. 16 -Tighten the screw (15). 3 Screw: 200 Nm RKZ11750 30-195 WB97S-5…
• Page 408
  2 -Loosen the tie rod locknut (1) and (16) of some turns till it is over the end of the threaded pin. Beat the nut with a hammer to remove the steering arm from the swivel housing. a Replace the nut at each disassembly. RKZC6590 30-196 WB97S-5…
• Page 409
  Insert the rod (21) into the cylinder body (23) and assemble the cylinder heads (19) and (23). RKZ11880 2 -Assemble the ball joints (5) and (12) to the ends of the cylinder rod (21). 3 Ball joints: 300 Nm RKZ11890 30-197 WB97S-5…
• Page 410
  Install the sensor (9) in the middle of the cylinder by means of properly tightened clamps (7) and (8). a The clamps (10) can be completely tightened only when the toe-in adjustment has been carried out. (For details see «10. Toe-in/steering angle»). RKZ11860 30-198 WB97S-5…
• Page 411
  (3) with a wrench. RKZ12390 2 -Remove the planetary carrier (3) from the wheel hub and collect the relative O-Ring (11). 3 -Position the planetary carrier (3) on a workbench and check its wear conditions. RKZC6640 30-199 WB97S-5…
• Page 412
  4 -Fit the thrust washers (8) and (9) to the planetary carrier (3) pins. a The intermediate thrust washers (8) has a hole for centering with the dowel pin (7) fitted on the planetary carrier (3) pins. 5 -Assemble the fastening bolt (10). 3 Screw: 79 Nm RKZC6670 30-200 WB97S-5…
• Page 413
  REMOVAL AND INSTALLATION FRONT AXLE 6 -Assemble a new O-Ring (11) on the wheel hub. 7 -Fit the epicyclic reduction gear assembly to the wheel hub. 8 -Screw the fastening screws (1). 3 Screw: 25 Nm RKZC6680 30-201 WB97S-5…
• Page 414
  (1) removal. a Be careful to avoid damaging the double U-Joint. RKZC6700 2 -Remove the lock ring (1) from the double U-Joint shaft. Collect the double U-Joint shaft washers (2, 3). RKZC6710 30-202 WB97S-5…
• Page 415
  7 -Only if necessary, remove the centering bushes (6) from the wheel carrier with a hammer and the special tool D11. RKZC6740 8 -Remove the wheel hub (11) using levers and a hammer to facilitate the operation. a Collect the bearing cone (9). RKZC6760 30-203 WB97S-5…
• Page 416
  15 -Position the swivel housing (14) on a flat surface and take the seal ring (23) out with a lever. a Replace the seal ring (23) at each disassembly. 16 -Turn the swivel housing and take the bush (24) out, using a suitable drift and a hammer. RKZC6800 30-204 WB97S-5…
• Page 417
  9 -Protect the splined end of the axle shaft by winding it with an adhesive tape to avoid damage to the seal ring (23). Assemble the swivel housing (14) on the axle beam and after assembly, remove completely the adhesive tape. RKZC6790 30-205 WB97S-5…
• Page 418
  Do not lubricate the seal ring (13). RKZC6840 14 -Assemble the bearing cone (12) on the swivel housing (14) end. 15 -Assemble the wheel hub (11) on the swivel housing (14) and fit the bearing cone (9). RKZC6850 30-206 WB97S-5…
• Page 419
  RKZC6870 19 -Force all the hub dowel bushes (6) completely with the special tool D11 and a hammer. Assemble the wheel carrier (7) fastening bolts (5). 3 Screw: 220 Nm RKZC6880 30-207 WB97S-5…
• Page 420
  Insert the lock ring (1) at the end of the splined hub and push it into its housing. a Check that the lock ring (1) is correctly fitted in its seat. 22 -Push the double U-Joint thoroughly. RKZC6711 30-208 WB97S-5…
• Page 421
  2 -Remove the seal rings (5) from the axle beam (1). a Replace the seal rings at each disassembly. 3 -Remove the bush (4) from the axle beam (1) only if the wear conditions require this. a Be careful not to damage the bush seat. RKZ12020 30-209 WB97S-5…
• Page 422
  D17 and a hammer. 5 -Assemble the seal ring (5) on the axle beam with the special tool D18 and a hammer. 2 Sealing rings: POLYMER 400 Tecnolube RKZ12030 6 -Assemble the seal ring (5) as in figure. RKZ12030 30-210 WB97S-5…
• Page 423
  REMOVAL AND INSTALLATION FRONT AXLE 7 -Insert the double U-Joint (6) inside the axle beam (1). a Be careful not to damage the seal ring (5). RKZC6890 30-211 WB97S-5…
• Page 424
  (1). Remove the differential support (1) from the axle housing (15). 2 -support the differential support with a rope or other appropriate means. RKZ12060 3 -Loosen and remove the screws (3) to remove the two ring nut retainers (4). RKZ12070 30-212 WB97S-5…
• Page 425
  Check that the bushes (10) remains in their housings. RKZ12090 7 -Remove out the differential case (7). a The bearing cones (6) and (8) are removed together with the differential housing. a Do not invert the bearing cone if the bearings are not replaced. RKZ12100 30-213 WB97S-5…
• Page 426
  6 -Tighten both ring nuts (5) and (9) with special tools D16, till the backlash is eliminated and the differential bearings are slightly preloaded. a Knock lightly with a soft hammer in order to properly set the bearings in position. RKZ12080 30-214 WB97S-5…
• Page 427
  12 -Once the adjustment of the pinion-ring gear backlash has been carried out, check also that there is a minimum preloading on the differential box bearings. 13 -Repeat the whole sequence of the above mentioned operations till the indicated conditions are reached. RKZ12130 30-215 WB97S-5…
• Page 428
  B — if the total preloading is greater than the given range, unscrew both adjuster ring nuts (5) and (9) by the same measure, keeping the pinion-ring gear backlash value unchanged. RKZ12400 30-216 WB97S-5…
• Page 429
  Check that two dowel bushes (14) are in their seats; the dowel pin (13) must be in their seat on the half collar (11). RKZ12160 22 -Assemble the differential support (1) to the axle housing (15), and tighten the retaining bolts (2). 3 Screw: 169 Nm RKZ12060 30-217 WB97S-5…
• Page 430
  RKZ12170 Movements to correct: 1 -> move the pinion for type X contact adjustment X. 2 -> move the pinion for type X contact adjustment Z. RKZ12430 30-218 WB97S-5…
• Page 431
  2 -Disassemble the differential box in two half boxes (4), (16) complete with the relevant components. a Make alignement marks on the half boxes before separating them. 3 -Disassemble all the components. a Check the operating and wear conditions of the components. RKZ12190 30-219 WB97S-5…
• Page 432
  3 -Position the bevel crown gear (2) on the half box (4). a Clean with care the matching surfaces. 4 -Apply the specified sealant on the thread and tighten the bolts (1). 2 Screw: Loctite 510 3 Screw: 155 Nm RKZC6950 30-220 WB97S-5…
• Page 433
  Take care not to drop the pinion. RKZC6970 3 -Collect the washer (4) and (6), the collapsible spacer (5), the bearing cone (8) and the retaining washer (9). RKZC7000 4 -Remove the bearing cups (3) and (8) using a driver and a hammer. RKZC6980 30-221 WB97S-5…
• Page 434
  1 -Fit the bearings cups (3) and (8) using the special tools D14, D5 and a hammer. RKZC7020 2 -Prepare ithe kit consisting of the special tools called «false pinion» D4 and «false differential box» D3 and D7 and a depth gauge (a4). RKZC7030 30-222 WB97S-5…
• Page 435
  RKZ12250 6 -In order to determine the necessary thickness value (S) between pinion and bearing, subtract the value (S) stamped on pinion head (V = requested distance) from the measured value (X). S= X — V mm RKZ12260 30-223 WB97S-5…
• Page 436
  10 -Insert the bevel pinion (1) unit into the differential support housing (7) and the bearing cone (8) into the pinion end, as shown in figure. Use the special tool D8 and a hammer to drive the bearing (8). RKZ12290 30-224 WB97S-5…
• Page 437
  T P w i t h a torquemeter. a Warning:All preloadings must be measured without seal ring. RKZC6750 30-225 WB97S-5…
• Page 438
  The adjustment is carried out by increasing the ring nut (10) torque gradually, being careful not to exceed. RKZ12150 16 -Once the requested preloading value is achieved, caulk the ring nut (10), using a hammer and a chisel. RKZC7080 30-226 WB97S-5…
• Page 439
  RKZC7090 2 -Measure the distance in mm M between the bars ends with a tapeline. a Keep minimum value, swinging measurement point. RKZC7100 30-227 WB97S-5…
• Page 440
  (1) screwing in and out the two joint tie rods (3) equally till the toe-in is within the requested tolerance. RKZC7110 5 -After adjusting, screw in the lock nuts (2) of the steering arms (1). 3 Nuts: 250 Nm RKZC7120 30-228 WB97S-5…
• Page 441
  (5), locking them with the locknut (4). 3 Lock nut: 150 Nm RKZC7150 4 -Check the position of the stops on the opposite side, both screws must touch the steering stop pads at the same time. RKZ12320 30-229 WB97S-5…
• Page 442
  Do not lock the clamps. 8 -Insert into the clamp (8) the plastic support (9) as shown. RKZC7160 9 -Connect the steering sensor (6) with the special testing system D22. Supply 18 V dc with a battery to the testing system. RKZ12340 30-230 WB97S-5…
• Page 443
  RKZ12360 e — turn the sensor (6) in the shown position; RKZ12370 f — lock the sensor with the clamps (7) and (8). a The clamps must be tightened with the screw head in the shown position. RKZ12380 30-231 WB97S-5…
• Page 444
  Repeat the same operation in the opposite direction (reverse gear). 5 -IF ONE WHEEL DOES NOT ROTATE FREELY IN BOTH DIRECTIONS, then check step by step all assembly operations. Check and see that the brakes are regulated correctly and functioning properly. 30-232 WB97S-5…
• Page 445
  6 -Stop the engine and completely release residual pressures from all the circuits. (For details, see «20 TESTING AND ADJUSTMENTS»). 7 -Loosen and remove nuts (3) and disconnect the parking brake cable (5) from the axle (4). [*2] 30-233 WB97S-5…
• Page 446
  [*4] 11 -Loose nuts (11) (No. 4) until release tightening torque. [*5] RKZC8300 12 -Position a jack “C” and some blocks beneath the axle (4). Raise the jack until the blocks can be forced under the axle arms. 30-234 WB97S-5…
• Page 447
  «20 TESTING AND ADJUSTMENTS»). [*3] a Adjust the stroke of the parking brake lever. (For details, see «20 TESTING AND ADJUSTMENTS»). [*4] 3 Cardan shaft screws: 38 Nm [*5] 2 Nuts: Loctite 242 3 Nuts: _________ Nm 30-235 WB97S-5…
• Page 448
  If necessary, use a hammer. a Don’t damage the threaded pin ends. a Replace the nuts (2), (18) at each disassembly. RKZC6591 2 -Remove the clamps (19) and (22), sensor (21) and receptacle bracket (20) from the cylinder (12). RKZ12450 30-236 WB97S-5…
• Page 449
  1 -Assemble new seals and O-Rings (23, 24, 26, 28, 30 and 31) on the cylinder heads (29), on the piston (27) and on the cylinder body (25). Insert the rod (27) into the cylinder (25) then assemble the cylinder head (29). RKZ12481 30-237 WB97S-5…
• Page 450
  Screw the tie rod (7) so that its ball joint can be inserted into the swivel housing (1) arm. a It’s important to unscrew the lock nut (8) to carry out this operation. 8 -Repeat the operation for the opposite side. RKZC7220 30-238 WB97S-5…
• Page 451
  12 -Assemble the sensor (21) and receptacle bracket (20) with the clamps (19) and (22) to the steering cylinder (12). RKZ12510 a The clamps can be completely tightened only when the toe-in adjustment has been carried out. (For details, see «10.1 Toe-in adjustment»). RKZC7250 30-239 WB97S-5…
• Page 452
  REAR AXLE 2. Epicyclic reduction gear group 2.1 Disassembly RKZ11910 1 -Drain the oil completely from the epicyclic reduction gear. RKZC6630 2 -Unscrew and remove both fastening screws (1) of the planetary carrier (3) with a wrench. RKZ12390 30-240 WB97S-5…
• Page 453
  3 -Insert the needles (5), the thrust washer (4) and the needles (5) in the epicyclic gears (6). a Grease well the needles (5). 4 -Insert the thrust washer (4) and the assembled epicyclic gears (6) in the planetary carrier (3) pins. RKZC6660 30-241 WB97S-5…
• Page 454
  Screw the fastening screws (1). 3 Screw: 25 Nm RKZC6680 8 -Top up the oil on the wheel hub. (For details, see _______). 9 -Fit the plug (2) on the epicyclic reduction gear (3). 3 Plug: 60 Nm RKZC6690 30-242 WB97S-5…
• Page 455
  (1) removal. a Do not damage the double U-Joint. RKZC6700 2 -Remove the lock ring (1) from the double U-Joint shaft. Collect the double U-Joint shaft washers (2, 3). RKZC6710 30-243 WB97S-5…
• Page 456
  Only if necessary, remove the centering bushes (6) from the wheel carrier with a hammer and the special tool E7. RKZC6740 6 -Remove the wheel hub (11) using levers and a hammer to facilitate the operation. a Collect the bearing cone (9). RKZC6760 30-244 WB97S-5…
• Page 457
  12 -Position the swivel housing (14) on a flat surface and take the seal ring (24) out with a lever. a Replace the seal ring at each disassembly. 13 -Turn the swivel housing and take the bush (25) out, using a suitable drift and a hammer. RKZC6801 30-245 WB97S-5…
• Page 458
  Protect the splined end of the axle shaft by winding it with an adhesive tape to avoid damage to the seal ring (24). Assemble the swivel housing (14) on the axle beam and after assembly, remove completely the adhesive tape. RKZC6790 30-246 WB97S-5…
• Page 459
  Do not lubricate the seal ring (13). RKZC6841 8 -Assemble the bearing cone (12) on the swivel housing (14) end. Assemble the wheel hub (11) on the swivel housing (14) and fit the bearing cone (9). RKZC6850 30-247 WB97S-5…
• Page 460
  RKZC6870 12 -Force all the hub dowel bushes (6) completely with the special tool E7 and a hammer. Assemble the wheel carrier (7) fastening bolts (5). 3 Screw: 230 Nm RKZC6881 30-248 WB97S-5…
• Page 461
  Insert the lock ring (1) at the end of the splined hub and push it into its housing. a Check that the lock ring (1) is correctly fitted in its seat. 15 -Push the double U-Joint thoroughly. RKZC6712 30-249 WB97S-5…
• Page 462
  4. Axle beam group 4.1 Disassembly RKZ12540 1 — Drain the oil completely from the axle. 2 -Remove the screws (13). Unscrew the oil pipe nuts (11). RKZ12550 3 -Remove the oil pipe (12). Collect the washer (10). RKZ12560 30-250 WB97S-5…
• Page 463
  6 -Remove the fastening screws (6). RKZC7830 7 -Remove the beam trumpet (7) and collect the O-Ring (8). a Once the beam trumpet has been removed, the brake group is free. RKZ12580 30-251 WB97S-5…
• Page 464
  E20 and a hammer. Assemble the seal ring (2) on the axle beam (7) with the special tool E21 and a hammer. See: next step. a Grease carefully the seal rings 2 Seal rings: POLYMER 400 Tecnolube RKZ12600 30-252 WB97S-5…
• Page 465
  Be careful not to damage the O-ring (8). RKZ12630 16 -Assemble the fastening screws (6). Tighten the fastening screws (6) to the requested torque according to the shown sequence. 3 Screw: see next step RKZ12640 30-253 WB97S-5…
• Page 466
  Be careful not to damage the seal rings. RKZC6891 19 -Position the washer (10) on the beam trumpet (7). RKZ12561 20 -Tighten the screws (13). Tighten the oil pipe nuts (11). 3 Nuts: 60 Nm 21 -Fill the axle with specified oil. RKZ12660 30-254 WB97S-5…
• Page 467
  (7) and brake plates (8), brake disk carrier gear (9), brake counterplates (10) and plates (11). a Remember the position of the the brake disk carrier, it must be reassembled in the same position. RKZ12690 RKZ12680 30-255 WB97S-5…
• Page 468
  If necessary, blow in air through the brake oil input hole to eject the piston, using the minimum pressure. k Possible swift ejection of the piston. RKZ12720 RKZ12680 6 -Remove the O-Rings (2) and (3) from the brake piston (4). RKZ12730 RKZ12680 30-256 WB97S-5…
• Page 469
  (5). a Do not damage the O-rings. 4 -With a lever anchored to an eyebolt, exert a pressure just enough to insert the piston into the brake flange. RKZC7850 30-257 WB97S-5…
• Page 470
  (6). RKZC7290 7 -Assemble the bush, the washer and the screw of the self-adjust kit (5). RKZC7300 8 -Screw the fastening screws of both kits and tighten them to the prescribed torque 3 Screw: 10 Nm RKZC7310 30-258 WB97S-5…
• Page 471
  (7 and 10) do not present any sign of burning; on the contrary, replace them. Furthermore check brake plate wear and if necessary replace it. a If new brake plate are installed, before assembling they should be dipped in the prescribed oil 2 Plate: Axle oil RKZC7340 30-259 WB97S-5…
• Page 472
  RKZ12750 RKZ12680 a This is the correct position of the teeth on the external surfaces of the brake disk carrier (9). RKZ12760 RKZ12680 14 -Reassemble the beam trumpet and half-shaft. (For details, see «4. Axle beam group»). RKZ12681 30-260 WB97S-5…
• Page 473
  1 — Remove the beam trumpet group. (For details see «4. Axle beam group»). RKZ12780 2 -Remove from the brake flange (18): brake counter plates and brake plates and brake disk carrier. For details see «5. Brake group»). RKZ12790 30-261 WB97S-5…
• Page 474
  6 -Put an alignment mark on the lever (3) and shaft (8) for use during installation and to distinguish between right and left control (for example: you can put two marks on the right and only one on the left). RKZC7790 30-262 WB97S-5…
• Page 475
  REAR AXLE 7 -Loosen the lever (3) to release the tension on the spring (4). RKZC7800 8 -Remove the lever (3). RKZC7810 9 -Remove the spring (4). RKZC7820 10 -Remove the washer (5) and the spacer (6). RKZC7860 30-263 WB97S-5…
• Page 476
  (9) align with the top of the roll pin, for use during assembly. As already done for the control lever, distinguish between right operation side and left one. RKZC8350 14 -Free the cam (10) unscrewing the screw (9). RKZC7400 30-264 WB97S-5…
• Page 477
  15 -Unscrew the shaft screw (12), being careful the steel ball (11) does not get lost RKZC7410 16 -Collect the steel ball (11). RKZC7420 17 -Remove the O-Ring (7). RKZC7430 18 -Remove the shaft (8) and collect the cam (10). RKZC7440 30-265 WB97S-5…
• Page 478
  4 -Assemble a new screw (9) to the shaft (8). a If you remove the screw (9) apply the sealant on the thread before reassemble it. 2 Screw: Loctite 542 RKZC7470 5 -Tighten the screw (9). 3 Screw: 10 Nm RKZC7480 30-266 WB97S-5…
• Page 479
  8 -Tighten the screw (12). 3 Screw: 25 Nm 2 Screw: Loctite 270 RKZC7490 9 -Insert a new O-ring (7) on the shaft. RKZC7500 10 -Position the supporting bracket (14). 11 -Assemble the fastening screws (16) and (17). RKZC7510 30-267 WB97S-5…
• Page 480
  This could cause the uncorrect positioning of the discs and of the self-adjust groups with the consequent reduction of brake efficiency. a Align the holes on the friction discs; such alignment is necessary to grant the correct oil flow inside the brake group. RKZC7550 30-268 WB97S-5…
• Page 481
  • Repeat the checking operation and the further adjustment till the requested conditions are reached. 16 -Release the brake control levers (3), assemble the fastening screws (1) and the relative washers (2). RKZC7560 30-269 WB97S-5…
• Page 482
  (For detail see the point 15). ¸ RKZ12740 20 -Assemble the nuts (16) on the adjusting screws (13). Assemble the adjusting screws (13) on the brackets (14) and screw in them, till they are in contact with the levers (3). RKZC7590 30-270 WB97S-5…
• Page 483
  315 – 300 mm (about 3 mm between lever and bracket will remain). ¸ RKZ12820 22 -If the screw is not perpendicular to the side surface of the lever, adjust its position by moving the supporting bracket (14). RKZ12830 30-271 WB97S-5…
• Page 484
  7. Differential support group 7.1 Disassembly RKZ12840 1 -Remove the brake disks and counterdisks. (For details see «5. Brake group»). RKZ12790 2 -Secure the brake cylinder (5) to a hoist with ropes or safety belts. Remove the fastening screw (4). RKZ12850 30-272 WB97S-5…
• Page 485
  5 -Remove out the differential case (8). RKZ12870 6 -Remove the O-Ring (9) from the central body (10). RKZ12880 7 -Unscrew and remove the screw (2) and the ring nut retainer (1) from the brake cylinder (5). RKZ12890 30-273 WB97S-5…
• Page 486
  Do not invert the bearing cups if the bearings are not replaced. RKZ12910 7.2 Assembly Assemble the pinion group before assemble the differential support group. (For details see «9. Pinion group»). RKZ12920 1 -Lubricate and assemble new O-Ring (9) on every side of the central body (10). RKZ12930 30-274 WB97S-5…
• Page 487
  RKZC7610 6 -Assemble the fastening screws (4). Tighten the fastening screws. 3 Screw: 80 Nm 7 -Assemble in the shown position a fastening screws M16 x 130 mm to torque of 80 Nm on both sides. RKZ12950 30-275 WB97S-5…
• Page 488
  Measure the backlash between pinion and crown. Check if the measured backlash value is within the prescribed range: 0.18 –0.23 mm 12 -Set the backlash by turning the adjusting ring nuts (10) using the wrench E15. RKZC7630 30-276 WB97S-5…
• Page 489
  The measured value should be within the following range: Tm= (Pm+12.4) – (Pm+18.6) N where Pm is the effectively preloading measured on the special tool E23 (gauge diameter Dm= 104.4 mm). (For details see «9. Pinion group» — «9.2 Assembly» at point 14). RKZ12990 30-277 WB97S-5…
• Page 490
  (2) and their respective screws (1) 3 Screw: 13 Nm a Turn the adjuster ring nuts (3) slightly in order to allow the assembly. 20 -Remove the fastening screws M16 x 130 mm on both sides RKZ13010 30-278 WB97S-5…
• Page 491
  RKZ12170 Movements to correct: 1 -> move the pinion for type X contact adjustment 2 -> move the pinion for type Z contact adjustment. RKZ12430 30-279 WB97S-5…
• Page 492
  Mark the two half boxes before disjoining them, in order to reassemble them in the same position as the one before disassembling. 3 -Disassemble all the components. Check the operating and wear conditions of the components. RKZ13030 30-280 WB97S-5…
• Page 493
  1 -Assemble the bushes (14) to the half housings (4) and (12) with the special tool E14 and a hammer. RKZ13050 2 -Assemble the bearing cones (3) and (13) on the half housings (4) and (12), using the special tool E3 and a hammer. RKZ12211 30-281 WB97S-5…
• Page 494
  5 -Position the bevel crown gear (2) on the half box (4). a Check dowel pins (15) position. 6 -Apply the specified sealant on the thread and tighten the bolts (1). 3 Screw: 155 Nm 2 Screw: Loctite 270 RKZC7840 30-282 WB97S-5…
• Page 495
  1 -Remove the lock ring (17). Remove the flange (16) and the seal ring (15). a Replace the seal ring at each disassembly. RKZ13070 2 -Remove the O-ring (14), the spacer (13), the O-ring (12) and the washer (11). RKZ13080 30-283 WB97S-5…
• Page 496
  The collapsible spacer (5) must be replaced when assembling the group. RKZC7680 6 -Check the bearing cups wear condition. If bearings replacement is necessary, remove bearing cups (3) and (8) from central body with a drift and a hammer. RKZC7690 30-284 WB97S-5…
• Page 497
  Tighten the ring nut (10) to eliminate the backlash. RKZC7710 3 -Check the correct positioning of the right and left brake cylinder and differential housing supports, using the reference marks on them and on the central body (7). Assemble the differential housing supports. RKZC7720 30-285 WB97S-5…
• Page 498
  6 -From the value “X” deduct the value “V” (stamped on the pinion head) to get the value “S”. S= X — V mm RKZ12260 7 -Select the shim (2) of thickness value (S) among the range of available shims. RKZ12270 30-286 WB97S-5…
• Page 499
  12 -When you check the preloading, it is advisable to beat slightly both pinion (1) ends with a soft hammer, so as to RKZC7760 help setting the bearings (3) and (8). 30-287 WB97S-5…
• Page 500
  TP with a torquemeter and the special wrench E5. a All preloadings should be measured without the seal ring. RKZC7760 17 -The measured value TP must be within the following range: TP= 1.6–2.4 Nm RKZ13130 30-288 WB97S-5…
• Page 501
  19 -Assemble the washer (11), the O-ring (12), the spacer (13), the O-ring (14). RKZ13080 20 -Assemble the new seal ring (15) using the special tool E22 and a hammer. Assemble the flange (16). Lock the whole with the snap ring (17). RKZ13070 30-289 WB97S-5…
• Page 502
  RKZC7090 2 -Measure the distance in mm M between the bars ends with a tapeline. a Keep minimum value, swinging measurement point. RKZC7100 30-290 WB97S-5…
• Page 503
  (1) screwing in and out the two joint tie rods (3) equally till the toe-in is within the requested tolerance. RKZC7110 6 -After adjusting, screw in the lock nuts (2) of the steering arms (1). 3 Nuts: 250 Nm RKZC7120 30-291 WB97S-5…
• Page 504
  3 Nuts: 150 Nm a Apply the prescribed sealant on the thread of the screws. RKZC7151 k Check the position of the stops on the opposite side, both screws must touch the steering stop pads at the same time. RKZ12320 30-292 WB97S-5…
• Page 505
  Do not lock the clamps. 5 -Insert into the clamp (8) the plastic support (7) as shown. RKZC7160 6 -Connect the steering sensor (6) with the special testing system E25. Supply 18 V dc with a battery to the testing system. RKZ12340 30-293 WB97S-5…
• Page 506
  «P2» with tolerance ±1mm. RKZ13170 5 -turn the sensor (6) in the shown position; RKZ13180 6 -lock the sensor with the clamps (8) and (9). a The clamps must be tightened with the screw head in the shown position. RKZ13190 30-294 WB97S-5…
• Page 507
  Repeat the same operation in the opposite direction (reverse gear). 5 -IF ONE WHEEL DOES NOT ROTATE FREELY IN BOTH DIRECTIONS, then check step by step all assembly operations. Check and see that the brakes are regulated correctly and functioning properly. 30-295 WB97S-5…
• Page 508
  PAGE INTENTIONALLY LEFT BLANK…
• Page 509
  Check to ensure that hoses are marked; scribble match marks if necessary. [*1] a Cap the hoses and holes to prevent contamination. RKZC2140 4 -Loosen and remove screws (6) and remove the complete PPC valve (4). RKZC2150 30-297 WB97S-5…
• Page 510
  Carefully inspect the hoses for the proper position when connecting them. ( F o r d e t a i l s , s e e » 1 0 S T R U C T U R E A N D FUNCTION»). RKZ10760 30-298 WB97S-5…
• Page 511
  5 -Extract pin (6) to expose piston eye and safety rod (9). 6 -Remove rod. RKZC2180 7 -Lower cylinder (10) until it rests on blocks “B”. 8 -Start the engine to retract the piston. [*1] [*2] k Stop the engine and eliminate residual pressure. RKZC2190 30-299 WB97S-5…
• Page 512
  Do not insert fingers into the holes to check alignment. [*2] 2 Internal bushing: ASL800050 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-300 WB97S-5…
• Page 513
  Cap the hoses and holes to prevent contamination. RKZC2250 8 -Remove the snap-ring (13) and the spacer (14). 9 -Remove cylinder (3). 4 Tilt cylinder; approx 35 kg a Recover spacer (15) between frame and cylinder. RKZC2260 30-301 WB97S-5…
• Page 514
  (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. Machines equipped with return-to-dig only 2 -Check sensor position and adjust as necessary. (For details, see «20 TESTING AND ADJUSTMENTS»). 30-302 WB97S-5…

• Page 515: Boom

  To install, reverse removal procedure. [*1] k 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] 2 Internal bushing: ASL800050 30-303 WB97S-5…

• Page 516
  (3) of the boom (4). Close the front hood. RKZC2290 4 -Put a sling round the boom (4) as shown in the figure, and attach it to the hoisting tackle. Apply a slight tension to the cables. RKZC2280 30-304 WB97S-5…
• Page 517
  Do not insert fingers into the holes to check alignment. [*2] 2 Internal bushing: ASL800050 • Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-305 WB97S-5…
• Page 518
  (6). RKZB6823 9 -Disconnect the connector (9). 10 -Ensure that the hoses are marked (10), then disconnect the hoses from the PPC valve. [*1] a Mark the hoses, if necessary. a Plug all pipes/hoses to prevent contamination. RKZB6831 30-306 WB97S-5…
• Page 519
  Carefully inspect the hoses for the proper position when connecting them. ( F o r d e t a i l s , s e e » 1 0 S T R U C T U R E A N D FUNCTION»). 30-307 WB97S-5…
• Page 520
  2 -Remove the rear mat (1). RKZC6400 3 -Take out the screws (2) and remove the platform (3). RKZC6410 4 -Fully raise the boot (4). 5 -Loosen and remove the screws (5) that retain the PPC valve and armrest (6). RKZB6814 30-308 WB97S-5…
• Page 521
  (15). 11 -Remove the entire lever assembly (15). RKZB6861 12 -Loosen the nut (16) and disengage the sheath (18) from the support (17). 13 -Disconnect the cable (20) from the lower locking lever (19). RKZB6871 30-309 WB97S-5…
• Page 522
  Installation and adjusting • To install, reverse removal procedure. 1 -Using the tensioner (22), adjust cable tension to obtain safe locking and friction-free unlocking of the column. 2 -Lock the nut while holding the tensioner into position (21). RKZB7071 30-310 WB97S-5…
• Page 523
  2 -Remove the rear mat (1). RKZB6772 3 -Take out the screws (2) and remove the platform (3). RKZC6410 4 -Fully loosen the stop knob (4) of the PPC valve support (5) you are working on. RKZC6420 30-311 WB97S-5…
• Page 524
  Raise until the gas spring (16) becomes fully disengaged. RKZB6853 11- Loosen the nut (17) and remove the snap ring (18) and washer (19). 12- Disconnect the gas spring (16) and remove it. Installation • To install, reverse removal procedure. RKZB7081 30-312 WB97S-5…
• Page 525
  5 -Mark and disconnnect all hoses (5). a Cap pipes, hoses holes prevent contamination. 6 -Loosen and remove two screws (6) and washers; remove the solenoid valve group (7) together with the accumulator. RKZC2323 30-313 WB97S-5…
• Page 526
  REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment) Installation • To install, reverse removal procedure. 1 -Start the engine and perform all possible manoeuvres to eliminate the air from all circuits. 30-314 WB97S-5…
• Page 527
  5 -Remove pins (4) and disconnect tie rod (6) from boom retaining lever (5). RKZC2340 6 -Loosen and remove the screws, remove the group (7) controlling the levers (5) and position it aside. RKZC2350 7 -Remove snap rings (8), shims (9), and levers (5). RKZC2360 30-315 WB97S-5…
• Page 528
  Do not engage the hoses with the band. 11 -Pull out pin (13) and recover spacers (14). [*1] [*2] 12 -Start the engine and retract the piston. Stop the engine and release residual pressures. 13 -Remove snap ring (15). RKZC2400 30-316 WB97S-5…
• Page 529
  Do not insert fingers into the holes to check alignment. [*2] 2 Internal bushing: ASL800050 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-317 WB97S-5…
• Page 530
  8 -Remove the snap ring (6) retaining the cylinder fulcrum pin (7) and the screw (8) retaining the piston pin (9). RKZC2440 9 -Disconnect hoses (10) and (11) from cylinder (4). a Cap pipes, hoses holes prevent contamination. RKZC2450 30-318 WB97S-5…
• Page 531
  Do not insert fingers into the holes to check alignment. [*2] 2 Internal bushing: ASL800050 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-319 WB97S-5…
• Page 532
  Do not insert fingers into the holes to check alignment. RKZA7951 [*2] 2 Internal bushing: ASL800050 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-320 WB97S-5…
• Page 533
  4 -Disconnect from cylinder (5) the pipes (4) and plug them to avoid impurity entry. a Plug also the union to avoid the movement of piston. RKZC2500 5 -Take off snap ring (6) and slide pin (7) out until cylinder [*1] [*2] (5) is disengaged. RKZC2510 30-321 WB97S-5…
• Page 534
  Do not insert fingers into the holes to check alignment. [*2] 2 Internal bushing: ASL800050 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-322 WB97S-5…
• Page 535
  2 -Loosen and remove screws (1) and release hose clamp (2). RKZC2540 3 -Loosen and remove the four screws (3) and washers. [*1] RKZC2550 4 -Lift the hoses (4) to the backhoe cylinders and retain them in position with a band. RKZC2560 30-323 WB97S-5…
• Page 536
  RKZC2580 7 -Take out the screws (8) and remove the pins (9). 8 -Rotate the cylinders to disengage the piston heads from the swing bracket (10) and remove the cylinders (6). 4 Cylinder: approx. 34 kg RKZC2590 30-324 WB97S-5…
• Page 537
  Do not insert fingers into the holes to check alignment. [*3] 2 Internal bushing: ASL800050 4 -Bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. RKZC2591 30-325 WB97S-5…
• Page 538
  Stop the engine and release residual pressures. RKZC2620 7 -Disconnect the tubes (7) and (8). a Cap pipes, hoses holes prevent contamination. 8 -Take off the snap ring (9) and remove the pin (10). [*1] [*2] RKZC2630 30-326 WB97S-5…
• Page 539
  Tighten the locknut completely, then release it half a turn. 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-327 WB97S-5…
• Page 540
  5 -Loosen and remove nut (7) and remove tie rod (8). RKZC2640 6 -Disconnect feed hose (9). a Cap the hose and hole to prevent contamination. 7 -Loosen and remove the screws (10) and the cylinder (11). RKZC2650 30-328 WB97S-5…
• Page 541
  Installation • To install, reverse removal procedure. 1 -Start the engine and operate the cylinder several times to eliminate the air from the circuit. 2 -Lift the boom and check to ensure that the safety connection is correct. 30-329 WB97S-5…
• Page 542
  — Jig arm: Key 46 mm q Remove safety dowel first RKZ11440 Q Lift calking first 6 -Slide piston (6) and head (2) off rod (5). a Arm only: Note down direction of installation of brake bushing (5a). RKZ11620 30-330 WB97S-5…
• Page 543
  10 -Remove O-ring (12) with anti-extrusion ring, O-ring (13), snap ring (14) and scraper ring (15) from head. 11 -Remove gaskets (16) and (17). a Note down direction fo installation of anti-extrusion ring and position of ring (12). 12 -Boom head Remove bushing (18). RKZ11460 30-331 WB97S-5…
• Page 544
  1 –Using tool U4 expand seal (11) and fit it on the piston. 2 -Calibrate seal (11) using calibrator U5. 3 -Boom cylinder only. Install anti-extrusion rings and O-ring (12). 4 -Assemble the guide ring (10). RKZ11530 RKZ11470 30-332 WB97S-5…
• Page 545
  3 -Boom cylinder only. Thread piston (5) onto rod (6) and lock into position with a wrench U3 with torque amplifier. 3 Piston: 280–290 kgm 4 -Install safety dowel (19) and tighten until snug. 2 Dowel: Loctite 542 RKZ11590 30-333 WB97S-5…
• Page 546
  Jig arm: 55±5.5 kgm RKZ11641 Boom: 100±10 kgm E Loosen down to 0 kg, tighten up to 40 kgm, and then tighten angle-wise for 3.5–4.5 mm 3 -When assembly is complete, plug union fitting holes to prevent contamination. RKZ11420 30-334 WB97S-5…
• Page 547
  Place a receptacle to collect the oil. RKZ11430 4 -Position the complete piston (3) to equipment U1. RKZ11540 5 -Remove safety screw (4) (M8x1.25). a If removal is awkward, tighten screw until snug and work thread with a tap. RKZ11450 30-335 WB97S-5…
• Page 548
  8 -Remove guide ring (7), seal (8), O-ring (9) and their respective anti-extrusion rings from piston. RKZ11650 9 -Remove the snap-ring (10), the spacer (11) and the ring (12). a Note down orientation of ring (12) and position of spacer (11). RKZ11660 30-336 WB97S-5…
• Page 549
  10 -Remove O-ring (13) with anti-extrusion ring, O-ring (14), snap ring (15) and scraper ring (16) from head. 11 -Remove gaskets (17) and (18). a Note down direction fo installation of anti-extrusion ring and position of ring (13). 12 -Remove the bushing (19). RKZ11511 30-337 WB97S-5…
• Page 550
  2 -Calibrate seal (8) using calibrator U5. 3 -Install anti-extrusion rings and O-ring (9). 4 -Assemble the guide ring (7). 5 -Install ring (12), spacer (11) and snap ring (10) to rod (5). a Pay attention to the orientation of ring (12). RKZ11531 RKZ11500 30-338 WB97S-5…
• Page 551
  Hole Ø 6.8 – depth 31 mm Thread: M8x1.25 — depth 25 mm 4 -Remove any dirt or shaving and install the safety screw (4). 2 Screw: Loctite 262 3 Screw: 13.25±1.45 Nm 5 -Calk screw (4) in four locations. RKZ11550 RKZ11560 RKZ11570 30-339 WB97S-5…
• Page 552
  (1). 2 -Position cylinder (1) to equipment U1 and tighten head (2) using tool U2; tighten to torque. 3 Head: 785±78.5 Nm a When assembly is complete, plug cylinder union fittings to prevent contamination. RKZ11420 30-340 WB97S-5…
• Page 553
  8 -Release boom and arm cylinder hoses and bucket cylinder hoses from the three hose clamps (6). 9 -Disconnect hoses (7) and (8) from boom and arm cylinder. a Mark the pipes to avoid exchanging them during installation. a Plug all pipes/hoses to prevent contamination. 30-341 WB97S-5…
• Page 554
  To install, reverse removal procedure. 1 -Start the engine and bleed the air from all circuits. (For details, see «20 TESTING AND ADJUSTMENTS»). 2 -Stop the engine, check the level in the tank and, if necessary, top it up. 30-342 WB97S-5…
• Page 555
  To install, reverse removal procedure. [*1] k 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] 2 Internal bushing: ASL800050 30-343 WB97S-5…
• Page 556
  Do not insert fingers into the holes to check alignment. [*2] 2 Internal bushing: ASL800050 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-344 WB97S-5…
• Page 557
  Tighten the locknut completely, then release it half a turn. [*3] k 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. RKZC2740 30-345 WB97S-5…
• Page 558
  To install, reverse removal procedure. [*1] k When aligning the positions between hole and pin, do not insert fingers into the holes to check on alignment. [*2] 2 Internal bushing: ASL800050 a Tighten the locknut completely, then release it half a turn. 30-346 WB97S-5…
• Page 559
  [*1] k When aligning the positions between hole and pin, do not insert fingers into the holes to check on alignment. [*2] 2 Internal bushing: ASL800050 [*3] a Tighten the locknut completely, then release it half a turn. 30-347 WB97S-5…
• Page 560
  To install, reverse removal procedure. [*1] 2 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 TESTING AND ADJUSTMENTS»). RKZA8030 30-348 WB97S-5…
• Page 561
  2 Internal bushing: ASL800050 RKZC2750 [*3] a Insert the shims. 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. RKZ01330 30-349 WB97S-5…
• Page 562
  (8). [*1] RKZC2780 7 -Put a sling round the backframe (5) and apply slight tension to the cables. 8 -Remove external nuts (6), washers and screws (7). [*1] 9 -Remove slide block (9) and spacers (10). RKZC2790 30-350 WB97S-5…
• Page 563
  2 Nuts: Loctite 262 3 Nuts: 980 ± 98 Nm 1 -Start the engine and bleed the air from the cylinders. (For details, see «20 TESTING AND ADJUSTMENTS»). a After bleeding the air, check the oil level in the tank. 30-351 WB97S-5…
• Page 564
  Use a rag or non-slip gloves to accompany the piston as it is being ejected. RKZC2820 REPLACING SEALS 1 -Remove seal (8), guide ring (9), and seal (10). a Note down direction of installation of seal (10). RKZC2830 30-352 WB97S-5…
• Page 565
  3 -Lubricate the seals, guide ring, and piston seat. 2 Seal and seat: Hydraulic oil: RKZC2840 4 -Apply a band “A” for seal compression and install piston (6). RKZC2850 Installation • To install, reverse removal procedure. 30-353 WB97S-5…

• Page 567: Standard Maintenance

  40 STANDARD MAINTENANCE TRANSMISSION………….2 SHOVEL CYLINDERS ……….32 FRONT AXLE…………..5 BACKHOE CYLINDERS ……….34 REAR AXLE …………..8 FRONT WORKING EQUIPMENT …….. 38 HYDRAULIC PUMP …………12 SWING BRACKET …………40 CONTROL VALVE …………14 BACKHOE WORKING EQUIPMENT ……42 PPC VALVES…………..30 40-1 WB97S-5…

• Page 568
  3 23 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 23 Nm 3 30 Nm 3 30 Nm RKZ11670 40-2 WB97S-5…
• Page 569
  STANDARD MAINTENANCE TRANSMISSION 2 Loctite 510 3 50 Nm 2 Loctite 510 3 50 Nm 3 139 Nm 3 139 Nm 3 50 Nm 2 Loctite 542 3 50 Nm 2 Loctite 542 RKZ11410 40-3 WB97S-5…
• Page 570
  STANDARD MAINTENANCE TRANSMISSION 3 23 Nm 3 30 Nm 3 50 Nm 3 23 Nm 3 50 Nm RKZ11680 40-4 WB97S-5…
• Page 571
  Standard clearance Clearance limit Backlash of crown wheel and pinion 0.20–0.30 – Pinion rotation force (without sealing ring) 92–137 Nm Adjust As measured on Ø 34.8 Pinion-crown rotation force (P+32)–(P+47)N (without sealing ring) As measured on Ø 34.8 40-5 WB97S-5…
• Page 572
  STANDARD MAINTENANCE FRONT AXLE Planetary — Joint 3 70 Nm 2 Loctite 270 3 300 Nm 3 8 Nm 3 79 Nm 3 220 Nm 3 25 Nm 3 60 Nm 3 8 Nm RKZ13410 40-6 WB97S-5…
• Page 573
  3 280 Nm 3 150 Nm RKZ13421 Unit: mm Check item Criteria Remedy Tolerance Replace Standard Standard Clearance Clearance between bushing b u s h i n g size clearance limit Shaft Hole and pin – – – – – 40-7 WB97S-5…
• Page 574
  Standard clearance Clearance limit Backlash of crown wheel and pinion 0.18–0.23 – Pinion rotation force (without sealing ring) 92–137 Nm Adjust As measured on Ø 34.8 Pinion-crown rotation force (P+37.2)–(P+55.9)N (without sealing ring) As measured on Ø 34.8 40-8 WB97S-5…
• Page 575
  STANDARD MAINTENANCE REAR AXLE Planetary 3 70 Nm 2 Loctite 270 3 300 Nm 3 79 Nm 3 8 Nm 3 230 Nm 3 60 Nm 3 25 Nm 3 300 Nm 3 8 Nm RKZ13440 40-9 WB97S-5…
• Page 576
  Brakes 3 190 Nm 3 12 Nm 3 10 Nm 3 10 Nm 3 35 Nm 3 25 Nm 2 Loctite 270 RKZ13451 Unit: mm Check item Criteria Remedy Standard thickness Min. thickness Disc thickness Replace 4.83 4.53 40-10 WB97S-5…
• Page 577
  STANDARD MAINTENANCE REAR AXLE Steering unit cylinder 3 23 Nm 3 250 Nm 3 800 Nm 3 300 Nm 3 150 Nm 3 280 Nm 2 Loctite 270 40-11 WB97S-5…
• Page 578
  STANDARD MAINTENANCE HYDRAULIC PUMP HYDRAULIC PUMP 3 19.6–24.5 Nm 3 157–196 Nm 3 68.6–83.4 Nm 3 27.4–34.3 Nm 3 7.8–9.8 Nm 3 68.6–83.4 Nm 3 19.6–27.4 Nm 3 11.8–14.7 Nm RKZ10440 40-12 WB97S-5…
• Page 579
  STANDARD MAINTENANCE HYDRAULIC PUMP 3 27.4–34.3 Nm 3 27.4–34.3 Nm 3 27.4–34.3 Nm 3 27.4–34.3 Nm 40-13 WB97S-5…
• Page 580
  STANDARD MAINTENANCE CONTROL VALVE CONTROL VALVE 8-SPOOL VERSION 3 9.8–12.7 Nm Komatsu Ltd. 3 9.8–12.7 Nm 3 9.8–12.7 Nm 3 9.8–12.7 Nm 3 58.8–73.5 Nm 3 29.4–34.3 Nm RKZ09062 40-14 WB97S-5…
• Page 581
  STANDARD MAINTENANCE CONTROL VALVE RKZ09071 40-15 WB97S-5…
• Page 582
  STANDARD MAINTENANCE CONTROL VALVE 3 49–58.8 Nm 3 39.2–49 Nm 39.2–49 Nm 3 39.2–49 Nm 39.2–49 Nm 3 39.2–49 Nm RKZ09080 40-16 WB97S-5…
• Page 583
  Spool return spring – (shovel arm 19.4×17.6 14.7N 11.8N float control) Spool return spring (shovel arm 38.7×18 27.6 355.7N – 284.6N lower control) – Priority valve spring 56.8×15.2 48.5 29.6N 23.7N – 10 Unloading valve spring 25.5×19.3 121.5N 97.2N 40-17 WB97S-5…
• Page 584
  STANDARD MAINTENANCE CONTROL VALVE 3 117.6–161.8 Nm 3 19.6–24.5 Nm 3 14.7–19.6 Nm 3 24.5–34.3 Nm 3 14.7–19.6 Nm 3 24.5–34.3 Nm RKZ08341 40-18 WB97S-5…
• Page 585
  Pressure compensation valve – spring. 20×8.4 4.32N 3.45N (boom, shovel arm) – Check valve spring 27.2×6.9 4.70N 3.76N – Check valve spring 27.2×6.9 3.92N 3.14N Check valve spring 21.9×5 15.8 1.96N – 1.57N Check valve spring 11.3×4.3 1.72N – 1.38N 40-19 WB97S-5…
• Page 586
  Øe Spool return spring Replace 18.0×18 17.5 39.2N – 31.4N (Outrigger control) spring Spool return spring 20.2×14.2 10.4 30.4N – 24.3N (Outrigger control Control valve spring 13.0×8.8 3.92N – 3.1N plate lock 40-20 WB97S-5…
• Page 587
  3 65.7–82.3 Nm RKZ08892 Unit: mm No. Check item Criteria Remedy Standard size Repair limit Free Installed Installed Free Installed installed Replace length load installed load x Øe spring Pressure compensation 31.7×9.2 27.5 43.1N – 34.5N valve spring. 40-21 WB97S-5…
• Page 588
  STANDARD MAINTENANCE CONTROL VALVE 10-SPOOL VERSION 3 9.8–12.7 Nm Komatsu Ltd. 3 9.8–12.7 Nm 3 9.8–12.7 Nm 3 9.8–12.7 Nm 3 29.4–34.3 Nm 3 58.8–73.5 Nm RKZ09121 40-22 WB97S-5…
• Page 589
  STANDARD MAINTENANCE CONTROL VALVE 40-23 WB97S-5…
• Page 590
  STANDARD MAINTENANCE CONTROL VALVE 3 49–58.8 Nm 39.2–49 Nm 39.2–49 Nm 39.2–49 Nm 39.2–49 Nm 39.2–49 Nm 40-24 WB97S-5…
• Page 591
  38.7×18 27.6 355.7N – 284.6N lower control) – Priority valve spring 56.8×15.2 48.5 29.6N 23.7N – 10 Unloading valve spring 25.5×19.3 121.5N 97.2N Spool return spring (jig arm control, 29×17.5 28.5 22.5N 18.0N 4 in 1 bucket control) 40-25 WB97S-5…
• Page 592
  STANDARD MAINTENANCE CONTROL VALVE 3 24.5–34.3 Nm 3 47–58.8 Nm 3 19.6–24.5 Nm 3 24.5–34.3 Nm 3 14.7–19.6 Nm 3 24.5–34.3 Nm 40-26 WB97S-5…
• Page 593
  (boom, shovel arm jig arm, 4 in 1 bucket) – Check valve spring 27.2×6.9 4.70N 3.76N – Check valve spring 27.2×6.9 3.92N 3.14N – Check valve spring 21.9×5 15.8 1.96N 1.57N – Check valve spring 11.3×4.3 1.72N 1.38N 40-27 WB97S-5…
• Page 594
  Øe Spool return spring Replace 18.0×18 17.5 39.2N – 31.4N (Outrigger control) spring Spool return spring 20.2×14.2 10.4 30.4N – 24.3N (Outrigger control Control valve spring 13.0×8.8 3.92N – 3.1N plate lock 40-28 WB97S-5…
• Page 595
  3 65.7–82.3 Nm RKZ08892 Unit: mm No. Check item Criteria Remedy Standard size Repair limit Free Installed Installed Free Installed installed Replace length load installed load x Øe spring Pressure compensation 31.7×9.2 27.5 43.1N – 34.5N valve spring. 40-29 WB97S-5…
• Page 596
  Criteria Remedy Standard size Repair limit Free Installed Installed Free Installed installed length load installed load x Øe Return spring (outer) Replace (for ports P1 and P2) Return spring (outer) (for ports P3 and P4) Adjusting screw (inner) 40-30 WB97S-5…
• Page 597
  Criteria Remedy Standard size Repair limit Free Installed Installed Free Installed installed length load installed load x Øe Return spring (outer) Replace (for ports P1 and P2) Return spring (outer) (for ports P3 and P4) Adjusting screw (inner) 40-31 WB97S-5…
• Page 598
  + 0.080 pin and — 0.060 + 0.174 bushing T ole ra nc e be twe en Lifting 0.160 0.280 — 0.106 + 0.100 bushing and cylinder mounting — 0.050 + 0.142 Dump 0.130 0.231 — 0.089 + 0.080 40-32 WB97S-5…
• Page 599
  — 0.025 + 0.064 0.05 0.114 piston rod and head — 0.050 + 0.025 Tolerance between b u s h i n g a n d p i s t o n h e a d 0.150 mounting pin 40-33 WB97S-5…
• Page 600
  STANDARD MAINTENANCE BACKHOE CYLINDERS BACKHOE CYLINDERS BOOM 3 2740–2840 Nm with Loctite 262 3 981±98 Nm 3 1670±170 Nm 3 961±96.1 Nm 707-00-0y871-1 BUCKET 31670±170 Nm 3 1176–1372 Nm 707-00-0y901-1 40-34 WB97S-5…
• Page 601
  + 0.100 T ol e r an c e b et w e en bushing — 0.060 + 0.174 0.160 0.280 and cylinder mounting — 0.106 + 0.100 — 0.050 + 0.142 Bucket 0.130 0.231 — 0.089 + 0.080 40-35 WB97S-5…
• Page 602
  Standard Standard Clearance size clearance limit Shaft Hole — 0.025 + 0.132 Outriggers 0.031 0.196 — 0.064 + 0.006 Clearance between Replace piston rod and head — 0.025 + 0.064 Jig arm 0.050 0.114 — 0.050 + 0.025 40-36 WB97S-5…
• Page 603
  PAGE INTENTIONALLY LEFT BLANK…
• Page 604
  STANDARD MAINTENANCE FRONT WORKING EQUIPMENT FRONT WORKING EQUIPMENT 40-38 WB97S-5…
• Page 605
  0.130–0.208 — 0.089 + 0.119 mounting pin Clearance between — 0.060 + 0.137 0.143–0.303 bushing and link mounting pin — 0.106 + 0.197 Clearance between bushing — 0.050 and boom mounting pin — 0.089 40-39 WB97S-5…
• Page 606
  STANDARD MAINTENANCE SWING BRACKET SWING BRACKET 40-40 WB97S-5…
• Page 607
  + 0.190 b u s h i n g bushing and (upper) swing 0.250–0.370 — 0.106 + 0.264 bracketrotating pin Standard size Limit size Upper shim thickness 2.50 0.1 Central shim thickness 4.75 0.1 Lower shim thickness 4.75 0.1 40-41 WB97S-5…
• Page 608
  STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT BACKHOE WORKING EQUIPMENT 40-42 WB97S-5…
• Page 609
  — 0.089 — 0.240 Clearance between — 0.050 — 0.080 bushings and arm mounting 0.130–0.208 — 0.089 — 0.119 Clearance between bushings — 0.060 — 0.137 0.197–0.303 and boom mounting pin — 0.106 — 0.197 40-43 WB97S-5…
• Page 611
  90 OTHER ELECTRICAL DIAGRAM (STANDARD VERSION) .. 3 90-1 WB97S-5…
• Page 613
  42-N-06 11460 42-N-06 11870 13 14 12 13 42-N-06 42-N-06 11450 11160 Y200 Y201 Y202 Y203 Y204 Y205 Y206 M116 B209 E101 B210 R114 B211 Y117 B115 B113 B112 B121 E103 12Vcc E100 G118 G119 42-N-06 11280 E34000-059U 90-3 WB97S-5…
• Page 616
  © 2006 KOMATSU UTILITY EUROPE S.p.A. All Rights Reserved Printed in Europe 06-2006…

Инструкция WB97S-5

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