Wb140ps-2n Serie A40034 Up (Ing)

CEBM012801
Shop
Manual
WB140PS-2N
WB150PS-2N
BACKHOE LOADER
SERIAL NUMBERS
ENGINE
WB140PS-2N A40034 and up

WB150PS-2N A70010 and up
S4D106-1
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2010 Komatsu

Printed in U.S.A.
Komatsu America Corp.
March 2010
FOREWORD
CONTENTS
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00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 b
WB140PS-2N WB150PS-2N
FOREWORD
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FOREWORD
SAFETY
12
SAFETY
SAFETY NOTICE
00
00
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols
and
are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
00
Mistakes in operation are extremely dangerous. Read the

OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the
precautions given on the decals which are fixed to the
machine.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
Always wear safety glasses when hitting parts with a

hammer.
Always wear safety glasses when grinding parts with a

grinder, etc.
3.
If welding repairs are needed, always have a trained,

experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work.
When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before starting
work, hang UNDER REPAIR signs on the controls in
the operator's compartment.
Keep all tools in good condition and learn the correct
way to use them.
Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
4.
5.
6.
PREPARATIONS FOR WORK

1.
2.
4.
When disassembling or assembling, support the

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

1.
2.
3.
4.
5.
6.
00
Before adding oil or making repairs, park the machine

on hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
Before starting work, lower blade, ripper, bucket or any
other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on
them.
3.
7.
8.
9.
00
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or
removing components of the oil, water or air circuits,
first remove the pressure completely from the circuit.
The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
oil and water to cool before carrying out any work on
the oil or water circuits.
Before starting work, remove the leads from the battery.
ALWAYS remove the lead from the negative (-) terminal first.
When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from
damage. Always use lifting equipment which has ample
capacity. Install the lifting equipment at the correct
places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not
work with any part still raised by the hoist or crane.
When removing covers which are under internal pressure or under pressure from a spring, always leave two
bolts in position on opposite sides. Slowly release the
pressure, then slowly loosen the bolts to remove.
When removing components, be careful not to break or
damage the wiring, Damaged wiring may cause electrical fires.
When removing piping, stop the fuel or oil from spilling
out. If any fuel or oil drips on to the floor, wipe it up
immediately. Fuel or oil on the floor can cause you to
slip, or can even start fires.
Gasoline or other fuels should never be used to clean
parts. Clean part with appropriate solvents.
Be sure to assemble all parts again in their original
places. Replace any damaged part with new parts.
00-3
FOREWORD
10.
11.
12.
13.
14.
SAFETY
When installing hoses and wires, be sure that they will

not be damaged by contact with other parts when the
machine is being operated.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when
installing tubes for high pressure circuits. Also check
that connecting parts are correctly installed.
When assembling or installing parts, always use the
specified tightening torques. When installing protective
parts such as guards, or parts which vibrate violently or
rotate at high speed, be particularly careful to check that
they are installed correctly.
When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a hole.
When measuring hydraulic pressure, check that the
measuring tool is correctly assembled before taking any
measurements.
Take care when removing or installing the tracks of
track-type machines. When removing the track, the
track separates suddenly, so never let anyone stand at
either end of the track.
When jump starting the machine, only use a machine of
similar size and voltage. Never use a arc welder or other
electrical generating equipment to jump start the
machine. Carefully review the safety and procedures for
jump starting the machine.
00-4
FOREWORD
GENERAL
12GENERAL
GENERAL
00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL

VOLUMES
00
Shop manuals are issued as a guide to carrying out repairs.

They are divided as follows:
Chassis volume:
Issued for every machine model
Engine volume:
Issued for each engine series
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model,
it is necessary that chassis, engine, electrical and attachment
be available.
DISTRIBUTION AND UPDATING
1.
2.
So that the shop manual can be of ample practical use,

important places for safety and quality are marked with the
following symbols.
Symbol
Item
Remarks
Safety
Special safety precautions are

necessary when performing the
work.
Caution
Special technical precautions or

other precautions for preserving
standards are necessary when
performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting

hoisting wire or when working
posture is important, etc.
Tightening
torque
Places that require special attention for tightening torque during

assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel

must be added, and the capacity.
Drain
Places where oil or water must

be drained, and quantity to be
drained.
00
Any additions, amendments or other changes will be sent to

your distributors. Get the most up-to-date information before
you start any work.
FILING METHOD
00
00
See the page number on the bottom of the page. File the
pages in correct order.
Following examples show how to read the page number:
Example:
10 - 3
Item number (10. Structure and Function)
Consecutive page number for each item
3.Additional pages: Additional pages are
indicated by a hyphen (-) and numbered after the page
number. File as in the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
00
00
00
REVISED EDITION MARK
00
When a manual is revised, an edition mark (bcd) is

recorded on the bottom outside corner of the pages.
REVISIONS
00
Revised pages are shown at the LIST OF REVISED PAGES

between the title page and SAFETY page.
SYMBOLS
00-6
00
FOREWORD
HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS
00
HOISTING
can result. Hooks have maximum strength at the middle

portion.
00
WARNING! Heavy parts (25 kg or

more) must be lifted
with a hoist etc. In the
DISASSEMBLY AND ASSEMBLY section, every part weighing
25 kg or more is indicated clearly
with the symbol.
1.
2.
If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
Check for removal of all bolts fastening the part to the
relative parts.
Check for existence of another part causing interface
with the part to be removed.
WIRE ROPES
1.
3.
00
WARNING! Slinging with one rope may

cause turning of the load during
hoisting, untwisting of the rope,
or slipping of the rope from its
original winding position on the
load, which can result in a dangerous accident
Use adequate ropes depending on the weight of parts to

be hoisted, referring to the table below:
Wire ropes
(Standard Z or S twist ropes without galvanizing)
Rope diameter
Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
load.
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
4.
Do not sling a heavy load with ropes forming a wide

hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to
sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of
total weight can be suspended. This weight becomes
1000 kg when two ropes make a 120 hanging angle. On
the other hand, two ropes are subject to an excessive
force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150
00
The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
00-7
FOREWORD
QUICK DISCONNECT COUPLER
12
00
WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual pressure from hydraulic tank.
WARNING! Even if the residual pressure is released

from the hydraulic tank, some hydraulic oil
flows out when the hose is disconnected.
Accordingly, prepare an oil receiving container.
TYPE 1
DISCONNECTION
00
00
1.
Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2.
Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3.
After the hose joint (2) is pushed into the adapter (3), press the rubber cap portion (4) against the adapter until it clicks.
4.
Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
CONNECTION
1.
2.
00
Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-8
FOREWORD
TYPE 2
DISCONNECTION

00
00
1.
Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and turn the lever (4) to the right,
clockwise.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION
1.
00
Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-9
FOREWORD
12
TYPE
DISCONNECTION

00
00
1.
Hold the mouthpiece of the tightening portion and push the body
(2) in straight until sliding prevention ring (1) contacts surface a of
the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and push until the cover (3) contacts surface a of the hexagonal portion at the male end.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION
1.
00
Hold the mouthpiece of the tightening portion and push the body
(2) in straight until the slide prevention ring (1) contacts surface a
of the hexagonal portion at the male end to connect it.
00-10
FOREWORD
COATING MATERIALS
12
COATING MATERIALS
00
The recommended coating materials prescribed in the shop manuals are listed below.
Category
Code
Adhesives
LT-1A
Part No.
790-129-9030
Quantity
Container
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pes.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
Adhesive:1
kg
Hardening
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three
bond
1735
179-129-9140
2g
Polyethylene
container
Main applications, features
Used to prevent rubber gaskets, rubber

cushions and cork plugs from coming out
Used in places requiring an immediately

effective, strong adhesive.
Used for plastics (except polyethylene,
polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and nonmetal.
Used as adhesive or sealant for metal, glass

or plastic.
Used as sealant for machined holes.
Used as heat-resisting sealant for repairing

engine.
Quick hardening type adhesive.

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers, plastics and woods.
Aronalpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
50 g
Polyethylene
container
LG-3
790-129-9070
1 kg
Features: Resistance to heat, chemicals

Used at joint portions subject to high temperature.
Used as adhesive or sealant for gaskets and
packing of power train case, etc.
Features: Resistance to heat

Used as sealant for flange surfaces and bolts
at high temperature locations; used to prevent seizure.
Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
Can
Quick hardening type adhesive.

Quick cure type (max. strength after 30
minutes).
Used mainly for adhesion of rubbers, plastics and metals.
Gasket
sealant
Features: Resistance to heat, chemicals

Used for anti-loosening and sealant purposes for bolts and plugs.
00-11
FOREWORD
Category
Code
COATING MATERIALS
Part No.
Quantity
Container
Main applications, features
LG-4
790-129-9020
200 g
Tube
LG-5
790-129-9080
1 kg
Polyethylene
container
Gasket sealant
LG-6
09940-00011
250 g
Tube
Molybdenum
disulphide
lubricant
LG-7
09920-00150
150 g
Tube
Three
bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYG2160CNCA
Various
Various
400 g (10 per

case)
Belows type
Molybdenum
disulphide lubricant
Grease
00-12
SYG2-400M
Features: Resistance to water, oil

Used as sealant for flange surface, thread.
Also possible to use as sealant for flanges
with large clearance.
Used as sealant for mating surfaces of final
drive case, transmission case.
Used as sealant for various threads, pipe
joints, flanges.
Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Features: Silicon based, resistant to heat,
cold.
Used as sealant for flange surface, thread.
Used as sealant for oil pan, final drive case,
etc.
Features: Silicon based, quick hardening
type.
Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Used as heat-resisting sealant for repairing

engines.
Used as lubricant for sliding parts (to prevent squeaking).
Used to prevent seizure or scuffing of the

thread when press fitting or shrink fitting.
Used as lubricant for linkage, bearings, etc.
General purpose type
Used for normal temperature, light load

bearing at places in contact with water or
steam.
Used for places with heavy load.
FOREWORD
STANDARD TIGHTENING TORQUE
12
00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
10
11.8 - 14.7
8.70 - 10.84
13
27 - 34
19.91 - 25.07
10
17
59 - 74
43.51 - 54.57
12
19
98 - 123
72.28 - 90.72
14
22
153 - 190
112.84 - 140.13
16
24
235 - 285
173.32 - 210.20
18
27
320 - 400
236.02 - 295.02
20
30
455 - 565
335.59 - 416.72
22
32
610 - 765
449.91 - 564.23
24
36
785 - 980
578.98 - 722.81
27
41
1150 - 1440
848.19 - 1062.09
30
46
1520 - 1910
1121.09 - 1408.74
33
50
1960 - 2450
1445.62 - 1807.02
36
55
2450 - 3040
1807.02 - 2242.19
39
60
2890 - 3630
2131.55 - 2677.35
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
10
5.9 - 9.8
4.35 - 7.22
13
13.7 - 23.5
10.10 - 17.33
10
14
34.3 - 46.1
25.29 - 34.00
12
27
74.5 - 90.2
54.94 - 66.52
00-13
FOREWORD
12
TIGHTENING
TORQUE OF HOSE NUTS
00
Use these torques for hose nuts.

Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
lbf ft
02
14
19
19.6 - 29.4
14.5 - 21.7
03
18
24
29.4 - 68.6
21.7 - 50.6
04
22
27
58.9 - 98.1
44.4 - 72.4
05
24
32
107.9 - 166.7
79.6 - 123.0
06
30
36
147.1 - 205.9
108.5 - 151.9
10
33
41
147.1 - 245.1
108.5 - 180.8
12
36
46
196.2 - 294.2
144.7 - 217.0
14
42
55
245.2 - 343.2
180.9 - 253.1
Nominal No.
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
00
Use these torques for split flange bolts.

Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
14
59 - 74
43.51 - 54.57
12
17
98 - 123
72.28 - 90.72
16
22
235 - 285
173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS
00
Use these torques for flared part of nut.
Thread diameter
Width across flat
mm
mm
Nm
lbf ft
14
19
24.5 4.9
18.0 3.6
18
24
49 19.6
36.1 14.4
22
27
78.5 19.6
57.8 14.4
24
32
137.3 29.4
101.2 21.6
30
36
176.5 29.4
130.1 21.6
33
41
196.1 49
144.6 36.1
36
46
245.2 49
180.8 36.1
42
55
294.2 49
216.9 36.1
00-14
Tightening torque
FOREWORD
12
TABLE
OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
00
Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
mm
14
20
24
33
42
Norminal No.
02
03, 04
05, 06
10, 12
14
Width across flat

mm
Varies depending on
type of connector.
Tightening torque (Nm {lbf ft})

Range
Target
35 - 63 {25.81 - 46.46}
44 {32.45}
84 - 132 {61.95 - 97.35}
103 {75.96}
128 - 186 {94.40 - 137.18}
157 {115.79}
363 - 480 {267.73 - 354.02}
422 {311.25}
746 - 1010 {550.22 - 744.93}
883 {651.26}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS
00
Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
mm
08
10
12
14
16
18
20
24
30
33
36
42
52
Norminal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Width across flat

mm
14
17
19
22
24
27
30
32
32
_
36
_
_
Tightening torque (Nm {lbf lb})

Range
Target
5.88 - 8.82 {4.33 - 6.50}
7.35 {5.42}
9.8 - 12.74 {7.22 - 9.39}
11.27 {8.31}
14.7 - 19.6 {10.84 - 14.45}
17.64 {13.01}
19.6 - 24.5 {14.45 - 18.07}
22.54 {16.62}
24.5 - 34.3 {18.07 - 25.29}
29.4 {21.68}
34.3 - 44.1 {25.29 - 32.52}
39.2 {28.91}
44.1 - 53.9 {32.52 - 39.75}
49.0 {36.14}
58.8 - 78.4 {43.36 - 57.82}
68.6 {50.59}
93.1 - 122.5 {68.66 - 90.35}
107.8 {79.50}
107.8 - 147.0 {79.50 - 108.42}
124.4 {91.75}
127.4 - 176.4 {93.96 - 130.10}
151.9 {112.03}
181.3 - 240.1 {133.72 - 177.08}
210.7 {155.40}
274.4 - 367.5 {202.38 - 271.05}
323.4 {238.52}
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE
SEAL TYPE)
00
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {lbf ft})
Nominal
Width
size of hose across flats
02
03
04
05
06
(10)
(12)
(14)
19
22
24
27
32
36
41
46
55
Range
Target
34 - 54 {25.0 - 39.8}
34 - 63 {25.0 - 46.4}
54 - 93 {39.8 - 68.5}
59 - 98 {43.5 - 72.2}
84 - 132 {61.9 - 97.3}
128 - 186 {94.4 - 137.1}
177 - 245 {130.5 - 180.7}
177 - 245 {130.5 - 180.7}
197 - 294 {145.3 - 216.8}
246 - 343 {181.4 - 252.9}
44 {32.4}
44 {32.4}
74 {54.5}
78 57.5}
103 {75.9}
157 {115.7}
216 {159.3}
216 {159.3}
245 {180.7}
294 {216.8}
Taper seal
type
Face seal type
Nominal thread
Thread size
Root diameter (mm)
size - Threads per
(mm)
(Reference)
inch, Thread series
9/16 - 18UN
14.3
14
11/16 -16UN
17.5
18
22
13/16 - 16UN
20.6
24
1 - 14UNS
25.4
30
1 3/16 - 12UN
30.2
33
36
42
-
00-15
FOREWORD
ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE
00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example:
05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
00
Copper wire
Nominal
number
Number of Dia. Of strand Cross section

strands
(mm)
(mm)
Cable O.D.
(mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
26
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Classification
Primary
Priority
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
Color
White &
Red
Black &
White
Red &
White
Yellow &
Red
Green &
White
Blue &
White
Code
WB
BY
RB
YB
GR
LR
Color
White &
Black
Yellow &
Black
Green &
Red
Blue & Red
Code
WL
BR
RY
YG
GY
LY
Color
White &
Blue
Black & Red
Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code
WG
RG
YL
GB
LB
Color
White &
Green
Red &
Green
Yellow &
Blue
Green &
Black
Blue &
Black
Code
RL
YW
GL
Color
Red & Blue
Yellow &
White
Green &
Blue
Auxiliary
00
Black & YelRed & Black

low
00-16
FOREWORD
CONVERSION TABLES
12
CONVERSION TABLES
00
METHOD OF USING THE CONVERSION TABLE
00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2.
Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
Millimeters to inches
1 mm = 0.03937 in
0
2
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
0.039
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
d
b
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
00-17
FOREWORD
CONVERSION TABLES
12
Millimeters to Inches
1 mm = 0.03937 in
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
00-18
1 kg = 2.2046 lb
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
FOREWORD
CONVERSION TABLES
12
Liter to U.S. Gallon
1 L = 0.2642 U.S. Gal

0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon
1 L = 0.21997 U.K. Gal

0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-19
FOREWORD
CONVERSION TABLES
12
Nm to lbf. ft.
1 Nm = 0.737 lbf. ft.

0
0
00-20
0.737
1.474
2.211
2.948
3.685
4.422
5.159
5.896
6.63
10
7.37
8.107
8.884
9.581
10.318
11.055
11.792
12.259
13.266
14.003
20
14.74
15.477
16.214
16.951
17.688
18.425
19.126
19.899
20.636
21.373
30
22.11
22.847
23.584
24.321
25.058
25.795
26.532
27.269
28.006
28.743
40
29.48
30.217
30.954
31.691
32.428
33.165
33.902
34.639
35.376
36.113
50
36.85
37.587
38.324
39.061
39.798
40.535
41.272
42.009
42.746
43.483
60
44.22
44.957
45.694
46.431
47.168
47.905
48.642
49.379
50.116
50.853
70
51.59
52.327
53.064
53.801
54.538
55.275
56.012
56.749
57.486
58.223
80
58.96
59.697
60.434
61.171
61.908
62.645
63.382
64.119
64.856
65.593
90
66.33
67.067
67.804
68.541
69.278
70.015
70.752
71.489
72.226
72.963
100
73.7
74.437
75.174
75.911
76.648
77.385
78.122
78.859
79.596
80.333
110
81.07
81.807
82.544
83.281
84.018
84.755
85.492
86.229
86.966
87.703
120
88.44
89.177
89.914
90.651
91.388
92.125
92.862
93.599
94.336
95.073
130
95.81
96.547
97.284
98.021
98.758
99.495 100.232 100.969 101.706 102.443
140
103.18
103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150
110.55
111.287
160
117.92
118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170
125.29
126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180
132.66
133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190
140.03
140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
112.024
112.761
113.498 114.235 114.972 115.709 116.446 117.183
FOREWORD
CONVERSION TABLES
12
Nm to lbf. inf
1 Nm = 8.85 lbf. inf

0
8.85
17.7
26.55
35.4
44.25
53.1
61.95
70.8
79.65
10
88.5
97.35
106.2
115.05
123.9
132.75
141.6
150.45
159.3
168.15
20
177
185.85
194.7
203.55
212.4
221.25
230.1
238.95
247.8
256.65
30
265.5
274.35
283.2
292.05
300.9
309.75
318.6
327.45
336.3
345.15
40
354
362.85
371.7
380.55
389.4
398.25
407.1
415.95
424.8
433.65
50
442.5
451.35
460.2
469.05
477.9
486.75
495.6
504.45
513.3
522.15
60
531
539.85
548.7
557.55
566.4
575.25
584.1
592.95
601.8
610.65
70
619.5
628.35
637.2
646.05
654.9
663.75
672.6
681.45
690.3
699.15
80
708
716.85
725.7
734.55
743.4
752.25
761.1
769.95
778.8
787.65
90
796.5
805.35
814.2
823.05
831.9
840.75
849.6
858.45
867.3
876.15
100
885
893.85
902.7
911.55
920.4
929.25
938.1
946.95
955.8
964.65
110
973.5
982.35
991.2
1000.05
1008.9
1017.75
1026.6
1035.45
1044.3
1053.15
120
1062
1070.85
1079.7
1088.55
1097.4
1106.25
1115.1
1123.95
1132.8
1141.65
130
1150.5
1159.35
1168.2
1177.05
1185.9
1194.75
1203.6
1212.45
1221.3
1230.15
140
1239
1247.85
1256.7
1265.55
1274.4
1283.25
1292.1
1300.95
1309.8
1318.65
150
1327.5
1336.35
1345.2
1354.05
1362.9
1371.75
1380.6
1389.45
1398.3
1407.15
160
1416
1424.85
1433.7
1442.55
1451.4
1460.25
1469.1
1477.95
1486.8
1495.65
170
1504.5
1513.35
1522.2
1531.05
1539.9
1548.75
1557.6
1566.45
1575.3
1584.15
180
1593
1601.85
1610.7
1619.55
1628.4
1637.25
1646.1
1654.95
1663.8
1672.65
190
1681.5
1690.35
1699.2
1708.05
1716.9
1725.75
1734.6
1743.45
1752.3
1761.15
00-21
FOREWORD
CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column
at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
C
-40.4
-37.2
-34.4
-31.7
-28.9
-40
-35
-30
-25
-20
F
-40.0
-31.0
-22.0
-13.0
-4.0
C
-11.7
-11.1
-10.6
-10.0
-9.4
11
12
13
14
15
F
51.8
53.6
55.4
57.2
59.0
C
7.8
8.3
8.9
9.4
10.0
-28.3
-27.8
-27.2
-26.7
-26.1
-19
-18
-17
-16
-15
-2.2
-0.4
1.4
3.2
5.0
-8.9
-8.3
-7.8
-7.2
-6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
-25.6
-25.0
-24.4
-23.9
-23.3
-14
-13
-12
-11
-10
6.8
8.6
10.4
12.2
14.0
-6.1
-5.6
-5.0
-4.4
-3.9
21
22
23
24
25
-22.8
-22.2
-21.7
-21.1
-20.6
-9
-8
-7
-6
-5
15.8
17.6
19.4
21.2
23.0
-3.3
-2.8
-2.2
-1.7
-1.1
-20.0
-19.4
-18.9
-18.3
-17.8
-4
-3
-2
-1
0
24.8
26.6
28.4
30.2
32.0
-17.2
-16.7
-16.1
-15.6
-15.0
1
2
3
4
5
-14.4
-13.9
-13.3
-12.8
-12.2
6
7
8
9
10
00-22
46
47
48
49
50
F
114.8
116.6
118.4
120.2
122.0
C
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
F
117.8
179.6
181.4
183.2
185.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
-0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
01
GENERAL
SPECIFICATIONS ................................................................................................................................................................ 01-2

WEIGHT TABLE .................................................................................................................................................................. 01-3
FUEL COOLANT AND LUBRICANTS .............................................................................................................................. 01-4
01-1
GENERAL
SPECIFICATIONS
12
SPECIFICATIONS
ITEM
UNIT
Minimum
Operating weight
WB140PS-2N
WB150PS-2N
7400
7400
8800
8800
1.03
1.03
0.20
0.20
S4D106-1FH
S4D106-1FA
kg
Maximum
Loader
Bucket capacity
m
Backhoe
Type
TIER I
Max power
kW
64.1 @ 2200 rpm
73 @ 2200 rpm
Max torque
Nm
330 @ 1500 rpm
375 @ 1500 rpm
S4D106-2XFH
S4D106-2SFA
Diesel engine
Type
TIER II
Electrical system
Max power
kW
65.1 @ 2200 rpm
70.1 @ 2200 rpm
Max torque
Nm
348 @ 1400 rpm
368 @ 1600 rpm
Alternator
12
12
Output
80
80
Ground
---
Negative
Negative
Battery
Ah @ V
155 @ 12
155 @ 12
Starter
kW
Forward 1st
Forward 2nd
11
11
Forward 3rd
21
21
39
39
Reverse 1st
Reverse 2nd
11
11
Reverse 3rd
21
21
Reverse 4th
39
39
3.2
3.2
2.2
2.2
Forward 4th
Travel speeds
km/h
Front 14-17.5 NHSPR10

Tire pressure
kg/cm
Rear 19.5 L24 PR10
01-2
GENERAL
12
WEIGHT
WEIGHT TABLE
TABLE
This table is a guide for use when transporting or handling components.

Unit : kg
Machine Model
WB140PS-2N
WB150PS-2N
01-3
GENERAL
12
FUEL
FUEL COOLANT AND LUBRICANTS
COOLANT AND LUBRICANTS
It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the
quality of the fuel, coolant and lubricant must remain with the supplier.
When in doubt, consult your Komatsu distributor. The following table shows specified fuel, coolant and lubricants recommended for this machine.
Reservoir
Kind of
fluid
Ambient Temperature
-30
-20
-10
10
20
30
Capacity
40
50C
Specified
Refill
7.9 L
7.9 L
150 L
92 L
150 L
92 L
6.5 L
6.5 L
1 L each
1 L each
14.5 L
14.5 L
1.5 L each
1.5 L each
20 L
17 L
0.8 L
0.8 L
130 L
14 L
SAE 5W-30
Engine oil
pan
Oil API CI-4 or JASO SH-1
SAE 10W
Hydraulic
system
SAE 20W-20
SAE 30
SAE 40
SAE 10W-30
SAE 15W-40
SAE 5W*
SAE 10W
SAE 30
SAE 10W-30
Front axle
diff
Final gear
Rear axle diff
HEES
Oil API CI-4
Hydraulic
system with
biodegrad-
See Note 1
Final gear
Transmission
ATF
GM DEXRON II D
Brakes
Fuel tank
Diesel
fuel
ASTM
D975 No. 1
ASTM D975 No. 2
Engine cooling system
Coolant
AF-NAC
OPTION FOR VERY COLD AREAS:If the temperature is below 10C, contact your distributor for advise on the type of oil
to be used.
01-4
GENERAL
FUEL COOLANT AND LUBRICANTS
12
Note 1:
For axle oil, use only the recommended oil as follows.
SHELL ..................................................................DONAX TD
CALTEX ...............................................................RPM TRACTOR HYDRAULIC FLUID
CHEVRON ...........................................................TRACTOR HYDRAULIC FLUID
TEXACO ..............................................................TEXTRAN TDH OIL
MOBIL..................................................................MOBILFLUID 422 or 424
API
American Petroleum Institute
ASTM American Society of Testing and Materials

NLGI
National Lubricating Grease Institute
SAE
Society of Automotive Engineers
Specified Capacity Total amount of oil including oil for components and piping.
Refill Capacity Amount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20C. Consult your Komatsu distributor for your specific needs.
NOTE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high pressure fuel
injection device to obtain good fuel consumption and good exhaust characteristics. For this reason, it requires
high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used,
there will be a significant drop in durability.
01-5
GENERAL
12
MEMORANDA
01-6
10
STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD
12
ENGINE MOUNTING............................................................................................................................................ 10-3
TIER I ENGINE ............................................................................................................................................... 10-3
TIER II ENGINE.............................................................................................................................................. 10-4
POWER TRAIN ...................................................................................................................................................... 10-5
TRANSMISSION DIAGRAM................................................................................................................................ 10-7
TRANSMISSION .................................................................................................................................................... 10-9
COMPLETE ASSEMBLY............................................................................................................................... 10-9
FORWARD REVERSE CLUTCH ................................................................................................................ 10-12
2ND GEAR CLUTCH.................................................................................................................................... 10-12
1ST, 3RD AND 4TH GEAR CLUTCH ......................................................................................................... 10-13
4WD SHAFT .................................................................................................................................................. 10-13
CONTROL VALVE....................................................................................................................................... 10-14
FRONT AXLE....................................................................................................................................................... 10-15
COMPLETE ASSEMBLY............................................................................................................................. 10-15
DIFFERENTIAL ............................................................................................................................................ 10-16
PLANETARY................................................................................................................................................. 10-17
REAR AXLE ......................................................................................................................................................... 10-18
COMPLETE ASSEMBLY............................................................................................................................. 10-18
DIFFERENTIAL ............................................................................................................................................ 10-19
PLANETARY................................................................................................................................................. 10-20
BRAKES ........................................................................................................................................................ 10-21
DIFFERENTIAL LOCK ................................................................................................................................ 10-22
HYDRAULIC PUMP ............................................................................................................................................ 10-23
FUNCTION .................................................................................................................................................... 10-27
STRUCTURE ................................................................................................................................................. 10-27
OPERATION.................................................................................................................................................. 10-28
PC VALVE, LS VALVE, SERVO PISTON.................................................................................................. 10-29
STEERING UNIT.................................................................................................................................................. 10-42
TECHNICAL DATA...................................................................................................................................... 10-42
OPERATION.................................................................................................................................................. 10-42
LOADER VALVE................................................................................................................................................. 10-43
2 SPOOL......................................................................................................................................................... 10-43
3 SPOOL VALVE .......................................................................................................................................... 10-45
BACKHOE CONTROL VALVE.......................................................................................................................... 10-47
MECHANICAL CONTROL.......................................................................................................................... 10-47
EXCAVATOR CONTROL............................................................................................................................ 10-57
CLSS ...................................................................................................................................................................... 10-67
CHARACTERISTICS.................................................................................................................................... 10-67
STRUCTURE ................................................................................................................................................. 10-67
OPERATING PRINCIPLES .......................................................................................................................... 10-68
UNLOADING VALVE.................................................................................................................................. 10-70
INTRODUCTION OF THE LS PRESSURE................................................................................................. 10-73
DELIVERY COMPENSATION .................................................................................................................... 10-74
LIFD CONTROL SYSTEM........................................................................................................................... 10-77
LS DECOMPRESSION VALVE................................................................................................................... 10-78
PRESSURE CUT OFF VALVE..................................................................................................................... 10-79
PRIORITY VALVE ....................................................................................................................................... 10-80
10-1

TABLE OF CONTENTS
PPC JOYSTICK .................................................................................................................................................... 10-81

LEFT VALVE ................................................................................................................................................ 10-81
RIGHT VALVE.............................................................................................................................................. 10-82
SOLENOID VALVE ............................................................................................................................................. 10-83
DIFFERENTIAL LOCK - BACKHOE BOOM LOCK................................................................................. 10-83
PPC SUPPLY VALVE - ST2......................................................................................................................... 10-84
PPC TELESCOPIC ARM .............................................................................................................................. 10-85
PPC HAMMER .............................................................................................................................................. 10-86
PPC ARM AND HAMMER .......................................................................................................................... 10-87
LOADER CYLINDERS........................................................................................................................................ 10-88
BOOM ARM .................................................................................................................................................. 10-88
BUCKET ........................................................................................................................................................ 10-89
MP BUCKET ................................................................................................................................................. 10-90
BACKHOE CYLINDERS..................................................................................................................................... 10-91
BOOM ............................................................................................................................................................ 10-91
ARM ............................................................................................................................................................... 10-92
BUCKET ........................................................................................................................................................ 10-93
TELESCOPIC ARM CYLINDER ................................................................................................................. 10-94
SWING ........................................................................................................................................................... 10-95
OUTRIGGER ................................................................................................................................................. 10-96
BOOM LOCK CYLINDER ........................................................................................................................... 10-97
FRONT WORK EQUIPMENT ............................................................................................................................. 10-98
REAR WORK EQUIPMENT ............................................................................................................................. 10-100
AIR CONDITIONING ........................................................................................................................................ 10-102
10-2

12
ENGINE
ENGINE MOUNTING
MOUNTING
TIER I ENGINE
10-3

12
B Engine
C Transmission
D Engine Mount
ENGINE MOUNTING
e Transmission Mount
F Rear Axle Input
G Front Axle Input
TIER II ENGINE
10-4

12
POWER
B
C
D
E
POWER TRAIN
TRAIN
F
G
H
I
Engine
Torque Converter
Transmission
Hydraulic Pump
Front Axle
Rear Axle
Front Drive Shaft
Rear Drive Shaft
DESCRIPTION
The driving power for the engine b is transmitted through the flywheel to the converter c. The converter uses hydraulic
oil to convert the torque transmitted by the engine into driving power. The converter transmits motion to the drive shaft of
the transmission d and to the drive shaft of the hydraulic pump e.
The transmission d has two hydraulically activated clutches that can be selected by an electrically controlled gear selector. The same switch also controls the four speed clutch packs.
The driving power is transmitted from the transmission flanges to the front f and rear g axles through the drive shafts h
and i.
The driving power transmitted to the front f and rear g axles is reduced by the differentials and then transmitted to the
planetary gear through the differential shafts.
POWER FLOW
Gear
1st
2nd
3rd
4th
Trans
4.374
2.436
1.232
0.651
Front Axle
Diff
2.436
Planet
6.000
Total
62.592
34.859
17.630
9.316
Trans
5.44
3.030
1.5532
0.810
Rear Axle
Diff
Planet
2.846
6.000
Total
92.893
51.74
26.16
13.832
10-5

POWER TRAIN
12
b Engine
c Convert Transmission
d Hydraulic Pump
10-6
E Rear Drive Shaft

F Rear Axle
G Rear Tires
H Front Drive Shaft

I Front Axle
J Front Tires

12
TRANSMISSION
b
c
d
E
F
TRANSMISSION DIAGRAM
DIAGRAM
Engine
Torque Converter
Forward Clutch
Transmission
Reverse Clutch
G
H
I
J
1)
Hydraulic Pump
Rear Axle Flange
4WD Clutch
1! 3rd Speed Clutch

1@ 4th Speed Clutch
1# 1st Speed Clutch
Front Axle Flange

2nd Speed Clutch
10-7

TRANSMISSION DIAGRAM
12
B Transmission Sump
C Suction Filter .................... 20 micron
D Oil Pump
E Converter Relief Valve ..... 5.6 b
F Torque Converter .............. 11.2 b @ 127 C
rpm
G Oil Cooler ......................... 1425 -- 2745 LL @@ 900
2200 rpm
H Oil Temp Sensor ............... 112 to 118 C
- 1.8 b @ 900 rpm
I Lube Pressure ................... 0.2
0.7 - 2.5 b @ 2200 rpm
J Filter Relief Valve............. 23 - 26 b
1) Delivery Filter....................10 micron
1! Cold Oil By Pass Valve .....3.45 b
16 b @ 900 rpm
1@ Oil Pressure........................1415.5 - 18 b @ 2200 rpm
1# Oil Flow Divider
900 rpm
1$ Converter Pressure.............16 -- 114.5bb@@2200
rpm
1% Oil Pressure Sensor............9 - 11 b
1^ 2nd Gear Solenoid
- 14.5 b @ 900 rpm

1& 2nd Gear Pressure ............. 13.5
3# Forward Clutch Solenoid
15 - 17 b @ 2200 rpm
1* 2nd Gear Antishock Valve
3$ Forward Clutch Pressure
-14.5 b @ 900 rpm
- 15.5 b @ 900 rpm
1( 2nd Gear Filling Pressure.. 13.5
3% Forward Clutch Pressure ... 13.5
15 - 17 b @ 2200 rpm
14.5 - 16.5 b @ 2000 rpm
2) 2nd Gear Clutch
3^ Forward Clutch
2! 4WD Solenoid
3& 3rd Gear Solenoid
14 - 16 b @ 900 rpm
b @ 900 rpm
2@ 4WD Pressure.................... 15 - 17.5 b @ 2200 rpm 3* 3rd Gear Pressure.............. 1314.5- 15- 16.5
b @ 2200 rpm
2# 4WD Pressure
3( 3rd gear Antishock Valve
b @ 900 rpm
2$ 4WD Clutch
4) 3rd Gear Filling Pressure ... 1112 -13
- 14 b @ 2200 rpm
2% 4th Gear Solenoid
4! 3rd Gear Clutch
13 - 15 b @ 900 rpm
2^ 4th Gear Pressure .............. 14.5 - 16.5 b @ 2000 rpm 4@ 1st Gear Solenoid
- 14.5 b @ 900 rpm
b @ 900 rpm
2& 4th Gear Filling Pressure... 13.5
4# 1st Gear Pressure .............. 1314.5- 15- 16.5
15 - 17 b @ 2200 rpm
b @ 2200 rpm
2* 4th Gear Clutch
4% 1st gear Antishock Valve
b @ 900 rpm
2( Reverse Clutch Solenoid
4% 1st Gear Filling Pressure.... 1112 -13
- 14 b @ 2200 rpm
3) Reverse Clutch Pressure
4^ 1st Gear Clutch
- 15.5 b @ 900 rpm
3! Reverse Clutch Pressure.... 13.5
14.5 - 16.5 b @ 2000 rpm 4& Trans Control Valve
3@ Reverse Clutch
4* Transmission Breather
NOTE - One b (bar) equals 1.02 kg/cm
10-8

TRANSMISSION
12
TRANSMISSION
COMPLETE ASSEMBLY
B
C
D
E
F
G
Control Valve Group

Torque Converter
Delivery Filter
Plug
Plug
Suction Strainer
H
I
j
1)
1!
1@
Oil Temperature Sensor
a From Oil Cooler
4th Gear Filling Pressure Sensor
b To Oil Cooler
1st Gear Filling Pressure Sensor
c To Solenoid Valves
Speedometer Sensor
d From Solenoid Valves
3rd Gear Filling Pressure Sensor

2nd Gear Filling Pressure Sensor
10-9

TRANSMISSION
12
B
C
D
E
Pump Drive Shaft

Reverse Clutch
Reverse Shaft
2nd Gear Clutch
10-10
F
G
h
i
4th Gear Clutch

3rd Gear Clutch
1st Gear Clutch
j Forward Clutch
1) 4WD Clutch
1! Front Axle Flange
Rear Axle Flange

TRANSMISSION
12
10-11

12
FORWARD
TRANSMISSION
REVERSE CLUTCH
B Reverse Gear
C Forward Gear
D Forward Clutch Piston
E Reverse Clutch Piston

F Thrust Ring
G Shaft
a Reverse Clutch Port
d 4th Gear
e 1st Gear
F 2nd Gear Clutch Piston
b Forward Clutch Port

c Lubrication Port
2ND GEAR CLUTCH
B 3rd Gear
C 2nd Gear
10-12
a 2nd Gear Port

12
1ST,
B
C
D
E
F
TRANSMISSION
3RD AND 4TH GEAR CLUTCH
3rd Clutch Gear

2nd Driven Gear
4th Clutch Gear
1st Clutch Gear
1st Driven Gear
G
H
I
J
1)
Rear Output Shaft

1st Gear Piston
4th Gear Piston
a 1st Gear Port

b 4th Gear Port
c 3rd Gear Port
3rd Gear Piston

Speedometer Plate
4WD SHAFT
B Front Output Shaft

C 4WD Disengagement Clutch
D 4WD Clutch Gear

E Engage Piston
f Belleville Washers
a 4WD Pressure Port
10-13

TRANSMISSION
CONTROL VALVE
ELECTRICAL COMPONENT
b
c
d
e
f
g
C24 - 2nd Gear Solenoid Valve
h
i
C27 - 4WD Solenoid Valve
C23 - 1st Gear Solenoid Valve
MP
General Clutch Pressure
C07 - Oil Pressure Sensor
M4
Reverse Clutch Pressure
CHECK POINT
M3 Forward Gear Pressure
2nd Gear Pressure
M3a 3rd Gear Pressure
Torque Converter Pressure
M1a 1st Gear Pressure
C21 - Reverse Solenoid Valve
M2a
M2
C22 - Forward Solenoid Valve
M4WD 4WD Disengagement Pressure
C25 - 3rd Gear Solenoid Valve
M4a
C26 - 4th Gear Solenoid Valve
10-14
4th Gear Pressure

12
FRONT
FRONT AXLE
AXLE
COMPLETE ASSEMBLY
B Steering Cylinder
C Oil Refill Plug
D Oil Drain Plug
E Tie Rod Nut

F Adjustment Screw
G Lock Nut
h Mounting Pin Bushing

a Left Cylinder Port
b Right Cylinder Port
Unit:mm
Check Item
i Pin and Bushing Clearance
Criteria
Tolerance
Shaft
Bushing
Standard
Size
50
50
0
-0.039
50.19
+0.04
0
Standard
Clearance
Clearance
Limit
Remedy
---
---
Replace
10-15

FRONT AXLE
12
DIFFERENTIAL
B
C
D
E
F
G
Side Gear
Ring Gear
Driven Gear
Adjustment Lock Nut
Axle Shaft
Dowel Pin
H
I
J
1)
1!
1@
Differential Housing
Bearing Spacer
Outboard Pinion Bearing
Lip Seal Ring
Input Flange
1#
1$
1%
1^
1&
Pinion Bearing Lock Nut

Inboard Pinion Bearing
Pinion Gear
Dowel Pin
Oil Drain Plug
Lip Seal Ring Cover

Unit : mm
Check Item
1*
1(
2)
2!
Axle Clearance
Ring and Pinion Gear Backlash
Pinion Preload *
Ring and Pinion Gear Preload *
Criteria
Standard Clearance
Clearance Limit
----0.17 to 0.23
0.23
92 to 137 Nm
95.9 to 142.9 Nm
Remedy
Adjust
* - Without lip seal ring.
10-16

FRONT AXLE
12
PLANETARY
B
C
D
E
F
G
H
I
Planetary Carrier
Planetary Gear
Ring Gear
Carrier Gear
Wheel Hub
Lip Ring Seal
Upper King Pin
Adjustment Shim
Check Item
2% Hub Rotation Torque
2^ Axle Shaft Clearance
J
1)
1!
1@
1#
1$
1%
1^
Belleville Washer
Upper King Pin Bushing
Lip Ring Seal
Axle Housing
Spherical Bearing
Lower King Pin Bushing
Lower King Pin
Belleville Washer
Criteria
-----
1&
1*
1(
2)
2!
2@
2#
2$
Lip Ring Seal

Tapered Roller Bearing
Retaining Ring
Bolt Bushing
Stud Bolt
Oil Drain Plug
Sun Gear
Retaining Ring
Remedy
Adjust
10-17

12
REAR
REAR AXLE
AXLE
COMPLETE ASSEMBLY
B
C
D
E
Input Flange
Differential Portion
Brake Portion
Axle Housing
10-18
F
G
H
I
Parking Brake Levers
J Oil Drain Plug

1) Axle Housing Breather
Brake Bleeder Screws
a Brake Port ....................... 40.8 kg/cm
Oil Fill And Level Plugs
b Diff Lock Port............. 1295.4 kg/cm
Planetary Portion

REAR AXLE
12
DIFFERENTIAL
B
C
D
E
F

Side Gear
Rotating Gear
Ring Gear
G
H
I
J
1)
Bearing Lock Nut

Axle Shaft
Dowel Pin
Bearing Lock Nut
1!
1@
1#
1$
1%
Lip Oil Seal

Input Flange
Bearing Spacer
Pinion Gear
Unit : mm
Check Item
1^
1&
1*
1(
Axle Clearance
Ring And Pinion Gear Backlash
Pinion Gear Preload *
Pinion Ring Gear Preload *
Criteria
Standard Clearance
Clearance Limit
---
---
0.17 to 0.23
0.23
92 to 138 Nm
Remedy
Adjust
95.23 to 141.84 Nm
* - Without lip seal ring.
10-19

REAR AXLE
12
PLANETARY
B
C
D
E
F
G
Planetary Gear Carrier

Wheel Stud
Wheel Hub
Planet Gear
Gear Carrier
Tapered Roller Bearings
Check Item
1&
1*
10-20
H
I
J
1)
1!
1@
1#
1$
1%
1^
Lip Ring Seal

Shaft Coupler
Inner Axle Shaft
Sun Gear Shaft
Outer Ring Gear

Oil Fill And Drain Plug
Bolt Bushing
Planet Gear Shaft
Shaft Bushing
Retaining Ring
Criteria
Hub Rotation Torque
---
Axle Shaft Clearance
---
Remedy
Adjust

REAR AXLE
12
BRAKES
B
C
D
E
Disc Plate Bushing

Parking Brake Control Rod
Brake Bleeder Valve
Parking Brake Lever
f
g
h
i
Parking Brake Control Cam

Brake Disc Plate
j Inner Disc Separator Plate

1) Outer Disc Separator Plate
Actuator Piston
Brake Disc Plate Return Spring
Unit : mm
Check Item
Free
Length
1! Brake Disc Return Spring

1@ Disc Return Spring
1# Disc Thickness
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
27
13
127 Nm
21
10 Nm
35
19
369 Nm
21
10 Nm
4.85 to 5
Remedy
Replace
3.3
10-21

12
DIFFERENTIAL
LOCK
B Engagement Sleeve
C Locking Pin
D Control Rod
10-22
REAR AXLE
e Fork Spacer
f Shift Fork
g Piston
h Piston Cover
i Retaining Ring
a Diff Lock Port............. 1295.4 kg/cm

12
HYDRAULIC
HYDRAULIC PUMP
PUMP
b Delivery Variation Valve

c Valve Working Mode Solenoid
d Delivery Control Valve
a P Port From Hydraulic Tank Suction Line

b Case Drain To Suction Line
c LS Pressure From Loader Control Valve
d Output To Loader Control Valve
10-23

HYDRAULIC PUMP
12
b Delivery Variation Valve

c Valve Working Mode Solenoid
d Delivery Control Valve
a P Port From Hydraulic Tank Suction Line

b Case Drain To Suction Line
c LS Pressure From Loader Control Valve
d Output To Loader Control Valve
10-24

HYDRAULIC PUMP
12
b
c
d
e
f
g
Lip Seal Ring

Centering Spring
Drive Shaft
Swash Plate
H
I
J
1)
1!
1@
Positioning Piston
Swash Plate Positioning Spring
Cylinder Block
Swash Plate Positioning Piston
Pump Piston
Guide Shoe
10-25

HYDRAULIC PUMP
12
1#
Check Item
Bearing Preload
Criteria
0 to 0.05
Tolerance
Shaft
Hole
---
Standard
Size
1$
1%
1^
1&
Piston To Cylinder Backlash

Piston To Shoe Backlash
Drive Shaft Diameter
20
Piston Rod
f
g
h
Bushing
PC VALVE
Initial Adjust Spring
Spring
Standard
Clearance
Clearance
Limit
Remedy
0.065
0.15
34.91
Swash Plate Positioning Spring
POWER GOVERNOR
b
c
d
e
Unit : mm
Remedy
Adjust
Free
Length
---
Standard Size
Installed
Installed
Length
Load
88.7
276 12 N
Pressure Cut Off Screw
j
1)
Initial Adjust Screw
LS VALVE
Pressure Cut Off Spring
1!
1@
Spool
Repair Limit
Free
Installed
Length
Load
Remedy
Replace
1#
1$
1%
Internal Spring
External Spring
Throttles
Throttles
Spool
External Spring
Internal Spring
Unit : mm
Check Item
1^
1&
1*
1(
2)
Piston Rod Return Spring

Internal Power Reg Spring
External Power Reg Spring
External LS/PC Spring
Internal LS/PC Spring
10-26
Spring Criteria
Standard Size
Repair Limit
Install
Installed
Installed
Free Length
Free Length
Length
Load
Load
---
---
--125.4 10 N
180.2 12 N
40.2 3 N
81.7 14 N
---
Remedy
--Replace

HYDRAULIC PUMP
12
FUNCTION
The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered
according to the load requirements. The amount of oil delivered can be modified by changing the angle of the swash plate.
STRUCTURE
The cylinder block g is supported and connected to the shaft b by the spline a and the shaft is supported by the front and rear
tapered roller bearings.
The tip of the piston g is ball shaped. The shoe e is caulked to it to form one unit in such a way that the piston f and the shoe
together form a spherical bearing.
The swash plate d has a flat surface A and the shoe e remains pressed against this surface while sliding in a circular movement. The swash plate brings highly pressurized oil onto the cylindrical surface B fashioned in the pump body c, which
means that the swash plate slides on a hydrostatically supported bearing.
The pistons f perform their relative movements in an axial direction, inside cylindrical chambers fashioned in the cylinder
block g.
The oil is brought up to pressure in the chambers of the cylinder block g by the rotatory movement of the block itself. The
areas of pressure and suction are determined by the swash plate f. The surface of the swash plate is so designed that the oil
pressure always remains within acceptable limits. The oil in each chamber is drawn in and discharged through holes in the
valve plate h.
10-27

HYDRAULIC PUMP
12
OPERATION
PUMP OPERATION
1.
The cylinder block g rotates together with the shaft b and the shoe
e slides on the flat surface A. The swash plate d moves along the
cylindrical surface B. The angle formed between the center line
of the shaft and the center line X of the swash plate changes, thus
modifying the axial position of the pistons in relation to the cylinder block. Angle is known as the swash plate angle.
2.
When the center line X of the swash plate d maintains the angle
in relation to the center line of the shaft b, and hence also of the
cylinder block g, the flat surface A acts as a cam for the shoe e.
As the piston f rotates and slides inside the cylinder block, it creates a difference between the volumes C and D which provokes
intake and discharge of the oil in quantities equal to the difference
between the volumes (D - C = delivery). As the cylinder block
rotates, chamber D loses volume while the volume of chamber C is
increased, thus provoking an intake of oil. The figure indicates the
state of the pump when the intake of chamber D and the delivery of
chamber C have been completed.
3.
When the center line X of the swash plate d and the center line of
the cylinder block g are perfectly aligned (the swash plate angle
= 0), the difference between the volumes C and D within the cylinder block becomes 0 and the pump does not take in or deliver any
oil. In practice the swash plate angle never becomes = 0. Pump
delivery is directly proportional to the swash plate angle .
CONTROL OF DELIVERY
1.
As the swash plate angle grows larger, the difference between

volumes C and D increases, and the delivery Q also increases. The
swash plate angle is modified by servo pistons I and J.
2.
The servo piston I moves in a reciprocating linear motion caused

by pressure signals from the PC and LS valves. The linear movement is transmitted to the swash plate D, which is supported by the
cylindrical surface of the cradle C. The swash plate therefore has a
semi-circular reciprocating movement.
3.
The surfaces of the servo pistons receiving the pressures PP and

LS are dissimilar. The delivery pressure PP of the main pump is
always passed into the smaller (upper) pressure chamber, whereas
the pressure PEN coming from the LS valve is passed into the
larger (lower) pressure chamber.
The movement of the servo piston is governed by the relationship
between pressures PP and PEN, as well by the proportions between the surfaces (larger and smaller) of the servo piston.
10-28

12
PC
VALVE, LS VALVE, SERVO PISTON
POWER GOVERNOR
b
c
HYDRAULIC PUMP
Spring
Servo Piston
Servo Piston
LS VALVE
PC VALVE
E
F
G
H
Piston
Spring
Servo Piston
Spring
LS VALVE FUNCTION
The LS valve controls the pump delivery according to the stroke of the control valve level, i.e., in function of the delivery
demands made by the actuators. The LS valve detects the valve delivery needs by means of the differential pressure
UPLS existing between the pump delivery pressure PP and the pressure PLS coming from the control valve. This reading permits control of the main pump delivery Q. PP, PLS and UPLS are, respectively, the pump pressure, the Load
Sensing pressure, and the difference in pressure between these two values.
The LS valve detects the pressure difference UPLS generated by the passage of the oil flow through the surface freed by
the control valve spool, and controls the pump delivery Q so as to keep the pressure drop constant. Pump delivery is proportional to the demands made known by the control valve.
10-29

HYDRAULIC PUMP
12
OPERATION
1.
When the control valve is in a NEUTRAL position.
The pressure PLS of the LS coming from the control valve outlet passes into chamber a of the spring of the LS valve.
The pressure PP of the pump passes into chamber b of the opposite side.
The piston rod movement e is determined by the combination of the force generated by the pressure PLS, the force of
the spring g and the force generated on the side opposite the piston rod by the pressure PP.
Before the engine is started the servo piston d is pushed to the right by the spring b, corresponding to the maximum angle
of the swash plate.
If all the control valve spools are in their NEUTRAL position when the engine is started, the pressure PLS of the LS will
remain at 4.1 to 8.16 kg/cm because no oil is flowing through the control valve. At the same time the pump pressure PP
increases and is maintained at a value of about 27.54 kg/cm.
For this reason the piston e is thrust to the right (J) and a passage is formed between the delivery lines c and d. This
opening enables the pump pressure PP to enter chamber X of the servo piston d.
Although the pump pressure PP is always passed into chamber Y of the servo piston c, since the force exerted by that
pressure on piston d exceeds the force exerted on piston, the servo piston b moves to the right (J), i.e. towards the side
of the minimum angle of the swash plate.
10-30

HYDRAULIC PUMP
12
2. When a control valve lever is activated
When the control valve lever is moved out of its NEUTRAL position, the opening f is determined, allowing an LS signal
to be generated.
Until the UPLS generates a force less than the force exerted by the spring g on the spool e, the system will remain stable.
When the opening f is such as to provoke a reduction in UPLS, the spool moves to the left (I) to form a passage between delivery lines d and e. The chamber X loses pressure and the servo piston causes the swash plate to move towards
maximum displacement.
Equilibrium is reestablished in the system when the pressure UPLS generates on the spool e the difference in force exerted by the spring g, and the passage between delivery lines c and d is reopened.
10-31

HYDRAULIC PUMP
12
3. When the control valve opening is at its maximum, lever at the end of its stroke.
When the control lever is moved to full stroke, the spool opening reaches its maximum, the difference between the pump
pressure PP and the LS pressure PLS becomes smaller, differential pressure UPLS.
The LS pressure PLS introduced into the chamber a of the LS valve becomes about the same as the pump pressure PP
and the piston e is moved to the left (I) by the combined forces generated by the pressure PLS and the spring g. The
piston movement closes the delivery line c and forms a passage between lines d and e.
The pressurized oil present in the chamber X of the servo cylinder D flows through the lines d and e and reaches the
pump drainage chamber, so that the pressure in chamber X of the servo cylinder B becomes equal to the drainage pressure.
The servo piston D is thus moved to the right (J) by swash plate movement due to the pressure PP in the chamber Y of
the servo cylinder C. It is drawn in the direction of the increase in angle of the swash plate.
10-32

HYDRAULIC PUMP
12
4. When the spool makes very small movements, fine control.
When the control valve lever moves in very small increments towards the NEUTRAL position, when the control valve
opening f diminishes, the differential pressure UPLS between the pump pressure PP and the LS pressure PLS increases.
If the differential pressure UPLS generates on the spool e a difference in force that exceeds the force exerted by the
spring g, the spool moves to the right (J) and a passage is formed between the delivery lines c and d. The pressure PP
is introduced into the chamber X and the swash plate moves towards its minimum angle.
When the control valve lever performs small movements towards the position of maximum opening, when the opening f
of the control valve increases, the differential pressure UPLS diminishes.
If the differential pressure UPLS generates on the spool e a force difference that does not exceed the force exerted by
the spring g, the spool moves to the left (I) and a passage is formed between the delivery lines d and e. The chamber X
loses pressure and the servo piston provokes a movement of the swash plate towards maximum displacement.
Equilibrium is reestablished in the system when the pressure UPLS generates on the spool e the difference in force exerted by the spring g, and hence the passage between delivery lines c and d is also reopened.
10-33

HYDRAULIC PUMP
12
5. When pump flow matches the demands of the control valve
A1 will be the surface of the servo piston d, A2 the surface of the servo piston (2), PEN the pressure acting on the piston
b and PP the pressure acting on the piston side c.
When pump delivery reaches the quantity demanded by the control valve, the pump pressure PP in chamber b of the LS
valve is in equilibrium with the combined forces of the LS pressure PLS in chamber a, and the force exerted by the
spring g. Once equilibrium has been reached the piston e stops in the central position.
In this condition the passage from chamber c to chamber d remains only slightly open in order to maintain pressure in
chamber d. A flow of oil is introduced into the servo cylinder d at a pressure that balances the force generated by the
pump pressure PP in the cylinder c. PEN x A1 = PP x A2.
The stability of the equilibrium is guaranteed by a flow stabilized by the throttle g.
The force of the spring g is regulated so that the piston e is in equilibrium when PP - PLS = UPLS = 18.36 kg/cm.
The pump flow is made proportional to the section of the opening of the control valve, which maintains the differential
pressure. UPLS = 18.36 kg/cm.
10-34

HYDRAULIC PUMP
12
PC VALVE FUNCTION
The PC valve performs an approximate power check, and ensures

that the hydraulic horse power absorbed by the pump does not exceed the horse power delivered by the endothermal engine.
This is achieved by limiting the pump delivery Q in function of the

delivery pressure PP, even if the LS valve requests an increase in
delivery Q due to the larger section freed by the control valve
spool, in the presence of high pressure pump delivery.
During operation the delivery Q increases and the delivery pressure

PP also increases simultaneously, the PC valve reduces the pump
delivery Q. When the delivery pressure PP decreases, the PC
valve increases the pump flow.
The relationships between the pump delivery pressure PP and the

delivery Q are shown.
10-35

HYDRAULIC PUMP
12
Operation
1.
When the load on the actuators is heavy, high pump delivery pressure
When a higher delivery is required, the LS valve receives a signal from the control valve to bring the pump up to maximum displacement. When the swash plate moves it also moves the bushing c joined to it by the pin b, which releases the
spring d.
As the pressure of the actuators increases, pressure also increases in the delivery line c. When the calibrated setting of the
spring d is reached, the piston rod e is thrust to the left (I) and the passage between chamber b and the pump drainage
chamber a is opened.
The opening of the passage between the chambers b and a generates a flow of oil and hence, due to the calibrated hole g,
a UP is generated between chambers f and g at the sides opposite the spool f. UP = PP - PPC
When the value of PP exceeds the value of the spring loading h the spool f moves to the right (J) opening the passage
between the delivery lines d and e and sending the pump pressure PP towards the servo cylinder i. The pressure PP introduced into chamber X of the cylinder pushes it towards the minimum angle of the swash plate (I).
10-36

HYDRAULIC PUMP
12
2. When equilibrium has been reached
When the piston i is pushed to the left (I) the bushing c is also moved. The oil flow between the chambers b and a is reduced and the PPC pressure tends to approach the PP pressure value. The UP decreases and the spool f is pushed to the left
(I) by the force of the spring h.
Equilibrium is reached when the force generated by the PP pressure, the force generated by the PPC pressure, and the
force of the spring h are all balanced. The force generated by PP = the force generated by the PPC + the spring force.
In this condition the passage from chamber d to chamber e remains only slightly open in order to maintain pressure in
chamber e. A flow of oil is introduced into the cylinder i at a pressure that balances the force generated by the pump
pressure PP acting on the cylinder j. PEN x A1 = PP x A2
The stability of this equilibrium is generated by a continuous stabilized flow from the throttle 1).
10-37

HYDRAULIC PUMP
12
3. When the load on the actuators decreases, pump delivery pressure drops
When the load on the actuators diminishes and the pump delivery pressure PP drops, the PPC. pressure also drops.
The reduction in the PPC causes the spool e to move and the passage between chambers b, d and a is closed. The PPC
pressure and the PP pressure of the pump are equalized due to the interruption of the oil flow through the calibrated hole
g and the UP becomes zero UP = PP - PPC = 0.
The spring h pushes the spool f to the left (I) closing the passage between the chambers d and e and opening the passage between chambers e and g.
The pressurized oil present in chamber X of the servo cylinder i passes through chambers e and g and reaches the pump
drainage chamber, so that the pressure in chamber X of the servo cylinder becomes equal to the drainage pressure. The
servo piston j is caused to move by the PP pressure in chamber Y of the servo cylinder, in the direction of the increase
in the angle of the swash plate.
10-38

HYDRAULIC PUMP
12
4. The function of the spring
The loading on the springs d and 1! of the PC valve changes in

proportion to the angle of inclination of the pump swash plate. The
compression of the spring varies with the movements of the servo
piston i. When the piston moves to the left (I), the spring is compressed. If the piston moves even further to the left (I), the spring
1! comes into action to increase the loading. The overall loading of
the springs is varied by the piston, which either compresses or releases them.
The pump absorption torque curve, which indicates the relationship

between the pump delivery pressure PP and the delivery Q, is a
broken line. The position in which the piston i stops, the pump absorption torque, is determined by the position in which the PPC
pressure applied to the spool e is balanced by the force exerted by
the springs d and 1!. As pump delivery pressure PP increases, delivery Q decreases, and as pressure PP diminishes, pump delivery
Q increases.
10-39

HYDRAULIC PUMP
12
WORKING MODE SOLENOID VALVE
Function
Calibration of the pump absorption torque is normally performed

for the working mode E. When the solenoid valve of the working
mode is commutated the absorbed power of the pump is increased,
as indicated by the working mode curve.
Operation
WORKING MODE E
During normal operation, working mode E, the PC valve intervenes when a UP1 is generated equal to the loading on
the spring e.
The UP1 is generated by the calibrated hole d in the spool of the PC valve c when, at a determined pump delivery
pressure P1, the valve b puts the delivery line a into discharge, thus generating a flow F1 in the delivery line a.
10-40

HYDRAULIC PUMP
12
WORKING MODE P
When the solenoid valve g is commutated, working Mode P, the pressurized oil coming from the pump changes its route
and passes through the throttle f, which has a larger diameter than the calibrated hole d.
Because the throttle f has a larger diameter, the UP2 generated is less than is needed to overcome the force generated by
the spring e. The spool of the PC valve c is therefore pushed to the left (I) by the force of the spring. This shift obliges
the pump to increase displacement and hence the delivery.
The increase in flow causes an increment of the UP2 which, when the loading value of the spring is reached, allows the
spool to shift to the right (J).
The pump starts to work in normal fashion once again, and all the valves recommence normal functioning.
10-41

12
STEERING
STEERING UNIT
UNIT
a.
Port LS From the loader control valve
b.
Port T
To the hydraulic oil tank
c.
Port L
To the steering cylinder
d.
Port D
To the steering cylinder
e.
Port P
From the loader control valve
TECHNICAL DATA
Steering unit type .................................................LAGCSDS160P
Displacement ............................................................... 160 cc/rev.
OPERATION
The steering unit consists of a control valve and a rotating oil dispenser, and is of the hydrostatic type. When the steering wheel is
turned, the control valve sends oil from the pump P2, by means of
the rotating oil dispenser, to one side of the steering cylinder.
The rotating dispenser ensures that the volume of oil supplied to the
cylinder is proportionate to the angle of rotation of the steering
wheel. In the event of malfunction, the rotating oil dispenser will
function automatically as a hand pump, thus guaranteeing auxiliary
steering.
10-42

12
LOADER
LOADER VALVE
VALVE
2 SPOOL
a
b
c
d
e
f
g
h
j
b
c
d
e
f
g
Port D - To the Hydraulic Steering Unit

Port A2 - To the Bucket Cylinders
Port A1 - To the Boom Cylinders
Port LS - To the Pump
Port T - To the Hydraulic Oil Tank
Port P - From the Pump
Loader Relief Valve

Plug
Ball
Check Valve Spring
Priority Valve Piston Rod
Priority Valve Spring
Port B1 - To the Boom Cylinders

Port B2 - To the Bucket Cylinders
Port DLS - To the Hydraulic Steering Unit
Unit : mm
Check Item
Free
Length
h
i
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Check Valve Spring

10-43

b
c
d
e
f
Port Plug
Boom Raise Spool
Spool Return Spring
Spool Locking Spring
Detent Ball
G
H
I
J
1)
LOADER VALVE
Detent Lock Ball

Compensator
Anti Cavitation Valve
1! Holding Coil
1@ Check Valve Spring
1# Check Valve
Bucket Dump Spool

Spool Return Spring
Unit : mm
Check Item
Free
Length
1$
1%
1^
1&
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Spool Return Spring

Spool Return Spring
Check Valve Spring
10-44

12
3 SPOOL
a
b
c
d
e
f
g
h
j
LOADER VALVE
VALVE
k
m
b
c
d
e
f
g
Port D - To the Hydraulic Steering Unit

Port A3 - To the Auxiliary Cylinders
Port A2 - To the Bucket Cylinders
Port A1 - To the Boom Cylinders
Port LS - To the Pump
Port T - To the Hydraulic Oil Tank
Port P - From the Pump
Port B1 - To the Boom Cylinders
Port B3 - To the Auxiliary Cylinders

Port DLS - To the Hydraulic Steering Unit
Loader Relief Valve
Plug
Ball
Check Valve Spring
Priority Valve Piston Rod
Port B2 - To the Bucket Cylinders

Unit : mm
Check Item
Free
Length
h
i
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Check Valve Spring

10-45

LOADER VALVE
12
b
c
d
e
f
Port Plug
Boom Raise Spool
Spool Return Spring
Detent Ball
G
H
I
J
1)
Detent Lock Ball

Compensator
Anti Cavitation Valve
Bucket Dump Spool
1!
1@
1#
1$
Holding Coil
Check Valve Spring
Check Valve
Auxiliary Spool
Spool Return Spring

Unit : mm
Check Item
Free
Length
1%
1^
1&
1*
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy

Spool Return Spring
Check Valve Spring
Spool Return Spring
10-46

12
BACKHOE
BACKHOE CONTROL VALVE
CONTROL VALVE
MECHANICAL CONTROL
10-47

12
A
B
C
D
E
F
G
H
I
Inlet Section
Arm Cylinder Section
Swing Cylinder Section
Right Outrigger Cylinder Section
Left Outrigger Cylinder Section
Bucket Cylinder Section
Boom Cylinder Section
Telescopic Arm Cylinder Section
Hammer Cylinder Section
J
A1
A2
A3
A4
A5
A6
A7
A8

Outlet Section
Arm Cylinder Barrel
Right Swing Cylinder Barrel
Right Outrigger Cylinder Barrel
Left Outrigger Cylinder Barrel
Bucket Cylinder Barrel
Boom Cylinder Barrel
Telescopic Arm Cylinder Barrel
B1
B2
B3
B4
B5
B6
B7
B8
Arm Cylinder Rod

Right Swing Cylinder Rod
Right Outrigger Cylinder Rod
Left Outrigger Cylinder Rod
Bucket Cylinder Rod
Boom Cylinder Rod
Telescopic Arm Cylinder Rod
Hammer Inlet Port
Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve
b Return Spring
C Retainer Plug
D Pressure Cut Out Valve
E Unloading Valve
Unit : mm
Check Item
Free
Length
f
Return Spring
10-48
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

12
ARM SECTION VIEW C-C
a Adjustable Circuit Relief Valve

D Arm Cylinder Spool
b LIFD - Load Independent Flow Divider e Spool Return Spring
C Port Plug
f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Check Valve Return Spring
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-49

12
SWING SECTION VIEW D-D

D Swing Cylinder Spool
C Adjustable Circuit Relief Valve
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

10-50
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

12
LEFT OUTRIGGER SECTION VIEW E-E
a Port Plug
D Left Outrigger Cylinder Spool
C Port Plug
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-51

12
RIGHT OUTRIGGER SECTION VIEW F-F
a Port Plug
D Right Outrigger Cylinder Spool
C Port Plug
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

10-52
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

12
BUCKET SECTION VIEW G-G
a Circuit Relief Valve

D Bucket Cylinder Spool
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-53

12
BOOM SECTION VIEW H-H

D Boom Cylinder Spool
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball
10-54

12
TELESCOPIC ARM SECTION VIEW K-K
a Port Plug
D Telescopic Arm Cylinder Spool
C Anti Cavitation Valve
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-55

12
HAMMER SECTION VIEW L-L

D Hammer Spool
C Port Plug
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

10-56
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

12
EXCAVATOR
CONTROL
10-57

12
A
B
C
D
E
F
G
H
I
Inlet Section
Arm Cylinder Section
Swing Cylinder Section
Right Outrigger Cylinder Section
Left Outrigger Cylinder Section
Bucket Cylinder Section
Boom Cylinder Section
Telescopic Arm Cylinder Section
Hammer Cylinder Section
J
A1
A2
A3
A4
A5
A6
A7
A8

Outlet Section
Arm Cylinder Barrel
Right Swing Cylinder Barrel
Right Outrigger Cylinder Barrel
Left Outrigger Cylinder Barrel
Bucket Cylinder Barrel
Boom Cylinder Barrel
Telescopic Arm Cylinder Barrel
B1
B2
B3
B4
B5
B6
B7
B8
Arm Cylinder Rod

Right Swing Cylinder Rod
Right Outrigger Cylinder Rod
Left Outrigger Cylinder Rod
Bucket Cylinder Rod
Boom Cylinder Rod
Telescopic Arm Cylinder Rod
Hammer Inlet Port
Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve
b Return Spring
C Retainer Plug
D Pressure Cut Out Valve
E Unloading Valve
Unit : mm
Check Item
Free
Length
f
Return Spring
10-58
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

12
ARM SECTION VIEW C-C

D Arm Cylinder Spool
C Port Plug
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-59

12
SWING SECTION VIEW D-D

D Swing Cylinder Spool
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

10-60
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

12
LEFT OUTRIGGER SECTION VIEW E-E
a Port Plug
b LIFD - Load Independent Flow Divider
C Port Plug
D Left Outrigger Cylinder Spool

e Spool Return Spring
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-61

12
RIGHT OUTRIGGER SECTION VIEW F-F
a Port Plug
D Right Outrigger Cylinder Spool
C Port Plug
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

10-62
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

12
BUCKET SECTION VIEW G-G

D Bucket Cylinder Spool
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-63

12
BOOM SECTION VIEW H-H

D Boom Cylinder Spool

f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball
10-64

12
TELESCOPIC ARM SECTION VIEW K-K
a Port Plug
C Anti Cavitation Valve
D Telescopic Arm Cylinder Spool

f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
10-65

12
HAMMER SECTION VIEW L-L

D Hammer Spool
C Port Plug
f Check Valve
Unit : mm
Check Item
Free
Length
h
i
Spool Return Spring

10-66
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace

CLSS
12
CLSS
CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has
the following characteristics:
High precision control that is independent of the load applied to the

movement;
High precision control of digging action even during delicate manoeuvres.
Ability to perform complex operations, guaranteed by control of oil

flow in function of the aperture surfaces of the shuttles.
Energy savings guaranteed by control of pump delivery.
STRUCTURE
The CLSS system includes the variable flow pump, the control
valve and the working equipment.
The pump includes the main pump, the PC valve and the LS
valve.
10-67

12
OPERATING
1.
CLSS
PRINCIPLES
Control of the angle of the pumping plate.
The angle of the swash plate and the pump delivery, is controlled in such a way that the differential pressure UPLS
between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards the
actuator is maintained at a constant value. UPLS = pump delivery pressure PP minus pressure PLS of delivery to
the actuator.
If the differential pressure UPLS becomes lower than the set pressure of the LS valve, the angle of the swash plate
increases, delivery increasing.
If the differential pressure UPLS increases, the angle of the swash plate decreases.
10-68

CLSS
12
2. Pressure compensation control.
The pressure compensation valves are installed downstream from the control valve in order to balance the differential
pressure between the loads.
When two or more movements (cylinders) are activated simultaneously, the pressure differences UP between the
delivery at the control valve inlet and outlets of the control valve are compensated by these valves. This will obtain
the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
10-69

12
UNLOADING
CLSS
VALVE
FUNCTION
1.
When the control valve is in the NEUTRAL position, the flow of the pump, due to the swash plate being in the minimum
angle position, is sent to the control valve. In these conditions, the pump delivery pressure PP is regulated to 27.5 kg/cm
by the spring a inside the valve. PP = PLS + spring load with PLS = 6.1 kg/cm
OPERATION
When the control valve is in the NEUTRAL position
On the two surfaces of the shuttle b, the pump pressure PP acts on the right side, while the LS signal with pressure PLS
acts on the left side.
Because a LS signal is generated with a pressure PLS 6.1 2 kg/cm, when the control valve is in the NEUTRAL position, the pump delivery pressure PP is regulated by the combination of the pressure provided by the spring and by the LS
pressure PLS.
While the pump delivery pressure PP increases until it compensates for the loading on the spring a and for the LS pressure 27.5 kg/cm, the shuttle b moves to the left (I) and the PP circuit is put into communication with the tank circuit T.
This system ensures that the pump delivery pressure PP stays regulated at 27.5 kg/cm.
10-70

CLSS
12
1. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less than the
delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is regulated by the pressure PLS + 21.5 kg/cm. Because the unloading valve opens when the differential pressure between the pump delivery
pressure PP and the PLS LS pressure becomes equivalent to the loading of the spring a (21.5 kg/cm), the differential
LS pressure UPLS LS becomes 21.5 kg/cm.
Final control of control valve
When final control are performed with the control valve, a pressure PLS is generated that pressurizes the spring chamber,
acts on the left extremity of the valve b. The actuator pressure is introduced into the LS circuit and then into the spring
chamber. As a result, the pump pressure PP tends to increase.
When the differential pressure between the pump delivery pressure PP and the LS pressure PLS has the same value as
the loading on the spring a (21.5 kg/cm), the shuttle b moves to the left (I) and the pump circuit PP puts itself into
communication with the tank circuit T. The exceeding pump delivery, relative to the actuator request, is sent to the tank
circuit.
The pump delivery pressure PP is regulated by the combination of the pressure provided by the spring, 21.5 kg/cm, and
by the LS pressure PLS, i.e. when the pressure differential UPLS reaches the value of 21.5 kg/cm.
10-71

CLSS
12
2. When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control
valve, the connection to the tank circuit is eliminated and all the pump delivery is sent to the actuators.
When the control valve is in use
When the control valve shuttle is operated to execute a bigger stroke, the opening section of spool becomes bigger and
consequently the controlled delivery. Because the control valve passage is large, the difference between the LS pressure
PLS and the pump delivery pressure PP is reduced to 18.4 kg/cm, LS pump valve setting.
Because the differential pressure between the pump delivery pressure PP and the LS pressure PLS is not equal to the
pressure given by the spring loading a, 21.5 kg/cm, the shuttle b is pushed to the right (J) of the spring.
The result is that the connection between the pump delivery circuit PP and the tank circuit T is excluded and the entire
pump delivery is sent to the actuators.
10-72

12
INTRODUCTION
CLSS
OF THE LS PRESSURE
The LS pressure is the pressure generated by external forces acting on the actuators at the outlet of the control valve.
OPERATION
When the spool b is activated, pump pressure PP starts to flow into the actuator circuit A through chamber b.
At the same time the compensator c moves upwards (K) so that the flow controlled by spool b can flow towards the actuator A. Check valve a do not allow any flow up to when pressure in chamber c is higher than pressure in chamber b.
Pressure downstream of the spool flows in the PLS circuit downstream the compensator valve through the orifice d.
The PLS circuit of the LS is thus in communication with the tank circuit T by means of the LS decompression valve d.
The system stabilizes when a pressure difference of 18.4 kg/cm is generated across the spool b between pump pressure
PP and PLS pressure.
10-73

12
DELIVERY
CLSS
COMPENSATION
INTRODUCTION
The flow sent to each actuator is controlled by the opening area of each spool. While performing complex control, in traditional control valves the difference between actuators pressure might cause sudden and unexpected movements acceleration in
those actuators operated at lower pressure. The adoption of the pressure compensation valve allow to control those situation
guarantying the proportionality between each actuator. Compensation of actuator deliveries occurs when, during the simultaneous activation of two or more movements, the pressure of one actuator drops lower than that of the other, and pump delivery,
if not controlled, tends to be supplied the actuator operating at lower. In the diagram the actuator on the left is requesting
higher pressure.
OPERATION
1.
When activating an actuator at a pressure lower than the one already working. While operating actuator A starts operating
actuator B.
Until the pressure PBV downstream from the shuttle b reaches the same value requested by actuator B, no oil passes.
When the pressure requested by actuator B is exceeded, movement can commence. This creates a flow that adding to the
one controlled by spool d reduces the pressure upstream of spool b and d and therefore the UP between PLS and PP.
The pump compares the delivery pressures PP and PLS and senses that the difference UP<18.4 kg/cm. This variation
in UP causes an increase in oil flow increasing the swash plate angle. Until the pump realizes a UP of 18.4 kg/cm, i.e.
until the increase in oil flow compensates the requirements of the two actuators, the pump will continue to increase delivery.
UP of 18.4 kg/cm, will stabilize as soon as it is restored to. The compensator C is moved upwards by the oil flow and
stops when the aperture between the chambers a and b reduces the passage sufficiently to reduce the pressure in chamber
b to be sent to the actuator.
10-74

CLSS
12
2. When a low pressure actuator needs to work at a higher pressure than the other
If the actuator B needs to work at a higher pressure, PB>PA, the pressure PB will start to increase.
Since pressure PB is increasing, the compensator c moves upwards to restore the UP between the chambers a and b,
and therefore the UP does not vary upstream or downstream from the shuttle b.
When pressure PB exceeds pressure PA the compensator c is fully open and the pressure PB is introduced into the LS
circuit.
The increased pressure in the LS circuit obliges the pump to increase delivery until the UP is restored to 18.4 kg/cm.
Simultaneously the increase in pressure upstream from the shuttle d generates an increase in UP upstream and downstream from the shuttle. (PAV<PLS<PP)
Because the pressure PLS which is equal to the pressure PB acts on the upper side of the compensator a, and since the
pressure PAV is lower, the compensator is pushed downwards.
The compensator stops when the aperture between the chambers c and d generates a reduction of the passage sufficient to
reduce the pressure to be sent to the actuator, and to increase the pressure PAV until the UP is restored to the 18.4 kg/cm
necessary for equilibrium.
10-75

CLSS
12
3. When an increase in delivery is required by an actuator
When an increased delivery is required by actuator A, i.e. when the shuttle d is asked to execute a bigger movement, the
section of the aperture increases.
The increase in aperture provokes a drop in UP between the two sides of the shuttles b and d, because the flow, which
has remained unchanged until now, is divided between both the actuators.
At the same time the pump senses the variation in UP and increases the oil flow until the UP is restored to UP of 18.4
kg/cm between the two sides of the shuttle d and the compensator a changes position in order to restore the UP upstream and downstream from the shuttle d.
10-76

12
LIFD
CLSS
CONTROL SYSTEM
FUNCTION
The Load Independence Flow Divider, LIFD, intervenes automatically when the oil flow requested by the actuators exceeds the maximum delivery guaranteed by the pump. In this case, the oil flow is divided between the various actuators in
proportion to their requirements.
OPERATION
When, during the simultaneous operation of more than one actuator, one of them needs a higher pressure and the characteristics of the pump are exceeded, the pump guarantees a delivery limited by its calibration curve. At this point less oil
than requested is distributed to all the actuators.
Because the sections of the apertures remain unchanged, the pressure upstream and downstream from the shuttles drops.
Since the position of the compensator e is determined by the pressure of the LS signal, by the pressure PBV downstream from the shuttle d and by the flow of oil needed for the movement, the compensator is pushed downwards by the
higher pressure in the upper chamber until the pressure PBV downstream from the shuttle becomes equal to the pressure
PAV downstream from the shuttle b. This equalizes the pressure UP of the shuttle.
Thus the flow of each actuator is reduced by a percentage equal to the reduction or absence of pump delivery. When the
request for performance is excessive, the system can nevertheless guarantee proportionality and gradually for the movements in any load conditions.
If an increase in delivery is requested, rather than an increase in pressure, and the characteristics of the pump are exceeded, the system will function in the same way as described for the above case.
10-77

12
LS
CLSS
DECOMPRESSION VALVE
DESCRIPTION
The LS decompression valve is a throttle that continuously releases a
small quantity of oil from the LS circuit and that, when the shuttles are
brought back to a neutral position, releases the residual LS pressure.
This continued flow renders the PLS pressure increment more gentle
and gradual, and increases stability and control during the phases of
reducing the LS pressure.
OPERATION
When the LS pressure reaches chamber a of the valve, it generates

a force that opposes the force of the spring a.
Until the force generated by the LS pressure exceeds the force of

the spring a, LS pressure low, the shuttle b remains at rest and oil
flows through the calibrated orifice b in the tank circuit.
When the force generated by the LS pressure exceeds the force of

the spring a, the shuttle is pushed upwards (K) and the passages c
are closed. Oil continues to flow into the chamber d until the force
generated by the pressure contained in chamber d, together with
the force of the spring, exceeds the force generated by the LS pressure.
The shuttle is pushed downwards (L) and passage c is opened. The

system is in equilibrium, i.e. the shuttle is at rest, when the quantity
of oil allowed to flow into the tank circuit is equivalent to the quantity that generates a pressure difference UP such that PLS x S =
[PLS1 x S + F] where: PLS = LS pressure
PLS1 = LS pressure contained in chamber d

S = Section of the shuttle
F = Force of the spring
10-78

12
PRESSURE
CLSS
CUT OFF VALVE
DESCRIPTION
The function of the pressure cut off valve is to regulate the maximum
pressure of the LS signal and hence also the pressure of the pump.
OPERATION
The pressurized oil of the LS reaches the chamber a of the valve.
When the force generated by the LS pressure on the valve b exceeds the force of the spring a, the valve is pushed upwards (K)
opening the passage between the chamber a and the tank circuit.
10-79

12
PRIORITY
CLSS
VALVE
FUNCTION
The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic components. Distribution is
determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from the pump, the pressure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is such as to guarantee that delivery
to the steering unit will always correspond to the actual need.
10-80

12
PPC
PPC JOYSTICK
JOYSTICK
LEFT VALVE
a
b
c
d
e
f
Port 1
Port T
Port 4
Port 3
Port P
Port 2
To Backhoe Arm Control Valve - Crowd In .................................... Port PA1

To Hydraulic Tank
To Backhoe Swing Control Valve - Right ....................................... Port PB2
To Backhoe Arm Control Valve - Crowd Out.................................. Port PB1
To Solenoid Valve Group - ST2 ..................................................... Port S1
To Backhoe Swing Control Valve - Left.......................................... Port PA2
10-81

12
RIGHT
a
b
c
d
e
f
VALVE
Port 1
Port T
Port 4
Port 3
Port P
Port 2
10-82
PPC JOYSTICK
To Backhoe Boom Control Valve - Lower ...................................... Port PA6

To Hydraulic Tank
To Backhoe Bucket Control Valve - Dump..................................... Port PA5
To Backhoe Boom Control Valve - Raise....................................... Port PB6
To Solenoid Valve Group - ST2 ..................................................... Port S1
To Backhoe Bucket Control Valve - Curl........................................ Port PB5

12
SOLENOID
SOLENOID VALVE
VALVE
DIFFERENTIAL LOCK - BACKHOE BOOM LOCK
A EV4
B EV3
Backhoe Boom Lock
Port T
To the Transmission
Port 1
Boom Lock Cylinder
Port 2
To the Rear Axle
Port P
From the Transmission
Differential Lock
10-83

12
PPC
A
B
c
d
e
SOLENOID VALVE
SUPPLY VALVE - ST2
Y14
PPC Valve
ACC
Accumulator
Y23
Right Outrigger Lower
To Backhoe Control Valve Port M
Y16
Right Outrigger Raise
S1
To PPC Valve Port P
Y24
Left Outrigger Raise
A1
To Backhoe Right Outrigger Valve Port PA4
Y15
Left Outrigger Lower
A2
To Backhoe Left Outrigger Valve Port PA3
B2
To Backhoe Left Outrigger Valve Port PB3
B1
To Backhoe Right Outrigger Valve Port PB4
To Hydraulic Tank
10-84

12
PPC
SOLENOID VALVE
TELESCOPIC ARM
A Y22
B Y21
Telescopic Arm Retract
To Backhoe Control Valve Port PA7
Telescopic Arm Extend
To Backhoe Control Valve Port PB7
To PPC Supply Valve ST2 Port S1
To Hydraulic Tank
10-85

12
PPC
SOLENOID VALVE
HAMMER
A Y20
10-86
Hammer
To Hydraulic Tank and Backhoe Control

Valve Port PB8

12
PPC
SOLENOID VALVE
ARM AND HAMMER
A
B Y22
c Y21
Hammer
To Hyd. Tank and Control Valve Port PB7
Telescopic Arm Retract
Telescopic Arm Extend
A1
To Backhoe Control Valve Port PB7
B1
10-87

12
LOADER
LOADER CYLINDERS
CYLINDERS
BOOM ARM
A Piston Rod Bushing

B Barrel Bushing
C Cylinder Barrel
D Piston Retaining Nut

E Four Piece Piston Seal
F Cylinder Piston
G Cylinder Rod
H Cylinder Head
Unit : mm
Check Item
Standard
Size
Criteria
Tolerance
Shaft
Hole
Standard
Clearance
Piston Rod to Head
50
49.975
49.950
50.15
50.25
0.175
0.300
Piston Rod Bushing and Pin
45
44.950
44.911
45.08
45.24
0.13
0.33
50
49.950
49.911
50.08
50.24
0.13
0.33
1)
Barrel Bushing and Pin
Clearance
Limit
Remedy
Replace
Replace pin
and bushing
CHARACTERISTICS
Unit: mm
Piston Rod Diameter ..................................................................................................................... 50
Max Cylinder Length ................................................................................................................ 1880
Cylinder Barrel Bore ..................................................................................................................... 85
Min Cylinder Length ................................................................................................................. 1150
Piston Stroke................................................................................................................................ 730
Rod Thread for Piston Nut ............................................................................................................ 55
10-88

LOADER CYLINDERS
12
BUCKET

B Barrel Bushing
C Cylinder Barrel
Check Item

F Cylinder Piston
Standard
Size
G Cylinder Rod
H Cylinder Head
Criteria
Tolerance
Shaft
Hole
Unit : mm
Remedy
Standard
Clearance
Clearance
Limit
i Piston Rod to Head
50
49.975
49.950
50.15
50.25
0.175
0.300
Replace
j Piston Rod Bushing and Pin
45
44.950
44.911
45.08
45.24
0.13
0.33
1) Barrel Bushing and Pin
50
49.950
49.911
50.08
50.24
0.13
0.33
Replace pin
and bushing
CHARACTERISTICS
Unit: mm
Piston Rod Diameter ...............................................................................................................50
Max Cylinder Length ..........................................................................................................2145
Cylinder Barrel Bore ...............................................................................................................85
Min Cylinder Length ...........................................................................................................1390
Piston Stroke..........................................................................................................................755
Rod Thread for Piston Nut ......................................................................................................55
10-89

12
MP
LOADER CYLINDERS
BUCKET

B Cylinder Rod
C Cylinder Head
D Cylinder Piston
F Piston Retaining Pin
G Cylinder Barrel
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ...........................................................................................................45
Max Cylinder Length ........................................................................................................705
Cylinder Barrel Bore ........................................................................................................... 80
Min Cylinder Length .........................................................................................................450
Piston Stroke......................................................................................................................230
10-90

12
BACKHOE
BACKHOE CYLINDERS
CYLINDERS
BOOM
A
B
C
D
Piston Rod Bushing

Barrel Bushing
Cylinder Barrel
Stop Ball
E
F
G
H
i
j
1)
1!
Four Piece Piston Seal

Cylinder Piston
Cylinder Rod
Cylinder Head
Set Screw
Stop Pin
Check Valve
Check Valve Spring
Unit : mm
Check Item
Standard
Size
1@
Piston Rod to Head
60
1#
50
1$
50
Check Item
1%
Check Valve Spring
Free
Length
35
Criteria
Tolerance
Shaft
Hole
59.97
60.03
59.924
60.076
49.95
50.08
49.911
50.24
49.95
50.08
49.911
50.24
Standard
Clearance
Clearance
Limit
0.06
0.152
0.13
0.33
0.13
0.33
Spring Criteria
Standard Size
Repair Limit
Installed
Installed
Free
Installed
Length
Load
Length
Load
Remedy
Replace
Replace pin
and bushing
Remedy
Replace
CHARACTERISTICS
Unit: mm
Piston Rod Diameter ........................................................................................................... 60
Max Cylinder Length ......................................................................................................2050
Cylinder Barrel Bore .........................................................................................................120
Min Cylinder Length .......................................................................................................1200
Piston Stroke..................................................................................................................... 850
Rod Thread for Piston .........................................................................................................41
10-91

BACKHOE CYLINDERS
12
ARM

B Barrel Bushing
C Cylinder Barrel

F Cylinder Piston
G Cylinder Rod
H Cylinder Head
i Piston Spacer
Unit : mm
Check Item
j
Standard
Size
Criteria
Tolerance
Shaft
Hole
Standard
Clearance
45
44.950
44.911
45.08
45.24
0.13
0.33
50.08
50.24
0.13
0.33
60.030
60.076
0.060
0.152
1)
50
49.950
49.911
1!
Piston Rod to Head
60
59.970
59.924
Clearance
Limit
Remedy
Replace pin
and bushing
Replace
CHARACTERISTICS
Unit: mm
Piston Rod Diameter ........................................................................................................... 60
Max Cylinder Length ..................................................................................................... 2175
Cylinder Barrel Bore ......................................................................................................... 110
Min Cylinder Length ...................................................................................................... 1255
Piston Stroke......................................................................................................................920
Rod Thread for Piston Nut ................................................................................................. 36
10-92

BACKHOE CYLINDERS
12
BUCKET

B Barrel Bushing
C Cylinder Barrel
Check Item

F Cylinder Piston
Standard
Size
G Cylinder Rod
H Cylinder Head
Criteria
Tolerance
Shaft
Hole
Unit : mm
Remedy
Standard
Clearance
Clearance
Limit
Piston Rod to Head
60
59.970
59.924
60.030
60.076
0.060
0.152
Replace
45
44.950
44.911
45.08
45.24
0.13
0.33
1)
50
49.950
49.911
50.08
50.24
0.13
0.33
Replace pin
and bushing
CHARACTERISTICS
Unit: mm
Piston Rod Diameter ......................................................................................................... 60
Max Cylinder Length .................................................................................................... 1850
Min Cylinder Length ..................................................................................................... 1085
Piston Stroke.................................................................................................................... 765
10-93

12
TELESCOPIC
BACKHOE CYLINDERS
ARM CYLINDER

B Barrel Bushing
C Cylinder Barrel
D Wear Rings
E Piston Seal
F Cylinder Piston
G Cylinder Rod
H Cylinder Head
Unit : mm
Check Item
Standard
Size
Criteria
Tolerance
Shaft
Hole
Standard
Clearance
Piston Rod to Head
40
39.975
39.936
40.025
40.064
0.050
0.128
40
39.950
39.911
40.08
40.24
0.13
0.33
40
39.950
39.911
40.08
40.24
0.13
0.33
1)
Clearance
Limit
Remedy
Replace
Replace pin
and bushing
CHARACTERISTICS
Unit: mm
Min Cylinder Length ..................................................................................................... 1450
Piston Stroke.................................................................................................................. 1140
10-94

BACKHOE CYLINDERS
12
SWING

B Cylinder Rod
C Cylinder Barrel
D Cushion Valve
E Piston Seal
F Cylinder Piston
G Retaining Screw
H Cylinder Head
Unit : mm
Check Item
Standard
Size
Criteria
Tolerance
Shaft
Hole
Standard
Clearance
Clearance
Limit
Remedy
Piston Rod to Head
50
49.970
49.924
50.025
50.064
0.055
0.140
Replace
50
49.950
49.911
49.881
49.950
- 0.069
- 0.039
Replace pin
and bushing
1)
Inner Bushing and Cylinder
45
45.050
45.034
44.975
45.000
- 0.075
- 0.034
1!
Inner Bushing and Outer Bushing
55
54.950
54.911
55.000
55.046
0.050
0.135
1@
Outer Bushing and Frame
65
65.060
65.041
65.000
65.046
- 0.060
- 0.005
Replace
CHARACTERISTICS
Unit: mm
Max Cylinder Length ...................................................................................................... 678
Cylinder Barrel Bore ....................................................................................................... 115
Min Cylinder Length .................................................................................................... 446.5
Piston Stroke................................................................................................................. 231.5
10-95

BACKHOE CYLINDERS
12
OUTRIGGER

B Barrel Bushing
C Cylinder Barrel
D Retarder Pin
E Piston Seal
F Cylinder Piston
G Cylinder Rod
H Cylinder Head
Unit : mm
Check Item
Standard
Size
Criteria
Tolerance
Shaft
Hole
Standard
Clearance
Piston Rod to Head
55
54.97
54.94
55.030
55.076
45
44.950
44.911
45.08
45.24
0.13
0.33
45
44.950
44.911
45.08
45.24
0.13
0.33
1)
0.060
0.136
Clearance
Limit
Remedy
Replace
Replace pin
and bushing
CHARACTERISTICS
Unit: mm
Cylinder Barrel Bore ....................................................................................................... 110
Min Cylinder Length ....................................................................................................... 850
Piston Stroke.................................................................................................................... 515
10-96

12
BOOM
BACKHOE CYLINDERS
LOCK CYLINDER
A Cylinder Rod
B Cylinder Head and Seal
c Piston and Seal
d Cylinder Barrel
10-97

12
FRONT
10-98
FRONT WORK EQUIPMENT
WORK EQUIPMENT

FRONT WORK EQUIPMENT
12
Unit : mm
Check Item
Standard
Size
Criteria
Tolerance
Shaft
Hole
Standard
Clearance
Bucket/Arm Bushing and Pin
45
44.950
44.911
45.08
45.24
0.130
0.329
Lever/Arm Bushing and Pin
45
44.950
44.911
45.08
45.24
0.130
0.329
Lever/Cylinder Bushing and Pin
45
44.950
44.911
45.080
45.119
0.130
0.208
Cylinder/Arm Bushing and Pin
45
44.950
44.911
45.080
45.119
0.130
0.208
Arm/Frame Bushing and Pin
50
49.962
49.917
50.08
50.24
0.118
0.323
Clearance
Limit
Remedy
Replace
10-99

12
REAR
REAR WORK EQUIPMENT
WORK EQUIPMENT
Unit : mm
Check Item
Standard
Size
Top Swing Pin and Bushing
65
Bottom Swing Pin and Bushing
65
Bucket/Arm Pin and Bushing
40
Bucket/Link Pin and Bushing
40
Link/Arm Pin and Bushing
45
Link/Cylinder Pin and Bushing
45
Boom/Arm Pin and Bushing
50
Swing/Boom Pin and Bushing
50
Outrigger/Frame Pin and Bushing
45
Outrigger/Pad Pin and Bushing
45
10-100
Criteria
Tolerance
Shaft
Hole
64.940
64.894
64.940
64.894
39.950
39.911
39.950
39.911
44.950
44.911
44.950
44.911
49.950
49.911
49.950
49.911
44.950
44.911
44.950
44.911
65.190
65.264
65.190
65.264
40.08
40.24
40.08
40.24
45.08
45.24
45.08
45.24
50.000
50.062
50.000
50.062
45.08
45.24
45.2
45.3
Standard
Clearance
0.25
0.37
0.25
0.37
0.130
0.329
0.130
0.329
0.130
0.329
0.130
0.329
0.050
0.151
0.050
0.151
0.130
0.329
0.250
0.389
Clearance
Limit
Remedy
Replace

REAR WORK EQUIPMENT
12
10-101

12
AIR
A
B
C
D
AIR CONDITIONING
CONDITIONING
Magnetic Clutch
Compressor
Condenser
Dryer Filter Tank
10-102
E
F
G
H
Safety Pressure Switch

Expansion Valve
I Cab Air Circulation Fan

J Air Conveyor
Evaporator
Clutch Control Sensor

AIR CONDITIONING
12
The compressor b is driven directly by the engine shaft by means of a
belt, and made to rotate by a pulley fitted with an electromagnetically
engaged clutch a. A thermostatic sensor h controls the engagement
and disengagement of the clutch. It disengages the clutch when the
evaporator reaches the lower temperature limit and engages when the
evaporator reaches the upper temperature limit.
The coolant fluid, in gaseous phase is drawn into the compressor where
it is subjected to compression and an intense heating process. In these
conditions the fluid is then sent into the condenser c where, due to the
heat extracted by ambient temperature air flowing over fins, it reaches
condensation temperature, and passes into a high pressure liquid state.
Subsequently the coolant passes into the dryer filter group d which performs three functions: it filters out impurities, absorbs any moisture
present in the circuit and, finally, also functions as a reserve tank. The
coolant in its liquid state is then transferred to the evaporator G, first
passing through an expansion valve F. The task of this valve is the constant metering of the quantity of fluid in order to maintain optimum
evaporation. In the evaporator the coolant fluid is subjected to expansion, bringing it up to the critical evaporation point at a temperature of
approximately -8C.
The air flow generated by the centrifugal fan I which passes through
the evaporator G at ambient temperature is considerably warmer than 8C. For this reason it yields heat to the coolant fluid, bringing it up to
boiling point and complete evaporation. On leaving the evaporator G
the coolant is drawn once more into the compressor d and a new cycle
commences. The yielding of heat from the atmosphere in which the
evaporator is positioned leads to the condensation of the water suspended in the air, and hence to dehumidification. The condensate is
deposited on the evaporator fins where, if a temperature higher than 0C
is not maintained, it freezes and inhibits the functioning of the evaporator. The task of keeping the temperature of the evaporator above 0C,
and thus within the optimum limits for heat exchange, is entrusted to a
thermostatic sensor H.
The condensate that forms on the evaporator fins G also contains dust,
pollens and particles suspended in the air. Continual condensation therefore effectively purifies the air, and the droplets of condensate are discharged to the exterior. A fixed quantity of anti freeze oil is also
introduced into the circuit, with the function of lubricating all the
mechanical parts of the unit. A percentage of this oil circulates constantly throughout the unit in nebulized form, lubricating the compressor, pistons and bearings and the expansion valve. A pressure switch E
has been inserted in the electrical control circuit to protect the unit in the
case of a lack of coolant fluid or if the quantity becomes insufficient due
to leakages. This switch will inhibit the engagement of the electromagnetic clutch and hence the functioning of the air conditioning unit.
10-103

10-104
AIR CONDITIONING
20
TESTING, ADJUSTING AND

TROUBLESHOOTING
STANDARD VALUE TABLES FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

STANDARD VALUE TABLES FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
WB140PS-2N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
WB150PS-2N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32
FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
TENSION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
COMPRESSOR DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
CHECKING TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
ACCELERATOR PEDAL AND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
ACCELERATOR PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
ACCELERATOR LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
BRAKE PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
HYDRAULIC OIL TANK PRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
WORK CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
CHECK BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
LOADER CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
BACKHOE CONTROLS STYLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
EXCAVATOR CONTROLS STYLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
MAIN RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
SETTING RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
LOADER CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
TESTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
20-1
TESTING AND ADJUSTING
TABLE OF CONTENTS
SETTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54

BACKHOE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
TESTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
SETTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
LOAD SENSING (LS) VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
CLEANING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
CIRCUIT AND BRAKE PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
BRAKING GROUP LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
ENGINE SPEED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
PREPARING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
TORQUE CONVERTER STALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
TORQUE CONVERTER AND HYDRAULIC STALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
POWER TRAIN GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
PREPARING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
TRANSMISSION CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
PREPARATION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
RETURN TO DIG DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-69
HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
AIR CONDITIONING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-75
TESTING THE WORKING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-75
CHECKING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-75
EMPTYING THE AC UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-87
WARNING! When working with others, use agreed upon signals and do not let unauthorized persons
near the machine.
Before checking coolant level, wait until it has cooled. If the radiator cap is removed when the
coolant is hot, the coolant will spurt our and cause burns. Be careful when working close to
moving parts, fan, fan belt, etc. Entanglement with moving parts can cause serious injury.
Before testing, adjusting or troubleshooting, make sure the machine is parked on firm, level ground.
Check that all machine safety devices are applied and that blocks are in place to prevent the machine
from moving.
20-2

12
STANDARD
STANDARD VALUE TABLES FOR ENGINE
VALUE TABLES FOR ENGINE

Machine Model
WB140PS-2N
WB140PS-2N
Engine
S4D106-1FH - TIER I
S4D106-2XFH - TIER II
Check Item
Test Conditions
Unit
High idle
Engine Speed
Low idle
RPM
Set idle
Exhaust Gas
Color
Valve Clearance
Compression
Pressure
Blow By Pressure
Oil Pressure
Sudden acceleration
@
High idle speed
Intake valve @ 20C

Exhaust valve @ 20C
Bosch
Index
mm
Oil temperature @ 69 to 72C kg/cm
Standard
Value
Permissible
Value
Standard
Value
Permissible
Value
2375 50
2325 to 2425
2375 50
2325 to 2425
1050 50
1000 to 1100
1050 50
1000 to 1100
2200
2200
0.9
1.5
4.0
4.0
0.5
1.0
3.5
3.5
0.30 0.05
Max 0.35
0.25 0.1
Max 0.35
0.30 0.05
Max 0.35
0.25 0.1
Max 0.35
34.9 1
27.5 1
34.9 1
27.5 1
Using starter motor
RPM
250
250
250
250
Coolant temp within operating range @ high idle
mm
4.48
3.97 to 4.99
4.48
3.97 to 4.99
Set idle
Low idle
kg/cm
1.02
Min 1.02
1.02
Min 1.02
Oil Temperature
Entire speed range
120
Max 120
120
Max 120
Fuel Injection
Timing
Before top dead center
12.5
11.5 to 13.5
12.5
11.5 to 13.5
Belt Tension
Deflection when pressed with

mm
finger force of 10 kg
10
10 to 15
10
10 to 15
Machine Model
WB150PS-2N
Engine
Check Item
Test Conditions
S4D106-1FA - TIER I
Unit
High Idle
Engine Speed
Low Idle
RPM
Set Idle
Exhaust Gas
Color
Valve Clearance
Sudden Acceleration
@
High Idle
Intake Valve @ 20C

Exhaust Valve @ 20C
WB150PS-2N
Bosch
Index
mm
S4D106-2SFA - TIER II
Standard
Value
Permissible
Value
Standard
Value
Permissible
Value
2375 50
2325 to 2425
2375 50
2325 to 2425
1050 50
1000 to 1100
1050 50
1000 to 1100
2200
2050 100
0.9
1.5
4.0
4.0
0.5
1.0
3.5
3.5
0.30 0.05
Max 0.35
0.25 0.1
Max 0.35
0.30 0.05
Max 0.35
0.25 0.1
Max 0.35
34.9 1
27.5 1
34.9 1
27.5 1
250
250
Compression
Pressure
Oil Temperature @ 72C
kg/cm
Using starter motor
RPM
250
250
Blow By Pressure
Coolant temp within operating range @ high idle
mm
4.48
3.97 to 4.99
4.48
3.97 to 4.99
1.02
Min 1.02
1.02
Min 1.02
Oil Pressure
Set Idle
Low Idle
kg/cm
Oil Temperature Entire Speed Range
120
Max 120
120
Max 120
Fuel Injection
Timing
Before Top Dead Center
12.5
11.5 to 13.5
12.5
11.5 to 13.5
Belt Tension
Deflection when pressed with

mm
finger force of 10 kg
10
10 to 15
10
10 to 15
20-3

12
STANDARD
STANDARD VALUE TABLES FOR CHASSIS
VALUE TABLES FOR CHASSIS
WB140PS-2N
WB140PS-2N Engine
Control Valve
Engine Speed
Component
Accelerator
pedal
Accelerator
fuel
Test Conditions
Hydraulic oil temperature: 50C

Converter oil temperature: 80C
Engine oil temp cooling
circuit: in the limits
Max
Min
RPM
Max
Min
All Controls
less loader
arm
Loader Arm
Backhoe
Boom
Backhoe
Bucket
Backhoe
Swing
Backhoe
Outriggers
Telescopic
Arm
Hammer
Pedal
Fuel Lever
Accelerator
Pedal
Steering
Wheel
20-4
Raise
Lower
Dump
Neutral J
Curl
Raise
Neutral J
Lower
Extend
Engine
Neutral J
Retract
stopped
At center of Neutral J Dump
Curl
knob lever
Right
Valve readNeutral J
ing at the
Left
end of work
Up
Neutral J
stroke
Down
Attachments
Out
Neutral J
on ground
In
Right
Neutral J
Left
Min J Max
Neutral J
Loader
Boom
Backhoe
Arm
Standard Value Permissible Value
BHC
PPC
BHC
PPC
2350
2375
2300 to 2350 to
50
50
2400
2425
1050
1050
1000 to 1000 to
50
50
1100
1100
1900
1900
1850 to 1850 to
50
50
1950
1950
1050
1050
1000 to 1000 to
50
50
1100
1100
a b c
a
b
c
a b c
a b c
8 8
8 8
8 8
8 8
85
60 to 110
75
100
60 to 90 90 to 100
115
90 to 140
85
100
70 to 100 90 to 100
100
80 to 120
100
55
90 to 110 49 to 60
100
80 to 120
100
55
90 to 110 49 to 60
100
80 to 120
100
55
90 to 110 49 to 60
100
80 to 120
100
55
90 to 110 49 to 60
50
35 to 65
50
40 to 60
15
10 to 20
15
10 to 20
30
20 to 40
30
20 to 40
15
10 to 20
15
10 to 20
30
20 to 40
30
20 to 40
70
50 to 90
70
70
55 to 85
55 to 85
80
60 to 100
70
70
55 to 85
55 to 85
Max 2.5
2.2 to 2.5
mm
Loader
Arm
Travel of Levers and Pedals
Unit
S4D106-1FH - TIER I
Standard Permissible
Value
Value
mm
Min J Max
Right J Left
Left J Right
Rev
Max 2.5 2.2 to 2.5 Max 2.5 2.2 to 2.5

WB140PS-2N Engine
Component
Loader Arm
Lever
Test Conditions
Force for lever or pedal operation
Loader
Bucket Lever
Backhoe
Boom
Backhoe Arm
Backhoe
Bucket
Backhoe
Swing
Outrigger
Telescopic
Arm
Individual Circuits
Main Pressure
Hammer
Pedal
Fuel
Accelerator
Brake Pedals
Loader Valve
Backhoe
Valve
S4D106-1FH
Unit
Value
Value
Tool connected at knob

center and 90 from lever.
Value at 10 mm before end
of work stroke.
Distance between knob and
case: 95 mm
Engine speed: min.

Oil temp: 50C
Tool connected at
knob center and 90
from lever.
Tool connected on
edge, for pedals
Value at 10 mm before end of work
stroke.
kg
In
Out
Engine speed: min

Oil temp: 45 to 55C
Pump: economy mode.
Steering Unit Engine speed: 1500 50 RPM

Loader
Bucket Curl
Loader
Bucket Dump
Loader 3rd
Spool
Backhoe
Boom Raise
Backhoe
Boom Lower
Backhoe Arm
Retract
Backhoe
Swing
Backhoe
Bucket Curl
Hammer
Delivery
Steering Unit
Safety
Engine speed: min

Oil temp: 45 to 55C
Check one at a time
Pump: economy mode.
kg/cm
12

S4D106-2XFH
Standard Value
Permissible Value
BHC
PPC
BHC
PPC
2.5
2 to 3
2.5
2.5
1.5 to 3.5
1.5 to 3.5
2.5
2 to 3
1.7
1.7
1.2 to 2.2
1.2 to 2.2
1.5
1 to 2
1.6
2.0
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
2.0
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
2.5 to 3.5
3.8
2.3 to 5.3
3 to 4
3.0 to 4.0
6 to 10
6.0 to 10
6 to 10
6.0 to 10
12
10 to 14
3 to 5
3 to 5
2 to 4
2.5 to 5.5
2.5 to 5.5
30
Max 60
188.65
188.65 7.14
209.1
209.1 10.2
204
204 7.14
211.08
211.08 7.14
209.1
209.1 10.2
204
204 7.14
178.45
178.45 7.14
178.5
178.5 10.2
178.5
178.5 7.14
239.63
239.63 7.14
239.7
239.7 10.2
239.7
239.7 7.14
178.45
178.45 7.14
188.7
188.7 10.2
188.7
178.5 7.14
239.63
239.63 7.14
239.7
239.7 10.2
239.7
239.7 7.14
362
362.00 7.14
306.0
306.0 10.2
311.1
311.1 7.14
249.83
249.83 7.14
239.7
239.7 10.2
239.7
239.7 7.14
249.83
249.83 7.14
239.7
239.7 10.2
239.7
239.7 7.14
193.75
193.75 7.14
249.9
249.9 10.2
249.9
249.9 7.14
249.83
249.83 7.14
239.7
239.7 10.2
239.7
239.7 7.14
173.35
173.35 7.14
173.4
173.4 10.2
173.4
173.4 7.14
244.73
244.73 7.14
244.8
244.8 10.2
244.8
244.8 7.14
20-5

WB140PS-2N Engine
Component
Test Conditions
Converter
Stall
Converter
Converter/
Hydraulic
Stall
20-6
Unit
Engine speed (w/o load):

2350 50
Hydraulic oil temp: 50C
Converter oil temp: 80C
Machine in 4th gear
Working brakes applied

2350 50
Machine in 4th gear with
brakes applied
Front bucket curled stop
Steering at the end of stroke
S4D106-1FH
Standard
Permissible
Value
Value
2100 50
2050 to 2150
2000 50
1950 to 2050
S4D106-2XFH
BHC
PPC
BHC
PPC
2200 50 2275 50
2150
to
2250
2225
to
2325
2225
to
2325
2200
to
2300
RPM
12
2050
100
2250 50

12
12
The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe
bucket with the standard arm or telescopic arm closed.
WB140PS-2NEngine
Component
Test Conditions
Unit
Hydraulic Drift of Working Equipment
Loader
Complete
Working
Equipment
S4D106-1FH
S4D106-2XFH
Standard Permissible Standard Value Permissible Value
Value
Value
BHC PPC BHC
PPC
250
400
250
250
250
250
30
45
24
24
24
24
15
25
10
10
10
10
Complete
Working
Equipment
300
450
Max
325
Max
325
Max
300
Max
300
Boom
Cylinder
35
50
Max
24
Max
Max 24 Max 24
24
15
25
Max
13
Max
Max 13 Max 13
13
10
15
Max
10
Max
Max 10 Max 10
10
Boom
Cylinder
Backhoe
Bucket
Cylinder
Arm
Cylinder
Bucket
Cylinder
Measuring position
In this position, check feedback of
each cylinder and leakage with a load mm
applied at tip of cutting edge.
Ground level
Bucket: normal load 1500 kg
Engine stopped
Oil temperature: 45 to 55C
Make measurements as soon as
engine is stopped.
Measure changes every 5 min. and
total change after 15 min.
Measuring position
In this position, check the extension
of each cylinder and the leakage with mm
a normal load on the bucket.
On level ground.
Bucket: normal load (450 kg)
Engine stopped
Make measurements as soon as the
engine is stopped.
Measure the changes every 5 min.
and the total change after 15 min.
20-7

12
12
WB140PS-2NEngine
Component
Backhoe
Swing
Cylinders
Test Conditions
S4D106-1FH
Unit
Value
Value
Measuring position
Oil temp: 45 to 55C
mm
Backhoe balanced on guides,
bucket in transport position.
Arm and bucket cylinder in. Put
bucket link pin one meter from
ground and swing at end of boom
stroke in one of two directions.
Move machine onto an incline of
15 and apply parking brake.
Stop machine. After one min.
check cylinder feedback opposite
boom every 5 min. for a total of 15
min.
mm
Outriggers
S4D106-2XFH
Standard Value
BHC
PPC
Permissible Value
BHC
PPC
15
25
Max 20 Max 30 Max 20 Max 30
20
30
Measuring position
Backhoe balanced. Boom and arm
cylinders in, bucket cylinder out.
Outriggers at max extension.
Engine stopped.
Check frame lowering for each
side every 5 min. for a total of 15
min.
20-8

12
12
WB140PS-2NEngine
Boom
Max 8
Max 8 Max 8
Bucket
1.6
Max 6
1.6
1.6
Max 6 Max 6
3.3
Max 13.5
3.3
3.3
Max
13.5
Max
13.5
Max 12
Max
12
Max
12
2.4
Max 9.5
2.4
2.4
Max
9.5
Max
9.5
3.2
Max 13
3.2
3.2
Max
13
Max
13
Outrigger
3.3
Max 13.5
3.3
3.3
Max
13.5
Max
13.5
Telescopic
Arm
1.6
Max 6
1.6
1.6
3.5
3.1 to 3.9
3.6
3.5
2.9
to
4.3
3.1
to
3.9
3.5
3.1 to 3.9
3.6
3.5
2.9
to
4.3
3.1
to
3.9
Boom
Arm
Backhoe
Cylinder Leakage
Test Conditions
Bucket
Swing
Measuring position
Engine: Max. speed
Leak check: check low pressure side of
cylinder.
Check one cylinder at a time.
For loader bucket and arm or backhoe
swing, check cylinders separately.
cm/mm
Loader
Component
S4D106-1FH
S4D106-2XFH
Unit
Value
Value
BHC PPC BHC PPC
Backhoe
Work Equipment Speed
Right
Boom
swing
Right End
Travel to
Left End
Travel
Max 6 Max 6
Sec
Measuring position
Engine speed 1700 to 1750 RPM
Arm horizontal
Power mode
Time referenced is for cylinder
stroke without brake phase
Left
20-9

12
12
WB140PS-2NEngine
Loader
Component
Test Conditions
Arm Cylinders Out
To level
Measuring position
ground
Engine speed: Max
Speed up
Bucket Cylinders Out
Cylinders In Measuring position

Engine speed: Max
Speed up
S4D106-1FH
S4D106-2XFH
Unit
Value
Value
BHC PPC BHC PPC
Lower
3.6
3.1 to 4.1
3.5
3.5
3.2
to
3.8
3.2
to
3.8
Raise
2.5
2.1 to 2.9
2.6
2.6
2.3
to
2.9
2.3
to
2.9
Curl
2.5
2.1 to 2.9
2.5
1.9
2.1
to
2.9
1.6
to
2.2
2.6
to
3.1
Dump Sec
Backhoe
Raise
20-10
Boom Cylinder in
Measuring position

Bucket
Engine
speed, 1700 to 1750 rpm,
teeth on
is to be checked using procedure
level
described in this section.
ground
Backhoe balanced
Power mode
Time frame is for cylinder
Lower
3.2
2.7 to 3.7
3.2
2.8
2.8
to
3.6
2.3
1.9 to 2.7
2.6
2.6
2.3
to
2.9
2.3
to
2.9
1.9
1.8 to
2.6
1.6
to
2.2
1.6
1.2 to 2.0
2.2

12
12
WB140PS-2NEngine
Backhoe
Component
S4D106-1FH
S4D106-2XFH
Unit
Value
Value
BHC PPC BHC PPC
Test Conditions
Arm CylinMeasuring position

der In
Cylinder
Engine speed is to be checked
using procedure described in this
Out
section.
Backhoe balanced
Power mode
The time frame is for cylinder
Open
3.4
2.9 to 3.9
3.4
3.6
3.0
to
3.8
3.2
to
4.0
Close
4.3
3.8 to 4.8
4.4
4.5
4.0
to
4.8
4.1
to
4.9
2.1
1.7 to 2.5
2.2
2.6
1.8
to
2.6
2.4
to
2.8
3.1
2.6
to
3.4
2.6
to
3.4
Sec
Dump
Bucket Cylinder In
Measuring position

Cylinder
Engine speed, 1700 to 1750 rpm,
Out
is to be checked using procedure
described in this section.
Backhoe balanced
Power mode
Curl
2.9
2.5 to 3.3
3.0
20-11

12
12
WB140PS-2N Engine
Loader
Component
Test Conditions
Unit
Lift Arm
S4D106-1FH - TIER I
Value
Value
Standard Value
Permissible Value
BHC
PPC
BHC
PPC
Max 2
Max 2
Max 2
Max 2
Max 2 Max 2 Max 2
Max 2
Max 2
Max 2 Max 2 Max 2
Max 2

Time Lag
Measuring position
Engine speed: Min.
Check time needed to lift bucket
from level ground.
Measuring position
Engine speed: Min.
Sec
With attachments fully extended,
lower boom and check elapsed time
from beginning of machine lift
until bucket is on level ground.
Backhoe
Boom
Arm
20-12
Measuring position
Engine speed: Min.
Put boom at 45 and open arm
completely with bucket curled.
Extend arm cylinder and check
elapsed time between arm stop at
dead center and restart movement.

12
12
WB140PS-2N Engine
Component

Time Lag
Backhoe
Bucket
Test Conditions
S4D106-1FH - TIER I
Unit
Value
Value
Measuring position
Engine speed: Min.
Put arm in horizontal position. Tilt
back bucket cylinder and then
extend it.
Check elapsed time between
bucket stop at dead center and
restart movement.
Standard Value
Permissible Value
BHC
BHC
PPC
PPC
Max 2
Max 2 Max 2 Max 2
Max 2
Max 2
Max 2 Max 2 Max 2
Max 2
Sec
Outriggers
Measuring position
Engine speed: Min.
Boom, arm, and bucket fully
retracted and placed in machine
center position.
Check time needed for outriggers
to raise machine from level
ground.
Check each outrigger separately.
20-13
12
WB150PS-2N
WB150PS-2N Engine
Travel of Levers and Pedals
Control Valve
Engine Speed
Component
Accelerator
pedal
Accelerator
fuel
Test Conditions
Unit
Max
Engine oil temp cooling
circuit: in limits
Min
RPM
Max
Min
All Controls
less loader
arm
Loader Arm
Neutral J
Loader
Boom
Neutral J
Backhoe
Boom
Neutral J
Backhoe
Bucket
Backhoe
Swing
Backhoe
Outriggers
Telescopic
Arm
Hammer
Pedal
BHC
PPC
BHC
PPC
2350
2300 to 2350 to
2375 50
50
2400
2425
1050
1000 to 1000 to
1050 50
50
1100
1100
1900
1850 to 1850 to
1900 50
50
1950
1950
1050
1000 to 1000 to
1050 50
50
1100
1100
a b c
a b c
8 8
8 8
8 8
8 8
mm
Loader Arm
Backhoe
Arm
S4D106-1FH - TIER I
Value
Value
Engine
stopped
At center of
knob lever
Valve reading
at the end of
working
stroke
Attachments
on the ground
Neutral J
Neutral J
Neutral J
Neutral J
Neutral J
Neutral J
Raise
Lower
Dump
Curl
Raise
Lower
Extend
Retract
Dump
Curl
Right
Left
Up
Down
Out
In
Right
Left
mm
BHC
PPC
BHC
PPC
85
60 to 110
75
100
60 to 90 90 to 100
115
90 to 140
85
100
70 to 100 90 to 100
100
80 to 120
100
55
90 to 110 49 to 60
100
80 to 120
100
55
90 to 110 49 to 60
100
80 to 120
100
55
90 to 110 49 to 60
100
80 to 120
100
55
90 to 110 49 to 60
50
35 to 65
50
40 to 60
15
10 to 20
15
10 to 20
30
20 to 40
30
20 to 40
15
10 to 20
15
10 to 20
30
20 to 40
30
20 to 40
Fuel Control
Lever
Accelerator
Pedal
Min J Max
70
50 to 90
70
70
55 to 85 55 to 85
Min J Max
80
60 to 100
70
70
55 to 85 55 to 85
Steering
Wheel
Right J Left
Left J Right
Max 2.5
2.2 to 2.5
20-14
Rev
Max 2.5 2.2 to 2.5 Max 2.5 2.2 to 2.5

12
WB150PS-2N Engine
Component
Test Conditions
Loader Arm
Backhoe
Boom
Backhoe Arm
Backhoe
Bucket
Backhoe
Swing
Outrigger
Unit
Tool connection at knob

center and at 90 from lever.
Value at the 10 mm before
end of working stroke.
Distance between knob and
casing: 95 mm
Engine speed: min.

Oil tempe: 50C
Tool connection at
knob center and at
90 from the lever.
Tool connection on
In
Telescopic
edge, for pedals
Arm
Out
Value at 10 mm beHammer Pedal fore end of work
stroke.
Fuel Control
Accelerator
Brake Pedals
Engine speed: min
Loader Valve
Oil temp: 50C
Check one at a time
Backhoe
Valve
Pump: economy mode.
kg
Steering Unit Engine speed: 1500 50 RPM

Loader
Bucket Curl
Loader
Bucket Dump
Loader 3rd
Spool
Backhoe
Boom Raise
Backhoe
Boom Lower
Backhoe Arm
Retract
Backhoe
Swing
Backhoe
Bucket Curl
Hammer
Delivery
Steering Unit
Safety
kg/cm
Main Pressure
Force for lever or pedal operation
Loader Bucket
Individual Circuits
Engine speed: min

Oil temp: 50C
Check one at a time
Pump: economy mode.
S4D106-1FH - TIER I
Standard
Permissible
Value
Value
Standard Value
Permissible Value
BHC
PPC
BHC
PPC
2.5
2 to 3
2.5
2.5
1.5 to 3.5
1.5 to 3.5
2.5
2 to 3
1.7
1.7
1.2 to 2.2
1.2 to 2.2
1.5
1 to 2
1.6
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
2.5 to 3.5
3.8
2.3 to 5.3
3 to 4
3.0 to 4.0
6 to 10
6.0 to 10
6 to 10
6.0 to 10
12
10 to 14
3 to 5
3 to 5
2.5 to 5.5
2.5 to 5.5
2 to 4
30
Max 60
188.65
188.65 7.14
209.1
209.1
10.2
204
204 7.14
211.08
211.08 7.14
209.1
209.1
10.2
204
204 7.14
178.45
178.45 7.14
178.5
178.5
10.2
178.5
178.5 7.14
239.63
239.63 7.14
239.7
239.7
10.2
239.7
239.7 7.14
178.45
178.45 7.14
188.7
188.7
10.2
188.7
178.5 7.14
239.63
239.63 7.14
239.7
239.7
10.2
239.7
239.7 7.14
362
362.00 7.14
306.0
306.0
10.2
311.1
311.1 7.14
249.83
249.83 7.14
239.7
239.7
10.2
239.7
239.7 7.14
249.83
249.83 7.14
239.7
239.7
10.2
239.7
239.7 7.14
193.75
193.75 7.14
249.9
249.9
10.2
249.9
249.9 7.14
249.83
249.83 7.14
239.7
239.7
10.2
239.7
239.7 7.14
173.35
173.35 7.14
173.4
173.4
10.2
173.4
173.4 7.14
244.73
244.73 7.14
244.8
244.8
10.2
244.8
244.8 7.14
20-15

WB150PS-2N Engine
Component
Test Conditions
Converter
Stall
Converter
Converter/
Hydraulic
Stall
20-16
Unit

2350 50
Machine in 4th gear
Working brakes applied

2350 50
Machine in 4th gear with
brakes applied
Front bucket curled stop
Steering at end of stroke
S4D106-1FH - TIER I
Standard
Permissible
Value
Value
Standard Value
Permissible Value
BHC
PPC
BHC
PPC
2275 50
2225 to 2325
2200 50 2275 50
2150
to
2250
2225
to
2325
2000 50
1950 to 2050 2050 100 2250 50
2225
to
2325
2200
to
2300
RPM
12

12
12
WB150PS-2N Engine
Component
Test Conditions
Unit
Loader
Complete
Working
Equipment
S4D106-1FA
S4D106-2SFA
Standard
Value Permissible Value
Value
Value
BHC PPC BHC
PPC
250
400
250
250
250
250
30
45
24
24
24
24
15
25
10
10
10
10
Complete
Working
Equipment
300
450
Max Max
325 325
Max
300
Max
300
Boom
Cylinder
35
50
Max Max
24
24
Max
24
Max
24
15
25
Max Max
13
13
Max
13
Max
13
10
15
Max Max
10
10
Max
10
Max
10
Boom
Cylinder
Backhoe
Bucket
Cylinder
Arm
Cylinder
Bucket
Cylinder
Measuring position
In this position, check feedback of
each cylinder and leakage with a load
mm
applied to the tip of cutting edge.
Ground level
Engine stopped
Make measurements as soon as engine
is stopped.
Measure changes every 5 min. and the
Measuring position
In this position, check extension of
each cylinder and leakage with a nor- mm
mal load on bucket.
On level ground.
Engine stopped
Make measurements as soon as engine
is stopped.
Measure changes every 5 min. and
20-17

12
12
WB150PS-2N Engine
Component
Backhoe
Swing
Cylinders
Test Conditions
S4D106-1FA
Unit
Value
Value
Measuring position
mm
Backhoe balanced on guides,
bucket in transport position.
Arm and bucket cylinder in. Put
bucket link pin one meter from
ground and swing at end of boom
stroke in one of two directions.
Move the machine onto an incline
of 15 and apply the parking
brake.
Stop machine. After one min.
check cylinder feedback opposite
boom every 5 min. for a total of 15
min.
mm
Outriggers
S4D106-2SFA
Standard Value
BHC
PPC
Permissible Value
BHC
PPC
15
25
20
30
Measuring position
Backhoe balanced. Boom and arm
cylinders in, bucket cylinder out.
Outriggers at max extension.
Engine stopped.
Check frame lowering for each
side every 5 min. for a total of 15
min.
20-18

12
12
WB150PS-2N Engine
Max 8
Max 8 Max 8
Bucket
1.6
Max 6
1.6
1.6
Max 6 Max 6
3.3
Max 13.5
3.3
3.3
Max
13.5
Max
13.5
Max 12
Max
12
Max
12
2.4
Max 9.5
2.4
2.4
Max
9.5
Max
9.5
3.2
Max 13
3.2
3.2
Max
13
Max
13
Outrigger
3.3
Max 13.5
3.3
3.3
Max
13.5
Max
13.5
Telescopic
Arm
1.6
Max 6
1.6
1.6
3.5
3.1 to 3.9
3.6
3.5
2.9
to
4.3
3.1
to
3.9
3.5
2.9
to
4.3
3.1
to
3.9
Arm
Backhoe
Unit
Boom
Boom
Cylinder Leakage
Test Conditions
Bucket
Swing
Engine: Max. speed

Leak check: check low pressure side of
cylinder.
Check one cylinder at a time.
For loader bucket and arm or backhoe
swing, check cylinders separately.
cm/mm
Loader
Component
Backhoe
Right
S4D106-1FA
S4D106-2SFA
Standard
Value
Value
BHC PPC BHC
PPC
Boom
swing
Right end
travel
to
Left end
travel
Max 6 Max 6
Sec
Measuring position
Arm horizontal
Left
Power mode
The time referenced is for cylinder
3.5
3.1 to 3.9
3.6
20-19

12
12
WB150PS-2N Engine
Loader
Component
S4D106-1FA
S4D106-2SFA
Standard
Unit
Value
Value
BHC PPC BHC PPC
Test Conditions
Arm Cylinders Out
To level
Measuring position
ground
Engine speed: Max
Speed up
Lower
3.6
3.1 to 4.1
3.5
3.5
3.2
to
3.8
3.2.
to
3.8
Raise
2.5
2.1 to 2.9
2.6
2.6
2.3
to
2.9
2.3
to
2.9
1.6
to
2.2
Curl
Bucket Cylinders Out
Cylinders In Measuring position

Engine speed: Max
Speed up
Dump Sec
Backhoe
Raise
20-20
Boom CylMeasuring position

inder in
Engine
speed is to be checked
Bucket teeth
on level
section.
ground
Backhoe balanced
Lower
Power mode
The time referenced is for cylinder stroke without brake
phase
2.5
2.1 to 2.9
2.5
1.9
2.1
to
2.9
3.2
2.7 to 3.7
3.2
2.8
2.8
to
3.6
2.6
to
3.1
2.3
1.9 to 2.7
2.6
2.6
2.3
to
2.9
2.3
to
2.9
1.6
1.2 to 2.0
2.2
1.9
1.8
to
2.6
1.6
to
2.2

12
12
WB150PS-2N Engine
Component
S4D106-1FA
S4D106-2SFA
Standard
Unit
Value
Value
BHC PPC BHC PPC
Test Conditions
Backhoe
Open
Arm CylinMeasuring position

der In
Cylinder
Engine speed is to be checked
Out
section.
Backhoe balanced
Close
Power mode
Time referenced is for cylinSec
der stroke without brake phase
Bucket Cylinder In
Measuring position

Cylinder
Engine
speed is to be checked
Out
section.
Backhoe balanced
Power mode
3.4
2.9 to 3.9
3.4
3.6
3.0
to
3.8
3.2
to
4.0
4.3
3.8 to 4.8
4.4
4.5
4.0
to
4.8
4.1
to
4.9
2.4
to
2.8
2.6
to
3.4
Dump
2.1
1.7 to 2.5
2.2
2.6
1.8
to
2.6
Curl
2.9
2.5 to 3.3
3.0
3.1
2.6
to
3.4
20-21

12
12
WB150PS-2N Engine
Loader
Component
Test Conditions
Unit
Lift Arm
S4D106-1FA - TIER I
Value
Value
BHC PPC
BHC
PPC
Max 2
Max 2
Max 2
Max 2
Max 2 Max 2 Max 2
Max 2
Max 2
Max 2 Max 2 Max 2
Max 2

Time Lag
Measuring position
Engine speed: Min.
Check time needed to lift bucket
from level ground.
Measuring position
Sec
Engine speed: Min.
With attachments fully extended,
lower boom and check elapsed
time from beginning of machine
lift until bucket is on level ground.
Backhoe
Boom
Arm
Measuring position
Engine speed: Min.
Put boom at 45 and open arm
completely with bucket curled.
Extend arm cylinder and check
elapsed time between arm stop at
dead center and restart movement.
20-22

12
12
WB150PS-2N Engine
Component

Time Lag
Backhoe
Bucket
Test Conditions
S4D106-1FA - TIER I
Unit
Value
Value
Measuring position
Engine speed: Min.
Put arm in horizontal position. Tilt
back bucket cylinder and then
extend it.
Check elapsed time between
bucket stop at dead center and
restart movement.
Standard Value
Permissible Value
BHC
BHC
PPC
PPC
Max 2
Max 2 Max 2
Max 2
Max 2
Max 2
Max 2 Max 2
Max 2
Max 2
Sec
Outriggers
Measuring position
Engine speed: Min.
Boom, arm, and bucket fully
retracted and placed in machine
center position.
Check time needed for outriggers
to raise machine from level
ground.
Check each outrigger separately.
20-23

12
SPECIAL
SPECIAL TOOLS
TOOLS
MEASUREMENT POINT SYMBOL

Valve clearance
Compression gauge
Engine speed
Oil and coolant temp
E
Hydraulic pressure
CODE
Localize
QTY
NOTE
Feeler gauge
Compression gauge
Adapter
Kit Yanmar
TOL-97190080
Localize
Multi scale tachometer
20 to 4000 rpm
Localize
Digital thermometer
-50 to 1200C
Localize
Pressure gauge
Full scale 61 kg/cm
Localize
Pressure gauge
Full scale 255 kg/cm
Localize
Pressure gauge
Localize
Pressure gauge
Servo control kit
0 to1020 kg/cm
Flow meter
Delivery 0 to 300 L/min.
Pipe fitting kit
1
2
ATR800208
5
6
F
NAME
ATR800200
Air bleeding
ATR201490
Tank cap
Pump air bleeding
Hand brake
Localize
Spring dynamometer
Full scale 20 kg
Localize
Maintenance station
For coolant R134a
Localize
Thermometer hygrometer
Sampling every 15 sec
Leak detector
For coolant R134a
Air Conditioning unit
3 Localize
20-24

12
ENGINE
ENGINE SPEED
SPEED
WARNING! When checking the engine speed be careful, do

not touch high temperature parts or get caught in rotating
parts.
Check the engine speed under the following conditions:
Engine coolant temperature.........................................68 to 80C.
Hydraulic oil temperature............................................45 to 55C.
TIER I ENGINE
1.
Install and connect tachometer C.
2.
Start the engine and check:
Low idle speed w/o load, accelerator pedal released in minimum

position. High idle speed w/o load, accelerator pedal at the travel
end.
Low idle speed...................................................... 1050 50 RPM
High idle speed ..................................................... 2375 50 RPM
If the idle speeds are not within limits, without a load on the engine,
check the accelerator pedal stopper and wiring insulation before
going on with other operations. See ACCELERATOR PEDAL
AND LEVER on page 20-40.
TIER II ENGINE
1.
Remove the air filter a.
2.
Start the engine and check:
Low idle speed without load, accelerator pedal released in minimum position. High idle speed without load, accelerator pedal at
the travel end.
Low idle speed...................................................... 1050 50 RPM
High idle speed ..................................................... 2375 50 RPM
If the idle speeds are not within limits, without a load on the engine,
check the accelerator pedal stoppers and wiring insulation before
going on with other operations. See ACCELERATOR PEDAL
AND LEVER on page 20-40.
20-25

12
VALVE
VALVE CLEARANCE
CLEARANCE
TIER I ENGINE
Measurement conditions:
Engine.................................................................................... Cold
Adjust the valve and rocker lever clearance as follows:

Unit: mm
With cold engine
Engine
Intake Exhaust
S4D106-1FH
0.30 0.05
S4D106-1FA
0.30 0.05
Firing order .................................................. 1-3-4-2-1 at 180 steps

Normal rotation ............................ Counterclockwise from flywheel
Cylinder No. 1....................................................... Opposite fan side
ADJUSTING PROCEDURE
1.
Remove the air cleaner A, muffler B, and valve cover C.
2.
Rotate the crankshaft in its normal direction until the piston to be

checked is at full compression, Top Dead Center (TDC). In this
position the intake and exhaust valves are closed.
3.
Loosen the lock nut d and unscrew the tappet e one turn. Check
that valve insert f is laying flat on the valve stem and that it is not
worn. If the valve inserts are damaged, replace them with new ones.
Make sure that the inserts fit and lay flat on the valve stem.
4.
Place feeler gauge A between the insert and the rocker lever to be
adjusted. Rotate the tappet e until the rocker lever touches the
gauge. Secure the tappet with lock nut d.
Lock Nut ..................................................14.7 to 19.6 Nm
After tightening the lock nut, check the clearance again.
5.
Adjust the next cylinder valve using this same procedure. Repeat
the procedure for the other cylinders, according to their firing
order.
VALVE COVER INSTALLATION

1.
Check condition of valve cover c, gasket g, o-rings h and lock

nuts i; carefully clean the contact surface of the cylinder head.
Install the gasket, valve cover, fit o-rings and lock nuts.
Cover lock nut................................................... 25 3 Nm
20-26

12
TIER
VALVE CLEARANCE
II ENGINE
Engine: Cold
Adjust the valve and rocker lever clearance as follows::

Unit: mm
With cold engine
Engine
Intake Exhaust
S4D106-2XFH
0.25 0.01
S4D106-2SFA
0.25 0.01
Firing order .................................................. 1-3-4-2-1 at 180 steps

Normal rotation ............................ Counterclockwise from flywheel
Cylinder No. 1....................................................... Opposite fan side
ADJUSTING PROCEDURE
1.
Remove the air filter a and the muffler b.
2.
Loosen the muffler support screws d and remove the air intake
duct e.
3.
Disconnect the fuel feed pipes f. Remove clamp g and loosen

clamp h.
20-27
VALVE CLEARANCE
12
4. Loosen the fittings i connecting to the pump j on the fuel feed
pipes f.
5.
Rotate the pipes f until they become disengaged from the valve
cover 1).
6.
Remove the feed through fittings 1! and their seals.
7.
Loosen and remove the screws 1@ retaining the valve cover c.

Inspect the grommets.
8.
Remove the valve cover c.

Inspect the seal. Replace the seal if damaged or cracked.
20-28
VALVE CLEARANCE
12
9. Rotate the crankshaft in the normal direction until the piston of the
cylinder you want to check reaches the compression position at Top
Dead Center (TDC).
In this position, the intake and exhaust valves are closed.
10. Loosen the lock nut 1# and unscrew the tappet by about one half
turn 1$.
11. Introduce the A feeler gauge between the valve link 1% and the
rocker arm 1^; tighten the tappet 1$ until rubbing against the A
feeler gauge. Lock the tappet using the lock nut 1#.
Lock Nut ........................................................22 to 28 Nm
12. Loosen the nut 1& and, while applying pressure to the valve link 1%,
tighten the tappet 1* until it bottoms on the valve 1( and zeroes the
clearances. Lock the tappet using the nut.
Lock Nut ........................................................22 to 28 Nm
If the nut 1& is very tight, use pliers to hold the valve link in
position 1%.
20-29
VALVE CLEARANCE
12
13. Reinstall all previously removed parts.
Valve cover screws...................................16.7 to 22.5 Nm
Injectors pump fittings .............................19.6 to 24.5 Nm
Clamp screws ...............................................7.8 to 9.8 Nm
20-30

12
COMPRESSION
COMPRESSION PRESSURE
PRESSURE
WARNING! When measuring the compression pressure be

careful not to get caught in the cooling fan, alternator belt or
in any other rotating parts. For this measurement the engine
should be at operating temperature. Take every precaution
against burns.
Engine........................................................ Operating temperature
Hydraulic oil................................................................55 to 60C.
Battery ......................................................................... Full charge
Valve clearance................................................................Adjusted
TIER I ENGINE
1.
Disconnect the high pressure pipe a.
2.
Remove the nozzle holder b of the cylinder to be checked.
3.
Disconnect the connector c of the fuel cut off the solenoid valve
d.
4.
Crank the engine with the starting motor.
5.
Install B2 adapter and connect B1 pressure gauge. Check that the

seal is installed in the adapter and that it is not damaged.
6.
Crank the engine with the starting motor and measure the compression pressure.
Measure the compression pressure at the point where the pressure gauge indicator remains steady.
While measuring the compression pressure, monitor the engine
speed with a tachometer; if speed is not within the specified
range, refer to the diagram.
Compression value...........................35 1 kg/cm @ 250 RPM
Minimum permissible ...................27.5 1 kg/cm @ 250 RPM
Difference between cylinders .............................. 2 to 3 kg/cm
7.
After measuring, reinstall the nozzle holder b, reconnect the high

pressure pipe, feedback pipe and connector c.
Nozzle holder collar bolts ..............................10 to 12 Nm
High pressure union .......................................20 to 25 Nm
NOTE: Check compression in all cylinders.
20-31

12
TIER
II ENGINE
1.
Access the valves using the same procedure as in VALVE

CLEARANCE on page 20-26.
2.
Loosen and remove the fittings a retaining the fuel recovery piping
b and the seals.
3.
Loosen the fitting c and rotate the piping b outward.
4.
Loosen and remove the screw d retaining the bracket e retaining

the injector f.
5.
Turn the bracket e over and pull out the injector f.

Use care not to allow dirt inside the injector and/or its seat.
6.
Disconnect the engine shutdown connector g and ensure that the

accelerator is fully released, no fuel flow.
20-32
12
7. Using the starter motor, crank the engine complete a few revs.
8.
Apply the adaptor B2 and gauge B1 and follow the instructions

provided with the equipment.
Check for a seal inside the adaptor and verify that the seal is
not damaged.
9.
Crank the engine with the starting motor and measure the compression pressure.
Measure the compression pressure at the point where the pressure gauge indicator remains steady.
When measuring the compression pressure, check also engine
speed with a tachometer; if the speed is not within the specified
range, refer to diagram.
Compression value.......................... 35 1 kg/cm @ 250 RPM
Minimum permissible ..................... 28 1 kg/cm @ 250 RPM
Difference between cylinders .............................. 2 to 3 kg/cm
10. After completing the procedure, reinstall the injector f, reconnect

the fuel return pipe and complete the assembly procedure.
Nozzle holder collar bolts ................................8 to 10 Nm
High pressure union .......................................20 to 25 Nm
NOTE: Check compression in all cylinders.
20-33

12
FUEL
FUEL INJECTION TIMING
INJECTION TIMING
TIER I ENGINE
Check the fuel injection timing of the No. 1 cylinder by means of
the No. 1 delivery valve of the injection pump.
The cylinders are numbered 1 2 3 4 starting from the flywheel side.
1.
Rotate the crankshaft using the engine pulley a and put the No. 1
cylinder piston at top dead center (TDC).
Top dead center (TDC) is shown by the notch d on the pulley a

positioned on zero of the scale e and by the closing of both cylinder No. 1 valves.
If the notch d of the pulley a is in the zero position on the scale e
but the cylinder No. 1 valves are not closed, rotate the crankshaft
one full turn.
After recognition of TDC, rotate the crankshaft counterclockwise,
as viewed from the pulley side, 20.
2.
Disconnect the cylinder No. 1 high pressure tube C from the injection pump.
3.
Rotate the crankshaft slowly in the clockwise direction (as viewed

from the pulley side), checking the fuel level in the No. 1 delivery
holder of the injection pump.
4.
Stop the pulley B rotation as soon as the fuel level starts to

increase.
20-34
12
5. Check the notch d position on the crankshaft pulley a compared
with the scale e; the indicated value should correspond to the angle
of the fuel injection timing.
Standard fuel injection timing:
S4D106-1FA ............................................... 12.5 1
S4D106-1FH:.............................................. 12.5 1
NOTE: Repeat this procedure several times.
6.
If the injection timing does not meet the standard value, rotate the
injection pump f away from or toward the cylinder block after
loosening the pump nuts g (quantity 4) and lock nuts h which
attach the bracket i to the injection pump.
7.
To RETARD the injection timing, rotate the pump f away from

the cylinder block.
To ADVANCE the injection timing, rotate the pump f toward
the cylinder block.
Tighten the pump lock nuts g at the cylinder block and lock nuts h
at bracket i.
Nuts ................................................................34 to 44 Nm
Bracket lock nut .............................................44 to 54 Nm
8.
Reconnect the cylinder No. 1 high pressure pipe b to the injection

pump.
Delivery pipe union........................................20 to 25 Nm
TIER II ENGINE
WARNING! Remove the ignition key.
Check the fuel injection timing of No. 1 cylinder by means of the

No.1 delivery valve of the injection pump.
The cylinders are numbered 1 2 3 4 starting from the flywheel side.
1.
Rotate the crankshaft using the engine pulley and put the No. 1 cylinder piston at top dead center (TDC).
Top dead center (TDC) is shown by the notch d on the pulley
a positioned on zero of the scale e and by the closing of all
cylinder No. 1 valves.
20-35
12
If the notch d of the pulley a is in the zero position on the scale e
but cylinder No. 1 valves are not closed, rotate the crankshaft one
turn.
After recognition of TDC, rotate the crankshaft in the counterclockwise direction, from the pulley side view, 20.
2.
Disconnect the cylinder No.1 high pressure pipe b from the injection pump.
3.
Rotate the crankshaft slowly in the clockwise direction from the

pulley side, checking the fuel level into the No. 1 delivery valve of
the injection pump.
4.
Stop the pulley a rotation as soon as the fuel level starts to

increase.
5.
Check the notch d position on the crankshaft pulley a compared

with the scale e; the reading value corresponds to angle of the fuel
injection timing.
Standard fuel injection timing.................................... 12.5 1
NOTE: Repeat checking more than once.
6.
If the injection timing is not on the standard value, rotate the injection pump f inwards or outwards of the engine block after loosening the pump nuts g.
To RETARD the injection timing, rotate the pump f outward

from the engine block.
To ADVANCE the injection timing, rotate the pump f inward to
the engine block.
20-36
12
7. Tight the pump nuts g at the cylinder block.
Nuts ................................................................34 to 44 Nm
Bracket lock nut .............................................44 to 54 Nm
8.
Reconnect the cylinder No. 1 high pressure pipe b to the injection

pump.
Delivery pipe union........................................20 to 25 Nm
20-37

12
FAN
FAN BELT
BELT
TENSION CHECK
1.
Push the fan belt B at the midway point between the alternator C
and the water pump pulley A. Check the deflection with a pressure
of 10 kg.
New belt tension ............................................................7 to 9 mm
In use belt tension......................................................10 to 15 mm
TENSION ADJUSTMENT
1.
Loosen the alternator mounting bolt d and the mounting bolt e of

the adjustment plate.
2.
Rotate the alternator c to tension the fan belt b and tighten the
mounting bolts d and e.
3.
Check the fan belt b tension.
If the belt has been replaced, check the tension again after the first
20 hours of operation.
Bolt d.............................................................44 to 54 Nm
Bolt e.............................................................23 to 29 Nm
20-38

12
COMPRESSOR
COMPRESSOR DRIVE BELT
DRIVE BELT
CHECKING TENSION
1.
Push fan belt b at midway point between compressor c and pulley

d. Check the deflection with a pressure of 10 kg.
New belt tension ............................................................4 to 6 mm
In use belt tension........................................................7 to 10 mm
TENSION ADJUSTMENT
1.
Loosen the mounting bolt e of the eccentric d.
2.
Use a lever on the eccentric d to correctly tension the belt and

secure the adjustment with bolt e.
3.
Recheck the belt b tension.
If the belt has been replaced, recheck the tension again after 20
hours of operation.
Bolt........................................................................123 Nm
20-39

12
ACCELERATOR
ACCELERATOR PEDAL AND LEVER
PEDAL AND LEVER
Machine ......................... Shut down with safety features engaged
Engine................................ Stopped and at operating temperature
Idle speeds ................................................. Within standard value.
In order to check high speed engine idle, push the accelerator pedal
a manually.
ACCELERATOR PEDAL TRAVEL

1.
Make sure that the accelerator pedal a is fully raised and the accelerator lever b is at its minimum stroke.
2.
Check that the accelerator lever c is in contact with low idle speed
adjusting screw d.
3.
Adjust the nut e and locknut f of the accelerator pedal cable, and
the hand accelerator at a distance of 0.2 to 0.3 mm from the lever
g.
20-40
ACCELERATOR PEDAL AND LEVER
12
4. Push the accelerator pedal until the accelerator lever c contacts the
high idle adjusting screw h.
5.
Adjust the end travel stopper i of the accelerator pedal a in this

position and secure it with the nut j.
6.
Release the accelerator pedal a.
ACCELERATOR LEVER TRAVEL

1.
Remove the mat and lateral cover a.
2.
Loosen the nut b and tighten the end lever travel bolt c a few
turns.
3.
Start the engine.
4.
With the lever d, set the hand accelerator idle speeds.

High idle TIER I Engine...................................2000 50 RPM
High idle TIER II Engine .................................1900 50 RPM
Low idle ............................................................1050 50 RPM
5.
Loosen the end lever travel bolt c so that it is in contact with the
lever d and then secure the nut.
6.
Bring the engine to low idle and check the accelerator lever idle
speed adjustment by pushing the lever to the end of its stroke.
20-41

12
BRAKE
BRAKE PEDAL TRAVEL
PEDAL TRAVEL
1.
Engine............................................................................... Stopped
Machine ....................................................Attachments on ground
Check that the pedal A is at the stopper B and the pedals height
matches side view A measurement. If necessary, correct the height
by adjusting the stopper.
A measurement ...................................................... 313 3 mm
2.
Check that pin C can freely run and lock the pedals A.
TIER I ENGINE
MASTER CYLINDER ROD ADJUSTMENT
1.
Loosen the nut d which locks the adjusting rod e. Loosen the
adjusting rod until it touches the brake pump piston seat.
2.
Tighten the adjusting rod e one turn and lock it with nut d.
3.
Repeat Steps 1 and 2 for the other pedal.
After tightening the nuts d, check that the adjusting rod e touches
the brake pump piston seat.
MICROSWITCHES ADJUSTMENT
1.
Loosen the microswitch locking nuts f.
2.
Adjust the microswitches g and make sure there is a minimum

clearance, 1 mm with the pedals in the neutral position, between the
microswitches body and the pedal.
CHECKING ADJUSTMENT
1.
Verify the below measurements as shown in the figure.

A measurement ...............................With pedal in neutral position
B measurement ......................... With cylinder rod touching pump
C measurement ......................... With pedal touching microswitch
20-42

12
TIER
BRAKE PEDAL TRAVEL
II ENGINE
MASTER CYLINDER ROD

1.
Loosen the nut d locking the adjusting rod e and loosen until it
touches the brake pump piston seat.
2.
Tighten the adjusting rod e one turn and lock it with the nut d.
3.
Repeat operations 1 and 2 for the other pedal.

After tightened the nuts d, check that the adjusting rod e
touch the brake pump piston seat simultaneously.
CHECKING ADJUSTMENT
1.
Verify measurements shown in figure.

A measurement ....................................... Pedal in neutral position
B measurement................. Master cylinder rod touching the pump
20-43

12
BLEEDING
BLEEDING AIR
AIR
HYDRAULIC PUMP
Bleeding of air from the pump is necessary: make sure the pump is
full of oil
1.
When installing the pump.
2.
When replacing connecting hoses between the pump and hydraulic

tank.
3.
When replacing the hydraulic oil and hydraulic tank overhaul.

4.
Bleeding air is accomplished as follows:
5.
Fill the hydraulic tank with oil and install plug G. Remove plug b
on top side of pump c. Connect plug G to low pressure compressed air connection.
6.
Slowly and intermittently introduce compressed air into the

hydraulic tank until oil flows out without air bubbles.
Maximum pressure in tank ................................... 0.51 kg/cm
7.
Install plug b and lock it. While slowly depressurizing the hydraulic tank, check the oil level. Add oil as necessary to maintain the
proper level.
8.
Start the engine and run it for few minutes before bleeding air from
the whole system.
CYLINDERS
When the hydraulic cylinders or pipe fittings have been replaced, it
is necessary to bleed air before using the machine again.
Operate one movement at a time starting from the lift cylinders.
1.
Start the engine and run it at high idle speed for about 5 min. to
warm up the oil and pressurize the hydraulic system.
2.
Return the engine to low idle speed, extend and retract the piston 4
to 5 times.
Extend and retract pistons to within 100 mm of end of stroke.
3.
Bring the engine to high idle speed and repeat Step 2 above. Return
the engine to low idle speed and make a complete travel of the piston until the hydraulic pump reaches its maximum pressure.
4.
Repeat above operation, starting with Step 2 for all cylinders.
20-44
BLEEDING AIR
12REPEAT
ABOVE
(STARTING
FROM POINT 2)
FOR
ALL CYLIN.HE
AIR
BLEEDING
IS OBTAINED
HYDRAULIC
OILOPERATION
TANK
1.
Put the machine in oil level check position and remove the tank
plug. If necessary add oil to reach the correct level.
2.
After stopping the engine wait for a few minutes until the air bubbles disappear on oil surface.
3.
Install the tank plug.
HYDRAULIC OIL TANK PRESSURIZATION

1.
With engine at low idle speed, slowly extend all cylinders to their
end of stroke.
2.
Stop the engine and remove tank plug.
3.
Check the condition of gasket and reassemble plug.
Avoid increasing the engine speed until after completing all air
bleeding procedures and after the pressurization of oil tank.
After air bleeding procedures, operate the engine at low idle speed
for about 10 minutes before starting to work.
WORK CIRCUITS
1.
Put all work attachments on level ground, stop the engine.
2.
Move all control levers in all directions to completely release

remain pressure in the cylinders and the main circuit.
3.
Slowly loosen the oil filler from the tank to remove any residual
pressure.
BRAKE CIRCUIT
You must bleed air from the braking circuit every time maintenance is performed on the braking circuit, a component is replaced,
or when air has entered the circuit. Machine must be stopped with
all attachments on level ground.
1.
Make sure that oil in the brake system tank a is at maximum level.
Remove the pedal lock pin.
2.
Remove the safety plugs and connect a plastic hose to the bleed
screws b to catch the oil.
3.
Push the brake pedals to the bottom. Keeping them pushed, loosen
the bleed screw b of the left brake until the pedals reach the end of
their stroke.
4.
Keeping the pedal at the end of its stroke, tighten the bleed screw
b.
20-45
BLEEDING AIR
12
5. Release the brake pedals, wait for few seconds and repeat above
operations two or three times until oil without air bubbles flows out
from the bleed screw.
6.
Repeat same operations for the right brake unit.
7.
Disconnect the pedal lock pin.
8.
Push one brake pedal to bottom and, keeping it pushed, loosen the
bleed screw b of one of the two braking units until the pedal
reaches the end of its stroke.
Check that oil without air bubbles flows out from the bleed
screw b.
9.
Repeat same operations for the other brake unit.

Frequently check the oil level in the tank and refill it when the
level approaches minimum.
After bleeding the air, reinstall the safety plugs on the screws
b.
CHECK BRAKE CIRCUIT

1.
Start the engine and lower the backhoe outrigger and force them
downwards in order to raise the rear wheels.
2.
Engage forward gear in order to move the wheels.
3.
Return the machine to neutral and lower it. Stop the engine.
4.
Apply 50 kg on the pedal and verify measure D.
5.
Insert the pedal lock pin and applying the same mass, verify the
measurement D.
D measurement, one pedal................................. Not < 165 mm
D measurement with both pedals....................... Not < 170 mm
20-46

12
HYDRAULIC
HYDRAULIC CIRCUIT
CIRCUIT
INTRODUCTION
A Engine
B Transmission
C Hydraulic Pump
D Loader Control Valve

E Backhoe Control Valve
F Loader Relief Valve
G Backhoe Relief Valve

H Steering Valve
I Filtered Return To Tank
The machine is equipped with two control valves having the following functions:
Loader Control Valve, 2 or 3 spools: For front work attachments control.
Backhoe Control Valve, 6, 7 or 8-spools: For rear work attachments control.
The two control valves are each protected against overpressure by a main relief valve with adjustable setting.
Control valves are fed by hydraulic pump P1 which is controlled by a priority valve when the steering unit is used.
20-47

12
LOADER
HYDRAULIC CIRCUIT
CONTROL VALVES
2 SPOOL LOADER CONTROL VALVE
Arm
Bucket
Cylinder Control
Port
Lift
A1
Lower
B1
Curl
A2
Dump
B2
3 SPOOL LOADER CONTROL VALVE

Cylinder Control
Port
a Arm
Lift
A1
Lower
B1
b Bucket
Curl
A2
Dump
B2
Retract
A3
Extend
B3
MP Bucket Or
C Attachment
20-48

12
BACKHOE
HYDRAULIC CIRCUIT
CONTROLS STYLE VALVE
6 SPOOL BACKHOE CONTROL VALVE

Bottom Port
a
b
C
d
e
f
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3
Right Outrigger Up......................... A4 Down ................... B4

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6

Bottom Port
a
b
C
d
e
f
g
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6
Telescope Arm
In .......................... A7 Out ....................... B7

Bottom Port
a
b
C
d
e
f
h
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6
Hammer
Run ....................... A8 Blank ................... B8

Bottom Port
a
b
C
d
e
f
g
h
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6
Telescope Arm
In .......................... A7 Out ....................... B7
Hammer
Run ....................... A8 Blank ................... B7
20-49

12
EXCAVATOR
HYDRAULIC CIRCUIT
CONTROLS STYLE VALVE

Bottom Port
a
b
C
d
e
f
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6

Bottom Port
a
b
C
d
e
f
g
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6
Telescope Arm
In .......................... A7 Out ....................... B7

Bottom Port
a
b
C
d
e
f
h
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6
Hammer
Run ....................... A8 Blank ................... B8

Bottom Port
a
b
C
d
e
f
g
h
Top Port
Arm
Close..................... A1 Open .................... B1
Swing
Left ....................... A2 Right .................... B2
Left Outrigger
Up......................... A3 Down ................... B3

Bucket
Dump.................... A5 Curl ...................... B5
Boom
Lift........................ A6 Lower................... B6
Telescope Arm
In .......................... A7 Out ....................... B7
Hammer
Run ....................... A8 Blank ................... B7
20-50

12
MAIN
MAIN RELIEF VALVES
RELIEF VALVES
The pressure readings are to be taken from check points on both

control valves. Measurement conditions:
Engine....................................... Stopped at operating temperature
Hydraulic oil.................................................................55 to 60C
Parking brake.................................................................... Applied
TESTING
LOADER CONTROL VALVE (2 OR 3 SPOOL)
1.
Connect the pressure gauge E3 to the pressure adapter B of the

front shovel control valve A.
2.
Start the engine and bring up to max speed and check the nominal
pressure of the main relief valve E by rolling the front bucket to the
end of its stroke.
Nominal pressure:
WB140PS-2N: ........................................................ 189 7 kg/cm
WB150PS-2N: ........................................................ 204 7 kg/cm
BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS)

1.
Connect the pressure gauge E3 to the pressure adapter D of the

backhoe control valve c.
2.
Start the engine and bring up to max speed and check the nominal
pressure of the main relief valve F while forcing the bucket into
maximum curl position.
Nominal pressure:
WB140PS-2N: ........................................................ 211 7 kg/cm
WB150PS-2N: ........................................................ 224 7 kg/cm
If the main relief valve pressures do not correspond to the nominal

values, they must be reset.
SETTING RELIEF PRESSURE

WARNING! For adjustments, prepare the machine as for
pressure testing.
1.
Remove the safety plug.
2.
Loosen the lock nut g.
3.
Force the specific control lever to the end of its stroke.
Loader............. Force the bucket into the maximum curl position.
Backhoe .......... Force the bucket into the maximum curl position.
20-51
MAIN RELIEF VALVES
12
4. Adjust the pressure with the adjusting screw h.
To INCREASE the pressure, rotate the adjusting screw in the

CLOCKWISE direction.
To DECREASE the pressure, rotate the adjusting screw in the

COUNTERCLOCKWISE direction.
5.
Tighten the locknut g to secure the adjustment.
6.
Reinstall safety plug.
20-52

12
LOADER
LOADER CIRCUIT RELIEF VALVES
CIRCUIT RELIEF VALVES
TESTING PRESSURE
1.

loader control valve.
2.
Start the engine and bring the hand accelerator lever up to 1050
rpm.
3.
Set the main relief valve c to a value 30 kg/cm higher than the
maximum pressure to be tested.
4.
Check the circuit relief valve d, e, f and g single movement

pressure. Refer to the following tables for the cylinder and its
movement.
D
Raise the loader arm so that the bucket will clear the ground.
Fully curl the bucket and read and record the pressure on the
gauge.
Fully dump the bucket and read and record the pressure on the
gauge.
Fully extend the cylinder and read and record the pressure on
the gauge.
Fully retract the cylinder and read and record the pressure on
the gauge.
Unit: kg/cm
Port
Description
A2
Bucket Dump
235
B2
Bucket Curl
166
A3
Cylinder Retract
235
B3
Cylinder Extend
235
Pressure
20-53

12
SETTING
LOADER CIRCUIT RELIEF VALVES
PRESSURE
The pressure must be set while the control lever, for the cylinder
being tested, is forced to the end of its stroke.
1.
Remove the safety plug h.
2.
Loosen the locknut i.
3.
Adjust the pressure with the adjusting screw j.
4.
To INCREASE K the pressure........................... rotate Clockwise.
To DECREASE L the pressure.............. rotate Counterclockwise.
Tighten locknut i to secure the adjustment.

Locknut ............................................................. 10 1 Nm
WARNING! After the pressure is adjusted, install the safety
plug h to avoid unauthorized tampering.
5.
Reset the main relief valve pressure to the standard value after all
of the secondary valves have been checked and set.
20-54

12
BACKHOE
BACKHOE CIRCUIT RELIEF VALVES
CIRCUIT RELIEF VALVES
TESTING PRESSURE
1.

backhoe control valve a.
2.
Start the engine and bring the hand accelerator lever up to 1050
rpm.
3.
Set the main relief valve c to a value 40 kg/cm higher than the
maximum pressure to be tested.
4.
Check the circuit relief valve d, e, f, g, h and i single movement pressure. Refer to the following tables for the cylinder and its
movement.
d
Spread the backhoe along the ground. Curl the bucket and fully
retract the arm cylinder. Read and record the pressure on the
gauge.
Place the backhoe in the transport position and lock the boom.
Swing the backhoe to the full right. Read and record the pressure on the gauge.
With the backhoe in the transport position and the boom lock
in place, swing the backhoe to the full left. Read and record the
pressure on the gauge.
With the backhoe centered raise the boom and extend the arm
the bucket will clear when curled. Fully curl the bucket and
read and record the pressure on the gauge.
Place the backhoe in the transport position and lock the boom.
Lower the boom and read and record the pressure on the
gauge.
The backhoe boom raise circuit valve pressure can only be

checked and set during a bench test.
20-55

12
BACKHOE CIRCUIT RELIEF VALVES

Unit: kg/cm
Port Description
Pressure
d A1
Arm Retract
245
e B2
Swing Right
184
F A2
Swing Left
184
G B5
Bucket Curl
245
H B6
Boom Lower
245
I A6
Boom Raise
357
J A8
Not Used
163
The backhoe boom raise circuit valve pressure can only be checked
and set during a bench test.
SETTING PRESSURE
The pressure must be set while the control lever, for the cylinder
being tested, is forced to the end of its stroke.
1.
Remove the safety plug 1).
2.
Loosen the locknut 1!.
3.
Adjust the pressure with the adjusting screw 1@.
4.
To DECREASE L the pressure............. rotate CounterClockwise.
Tighten locknut 1! to secure the adjustment.

Locknut ............................................................. 10 1 Nm
WARNING! After the pressure is adjusted, install the
safety plug 1) to avoid unauthorized tampering.
5.
Reset the main relief valve pressure to the standard value after all
of the secondary valves have been checked and set.
20-56

12
UNLOADING
UNLOADING VALVE
VALVE
Engine................................. Stopped and at working temperature.
Machine: Front equipment on the ground, parking brake applied

and boom and arm fully extended.
Working mode .....................................................................Power
TESTING
1.
Disconnect the hose b from the load sensing line. Install a tee and
reconnect the hose.
2.
Remove the plug c and install pressure adapter.
3.
Connect pressure gauge E5 to the adapter.
4.
Start the engine and set it at 1050 50 rpm. Without any machine
movement, all the control levers in the neutral position, read the
UP pressure.
UP - Unloading Valve ................................................ 24.5 kg/cm
If the UP value is not within the limits, adjust the unloading
valve a.
ADJUSTMENT
1.
Remove plug e, spring f, washers g, and valve body h.
2.
Place a shim d under the spring f and install the valve.
One shim, 1 mm thick ................... Increases the UP by 3 kg/cm

Plug .......................................................................100 Nm
20-57

12
LOAD
LOAD SENSING (LS) VALVE
SENSING (LS) VALVE
Engine................................. Stopped and at working temperature.
Machine: front equipment on the ground, parking brake applied

and boom and arm fully extended.
Working mode .....................................................................Power
TESTING
1.
Disconnect the hose b from the load sensing line. Install a tee and
reconnect the hose.
2.
Remove the plug c and install a pressure adapter.
3.
Connect the pressure gauge E5 to the adapter.
4.
Start the engine and set at 1050 50 RPM. Without any machine
movement, and all levers in the neutral position, read the UP pressure on the gauge.
UP - Unloading Valve ................................................ 24.5 kg/cm
If the UP value is not within this limit, adjust the unloading
valve.
5.
Raise the boom up to the end of its stroke and read the UP pressure
on the gauge.
UP - Load Sensing Valve ........................................... 21.5 kg/cm
If the UP value is not within limits, adjust the load sensing
valve a.
ADJUSTMENT
1.
Remove the cover nut e. Loosen the locknut f.
2.
Adjust the pressure using the adjustment screw g.
3.
To DECREASE L the pressure.............. rotate Counterclockwise.
Tighten the locknut f to secure the adjustment.

Locknut ...................................................................21 Nm
4.
Check the gasket d and install the nut e.

Cover Nut................................................................21 Nm
20-58

12
FLOW
FLOW VALVE
VALVE
Engine.........................................Stopped at working temperature
Machine ............................................. Safe, parking brake applied
Control valve lever .............................................. Neutral position
1.
Disconnect the hose a from the load sensing line. Install the tee b
and reconnect the hose.
2.
Connect a pressure port and gauge E1 to the tee b.
3.
Connect a second gauge E1 to the rear control valve pressure port

c.
4.
Start the engine and at low idle without any machine movement,
check the pressure on both gauges.
P pressure at control valve gauge ........................ 30 3 kg/cm
Normal pressure PLS ........................................... 6 2 kg/cm
This value is due to the influence of the counterpressure
present in the steering circuit.
If any variations are found, they do not represent a problem
provided that the difference of 21 1 kg/cm between the two
readings is respected.
5.
If the difference between the readings is higher than 24 1 kg/cm,

stop the engine and release the residual pressures.
6.
Thoroughly clean the valve d and reinstall it.

Valve .......................................................................20 Nm
7.
If, after cleaning the valve d, the value still does not fall within the
tolerance limits of 24 1 kg/cm, install a new valve.
20-59

12
PRIORITY
PRIORITY VALVE
VALVE
TESTING
1.
Connect a pressure gauge E2 to the pressure adapter a of the backhoe control valve.
2.
Start the engine and set it at 1500 50 rpm. Check the gauge E2
pressure value with a stopped steering wheel.
3.
Pressure Value ...............................................................24 kg/cm
Slightly turn the steering wheel and check that pressure increases.
Continue turning the steering wheel to the end of a full turn and
check that while forcing the steering wheel, pressure increases to
the normal value.
Backhoe Controls .................................................178 10 kg/cm
Excavator Controls .................................................178 7 kg/cm
If the pressure does not reach the normal value, reset the pressure of the steering unit
If the pressure indicated by the gauge does not change while
turning the steering wheel, and it takes excessive force to turn
the wheel, the priority valve b needs to be cleaned.
CLEANING PRIORITY VALVE

1.
Remove the priority valve plug d, spring e and rod f.

Carefully check and make notes on the disassembly so that you
can reassemble the priority valve.
2.
Remove the plug g and ball h of the inside valve and the spring i.
Check that the hole j and nozzle c are completely clean. Replace
the spring i, ball h and plug g.
Plug ...................................................................Loctite 542
Plug ........................................................................ 20 Nm
Do not allow any Loctite to enter the hole j. Remove all
excess Loctite from the rod f.
3.
Lubricate the rod f and install it in its seat. Make sure that it slides
freely. Insert the spring e and plug d.
Plug .......................................................................100 Nm
4.
Start the engine and execute several steering manoeuvres. If the

fault is not corrected, replace the complete steering column with a
new one.
20-60

12
STEERING
STEERING SYSTEM
SYSTEM
Measurement condition:
TESTING
1.
Connect a pressure gauge E2 to the pressure adapter a of the backhoe control valve.
2.
Start the engine and set at 1500 50 rpm. Turn the steering wheel
from end to end.
3.
Force the steering wheel to the end of its rotation and check the
pressure.
4.
Backhoe Controlled Pressure ...............................178 10 kg/cm
Excavator Controlled Pressure ...............................178 7 kg/cm
Check the pressure at the other end of the steering direction as well.
SETTING
If the pressure is not within the permissible limits, reset the pressure on the upper valve b of the steering unit.
1.
Remove the plug c. Insert a wrench and loosen the screw d.
2.
Adjust the pressure with the screw e.
To INCREASE K the pressure............................ rotate Clockwise
To DECREASE L the pressure............... rotate Counterclockwise
3.
Stop the engine. Secure the adjustment screw e by tightening

screw d.
4.
Install the plug E making sure that the gasket f is properly seated.
20-61

12
BRAKE
BRAKE SYSTEM
SYSTEM
Measurement condition:
Engine............................................................................... Stopped
Machine: on solid and level ground, with the equipment raised

and safety devices engaged.
Brake pedals: independent, with the fluid container level at maximum.
Brake system testing is accomplished in two parts:

1.
Testing the circuit and brake pump tightness.
2.
Leak tightness test of the braking group.

WARNING! If both the tests give positive results, check for
leaks in the piping of the braking system.
CIRCUIT AND BRAKE PUMP TEST

1.
Disconnect the equalizer connecting pipe a from the brake pumps

b of the circuit being tested.
2.
Securely plug the equalizer orifice A when the pipe is disconnected.
3.
Remove clamp d and disconnect delivery lines e from the pumps.
4.
Connect a pressure gauge E2 to the pump b.
5.
Push the brake pedal corresponding to the pump and bring the circuit up to a pressure.
Brake Pressure ...........................................................122 kg/cm.
Do not exceed ............max permissible value - 153 5 kg/cm.

6.
Keep the pedal pushed for at least 2 minutes and check that the
pedal pressure and position remain steady.
If the position of the pedal changes to maintain the pressure,
the pressure loss is due to leaks inside the pump.
This can be confirmed by checking the oil. If there are leaks, it
will show signs of mixing.
7.
Repeat the test for the other brake pump.
20-62

12
BRAKING
BRAKE SYSTEM
GROUP LEAK TEST
1.
Disconnect the delivery tube e of the brake group being tested.
2.
Connect the tee between the delivery line f and the brake group.
Make sure to insert the pressure adapter between the brake
group and the cut off valve g.
3.
Connect a pressure gauge E2 to the pressure adapter of the tee and

open the valve g.
4.
Operate the brake pump to feed 122 kg/cm of pressure into the circuit.
Do not exceed the max permissible value of 158 5 kg/cm.
5.
Close the valve g to maintain pressure in the brake group being

tested.
6.
Release the brake pedal and observe the pressure indicated on

gauge E2 for 2 minutes.
If the pressure value shows a negative change, it means that the
brake piston seals are defective.
WARNING! For further confirmation of the leak can be obtained by an increase in the oil level in the axle, which leads
to a mixing of the oils. Change all the sealing rings between
the axle sections, and carry out a complete lubrication oil
change.
7.
Repeat the test for the other brake group, follow the same method.
8.
Reassemble the brake circuit.

WARNING! After testing and any repairs, bleed air from the
brake units, see BLEEDING AIR.
20-63

12
ENGINE
ENGINE SPEED UNDER LOAD
SPEED UNDER LOAD
Hydraulic oil................................................................45 to 55 C
Power train oil ............................................. Working temperature
Brake pedals ................................................................. Connected
Machine: on solid and level ground with the equipment raised

Two tests must be performed:

1.
Stall test with the torque converter under load.
2.
Stall test with the torque converter and the hydraulic system
under load.
The tests must be performed after a no load test of the engine

speed. For details, see ENGINE SPEED.
WARNING! During the following tests, while accelerating
the engine with the gear engaged, the condition of the brake
disks can also be checked. If, while force is being exerted on
the brake pedals, the machine moves, even slowly;
1.
2.
Release the accelerator immediately and stop the

engine.
Check the wear on the brake disks and change them
before completing the tests.
PREPARING THE MACHINE

1.
Prepare the tachometer C to measure the engine rpm.

When mounting an electronic transducer tachometer on a diesel delivery line to the injection nozzles, make sure that it is
placed far away from the clamp.
WARNING! Make sure that the brake pedals are fastened together with the cotter pin b.
TORQUE CONVERTER STALL

1.
Start the engine at set at the lowest idle. Engage 4th gear and apply
the brake firmly.
2.
While keeping the brake applied, accelerate the engine gradually up

to high idle and measure the speed reached.
WB140PS-2N TIER I Engine.............................2100 50 rpm
WB140PS-2N TIER II Engine BH Controls......2200 50 rpm
WB140PS-2N TIER II Engine EX Controls ......2275 50 rpm
WB150PS-2N TIER I Engine.............................2275 50 rpm
WB150PS-2N TIER II Engine BH Controls......2200 50 rpm
WB150PS-2N TIER II Engine EX Controls ......2275 50 rpm
3.
Release the accelerator pedal and move on to the next test.
20-64

12
TORQUE
ENGINE SPEED UNDER LOAD
CONVERTER AND HYDRAULIC STALL
1.
Start the motor at set at the low idle. Engage 4th gear and apply the
brake firmly.
2.
While keeping the brake applied, 4th gear engaged, accelerate the
engine gradually and at the same time activate the control valve
lever to curl the front bucket, and turn the steering wheel and hold
it at the end of its stroke.
3.
Once the maximum engine speed and maximum pressure of the

bucket circuit have been reached, note the speed reached by the
engine.
TIER I Engine ........................................................ 2000 50 rpm
TIER II Engine BH Controls ................................. 2050 50 rpm
TIER II Engine EX Controls.................................. 2250 50 rpm
If the engine rpm are higher than the permissible limit in both
tests, check the delivery pressure to the converter and the clutch
pressures.
If the engine rpm is lower than the permissible limit, check the
condition of the air filter, the engine compression, the timing, the
injection pump, and the valve clearances.
20-65

12
POWER
POWER TRAIN GROUP
TRAIN GROUP
The power train group can be used to perform pressure tests on the
internal hydraulic circuit. These are useful for identifying malfunctions.
Specifically, the tests involve:
1.
Converter oil pressure.
2.
Clutch engagement pressures for both directions of travel.
Test conditions:
Engine............................................................................... Stopped
Machine: On solid and level ground with the equipment raised

PREPARING THE MACHINE

1.
Prepare the tachometer C to measure the engine rpm.

placed far away from the line clamp.
WARNING! Make sure that the brake pedals are fastened together with the cotter pin b.
CONVERTER OIL PRESSURE

1.
Remove the plug P28 and connect pressure gauge E6.
2.
Start and engine and heat all the fluids up to working temperature.
Make sure that the power train oil reaches a temperature of 80
5C.
3.
With the engine at low idle, check the pressure on the pressure
gauge E6.
Normal pressure ...............................................Min. 0.5 kg/cm
4.
Gradually increase the engine speed to high idle. Take a new reading from the pressure gauge E6.
Normal pressure ....................................................... 9.2 kg/cm
5.
Bring the engine back to low idle and compare the pressure with
the normal value.
Normal pressure ...............................................Min. 0.5 kg/cm
If the maximum pressure value drops to below the permissible
lower limit, the power train pump needs an overhaul.
CLUTCH PRESSURE
1.
Remove the access plate from the cab floor.
2.
Remove plug P19 and connect pressure gauge E6.
20-66
POWER TRAIN GROUP
12
3. Start and heat the engine and all the fluids up to working temperature. Make sure that the power train oil reaches a temperature of 80
5C.
4.
With the engine at low idle, check the pressure on the gauge E6.
Normal pressure ............................................ Max. 0.32 kg/cm
5.
Select the REVERSE gear and gradually increase the engine speed
to high idle. Take a new reading from the pressure gauge E6.
Normal pressure ............................................... 11 to 13 kg/cm
6.
Bring the engine back to low idle and place the transmission in
neutral. Compare the pressure with the normal value.
Normal pressure ............................................ Max. 0.36 kg/cm
7.
Remove the pressure adapter and replace the plug P20.

Plug......................................................................... 23 Nm
8.
Repeat the same test for the FORWARD gear, reading the pressure
from the plug P19.
If the pressures are different for the travel directions, there is a

loss of pressure on the clutch piston with lowest pressure.
20-67
TRANSMISSION CLUTCHES
TRANSMISSION CLUTCHES
Test conditions:
Engine.............................................................................. Stopped.
Machine: on solid and level ground with the equipment raised

This test must be performed after having checked the pressures of

the power train group.
PREPARATION OF THE MACHINE

1.
Prepare tachometer C to measure the engine rpm.

placed far away from the line clamp.
WARNING! During the following tests, while accelerating the engine with the gear engaged, the condition
of the brake disks can also be checked. If, while force
is being exerted on the brake pedals, the machine
moves, even slowly;
1.
2.
Release the accelerator immediately and stop

the engine.
Check the wear on the brake disks and change
them before completing the tests.
WARNING! Make sure that the brake pedals are fastened together by the cotter pin a.
TESTING
1.
Start and heat the engine and all the fluids up to working temperature. Make sure that the power train oil reaches a temperature of 80
5C.
2.
With the engine at low idle, accelerate to high idle. Check that the
rpm remain within permissible limits.
3.
Brake hard and bring the engine up to high idle.
4.
Maintaining the braking action and the acceleration, engage the

FORWARD gear and check that the engine speed decreases until it
is once again within permissible limits.
5.
Repeat this test in REVERSE gear.
If the rpm are higher than the permissible limits, the clutches are
worn, and must be replaced.
20-68

12
RETURN
RETURN TO DIG DEVICE
TO DIG DEVICE
Adjustment conditions:
Machine ................................................On solid and level ground
Engine............................................................................... Stopped
Parking brake................................................................... Engaged
1.
Rest the bucket on the ground, making sure that the bottom is parallel to the surface.
2.
Stop the engine and remove the sensor guard a.
3.
Check that there is a distance of 3 to 4 mm between the sensor C

and rod D. If necessary, loosen the nuts E and adjust the distance
until the indicated measurement is obtained. Tighten the nuts to
secure the adjustment.
4.
Loosen screw F and move bracket G towards the rear until the sensor is completely free of rod D.
5.
Start the engine and set at low idle. Adjust the position of the
bracket G until the sensor C is engaged.
When the rod contacts the sensor, the warning lamp b will be
activated.
6.
Secure the bracket G position by tightening the screw.
7.
Perform several tests by raising and dumping the bucket. If the

bucket is able to rest flat on the ground, reinstall the sensor guard
a.
20-69

12
HYDRAULIC
HYDRAULIC DRIFT
DRIFT
If a working attachment drifts, check if the drift is due to the cylinder seals or the control valve.
Test conditions:
Remove and install pipes only after any residual pressure has
been removed.
LOADER
LIFT CYLINDER
1.
Position the bucket vertically with the cutting edge or teeth resting
on 10 cm blocks a.
2.
Stop the engine and remove any residual hydraulic pressure.
3.
Disconnect the hoses B and C from the lift cylinders D and plug
them.
4.
Plug the lift cylinder base side. Apply a temporary hose to the rod
side to catch any oil leakage.
5.
Start the engine and retract the bucket until the cutting edge or teeth
tilt 15 above horizontal.
6.
Stop the engine and check the bucket link position for 5 minutes.
If the bucket link has no lowering movement, drift is due to the

control valve.
To check each cylinder, proceed as follows:

7.
Position the bucket vertically with the teeth resting on 10 cm thick

blocks.
8.
Remove the plug (installed earlier in Step 4) from the base side of
one cylinder.
9.
Start the engine and retract the bucket until the teeth tilt 15 above
horizontal.
10. Stop the engine and check the bucket position for 5 minutes.
If the bucket link has a lowering movement, drift is due to gasket

seals of the plugged cylinder.
11. Repeat Steps 7 through 10 to check the other cylinder.
20-70
HYDRAULIC DRIFT
12
BUCKET CYLINDER
1.
Position the bucket on level ground and tilt the cutting edge or teeth
up 15 a. Put a 1500 kg weight into the bucket. Stop the engine
and remove any residual hydraulic pressure.
2.
Disconnect the hoses B and C from the dump cylinders D and plug
them.
3.
Plug the dump cylinder base side. Apply a temporary hose to the
rod side to catch any oil leakage.
4.
Start the engine and raise the bucket up to horizontal alignment of

the bucket hinge and arm hinge.
5.
Stop the engine and check the bucket cutting edge or teeth position
for 5 minutes.
If the bucket has no swing movement, drift is due to the control

valve.
To test the individual cylinders, proceed as follows:

6.
Lower the bucket to the ground.
7.
Remove the plug from one of the cylinders installed on the base
side in Step 3.
8.
Start the engine and raise the bucket as indicated in Step 4.
9.
Stop the engine and check the position of the bucket cutting edge or
teeth for 5 minutes.
If the bucket cutting edge or teeth turn, the drift is due to the gasket seals of the plugged cylinder.
10. Repeat Steps 6 through 10 to test the other cylinder.
20-71
HYDRAULIC DRIFT
12
BACKHOE
Test condition:
Backhoe ............................................................................ Aligned
Outriggers ........................................................................... Raised
BOOM CYLINDER
1.
Position the machine with its arm in vertical position with the bottom of the bucket resting on level ground.
2.
Stop the engine and remove any residual hydraulic pressure.
3.
Disconnect hoses B and C from cylinder D and plug them.
4.
Plug the cylinder head side.
5.
Apply a temporary hose to the base side to catch any oil leakage.
6.
Start the engine and extend the arm completely.
7.
Stop the engine and check the boom position for 5 minutes.
If the boom has a lowering movement, drift is due to cylinder

gaskets.
If the boom has no lowering movement, drift is due to the control

valve.
ARM CYLINDER
1.
Position the machine with its arm a fully extended with the bucket
opened and teeth on the ground.
20-72
HYDRAULIC DRIFT
12
2. Stop the engine and remove any residual hydraulic pressure.
3.
Disconnect the hoses B and C from the arm cylinder D and plug
them.
If a safety valve is installed, remove it for this test.
4.
Plug the arm cylinder port on the rod side. Attach a temporary hose
to the base side to catch any oil leakage.
5.
Start the engine and raise the boom.
6.
Stop the engine and check the arm position for 5 minutes.
If the arm has a lowering movement, the drift is due to the cylinder gaskets.
If the arm has no movement, the drift is due to the control valve.
BUCKET CYLINDER
1.
Position the machine with the bucket arm vertical and the bottom of
the bucket resting on level ground.
2.
Put a 450 kg weight a into the bucket
3.
Stop the engine and remove any remaining hydraulic pressure.
4.
Disconnect hoses b and c from bucket cylinder d and plug them.
5.
Plug the bucket cylinder hole on the base side and attach a temporary hose to the rod side to catch any oil leakage.
20-73
HYDRAULIC DRIFT
12R
6. Start the engine and raise the boom.
7.
Stop the engine and check the bucket position for 5 minutes.
If the bucket has an opening movement, drift is due to cylinder

gaskets.
If the bucket has no movement, drift is due to the control valve.
OUTRIGGER TESTING
1.
Position the machine with its arm in vertical position with the bottom of the bucket resting on level ground.
2.
Place support stands a of a suitable height beneath the outriggers,

and bring the cylinder eyes to a horizontal position.
3.
Without forcing them, lower the outriggers onto the support stands.
4.
Stop the engine and release any residual hydraulic pressure.
5.
Remove the hoses b and c from the cylinders d and plug them.
6.
Plug the cylinder base side c. Apply a temporary hose to the rod
side to catch any oil leakage.
7.
Start the engine. Use force on the boom to raise the machine and
remove the support stands supporting the outriggers.
8.
Lower the machine and stop the engine.
9.
Check the outriggers position for 5 minutes.
If one or both outriggers have a lowering movement, drift is due

to one or both cylinders.
If there is no lowering, drift is due to the control valve.
20-74

12
AIR
AIR CONDITIONING UNIT
CONDITIONING UNIT
Test conditions:
Machine on level ground with the work equipment raised and

safety devices engaged
Parking brake................................................................... Engaged
TESTING THE WORKING TEMPERATURE

1.
Connect the maintenance station to the high pressure valve and the
low pressure valve.
2.
Start the engine and bring it up to a speed of 1500 rpm.
3.
Switch on the AC unit using the switch in the cab.
4.
Select an intermediate ventilation speed inside the cab.
5.
Use the thermometer M2 to check that the temperature inside the

cab is equal to or lower than the ambient temperature.
If the temperature of the cab is higher than the ambient temperature, open the doors and widows and wait until the cab temperature stabilizes at the outside value.
6.
Close the doors and windows and let the AC unit operating these
conditions for 5 to 10 minutes.
7.
Use the thermometer M2 to check the temperature of the air at the

central outlets.
Position the probe as close as possible to the air outlets.
8.
Compare the average value of the measured temperatures using the

following table:
Ambient Air Temp C
20
25
30
35
Outgoing Air Temp C
6 to 8
8 to 10
8 to 12
9 to 14
9.
If the average value of the temperature measured does not fall

within the values given in the table, it will be necessary to thoroughly check the unit.
CHECKING THE UNIT

Check the unit after the Steps 1 through 4.and 6. of the preceding paragraph. A diagnosis of faults in the unit is based upon the working pressures.
When the pressures do not fall within the values given in the following
table, the causes must be found by checking the high-pressure and low
pressure gauges.
20-75
AIR CONDITIONING UNIT
12
Unit: kg/cm
Unit with R134a.
Outside Air
Temperature C
Low Pressure
High Pressure
Min
Max
Min
Max
20
1.2
2.5
6.0
9.0
25
1.0
2.5
7.5
10.5
30
1.1
2.4
9.5
13.0
35
1.3
2.4
12.0
15.5
40
1.5
1.8
18.0
18.8
45
1.8
1.9
21.5
22.0
The following conditions can be found:

CONDITIONS
CAUSES - FAULTS
LP high to HP normal or low
LP low to HP high or normal
LP normal to HP normal
LP high to HP high
LP normal or low to HP low
LP roughly equal to HP
Electromagnetic pulley that slips or does not engage correctly

Expansion valve blocked in open position
Compressor damaged
Expansion valve blocked in closed position or obstructed
Filter saturated with moisture
Obstruction in the LP line or in the HP line between the filter and the evaporator.
Infiltration of hot air into the evaporator group, the pipes or the cab
Hot air circulating in the heating group
Formation of ice on the evaporator
Normal condition with very high ambient temperature, higher than 43C
Excess coolant, 30 to 35% more
Overheating of condenser
Air present in the unit
Obstruction in the HP line between the compressor and the condenser filler tube behind
the measurement point of the HP
Normal condition with very low temperature, lower than 5C
Lack of coolant, 70 to 75% less, probable leakages
Obstruction in the HP line between the compressor and the condenser filler tube before
the measurement point of the HP
Compressor damaged
Compressor belt missing
Electromagnetic pulley that slips or does not engage
Compressor damaged
EMPTYING THE AC UNIT

1.
Connect the maintenance station M1 to service valves a and b

and follow the specific maintenance station instructions relative to
the drainage of the unit.
2.
Disconnect the group to be substituted or reconditioned immediately after switching off the maintenance station. Cap and plug the
disconnected tubes tightly and with a minimum of delay.
3.
Carefully check the quantity of R134A recovered and contained in

the disassembled parts, since the same quantity must be replaced
when the air conditioning unit is filled.
20-76
TROUBLESHOOTING
TROUBLESHOOTING GUIDE
12
TROUBLESHOOTING
GUIDE
FRONT AXLE
Wheel vibration; front tire resistance; half shaft breakage.
CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test
phases
Overloading incorrect weight distribution
Remove excessive weight and redistribute load following instructions

related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Bent half shaft
Replace half shaft
No differential action; jamming while steering.

CAUSES
REMEDY
Defective axle
phases
Broken half shaft
Replace half shaft
Bent half shaft
Replace half shaft
Steering is difficult; vehicle goes straight while trying to turn it.

CAUSES
REMEDY
Defective axle
phases
Overloading/incorrect weight distribution

Broken half shaft
Replace half shaft
Excess noise
CAUSES
REMEDY
Defective axle
phases

Bent or broken half shaft
Replace half shaft
Incorrect wheel adjustment
Verify group integrity and wheel side bearings
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various
of parts
parts of the axle.
20-77
TROUBLESHOOTING
12
Uneven wear of tires
CAUSES
REMEDY
Defective axle
phases

Replace half shaft
Blocked half shaft:

Abnormal
functioning of the differential or
breakage/blockage of control device
Vehicles with wide steering angle may proceed
with kicks, have steering difficulty or cause pneumatic wear on sharp turns.
Verify assembly of all components
Reduce the steering angle to minimum and decelerate when the

vehicle begins to kick.
Friction noise
CAUSES
REMEDY
Defective axle
phases
Replace half shaft
Damaged or worn out axle parts
Check the condition of the ring gear, pinion gear, bearings, etc.
Replace when necessary.
of parts
parts of the axle.
Incorrect adjustment of bevel gear set. Parts of the
Replace or adjust as required.
trans worn out transmission gears, U joint, etc.
Vibration during forward drive, intermittent noise

CAUSES
REMEDY
Defective axle
phases

Bent half shaft
Replace half shaft
20-78
TROUBLESHOOTING
12
Noise while driving
CAUSES
REMEDY
Excessive backlash between pinion and ring gear
Adjust
Worn out pinion and ring gear
Replace
Worn out pinion bearings
Replace
Pinion bearings loose
Adjust
Excessive axial pinion backlash
Adjust
Worn out differential bearings
Replace
Differential bearings loose
Adjust
Ring gear out of round
Replace
Low oil level
Oil level
Poor or worn oil
Replace
Bent half shaft
Replace
Noise while driving in neutral

CAUSES
REMEDY
Noises coming from axle are usually heard but not

Replace or adjust (see above)
loud when vehicle moves in neutral gear.
Incorrect backlash between pinion and ring, sound
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out
Adjust
Intermittent noise
CAUSES
REMEDY
Ring gear damaged
Replace bevel gear set
Differential box bolts loosened
Tighten to torque
Constant noise
CAUSES
REMEDY
Ring gear teeth or pinion damaged
Worn out bearings
Replace
Pinion spline worn out
Replace
Bent half shaft
Replace
Noise while steering

CAUSES
REMEDY
Worn out differential gears
Replace
Worn out differential box or spider
Replace
Differential thrust washers worn out
Replace
Half shaft spline worn out
Replace
20-79
TROUBLESHOOTING
12
Ring gear teeth broken at the outer side
CAUSES
REMEDY
Excessive gear load compared to the one foreseen

Incorrect gear adjustment (excessive backlash)
Replace bevel gear set. Carefully follow the recommended operations

for the adjustment of the bevel gear set free backlash.
Pinion nut loosened
Ring gear tooth broken

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

CAUSES
REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication
for the adjustment of the bevel gear set free play. Use correct lubricants, fill to proper levels and replace according to the recommended
schedule.
Overheated ring and pinion teeth

CAUSES
REMEDY
Prolonged operation at high temperature

Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule.
lubrication
Pinion teeth pitting

CAUSES
REMEDY
Excessive use
replace according to the recommended schedule.
Insufficient lubrication
Axle beam body bent

CAUSES
REMEDY
Vehicle overloaded
Vehicle accident
Replace axle beam body
Load bump
Worn out or pitted bearings

CAUSES
REMEDY
Insufficient lubrication; contaminated oil

Excessive use
Normal wear out
Replace bearings, use correct lubricants, fill to proper levels and

Pinion nut loosened
20-80
TROUBLESHOOTING
12
Oil leakage from gaskets and seals
CAUSES
REMEDY

Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Oil gasket assembled incorrectly

Seal lip damaged
Contaminated oil
Excessive wearing out of input flange spline

CAUSES
REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
worn. Replace bevel gear set if required
Pinion nut loosened

Pinion axle backlash
Fatigue failure of pinion teeth

CAUSES
REMEDY
Exhaustive use
Continuous overload
Pinion and ring teeth breakage

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

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

CAUSES
REMEDY
Use correct lubricants, fill to proper levels and replace according to the
Insufficient lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out

CAUSES
REMEDY
Excessive use axial pinion
Replace bearing. Check pinion axial backlash Use correct lubricants,

fill to proper levels and replace according to the recommended schedule.
Excessive pinion axial backlash

Bent or broken half shaft or half shaft broken at wheel side

CAUSES
REMEDY
Vehicle intensively operated or overloaded

Wheel support loosened
Replace. Check that wheel support is not worn out or incorrectly

adjusted.
Beam body bent
20-81
TROUBLESHOOTING
12
REAR
AXLE
Wheel vibration; front tire resistance; half shaft breakage.
CAUSES
REMEDY
Defective axle
phases

Bent half shaft
Replace half shaft
Steering is difficult; vehicle goes straight while trying to turn it.

CAUSES
REMEDY
Defective axle
phases

Broken half shaft
Replace half shaft
No differential action; jamming while steering.

CAUSES
REMEDY
Defective axle
phases
Broken half shaft
Replace half shaft
Bent half shaft
Replace half shaft
Excess noise
CAUSES
REMEDY
Defective axle
phases

Replace half shaft
of parts
parts of the axle.
20-82
TROUBLESHOOTING
12
Uneven wear of tires
CAUSES
REMEDY
Defective axle
phases

Replace half shaft
Blocked half shaft:

Abnormal functioning of the differential or breakage/blockage of control device.
Vehicles with wide steering angle may proceed

with kicks, have steering difficulty or cause pneumatic wear on sharp turns.
Verify assembly of all components
Reduce the steering angle to minimum and decelerate when the

vehicle begins to kick.
Friction noise
CAUSES
REMEDY
Defective axle
phases
Replace half shaft
Damaged or worn out axle parts
Check the condition of the ring gear, pinion gear, bearings, etc.
Replace when necessary.
of parts
parts of the axle.
Incorrect adjustment of bevel gear set.
Parts of the trans worn out transmission gears, U Replace or adjust as required.
joint, etc.
Vibration during forward drive, intermittent noise

CAUSES
REMEDY
Defective axle
phases

Bent half shaft
Replace half shaft
20-83
TROUBLESHOOTING
12
Noise while driving
CAUSES
REMEDY
Excessive backlash between pinion and ring gear
Adjust
Worn out pinion and ring gear
Replace
Replace
Pinion bearings loose
Adjust
Excessive axial pinion backlash
Adjust
Worn out differential bearings
Replace
Differential bearings loose
Adjust
Ring gear out of round
Replace
Low oil level
Oil level
Poor or worn oil
Replace
Bent half shaft
Replace
Noise while driving in neutral

CAUSES
REMEDY
Noises coming from axle are usually heard but not

Replace or adjust (see above)
loud when vehicle moves in neutral gear.
Incorrect backlash between pinion and ring sound
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out
Adjust
Intermittent noise
CAUSES
REMEDY
Ring gear damaged
Differential box bolts loosened
Tighten to torque
Constant noise
CAUSES
REMEDY
Ring gear teeth or pinion damaged
Worn out bearings
Replace
Pinion spline worn out
Replace
Bent half shaft
Replace
Noise while steering

CAUSES
REMEDY
Worn out differential gears
Replace
Worn out differential box or spider
Replace
Differential thrust washers worn out
Replace
Half shaft spline worn out
Replace
20-84
TROUBLESHOOTING
12
Ring gear teeth broken at the outer side
CAUSES
REMEDY
Excessive gear load compared to the one foreseen

Replace bevel gear set. Carefully follow the recommended operations
for the adjustment of the bevel gear set free backlash.
Incorrect gear adjustment, excessive backlash

Pinion nut loosened
Ring gear tooth broken

CAUSES
REMEDY
Load bump
Incorrect gear adjustment, insufficient backlash
Replace bevel gear set. Adjust bevel gear set free backlash.
Pinion nut loosened
Pinion or ring gear teeth worn

CAUSES
REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication
for the adjustment of the bevel gear set free play. Use correct lubricants, fill to proper levels and replace according to the recommended
schedule.
Overheated ring and pinion teeth

CAUSES
REMEDY

Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule.
lubrication
Pinion teeth pitting

CAUSES
REMEDY
Excessive use
Insufficient lubrication
Axle beam body bent

CAUSES
REMEDY
Vehicle overloaded
Vehicle accident
Replace axle beam body
Load bump
Worn out or pitted bearings

CAUSES
REMEDY

Excessive use
Normal wear out
Replace bearings. Use correct lubricants, fill to proper levels and

Pinion nut loosened
20-85
TROUBLESHOOTING
12
Oil leakage from gaskets and seals
CAUSES
REMEDY

Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Oil gasket assembled incorrectly

Seal lip damaged
Contaminated oil
Excessive wearing out of input flange spline

CAUSES
REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
worn. Replace bevel gear set if required
Pinion nut loosened

Pinion axle backlash
Fatigue failure of pinion teeth

CAUSES
REMEDY
Exhaustive use
Continuous overload
Pinion and ring teeth breakage

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

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

CAUSES
REMEDY
Use correct lubricants, fill to proper levels and replace according to the
Lack of lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out

CAUSES
REMEDY
Excessive use axial pinion
Replace bearing. Check pinion axial backlash. Use correct lubricants,

fill to proper levels and replace according to the recommended schedule.
Excessive pinion axial backlash

Bent or broken half shaft or half shaft broken at wheel side

CAUSES
REMEDY
Vehicle intensively operated or overloaded

Wheel support loosened
Replace. Check that wheel support is not worn out or incorrectly

adjusted.
Beam body bent
20-86
TROUBLESHOOTING
12
TRANSMISSION
Vehicle does not move

CAUSES
REMEDY
Faulty supply to solenoid valves
Check/Replace
Damaged wiring connections between transmission

Repair/Replace
and vehicle
Oxidized contacts in electrical wiring
Clean
Break in electrical cable
Replace
Damaged solenoids
Replace
Damaged sensors
Replace
Short circuits or open connections
Check/replace fuses
Incorrect oil level
Fill oil to proper level
Check for leaks
Repair
Blocked intake filter
Clean
Damaged oil pump
Replace
Damaged oil pump relief valve
Replace oil pump
Blocked/damaged transmission filter
Replace
Damaged/jammed control valve
Replace
Damaged converter
Replace
Oil temperature below 0C
Wait for oil to reach operating temperature (stall test)
Damaged rotary seals
Replace
Damaged synchronizers
Replace
Blocked reverse lever
Repair
Worn clutch
Replace/repair clutch
No drive transmission, broken gears, shafts, bearCheck/Repair/Replace

ings, etc.
Vehicle has reduced power transmission

CAUSES
REMEDY
Incorrect oil temperature
Wait for oil to reach operating temperature (stall test)
Transmission oil overheating
See Overheating
Incorrect operating pressure
Check hydraulic circuit and replace, oil pump, filters, control valve
Damaged converter
Replace
Incorrect oil level
Fill oil to proper level
Worn clutch
Replace/Repair
4WD clutch failure
Repair/Replace 4WD shaft group
Overheating solenoids
Replace
Damaged transmission and vehicle wiring connecRepair/Replace

tions
Damaged sensors
Replace
20-87
TROUBLESHOOTING
12
Overheating
CAUSES
REMEDY
Damaged hydraulic cooling system
Repair
Dirty heat exchanger
Clean
Parking brake inadvertently activated
Release
Excessive dirt on axle wheel hubs
Clean
Seizing, broken gears, shafts, bearings, etc.
Check/Repair/Replace
Braking force outside transmission: irregular axle

Check/Repair axle
operation
Clutch plate drag
Repair/Replace
Damaged converter
Replace
Damaged oil thermostat
Replace
Incorrect oil level
Add oil
Worn oil pump
Replace
Wheels rotate when vehicle is raised

CAUSES
REMEDY
Clutch plate drag
Repair/Replace
Low oil temperature (high oil viscosity)
Wail for oil to reach operating temperature (stall test)
Incorrect oil specifications
Replace oil and filters
Damaged control valve
Replace
Faulty reverser locking
Repair/Replace
Noise
CAUSES
REMEDY
Damaged converter
Replace
Damaged oil pump
Replace
Aeration/Cavitation
Check oil level
Seizing (broken gears, shafts, bearings, etc.)
Check/Repair/Replace
Worn clutch plates
Replace
Irregular actuation
CAUSES
REMEDY
Replace
Electrical system fault
Repair/Replace
Worn clutch plates
Replace
Damaged converter
Replace
Low oil temperature (high oil viscosity)
Wail for oil to reach operating temperature (stall test)
Overheating
See Overheating
Damaged hydraulic system
Repair/Replace
20-88
TROUBLESHOOTING
12
Gear remains engaged
CAUSES
REMEDY
Damaged/jammed shuttle shaft lever
Repair/Replace
Repair/Replace
Replace
Damaged hydraulic system
Repair/Replace
Damaged clutch
Repair/Replace
Damaged gear lever rod
Replace
Damaged synchronizer
Replace
No 4WD power transmission

CAUSES
REMEDY
Damaged 4WD clutch
Replace
Hydraulic system fault
Repair/Replace
Replace
Faulty brake sensor
Check/Replace
Repair/Replace
Gear shift will not engage

CAUSES
REMEDY
Damaged shifter
Replace
Damaged synchronizer
Replace
20-89
TROUBLESHOOTING
12
20-90
30
REMOVAL AND INSTALLATION
METHOD OF USING THIS MANUAL 3

REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES 3
PRECAUTIONS DURING SERVICE OPERATIONS 4
REMOVAL PRECAUTIONS 4
INSTALLATION PRECAUTIONS 4
SPECIAL TOOLS 5
LISTING 5
SKETCHES 8
ENGINE COMPONENTS 11
LOADER CYLINDER LOCK 12
LOCKING PROCEDURES 12
STARTER 13
REMOVAL 13
INSTALLATION 13
ALTERNATOR 14
REMOVAL 14
INSTALLATION 14
AC COMPRESSOR 15
REMOVAL 15
INSTALLATION 16
INJECTION PUMP 17
TIER I ENGINE 17
TIER II ENGINE 20
VALVE COVER 23
TIER I ENGINE 23
TIER II ENGINE 23
INJECTION NOZZLE 26
TIER I ENGINE 26
TIER II ENGINE 27
THERMOSTAT 29
TIER I ENGINE 29
TIER II ENGINE 30
COOLANT PUMP 31
TIER I ENGINE 31
TIER II ENGINE 33
TURBOCHARGER 36
REMOVAL 36
INSTALLATION 38
CYLINDER HEAD 39
TIER I ENGINE 39
TIER II ENGINE 43
BATTERY DISCONNECT SWITCH 48
REMOVAL 48
INSTALLATION 48
COUNTERWEIGHT 49
REMOVAL 49
INSTALLATION 49
RADIATOR OIL COOLERS 50
REMOVAL 50
INSTALLATION 52
AC CONDENSER 53
REMOVAL 53
INSTALLATION 53
MUFFLER 54
REMOVAL 54
INSTALLATION 54
EXHAUST STACK 55
REMOVAL 55
INSTALLATION 55
ENGINE HOOD 56
REMOVAL 56
INSTALLATION 56
CAB 57
TIER I ENGINE 57
TIER II ENGINE 61
AC AND HEATER 66
REMOVAL 66
INSTALLATION 67
FUEL TANK 68
REMOVAL 68
INSTALLATION 69
HYDRAULIC TANK 70
REMOVAL 70
INSTALLATION 71
ENGINE AND TRANSMISSION 72
REMOVAL 72
INSTALLATION 78
PISTON PUMP 79
REMOVAL 79
INSTALLATION 80
TRANSMISSION 81
REMOVAL 81
INSTALLATION 84
DISASSEMBLY 85
REASSEMBLY 133
TORQUE CONVERTER 182
REMOVAL 182
INSTALLATION 183
STEERING VALVE 184
REMOVAL 184
INSTALLATION 185
COLUMN CONTROL SWITCHES 186
REMOVAL 186
30-1 b
TABLE OF CONTENTS
INSTALLATION 187
MASTER BRAKE CYLINDER 188
REMOVAL 188
INSTALLATION 188
LOADER CONTROL VALVE 190
REMOVAL 190
INSTALLATION 191
FRONT AXLE 192
REMOVAL 192
INSTALLATION 193
DISASSEMBLY 193
REASSEMBLY 202
REAR AXLE 218
REMOVAL 218
INSTALLATION 219
DISASSEMBLY 219
REASSEMBLY 234
LOADER CYLINDERS 253
BOOM 253
BUCKET 257
INSTALLATION 258
MP BUCKET CYLINDER 262
FRONT EQUIPMENT 268
BUCKET 268
BOOM 269
BACKHOE CONTROL VALVE 272
BACKHOE CONTROL 272
INSTALLATION 273
EXCAVATOR CONTROLS 273
PPC CONTROLS 277
PPC VALVE 277
SUPPORT RELEASE CABLES 278
SUPPORT RETURN GAS SPRING 281
SOLENOID VALVE 283
SERVO CONTROL FEED VALVE 284
BACKHOE CYLINDERS 285
BOOM 285
INSTALLATION 285
ARM 291
BUCKET 295
TELESCOPIC ARM 300
OUTRIGGERS 305
SWING 311
BOOM LOCK 315
BACKHOE WORK EQUIPMENT 317
BOOM TO BUCKET 317
BUCKET 318
STANDARD ARM 319
TELESCOPIC ARM 320
INNER ARM 321
INNER ARM GUIDES 322
BOOM 323
SWING BRACKET 324
OUTRIGGERS 325
30-2 b
METHOD OF USING THIS MANUAL
12
METHOD OF USING THIS MANUAL

REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES
1.
When removing or installing any parts or unit assemblies, the order of work and techniques used are given for
removal operations. The order for installation operations is not given unless specified.
2.
Any special techniques applying only to the installation procedures are marked
. The same mark is placed after
the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
[Example]
{ { { { ASSEMBLY
REMOVAL
Component.
Operation to be performed.
WARNING
1.X X X X A
2. B
Precaution related to safety when carrying out the operation.

Step in operation.
Technique or important point to remember when removing
XXX (1).
Indicates a technique is listed for use during installation
INSTALLATION

Adding water, oil
See Lubricant and Coolant Table.

Operation to be perform
Carry out installation in the reverse order of removal.
Technique used during installation.
Technique or important point to remember when installing.
Step in operation.
Point to remember when adding water or oil.
1.
Quantity when filling with oil or water.

General precautions when carrying out installation or removal, disassembly or assembly of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the
operation.
2.
Listing of special tools
For details of the description, part number, and quantity of any tool (A1, etc.) that appears in the operation procedure,
see the SPECIAL TOOLS given in this manual.
Special tools marked in the table cannot be supplied.

Special tools with part number 79{T-{{{{-{{{ in the table are prohibited for supply.
Special tools marked { in the sketch column are tools introduced in this manual in sketches for special tools. However, note that Komatsu cannot accept any responsibility for special tools manufactured according to the sketch.
3.
General precautions when carrying out installation or removal (disassembly or assembly) of units given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, be sure to follow these precautions when performing the operation.
4.
List of special tools: For details of the description, part number and quantity of any tools that appear in the operation procedure, see SPECIAL TOOLS.
Remark A procedure that must be observed when performing a certain operation.
30-3 b
PRECAUTIONS DURING SERVICE OPERATIONS
12
PRECAUTIONS DURING SERVICE OPERATIONS

When dissembling, assembling or installing a part or component, always follow these listed general rules of safety. Failure to
do so may result in damage to the system being repaired or injury to the technician doing the repair.
REMOVAL PRECAUTIONS
Unless indicated otherwise, always lower all work equipment down until it rests firmly on the ground.
Always trap and recycle all coolants and oils. Be sure your containers are large enough.
Cap, cover or plug any openings to prevent dirt or debris from entering when you remove a component or part.
Before removing a cylinder, secure the ram in a retracted position.
Before removing or disassembling any parts, mark the order in which they came apart.
When removing hydraulic couplings, always support the line or hose you are removing it from to avoid twisting or
kinking the line.
When removing any lines always tag the line with a reference tag or mark as to where it is to be installed.
When using eye bolts to lift an item be sure the eye bolt is installed all the way in the part you will be lifting.
When removing a part in a wet attachment, be sure you have the proper drain pans to catch any residual fluids.
Keep your work area clean and organized at all times.
INSTALLATION PRECAUTIONS
Always use the specified torque when tighten nuts or bolts. Never dry torque a fastener, always lubricate the fastener
before torquing it.
Never use impact tools to start a nut or bolt. Always start nuts and bolts by hand first.
Secure all cotter keys according to the instructions listed.
When using adhesives on surfaces or fasteners, be sure the surface is clean and free of oil, dirt or grease.
Clean all parts before installing them.
Be sure snap rings are installed correctly and firmly in place.
When installing a component always follow the tightening pattern for multiple fasteners.
30-4 b
SPECIAL TOOLS
12
SPECIAL TOOLS
LISTING
Remark
...................... Cannot be substituted, should always be used.
...................... Extremely useful if available, can be substituted with localized part
New Remodel N/R: N ...................... Tools with new part numbers, newly developed for this model.
R ...................... Tools with upgraded part numbers, remodeled from items already
available for other models.
Blank................ Tools already available for other models, used w/o any modification.
Tools marked { in the Sketch column are tools introduced in the sketches of the special tools.
Necessity: NEC
Component
Symbol Part Number

1 ATR200620
2 Localize
Part Name
Cylinder stand
NEC
960117006
4A
Bushing driver - 45 mm
Nature Of Work
Cylinder overhaul
Bushing installation
1
Piston seal
Loader MP bucket
4B
Gland wrench - 85 mm
Backhoe telescopic arm
4C
Loader bucket
4D
Loader boom
4E
Backhoe bucket
4F
Backhoe arm/outrigger
Backhoe boom
6 ATR200300
Backhoe swing
7 Localize
Work Cylinders
Sketch
Seal compressor
Gland wrench - -- mm
N/R
960117005
Qty
8 Localize
Six point socket - 45 mm
Wiper seal driver - 40 mm
ATR201000
Seal guide - 78 mm piston
ATR201020
ATR201030
9 ATR201050
ATR201060
ATR201340
ATR201410
ATR201160
Seal guide - 40 mm rod
ATR201170
10 ATR201180
ATR201470
ATR201480
ATR201200
Seal guide - 85 mm barrel
ATR201220
ATR201230
11 ATR201250
ATR201260
ATR201430
ATR201440
Piston retention
Rod wIper seal
Piston seal installation
Piston rod installation
Piston/gland in barrel
12Piston/gland
barrel
in
30-5 b

Component
Air Conditioning Unit
Transmission
Symbol Part Number

B
30-6 b
Part Name
Localize
Maintenance station
CA 119 033
NEC
Qty
N/R
Sketch
Nature Of Work
Draining and refilling
Universal driver handle
Used with drivers
1 CA 715 404
Pump extractor
Oil pump
2 CA 715 409
Pump seal driver
3 CA 715 407
Flange retainer
Output flanges
4 CA 715 405
Seal driver
Oil seal
5 CA 715 412
Bearing extractor
Shaft bearings
6 CA 715 406
Cover hook
Front cover hanger
7 CA 715 179
Bearing driver
8 CA 715 004
Bearing driver
9 CA 715 410
Shaft bearings
Spring compressor
Clutch springs
10 CA 715 377
Bearing driver
Shaft bearings
11 CA 715 408
Clutch lifter
Clutch packs
12 CA 715 148
Bearing driver
Shaft bearing
13 CA 715 414
Seal tester
Piston seals
14 CA 715 376
Bearing driver
Shaft bearings
Used with drivers
CA 119 033
Front Axle
SPECIAL TOOLS
1 CA 715 027
Bushing driver
Wheel carrier bushing
2 CA 715 265
Ring nut adjuster
Differential ring nut
3 CA 715 022
Pinion gear wrench
Pinion gear
4 CA 119 099
Pinion gear wrench
Pinion gear
Pinion bearing cups
5 CA 119 225
Bearing driver
6 CA 715 023
False pinion gear
7 CA 119 228
False differential half
8 CA 119 182
False differential half
Differential set up
9 CA 715 021
Bearing driver
Pinion bearing cone
10 CA 119 230
Bearing driver
Differential bearing cone

Pinion shaft seal
11 CA 715 087
Seal driver
12 CA 715 163
Seal driver
13 CA 715 164
Bushing driver
14 CA 715 034
Bushing driver
15 CA 119 055
Bushing driver
16 CA 715 396
Seal driver
Axle pivot pin

King pin bushings
Housing ends
17 CA 119 043
Bushing driver
18 CA 715 087
Seal driver
19 CA 715 035
Bearing driver
Lower king pin
20 CA 715 026
Bearing driver
Wheel hub bearing cup
21 CA 119 143
Seal driver
Wheel hub seal
Steering knuckle

Component
Symbol Part Number

1 CA 715 027
Rear Axle
Fuel Injection Pump
SPECIAL TOOLS
Part Name
NEC
Qty
N/R
Sketch
Nature Of Work
Bushing driver
Wheel carrier bushing
2 CA 715 265
Ring nut adjuster
Differential ring nut
3 CA 715 022
Pinion gear wrench
4 CA 119 099
Pinion gear wrench
5 CA 715 380
Bearing driver
Pinion bearing cups
6 CA 715 128
False pinion kit
Pinion gear
7 CA 715 388
False differential kit
Differential
8 CA 715 167
Bearing driver
Pinion bearing cones
9 CA 715 028
Bearing driver
Differential bearing cones
10 CA 715 391
Bearing driver
Differential bearing cups
11 CA 119 033
Used with drivers
12 CA 715 056
Insert kit
Brake piston
13 CA 715 055
Backlash kit
Ring and pinion gears
14 CA 715 466
Seal ring driver
Pinion gear
15 CA 119 187
Bushing driver
16 CA 715 467
Seal driver
17 CA 715 026
Bearing driver
18 CA 119 143
Seal driver
Puller
Puller bolts
Pinion gear
Axle housing
Wheel hub
Fuel pump
30-7 b
SPECIAL TOOLS
12
SKETCHES
Unit - mm
ITEM
A4D
A4E
A5
A6
492
A4A
492
A4B
492
A4C
492
492
492
A4F
492
492
20
20
20
20
20
20
20
20
35
35
35
35
35
35
35
35
480
480
480
480
480
480
480
480
115
125
130
140
155
170
120
85
95
100
110
125
140
90
55
65
g
h
30
30
70
80
95
110
60
30
30
30
30
30
30
R27.5
R32.5
R35
R40
R47.5
R55
R30
R42.5
R47.5
R50
R55
R62.5
R70
R45
1)
1!
R57.5
R100
R100
R62.5
R100
R60
R70
R100
R100
R77.5
R100
R85
R60
R100
R100
1@
5x45
5x45
5x45
5x45
5x45
5x45
5x45
5x45
1#
1$
12
12
12
12
12
12
12
12
1%
1^
35
35
35
35
35
35
35
35
1&
9.8
9.8
9.8
9.8
9.8
9.8
9.8
9.8
1*
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
1(
6x6
6x6
6x6
6x6
6x6
6x6
6x6
6x6
2)
22
22
22
22
22
22
22
22
2!
80
80
80
80
80
80
80
80
2@
17.5
17.5
17.5
17.5
17.5
17.5
17.5
17.5
30-8 b

12
SPECIAL TOOLS
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
30-9 b
SPECIAL TOOLS
12
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
E11
E12
E13
E14
E15
E16
E17
E18
30-10 b
ENGINE COMPONENTS
12
ENGINE COMPONENTS
For removal, installation, disassembly and assembly of engine
components, see the ENGINE SHOP MANUAL.
30-11 b
LOADER CYLINDER LOCK
12
LOADER CYLINDER LOCK

For removal and installation of components under the engine hood that
cannot be easily accessed without raising the front end loader. In order
to remove, install or service these components the front end loader must
be raised and properly secured in place. Failure to do so may result in
injury or even death to the technician performing these procedures.
LOCKING PROCEDURES
In A, the front end loader cylinder lock b must be used any time you
will be performing maintenance on the machine with the front end loader raised. To use the cylinder lock:
1.
In B, remove the cylinder lock assembly pin a holding on to the

lock unit b.
2.
Using both hands lower the lock unit b down from its storage position and remove it from the lift arm.
3.
Raise the front end loader unit completely in the air extending the
lifting cylinders.
4.
Install the cylinder lock b in the position shown in A, keeping the

safety pin boss against the lift cylinder gland nut.
5.
Insert the safety pin a completely into the predrilled holes and lock
the pin in place with the smaller pin provided.
6.
Slowly lower the front end loader unit until it makes contact with
the cylinder lock.
7.
Check to be sure the cylinder lock is secularly in place before proceeding with any procedures under the front end loader.
30-12 b
STARTER
12
STARTER
REMOVAL
1.
With the front loader raised and secured in place, stop the engine
and set the parking brake.
2.
Cut off the electrical supply to the system using the knob a of main
electrical disconnect switch b.
3.
Disconnect the electrical supply, turn the battery disconnect switch

counterclockwise. To connect the electrical supply turn the switch
clockwise
WARNING! Never remove or service the starter without disconnecting the electrical supply.
4.
Disconnect the electrical wiring d and tag the wires.
5.
Loosen the two bolts e holding the starter in place and carefully remove the starter motor c.
Remark Do not let the starter hang by the wiring harness, damage to the wiring may result. Remove the wiring first
before removing the starter motor.
INSTALLATION
Starter motor mounting bolts 80 Nm
30-13 b
ALTERNATOR
12
ALTERNATOR
REMOVAL
1.
With the front end loader raised and secured in place, stop the engine and set the parking brake.
2.
Cut off the electrical supply to the system using the knob a of main
electrical disconnect switch b.
3.
Disconnect the electrical supply, turn the disconnect switch counterclockwise. To reconnect the electrical supply turn the switch
clockwise.
WARNING! Never remove or service the alternator
without disconnecting the electrical supply.
4.
Disconnect the exciter cable c, and connectors d and e.
5.
Loosen the adjustment bolts g, h and mount bolt i. Loosening

these fasteners will leave the alternator f free to move.
6.
Loosen the bolt h and remove the bolt g.
7.
Push the alternator f rearward towards the engine to remove the

belt j.
8.
Once the belt j is off the alternator, remove support bolt h and lift
the alternator f from the mounting boss.
INSTALLATION

Adjust the fan belt tension. For details, see TESTING AND
ADJUSTMENT.
30-14 b
AC COMPRESSOR
12
AC COMPRESSOR
WARNING! Do not discharge the refrigerant into the open
atmosphere, doing so is in violation of the law and could
produce dangerous gasses if exposed to an open flame.
REMOVAL
1.
With the front end loader raised and secured in place, stop the engine and set the parking brake.
2.
Remove the fan guard A.
3.
Before preceding with any removal procedures, it is important to

capture and recycle all the refrigerant from the system first. Remove the caps B and C and install the recycling machine B.
4.
Disconnect the electrical connector d from the compressor g.
5.
Loosen the idler pulley bolt e and remove the belt f from the compressor.
6.
Once the system is completely discharged, special tool B remove

the bolt h from the bracket i. Once the suction and delivery lines
j and 1) are removed, cap and plug to prevent moisture from entering into system.
30-15 b
AC COMPRESSOR
12
7. Remove the front mounting bolts 1@ and rear nuts 1!.
8.
Carefully lift the compressor g from the mounting boss along with
bracket 1#.
INSTALLATION
Adjust the compressor belt tension. For details, see section

TESTING AND ADJUSTMENT.
Idler pulley mounting bolt 123 Nm
- TIER I Engine
Compressor mounting bolt 32 Nm
- TIER II Engine
Tighten the flanges on the compressor.
Compressor mounting bolt 32 Nm

R134A quantity - TIER I Engine 975 g
R134A quantity - TIER II Engine 2250 150 g
30-16 b
INJECTION PUMP
12
INJECTION PUMP
WARNING! Fully raise the loader equipment and engage
the safety stop. Lower the backhoe to the ground. Set the
parking brake.
TIER I ENGINE
REMOVAL
1.
Cut off the electrical supply to the system using the knob b of main
electrical disconnect switch a. To disconnect the electrical supply,
turn the battery disconnect switch lever counterclockwise. To reconnect the electrical supply turn the switch lever clockwise
Plug all tubes that have been removed or disconnected to prevent

entry of impurities.
2.
Remove the engine coolant liquid container c.
3.
Disconnect the fuel supply e and flow back hoses f from the injection pump d.
4.
Disconnect the high pressure pipes g.
5.
Disconnect the fuel feed hose i and delivery tube j from the feed
pump h.
6.
Disconnect the tube 1) from the oil level dipstick and remove it.
Remove the support bracket 1! of the pump.
30-17 b
INJECTION PUMP
12
7. Disconnect the accelerator cable support 1# from the lever 1@.
8.
Disconnect the engine stop solenoid 1$ from the injection pump d.

Lift out the entire group.
9.
Remove the retaining clip 1% of the injection pump lubrication tube.
10. Disconnect the lubrication tube 1^.
11. Remove the access cover 1& to the distribution gear and the oil filler
plug 1*.
30-18 b
INJECTION PUMP
12
12. Loosen and lift off the retaining nut 1( and safety washer 2) of the
pump driving gear 2!.
Take great care not to drop the safety washer 2) into the pump
casing.
13. Remove the driving gear 2! of the pump d.

Before removing the pump driving gear, mark its position with
respect to the idle gear.
For removal, use puller X1. The puller bolts X2 thread directly into the gear 2!. Take care not to damage the pump shaft
threads. During removal, be careful not to let the key 2@ drop
into the housing.
14. Take out the four nuts 2$ and remove the injection pump d with its
o-ring seal 2#.
INSTALLATION
To install, reverse the removal procedure.
Fuel feed hoses 25 to 34 Nm
Fuel feed hoses 22 8 Nm

Bolt, pump side 44 to 54 Nm
Put in a new safety cotter pin.
Cover gasket ASL800070

Cover bolts 18 Nm
30-19 b
INJECTION PUMP
12
Align the marks between the gears before installing the pump
and mounting the nut.
Gear locking nut 84 to 93 Nm
Pump locking nut 35 to 43 Nm

1.
Check fuel injection timing, for details, see TESTING AND ADJUSTMENTS.
TIER II ENGINE
REMOVAL
1.
turn the disconnect switch lever counterclockwise. To connect the
electrical supply turn the switch lever clockwise
Plug and cap all tubes and fittings that have been removed or disconnected to prevent entry of impurities.
2.
3.
Disconnect the fuel supply e and flow back f hoses from the injection pump d.
4.
Disconnect the high pressure tubes g.
30-20 b
INJECTION PUMP
12
5. Disconnect the tube h from the oil level dipstick and remove.
6.
Disconnect the hoses i and j from the feed pump 1).
7.
Disconnect the connector 1!.
8.
Disconnect the accelerator cable support 1@ from the lever 1#.
9.
Remove the retaining clip 1$ of the injection pump lubrication tube.
10. Disconnect the lubrication tube 1% and remove. Remove the bracket
1^.
11. Remove the access cover 1& to the distribution gear and the oil filler
plug 1*.
30-21 b
INJECTION PUMP
12
12. Loosen and lift off the retaining nut 1( and safety washer 2) of the
pump driving gear 2!.
Take great care not to drop the safety washer 1( into the pump
casing.
13. Remove the driving gear 2! of the pump.

Before removing the pump driving gear, mark its position with
respect to the idle gear.
For removal use a puller X1. The puller bolts X2 bolt directly
into the gear 2!. Take great care not to damage the pump shaft
thread. During removal, be careful not to let the key 2@ drop into the housing.
14. Take out the four nuts 2$ and remove the injection pump c with its
o-ring seal 2#.
INSTALLATION
Bolt, pump side 44 to 54 Nm

Fuel feed hoses 22 8 Nm
Cover gasket ASL800070

Cover bolts 18 Nm
Align the marks between the gears before installing the pump
and mounting the nut.
Gear locking nut 84 to 93 Nm
Pump locking nut 35 to 43 Nm

1.
Check fuel injection timing, for details, see TESTING AND ADJUSTMENTS.
30-22 b
VALVE COVER
12
VALVE COVER
parking brake.
TIER I ENGINE
REMOVAL
1.
Remove the air filter a and muffler b. Remove the hardware and
valve cover c.
2.
Check condition of valve cover c, gasket d, o-rings e and plugs

f; carefully clean the contact surface of the cylinder head.
INSTALLATION
Cover lock nuts 25 3 Nm
TIER II ENGINE
REMOVAL
1.
Remove the air filter A and the muffler B.
2.
Loosen the muffler support bolts c and remove the air intake duct
d and cold start aid e.
Cap the turbocharger and intake holes to prevent contamination.
Inspect the seals for signs of damage.
30-23 b
VALVE COVER
12
3. Disconnect the injector fuel feed pipes f.
4.
Remove clamp g and loosen clamp h.
5.
Loosen the fittings of the fuel feed pipes i on the pump j.
6.
Rotate the pipes f until they become disengaged from the valve
cover 1).
7.
Remove the feed through fittings 1! and their seals.
30-24 b
VALVE COVER
12
8. Loosen and remove the bolts 1@ retaining the valve cover 1).
Inspect the grommets.
9.
Remove the valve cover 1).

Inspect the seal. Replace the seal if it is damaged or cracked.
INSTALLATION
Bolt Loctite 262

Bolt 45 to 55 Nm
Union 19 to24 Nm
Bolt 7 to 9 Nm
Nut 16 to 22 Nm
30-25 b
INJECTION NOZZLE
12
INJECTION NOZZLE
parking brake.
TIER I ENGINE
REMOVAL
1.
turn the battery disconnect switch lever counterclockwise. To connect the electrical supply turn the switch lever clockwise.
2.
Disconnect the sensor c for a clogged air filter.
3.
Remove the air filter d, the supporting bracket e and the intake
sleeve f.
4.
Remove the muffler, for details, see MUFFLER.
5.
Remove the intake duct g.
6.
Loosen the clip h and remove the high pressure lines i.
7.
Disconnect the fuel flow back pipes j.
8.
Remove the nuts 1) that secure the collar 1! and take out the injector
1@, the seating 1# and the protection piece 1$.
INSTALLATION
Bracket bolt Loctite 262
Bracket bolt Loctite 262

Bracket bolt 45 to 55 Nm
High pressure pipes 20 to 28 Nm

Hose clamp bolts 10 to 12 Nm
Collar lock nuts 10 to 12 Nm
30-26 b

12
TIER
INJECTION NOZZLE
II ENGINE
REMOVAL
1.
turn the disconnect switch lever counterclockwise. To connect the
electrical supply turn the switch lever clockwise.
2.
Disconnect the sensor c for a clogged air filter.
3.
Remove the air filter d, the supporting bracket e and the intake
sleeve f.
4.
Remove the muffler, for details, see MUFFLER.
5.
Remove the intake duct g and the cold start aid h.

Cap the turbo and intake holes to prevent contamination.
Inspect the seals for signs of damage.
6.
Remove clamp i and loosen clamp j.
7.
Remove the valve cover, see VALVE COVER.
30-27 b
INJECTION NOZZLE
12
8. Loosen and remove the fittings 1) retaining the fuel recovery pipe
1!, and the seals.
9.
Loosen the fitting 1@ and rotate the pipe 1# outward.
10. Loosen and remove the bolt 1$ retaining the injection nozzle clamp
1%.
11. Turn the bracket 1% over and pull out the injection nozzle 1^.
Use care not allow dirt inside the injection nozzle and the injector nozzle seat.
INSTALLATION
Clamp bolts 10 to 12 Nm
Union 8 to 10 Nm
Bracket bolt 22 to 28 Nm
30-28 b
THERMOSTAT
12
THERMOSTAT
WARNING! Fully raise the front work equipment and engage the safety stop. Lower the backhoe to the ground.
Set the parking brake.
TIER I ENGINE
REMOVAL
1.
Drain the engine coolant liquid.
Coolant liquid 18 l
2.
Disconnect the cable c to the clogged air filter indicator d and remove the entire suction filter e.
3.
Remove the fan guard f.
4.
Disconnect the radiator connection sleeve h from the thermostat

cover g.
5.
Take out the bolts and remove the thermostat cover g.
6.
Remove the gasket i, the thermostat j and the ring seal 1).
Put in new seals.
INSTALLATION
1.
Refill the coolant liquid tank.

Coolant liquid 18 l
2.
Start the engine at low idle to circulate the coolant liquid

through all circuits.
3.
Accelerate gradually up to 1700 rpm. After about one minute,

stop the engine and check or top up the level in the container.
Check that there are no leaks.
Cover bolts 22 to 28 Nm
30-29 b
THERMOSTAT
12
TIER II ENGINE
REMOVAL
1.
turn the battery disconnect switch lever counterclockwise. To reconnect the electrical supply turn the switch lever clockwise.

Coolant liquid 18 l
2.
Disconnect the cable c to the clogged air filter indicator d and remove the entire filter e.
3.
Remove the fan guard f.
4.
Disconnect the radiator upper hose h from the thermostat cover g.
5.
Take out the bolts and remove the thermostat cover g.
6.
Remove the gasket i, the thermostat j and the ring seal 1).
Put in new seals.
INSTALLATION
1.

Coolant liquid 18 l
2.
Start the engine at low idle to circulate the coolant liquid

through all circuits.
3.

Cover bolts 22 to 28 Nm
30-30 b
COOLANT PUMP
12
COOLANT PUMP
TIER I ENGINE
REMOVAL
1.

Coolant liquid 18 l
2.
3.
Remove the fan guard d.
4.
Disconnect the cable e of the clogged filter indicator and remove

the air filter f.
5.
Remove the alternator and its support g for details, see ALTERNATOR.
30-31 b
COOLANT PUMP
12
6. AC Machines: Remove the air-conditioning unit compressor h and
its supports. Put the compressor to one side, for details, see AC
COMPRESSOR.
7.
Disconnect the cab heating pipes i.
8.
Disconnect the temperature sensor cables.
9.
Remove the radiator oil cooler, for details, see RADIATOR.
10. Remove the fan j, the spacer 1) and the pulley 1!.
11. Remove the four bolts 1@ and then the pump 1#.
Replace all seals with new ones.
INSTALLATION
1.
Refill the coolant liquid tank. Start the engine at low idle to circulate the coolant liquid through all circuits.
Coolant liquid 18 l
30-32 b

12 2.
COOLANT PUMP

Check that there are no leaks. Apply tension to the alternator

belt.
Bolts for alternator support 22 to 28 Nm
Bolts for pulley and fan 44 to 54 Nm
Pump bolts 22 to 28 Nm
Locking bolt for compressor 64 Nm
TIER II ENGINE
REMOVAL
1.

Coolant liquid 18 l
2.
30-33 b
COOLANT PUMP
12
3. Remove the fan guard d.
4.
Disconnect the cable e of the clogged filter indicator and remove

the air filter f.
5.
Remove the alternator and its support g, for details, see ALTERNATOR.
6.
Remove the AC compressor H and its supports. Put the compressor

to one side, for details, see AC COMPRESSOR.
7.
Disconnect the cab heating pipes I.
8.
Disconnect the temperature sensor cables.
9.
Remove the radiator oil cooler, for details, see RADIATOR.
30-34 b
COOLANT PUMP
12
10. Remove the fan J, the spacer 1) and the pulley 1!.
11. Remove the bolts 1@ and then the complete pump 1#.
Replace all seals with new ones.
INSTALLATION
1.

Coolant liquid 18 l
2.
Start the engine at low idle to circulate the coolant through all
circuits.
3.

stop the engine and check or top off the level in the container.

Apply tension to the alternator belt.
Bolts for alternator support 22 to 28 Nm
Bolts for pulley and fan 44 to 54 Nm
Pump bolts 22 to 28 Nm
Locking bolt for compressor 64 Nm
30-35 b
TURBOCHARGER
12
TURBOCHARGER
REMOVAL
1.
2.
Disconnect the clogged air filter indicator d cable c and remove

the air cleaner e.
3.
Remove the muffler, see MUFFLER.
4.
Disconnect the turbo g coupling f from the intake manifold.
30-36 b
TURBOCHARGER
12
5. Remove the bolts out of the clips h and disconnect the tube i that
delivers the lube oil.
6.
Remove the tube retaining bolts j and the bolts 1) that secure the
flange of the lubrication oil drain tube 1!.
7.
Remove the bolts 1@ that join the turbo to the coupling, and remove
the coupling 1#.
8.
Remove the bolts 1$ and remove the bracket 1%.
9.
Remove the nuts 1^, and washers 1& and lift off the turbocharger g.
Carefully check the state of all the sealing gaskets. Replace
them if there is any sign of damage.
30-37 b
TURBOCHARGER
12
INSTALLATION
Tube bolts 23 to 28 Nm
Flange bolts 8 to 9 Nm
Coupling joint bolts 23 to 28 Nm
Bracket bolts 23 to 28 Nm
1.
Start the engine and check that there are no leaks in the turbocharger lubrication tubes.
30-38 b
CYLINDER HEAD
12
CYLINDER HEAD
TIER I ENGINE
REMOVAL
1.

Coolant liquid 18 l
2.
Remove the container c.
3.
Disconnect the cable d of the clogged air filter sensor e and remove the air filter f and its support.
Remove the turbocharger, see TURBOCHARGER.
4.
AC unit: Remove the alternator g, the compressor h and the supporting bracket i. For details, see ALTERNATOR and AC COMPRESSOR.
30-39 b
CYLINDER HEAD
12
5. Remove the support j.
6.
Disconnect the cable 1) of the cold start. Remove the suction manifold 1! and the cold start 1@.
7.
Remove the diesel fuel filter 1# and place it to one side. Disconnect
the clip 1$ that secure the heater pipes.
8.
Disconnect the breather tube 1% from the engine head.
9.
Remove the muffler 1^. For details, see MUFFLER.
10. Remove the muffler support bracket 1&.
30-40 b
CYLINDER HEAD
12
11. Disconnect the cables 1* from the temperature sensors 1(.
12. Disconnect the heating pipes 2). Remove the radiator pipes 2!.
13. Remove the coolant pump, see COOLANT PUMP.
14. Disconnect the fuel return hose 2@ from the nozzles and remove the
nozzles, see INJECTION NOZZLE.
15. Remove the valve cover 2#.
16. Remove the valve rocker arm shaft 2&.
Loosen the nuts and unscrew the tappets by 2 to 3 turns
17. Remove the rocker arm control rods 2$.
18. Remove the bolts 2% and the cylinder head 2^. Follow the indicated
sequence for loosening the bolts.
Sequence to be followed
>>>>>>
Loosen the cylinder head retaining bolts in two stages.

INSTALLATION

1.
Refill the coolant liquid tank. Check that there are no leaks.
Coolant liquid 18 l
30-41 b
CYLINDER HEAD
12
Support bolts 32 Nm
Front bolts M8 32 Nm
Side bolts M10 64 Nm
Intake line bolts Loctite 262
Bracket and Intake line bolts 45 to 55 Nm
Pipe fittings 25 to 34 Nm

Check the condition of the seals of the tappet cover and the orings of the fastening nuts. Thoroughly clean the contact surfaces on the cylinder heads.
Check that the tappets are firmly engaged in their rods and that
the valve collars are correctly assembled.
Tappet rods Engine oil
Start tightening the rocker arm shaft from the center towards
the outside bolts and nuts for the rocker arm shaft.
Rocker arm shaft bolts and nuts 23 to 28 Nm
Adjust the valve clearances.
Assemble a new gasket. Tighten bolts, manually at first, and
then in two stages, following the sequence indicated. >>>
Bolt and cylinder block threads Engine oil
Cylinder head bolts - 1st 84 to 98 Nm
Cylinder head bolts - FINAL 182 to 191 Nm
Start the engine at low idle to circulate the coolant through all circuits. Accelerate gradually up to 1700 rpm. After about one minute,
30-42 b
CYLINDER HEAD
12
TIER II ENGINE
REMOVAL
1.

Coolant liquid 18 l
2.
Remove the container c.
3.
Disconnect the cable d of the clogged air filter sensor e and remove the air filter f and its support.
Remove the turbocharger, see TURBOCHARGER.
4.
AC unit: Remove the alternator g, the compressor h and the supporting bracket i. For details, see ALTERNATOR and AC COMPRESSOR.
30-43 b
CYLINDER HEAD
12
5. Remove the support j.
6.
7.
Disconnect the cable 1) of the cold start.
Remove the valve cover 1!, see VALVE COVER.

Replace the gasket.
8.
Remove the fuel filter 1@ and move it to one side.

Mark the hoses for easier reassembly.
9.
Disconnect the clips 1# that secure the heater pipes.
30-44 b
CYLINDER HEAD
12
10. Disconnect the breather tube 1$ from the engine head.
11. Loosen the screws 1% and remove the muffler support 1^.
12. Disconnect the cables 1& and 1( from the temperature sensors 1* and
2).
13. Disconnect the heating pipes 2!.

14. Remove the radiator connection pipes 2@.
15. Remove the coolant pump 2# and hardware 2$, see COOLANT
PUMP.
30-45 b
CYLINDER HEAD
12
16. Remove the injection nozzles 2%, see INJECTION NOZZLE.
Protect the injection nozzle hole and threads to prevent contamination.
17. Loosen the tappets of the rocker arms 2 to 3 turns, 4 places.

18. Loosen and remove the screws 2^ and remove the rocker arm shaft
2&.
19. Loosen and remove the screws 2* and remove the whole cylinder
head 2(.
20. Follow the indicated order for loosening the bolts.

21. Loosen bolts.
>>>>>
Loosen the cylinder head retaining bolts in two stages.

INSTALLATION
1.

Coolant liquid 18 l
2.
30-46 b
CYLINDER HEAD
12
Support bolts 35 Nm
Check the condition of the seals of the valve cover and the orings of the fastening nuts. Thoroughly clean the contact surfaces on the cylinder heads.
Cover lock nuts 17 to 22 Nm
Check that the tappets are firmly engaged in their rods and that
the valve collars are correctly assembled.
Tappet rods Engine oil
Start tightening the rocker arm shaft from the center towards
the outside bolts and nuts for the rocker arm shaft.
Rocker arm shaft bolts and nuts 23 to 28 Nm
Adjust the valve clearances, see 20 VALVE CLEARANCE.
Assemble a new gasket.
Bolt and cylinder block threads Engine oil
Tighten the bolts, manually at first, and then in two stages, following the sequence indicated. > > > > > >
Cylinder head bolts - 1st 84 to 98 Nm
Cylinder head bolts - FINAL 182 to 191 Nm
3.
Start the engine at low idle to circulate coolant through all circuits.
4.

30-47 b
BATTERY DISCONNECT SWITCH
12
BATTERY DISCONNECT SWITCH

REMOVAL
1.
Remove the battery cover a from the fuel tank b housing.
2.
Loosen the battery hold down c and move the battery d outwards.
Lift the protective flap e.
3.
Remove the negative (-) terminal clamp first and then the positive
(+) terminal clamp next.
WARNING! It is important that the negative (-) battery
terminal clamp is removed first. Doing so will prevent
the chance of a short to ground causing sparks.
4.
Once the battery is completely disconnected, open the engine hood

and remove the mounting bolts f that secure the switch g to the
frame.
5.
Remove the bolts f that secure the switch support g to the frame.
Turn the switch h over and remove the cables i and j.
Make a note of the cable attachment locations.
INSTALLATION
WARNING! It is important that the positive (+) battery

terminal clamp is installed first. Doing so will prevent
the chance of a short to ground causing sparks
1.
When installing the battery cables, hook the positive (+) cable
up first then the negative (-) cable next.
Adjust the engine hood guide 1).
30-48 b
COUNTERWEIGHT
12
COUNTERWEIGHT
REMOVAL
1.
Loosen the front mounting bolts a slightly first. Using a forklift

truck, position the forks into the openings on the counterweight b
front.
2.
Tilt the forks back slightly and remove the mounting bolts a and
washers c carefully.
WARNING! When performing this operation, stand
clear of the counterweight in case it should slip off the
forks.
3.
Remove the counterweight b carefully.

Counterweight 300 kg
INSTALLATION
Counterweight mounting bolts 330 Nm
30-49 b
RADIATOR OIL COOLERS
12

WARNING! Raise the front work equipment and engage
parking brake.
REMOVAL
1.
Remove the engine hood and gas struts a first, see ENGINE
HOOD.
2.
Remove the bolts b and front frame c.

Completely eliminate residual pressures in all the
circuits, see TESTING AND ADJUSTMENTS.
Drain and capture all engine coolant and recycle.

WARNING! Do not dump engine coolants down the
drain, on to the ground or into a body of water, doing
so is in violation of the law.
Engine coolant 18 l
3.
Disconnect the cable d from the horn e. Loosen the bracket g

bolts f.
4.
AC Machines: Capture and recycle the refrigerant first, then remove the lines h and i. Cap both lines immediately.
WARNING! Do not discharge any refrigerant into the
open atmosphere, doing so is in violation of the law
and could produce dangerous gasses if exposed to an
open flame.
30-50 b
12
5. Disconnect the engine hoses j and 1).
6.
Slowly loosen the hoses 1! and 1@ to drain the hydraulic oil from the
radiator 1#. When the oil is fully drained, disconnect the hoses, cap
and plug them to prevent entry of impurities.
7.
Loosen the radiator nuts 1$ and remove them.
8.
Disconnect the hoses 1%, cap and plug them to prevent entry of impurities.
9.
Take out the nuts 1$ of the lower iso mounts and remove the entire
radiator group.
30-51 b
12
INSTALLATION

Refill the engine coolant.
Coolant refill amount 18 l
Recharge the air conditioning system.

TIER I Engine R134a quantity 1 kg
TIER II Engine R134a quantity 2.25 kg
Align the radiator with the fan and make sure that the fan is inserted in the inner conveyor for 2/3 of the blade width.
Ensure that the level of hydraulic oil in the tank is at max.
Ensure that the level of transmission oil is at max.
1.
Start the engine at low idle to circulate all the fluids and to fill up
the systems.
2.
Accelerate gradually up to 1700 rpm. After about one minute, stop

the engine and top off all levels.
Check carefully that there are no leaks.
30-52 b
AC CONDENSER
12
AC CONDENSER
REMOVAL
1.
Remove the engine hood and gas struts a first, see ENGINE
HOOD.
2.
Remove the bolts b and front frame c.

Completely eliminate residual pressures in all the
circuits, see TESTING AND ADJUSTMENTS.
3.
Disconnect the cable d from the horn e. Loosen the bracket g

bolts f.
4.
Capture and recycle the refrigerant first, then remove the lines h
and i. Cap and plug both lines immediately.
WARNING! Do not discharge refrigerant into the open atmosphere, doing so is in violation of the law and could
5.
Loosen mounting bolts j and remove them.
6.
Remove mounting bolt f and lift out the condenser.
INSTALLATION

30-53 b
MUFFLER
12
MUFFLER
REMOVAL
1.
Loosen the exhaust clamp a and remove it from the stack pipe b.
2.
Remove mounting bolts c.
3.
Remove the four bolts d and remove the complete muffler e.
INSTALLATION

Replace all gaskets with new.
30-54 b
EXHAUST STACK
12
EXHAUST STACK
REMOVAL
1.
Loosen the exhaust clamp a and remove it from the stack pipe b.
2.
Take out two of the three lower bolts c of the connecting flange d.
Loosen the third bolt and leave it in place for safety.
3.
Take out the nut e and the washer of the upper anti vibration unit
f.
4.
Take out the last screw c and remove the exhaust pipe g.
INSTALLATION
30-55 b
ENGINE HOOD
12
ENGINE HOOD
WARNING! Lower all work equipment to the ground. Stop
the engine and remove the ignition key.
REMOVAL
1.
Loosen and remove the screws a and washers and remove the front
grill b.
2.
Fully raise the engine hood c, remove the safety pins d and disconnect the gas spring e from the chassis.
3.
Remove the snap rings f and washers g.
4.
Pull out the fulcrum pins h while holding the engine hood c.
5.
Remove the hood c.
INSTALLATION

Check the lock engagement.
30-56 b
CAB
12
CAB
WARNING! Be sure all work equipment is lowered to the
ground. Turn the electrical supply off using the disconnect
switch a. On machines equipped with air conditioning,
capture and recycle all refrigerants before proceeding with
any removal procedures.
WARNING! Do not discharge refrigerant into the open atmosphere, doing so is in violation of the law and could
Eliminate residual pressures in all the circuits. For details, see TESTING AND ADJUSTMENTS.
TIER I ENGINE
REMOVAL
1.
Disconnect the throttle linkage and accelerator pedal cable b from

the injection pump mounting support c.
2.
Disconnect the parking brake cable D and the differential lock tube
F from the rear axle E. Cap the opening.
3.
Disconnect the brake lines G from the rear axle E.

Cap the openings and mark the line locations and lines.
30-57 b
CAB
12
4. Disconnect the hoses H from the front axle steering cylinder.
5.
Disconnect the steering valve lines i, j and 1) from the valve.

6.
Disconnect the transmission connectors 1! and 1@ as well as the

ground cable 1#.
7.
Disconnect the five connectors 1$ from the sensor, the speed control
connector 1% and the solenoid connector 1^ from the transmission.
8.
Disconnect the harness 1& from the grounding stud.
9.
Disconnect the connector 1* from the bucket control lever.
10. Disconnect the converter connector 1( from the switch.

11. Disconnect the differential and backhoe solenoid connector 2).
12. Disconnect the power engagement connector 2!.
30-58 b
CAB
12
13. Disconnect the harness connector 2@ from the alarm, 2# from the
rear lights 2$ and from the backhoe control.
14. Disconnect the heater core hoses 2% and 2^.

15. Capture and recycle the refrigerant first, then remove the lines 2&
and 2* connecting the expansion valve 2(. Cap and plug both lines
immediately.
open flame.
16. Remove the lower left guard from the bottom of the cab and disconnect connector 3) from the fuel level indicator.
17. Remove the floor mat 3! and fender trim piece 3@.
Push the boot on the loader lever 3# down into the trim piece 3@.
30-59 b
CAB
12
18. Remove the outrigger control lever knobs 3$ and lift the cover 3% off
the control levers.
19. Remove the self locking nuts 3^ and the four fasteners that secure
the cab in place.
20. Disconnect hoses 3& and 3* from the control valve 3( and cap all
openings.
21. Remove the protective plugs and install two eyebolts A into the
threaded holes on the cab.
22. Using the tool shown, carefully lift the cab 4) off the frame. Slowly
raise the cab making sure the electrical leads and control levers
clear the chassis frame.
Cab weight 630 kg
INSTALLATION

Check the adjustments of the throttle and accelerator pedal, see
Check the adjustment of the parking brake lever, see TESTING AND ADJUSTMENT.
Bleed the air from the brake system, see TESTING AND ADJUSTMENT.
Bleed the air from the steering circuit, see TESTING AND
ADJUSTMENT.
Cab mounting bolts 170 Nm
30-60 b

12
TIER
CAB
II ENGINE
REMOVAL
1.
Disconnect the throttle linkage and accelerator pedal cable b from

the injection pump mounting support c.
2.
Disconnect the parking brake cable D and the differential lock tube
F from the rear axel E. Cap the opening.
3.
Disconnect the brake lines G from the rear axle E.

Cap and plug the openings and mark the locations and lines.
4.
Disconnect the hoses H from the front axle steering cylinder.

30-61 b
CAB
12
5. Disconnect the steering valve lines i, j and 1) from the valve.
6.
Disconnect the transmission connectors 1! and 1@ as well as the

ground cable 1#.
7.
Disconnect the five connectors 1$ from the sensor, the speed control
connector 1% and the solenoid connector 1^ from the transmission.
8.
Disconnect the harness 1& from the grounding stud.
9.
Disconnect the connector 1* from the bucket control lever.
10. Disconnect the converter connector 1( from the switch.

11. Disconnect the differential and backhoe solenoid connector 2).
12. Disconnect the power engagement connector 2!.
13. Disconnect the harness connector 2@ from the alarm, 2# from the
rear lights 2$ and from the backhoe control.
30-62 b
CAB
12
14. Disconnect the heater core hoses 2% and 2^.
15. Capture and recycle the refrigerant first, then remove the lines 2&
and 2* connecting the dryer 2( to the expansion valve 3). Cap and
plug both lines immediately.
open flame.
16. Remove the lower right and left guards from the bottom of the cab
and disconnect connector 3! from the fuel level indicator.
17. Remove the floor mat 3@ and fender trim piece 3#.
Push the boot on the shifter lever 3$ down in the trim piece 3@.
18. Remove the outrigger control lever knobs 3% and lift the cover 3^ off
the control levers.
30-63 b
CAB
12
19. Remove the platform 3&.
20. Disconnect the control valve hoses 3( from the junction blocks 3*.
IMPORTANT - Ensure that both the hoses and their
connection positions are clearly marked. Cap the
hoses and holes to prevent contamination.
21. Loosen and remove the self locking nuts 4) and remove the bolts
that secure the cab.
22. Disconnect hoses 4! and 4@ from the control valve 4# and cap all
openings.
23. Remove the protective plugs and install two eyebolts A into the
threaded holes on the cab.
30-64 b
CAB
12
24. Using the tool shown, carefully lift the cab 4$ off the frame. Slowly
raise the cab making sure the electrical leads and control levers
clear the chassis frame.
Cab weight 630 kg
INSTALLATION

Check the adjustments of the throttle and accelerator pedal, see
Check the adjustment of the parking brake lever, see TESTING AND ADJUSTMENT.
Bleed the air from the brake system, see TESTING AND ADJUSTMENT.
Bleed the air from the steering circuit, see TESTING AND
ADJUSTMENT.
Cab mounting bolts 170 Nm
30-65 b
AC AND HEATER
12
AC AND HEATER
Remark If the machine is not equipped with the air conditioning,
perform only those operations relating to the heater
unit.
switch a. On machines equipped with air conditioning,
capture and recycle all refrigerants before proceeding with
any removal procedures.
REMOVAL
Capture and recycle the refrigerant first, then proceed with removing the system.
open flame.
Drain and capture all engine coolant and recycle.

Coolant liquid 18 l
WARNING! Do not dump engine coolants down the
1.
Disconnect the flexible hose B of the heater valves.
2.
Disconnect the power supply cabling c and the clamp d.
3.
Disconnect the connector f from the pressure switch e.
4.
Disconnect the delivery pipe h and the return pipe i from the expansion valve g.
Immediately cap and plug the tubes and the orifices tightly to
prevent impurities from entering into the air conditioning circuit. Reuse the o-ring.
30-66 b
AC AND HEATER
12
5. Disconnect the pipes 1) from the fan cooler j.
6.
Disconnect the tubes 1! and 1@ that connect with the engine.
7.
Remove the four nuts 1# and remove the group j.
INSTALLATION

TIER I Engine R134a 1 kg
TIER II Engine R134a 2.25 kg
Refill the engine coolant.

Engine coolant 18 l
Start the engine and use a leak detector to check the AC unit.
30-67 b
FUEL TANK
12
FUEL TANK
switch a.
REMOVAL
Position a suitable collection pan under the fuel tank. Remove the
filler cap b from the fuel tank. Remove the bottom plug in order to
drain the fuel.
Fuel: max 130 l
1.
Remove the lower left guard shield c from the cab.
2.
Remove the hose clamp d nut e and move the hoses out of the
way.
3.
Remove battery cover f from fuel tank g housing.
4.
Loosen the battery hold down h and bracket i and move the battery j outwards. Lift the protective flap if needed. Remove the
negative (-) terminal clamp 1) first and then the positive (+) terminal clamp 1! next. Remove the battery and store in a well ventilated
area.
WARNING! It is important that the negative (-) battery terminal clamp is removed first. Doing so will prevent the
chance of a short to ground causing sparks.
5.
Disconnect the fuel level indicator 1@ connector 1# and supply pump

connector 1$.
6.
Disconnect the supply and return lines 1%, 1^ and cap the openings.
Mark the locations and hoses for proper reassembly.
7.
Remove the bolts 1& and the guard 1*.
30-68 b
FUEL TANK
12
8. Support the fuel tank and remove the mounting bolts 1(. Remove
the fuel tank carefully.
Empty fuel tank weight 74 kg
INSTALLATION

Refill the fuel tank:
Fuel: max 130 l
Fuel tank bolts 120 Nm

1.
Bleed air from the fuel circuit then start the engine.
30-69 b
HYDRAULIC TANK
12
HYDRAULIC TANK
switch a.
Eliminate all residual pressures in all the circuits. For

details, see TESTING AND ADJUSTMENTS.
REMOVAL
1.
2.
Remove the lower right guard b and step plate c.
Drain the reservoir d as follows:

1.
Position a suitable collection pan under the hydraulic tank
2.
Remove the fill plug e to aid in drainage.
3.
From under the tank, remove the drain plug f and allow the oil
to drain.
Hydraulic oil 92 l
30-70 b
REMOVAL
12
3. Disconnect the lower suction line G and hoses H from the tank.
Cap or plug all openings.
4.
Disconnect the upper lines I, J and 1) and remove the check valve
1! and T adapter piece 1@.
Mark the hose locations and hoses for proper reassembly.
5.
Support the tank and remove the four retainer bolts 1#. Carefully remove the tank from the chassis.
Empty hydraulic tank weight 77 kg
INSTALLATION

Refill the hydraulic tank:
Fuel: max 92 l
Fuel tank bolts 120 Nm

1.
Bleed air from the hydraulic circuit then start the engine. See
Stop the engine and check oil level.
30-71 b
ENGINE AND TRANSMISSION
12

switch a.

Into suitable containers, drain the following systems:

Hydraulic system 92 ll
Cooling system 18 l
Transmission system 16 l
WARNING! Do not dump any of the above systems
down the drain, on to the ground or into a body of water,
doing so is in violation of the law.
Capture and recycle the AC refrigerant.

WARNING! Do not discharge refrigerant into the open
atmosphere, doing so is in violation of the law and could
REMOVAL
1.
Remove the front work equipment, see BOOM.
2.
Remove the engine hood, see ENGINE HOOD.
3.
Remove the counterweight b, c see COUNTERWEIGHT.
4.
Remove the radiator oil cooler, see RADIATOR OIL COOLERS.
5.
Lift the boot d (not shown) and disconnect the switch e from the
loader lever f.
6.
Disconnect rear drive shaft h from transmission g.
30-72 b
12
7. Remove the front drive shaft i.
8.
Disconnect the suction hose 1) and drain line 1! from the pump j.
Cap or plug all openings. Disconnect the pump solenoid.
9.
Disconnect the LS line 1@ and the delivery line 1# from valve 1$.
Cap or plug all openings.
10. Disconnect the transmission unit 1%, solenoid valve 1^, hoses 1&, and
the wiring harness 1*. Cap or plug all openings.
30-73 b
12
11. Disconnect the sensors 1* and thermostat 1(.
12. Disconnect the engine coolant temperature sensors 2! and 2@.

13. Disconnect the cab heater hoses 2# from the coolant pump.
14. Disconnect the oil pressure sensor 2$ and the engine stop solenoid
2%.
15. Disconnect the cable 2^ from the cold start equipment, cab heater
hose support 2& and fuel tank back flow line 2*.
30-74 b
12
16. Disconnect the throttle and accelerator cables 2( from the support
3).
17. Disconnect the fuel lines 3@ from the water separator 3! and cap or
plug all openings. Remove the separator.
30-75 b
12
18. Disconnect the wiring 3# from the starter motor 3$.
19. Disconnect the wiring 3% from the alternator 3^.
20. AC machines; Disconnect the refrigerant lines 3* and 3( from the

compressor 3& and cap or plug all openings.
open flame.
21. Disconnect the wiring harness connectors 4) and 4!.
22. Remove the support shield 4@ and slide it towards the engine.
23. Disconnect the muffler clamp 4# from the pipe 4$.
30-76 b
12
24. Attach a chain hoist to the engine bracket 4% and muffler support 4^.
Apply slight tension to the chains and measure and adjust them for
a proper lift.
The chains should have a total length of 800 mm and the difference between chain lengths should be 53 mm.
The shortest length should be attached to bracket 4%. When lift
tension is applied, the distance between chains should be 200
mm.
25. Loosen and remove the nuts 4& from the support grommets 4* and
remove the bolts 4(.
26. Lift the engine and transmission up and out carefully. Make sure all
items listed are disconnected.
Engine and transmission 740 kg
30-77 b
12
INSTALLATION

Fill the hydraulic tank, cooling system, and transmission.
Hydraulic system 92 l
Cooling system 18 l
If equipped with air conditioning, recharge the system.
Refrigerant R134a - TIER I Engine 1 kg
Refrigerant R134a - TIER II Engine 2.5 kg
Drive shaft bolts
Drive shaft bolts 70 Nm
Drive shaft bolts Loctite 262
Axle mounting nuts

Axle mounting nuts 70 Nm
Fill the pump housing and lines, see section TESTING AND
ADJUSTMENT.
Bleed the air from the fuel system.
Vibration grommet nuts 175 Nm

1.
Start the engine to circulate the oil and coolant liquid. Check that
there are no leaks.
2.
Use a leak detector to check the leak tightness of the delivery and
return pipes of the AC compressor.
3.
Bleed the air from the work equipment circuits, see TESTING
AND ADJUSTMENTS.
4.
Stop the engine, check the levels and, if necessary, top them off.
30-78 b
PISTON PUMP
120000
PISTON PUMP
switch a.

Into suitable containers, drain the hydraulic system:

WARNING! Do not dump the hydraulic oil down the
REMOVAL
1.
Disconnect the suction hose c and drain line d from the piston
pump b. Cap and plug all openings.
2.
Disconnect the delivery line e and the LS signal line f. Cap and
plug all openings. Disconnect the solenoid connector g.
3.
Remove the drive shaft h.
4.
Support the piston pump with a suitable hoist.
5.
Remove the two mounting bolts I and then carefully remove the
pump.
Piston pump 40 kg
30-79 b
PISTON PUMP
12
6. Discard o-ring j and replace with new.
INSTALLATION

Fill the hydraulic system.
Fill the pump housing and lines. For details, see TESTING
AND ADJUSTMENT.
Suction flange fasteners 100 Nm

Delivery flange fasteners 60 Nm
Transmission bolts Loctite 262

Transmission bolts 70 Nm
Axle nuts 70 Nm
Pump bolts Loctite 262

Pump bolts 220 Nm
1.
Start the engine to circulate hydraulic oil through the system.
2.
Stop the engine and check for leaks.
30-80 b
TRANSMISSION
12
TRANSMISSION
switch a.


down the drain, on to the ground or into a body of water, doing so is in violation of the law.
REMOVAL
1.
Remove the piston pump, see PISTON PUMP.
2.
Lift the loader lever boot b (not shown) and unclip the connector c
from the loader lever d.
3.
Remove the filler tube e from the transmission.
4.
Remove the drive shaft f.
5.
Remove the cover g and six retainer bolts h from the flex plate i
and flywheel.
Mark the flex plate and flywheel with a location point.
30-81 b
TRANSMISSION
12
6. Unclip the connectors j from the solenoids and disconnect the oil
cooler hoses 1).
7.
Unclip the connectors from the sensors 1!. Remove the lead at the
temperature sensor.
8.
Remove the support shield 1@ and slide it back towards the engine.
9.
Attach the engine/transmission to a chain hoist using bracket 1# and

muffler support 1$. Apply slight tension to the chain and lift the engine.
30-82 b
TRANSMISSION
12
10. Remove the nuts 1%, bolts 1^ and rubber grommets 1&.
11. Remove the transmission support 1* and attach the support brackets.
12. Using a lifting tool and spacers secure the transmission 1( in place
with mountings.
13. Remove the twelve converter housing bolts 2).
14. Carefully slide the transmission 1( back and lower it until it is all
the way down on the jack.
Transmission 230 kg
30-83 b
TRANSMISSION
12
INSTALLATION

Fill the hydraulic tank, cooling system, and transmission.
Fill the pump housing and lines, see TESTING AND ADJUSTMENT.
Lever bolts 70 Nm
Filler pipe bolts Loctite 262
Flex plate bolts 70 Nm

Flex plate bolts Loctite 262
Iso mount nuts 196 19 Nm
1.
Start the engine to circulate the oil. Check that there are no leaks.
2.
AND ADJUSTMENTS.
3.
Stop the engine, check the levels and, if necessary, top off.
30-84 b
TRANSMISSION
12
DISASSEMBLY
CONVERTER GROUP
1.
Drain the oil from the transmission hydraulic circuit and remove
the torque converter a.
2.
Remove the bolts b from the bell housing c.
30-85 b
TRANSMISSION
12
3. Remove the bell housing c.
4.
Remove the seal d.
PLUGS AND FILTERS
30-86 b
TRANSMISSION
12
1. Drain the oil from the transmission hydraulic circuit and remove
the oil drain plugs A. Clean the magnet.
2.
Remove the oil fill plug B.
3.
With a filter wrench remove the filter C.
4.
Remove the plug D and clean the magnet.
30-87 b
TRANSMISSION
12
5. Remove the filter E.
The filter must be replaced every disassembly.
OIL PUMP
1.
Drain the oil from the transmission hydraulic circuit. Remove the
bolts a.
Mark pump position before removing the bolts.
30-88 b
TRANSMISSION
12
2. Remove the oil pump b by means of tool C1.
Take a care to not damage the oil pump seal.
3.
Remove the o-ring c and seal ring d.
TUBING AND SENSORS
30-89 b
TRANSMISSION
12
1. Drain the oil from the transmission, disconnect all electrical connections and loosen the 3rd gear tube upper fitting a.
2.
Loosen the 3rd gear tube lower fitting and remove pipe b.
3.
Remove the 3rd gear antishock valve c.
4.
Loosen the 1st gear tube upper fitting d.
30-90 b
TRANSMISSION
12
5. Loosen the 1st gear tube e and the lower fitting f. Remove the
tube.
6.
Remove 1st gear antishock valve g.
7.
Remove the 4th gear pressure sensor H.
8.
Remove the 1st gear pressure sensor i.
30-91 b
TRANSMISSION
12
9. Remove the pressure sensor j.
10. Remove the oil temperature sensor 1).
11. Remove the bolts 1! of the sensor cover.
12. Remove the sensor cover 1@ and gasket 1#.
30-92 b
TRANSMISSION
12
13. Remove the sensor/inductor 1$ and O-ring 1%.
14. Loosen the FWD delivery pipe 1^ and upper fitting 1&.
15. Loosen the FWD delivery pipe 1^ and lower fitting 1*.
16. Loosen the upper fitting 2) and the 2nd gear delivery tube 1(.
30-93 b
TRANSMISSION
12
17. Loosen the lower fitting, 2nd gear tube 1( and upper fitting.
18. Remove the tube 1( and upper fitting 2) (not shown here). Remove
the 2nd gear antishock valve 2! and lower fitting 2@.
19. Loosen the 3rd gear tube upper fitting 2#.
20. Loosen the 4th gear tube 2$ lower fitting 2% and remove the tube.
30-94 b
TRANSMISSION
12
21. Remove the 2nd gear pressure sensor 2^.
22. Remove the 4th gear pressure sensor 2*.
CONTROL VALVE
30-95 b
TRANSMISSION
12
1. Drain the oil from the transmission. Disconnect all electrical connections. Loosen all the fitting of the tubes connected with the control valve.
2.
Remove the bolts a retainer the control valve to the transmission.
3.
Lift the control valve b and remove the gasket c.
4.
Remove the solenoid valve retainer nut d.
5.
Remove the o-ring e, solenoid valve f and o-ring g.
6.
Remove the solenoid valve spool h.
30-96 b
TRANSMISSION
12
HOUSING
1.
Remove the bearing retaining ring a.
2.
Remove the flange retaining bolt b, washer c and o-ring d. Use

tool C3 to avoid flange rotation.
30-97 b
TRANSMISSION
12
3. Remove the flange e.
4.
Remove the bolts f, cover g and o-ring h.
5.
Remove the bearing i.
6.
Remove the oil seal j. Use tool C4.
30-98 b
TRANSMISSION
12
7. Remove the bolts 1).
8.
Remove the flange 1! and o-ring 1@.
9.
Remove the pump shaft 1#; by pushing from the opposite side.
10. Remove the retaining ring 1$.
30-99 b
TRANSMISSION
12
11. Remove the retaining ring 1%.
12. Extract the bearing 1^ with tool C5.
13. Remove the bolts 1& and cover 1*.
14. Remove the retaining ring 1(.
30-100 b
TRANSMISSION
12
15. Remove the bolts 2) and cover 2!.
16. Remove the retaining ring 2@.
17. Remove the flange retaining bolt 2#, washer 2$ and o-ring 2%. Use
tool C3.
18. Remove the flange 2^.
30-101 b
TRANSMISSION
12
19. Remove the bolts 2& and cover 2*.
20. Remove the retaining ring 2(.
21. Remove the oil seal 3). Use tool C4.
22. Remove the bolts 3!.
30-102 b
TRANSMISSION
12
23. Remove the bolts 3@.
24. Insert a lever in the special slot A and break loose the housings 3#
and 3$.
25. Lift the front half housing 3#. Use tool C6.
FORWARD REVERSE SHAFT

1.
Install a puller arrangement to the forward reverse shaft and moving the reverse idler shaft to the side remove from housing. Remove the reverse idler shaft.
30-103 b
TRANSMISSION
12
2.
Remove the rotary seal a.
30-104 b
TRANSMISSION
12
3. Remove the retaining ring b.
4.
Using an extractor, remove the bearing c.
5.
Remove the spacer d and washer e.
6.
Remove the roll pin f.
30-105 b
TRANSMISSION
12
7. Remove the gear g.
8.
Remove the roller bearings h and washer i.
9.
Lower the end plate 1) to remove the retaining ring j.
10. Remove the retaining ring j and end plate 1).
30-106 b
TRANSMISSION
12
11. Lower the spring retainer 1!. Remove roll pin 1@. Use tool C9 and a
hydraulic press.
12. Remove the retaining ring 1#.
13. Remove the spring retainer 1! and spring 1$.
14. Remove the friction discs 1% and separator plates 1^.
30-107 b
TRANSMISSION
12
15. Remove the clutch piston 1& by blowing in low pressure compressed air through the port.
Max air pressure 6 kg/cm
16. Remove the rotary seal 1*.
17. Remove the rotary seal 1(.
18. Remove the rotary seals 2).
30-108 b
TRANSMISSION
12
19. Remove the retaining ring 2!.
20. Remove the bearing 2@ using a puller.
21. Remove the bearing 2@ and thrust washer 2#.
22. Remove the roll pin 2$.
30-109 b
TRANSMISSION
12
23. Remove the gear 2%.
24. Remove the roller bearings 2^, spacer 2& and thrust washer 2*.
25. Lower the end plate 2( to allow retaining ring 3) removal.
26. Remove the retaining ring 3) and end plate 2(.
30-110 b
TRANSMISSION
12
27. Lower the spring retainer. Remove the spring pin 3!. Use tool C9
and a hydraulic press.
29. Remove the spring retainer 3# and spring 3$.
30-111 b
TRANSMISSION
12
31. Remove the clutch piston 3& by blowing in low pressure compressed air through the port.
32. Remove the rotary seal 3*.
33. Remove the rotary seal 3(.
34. Remove the reverse idler shaft 4) bearing 4! using a puller.
30-112 b
TRANSMISSION
12
2ND GEAR SHAFT
1.
Lift the three shafts at the same time. Use tool C11.
30-113 b
TRANSMISSION
12
2. Remove the rotary seals a.
3.
Remove the retaining ring b.
4.
Remove the spacer c.
5.
Using an extractor, remove the bearing d.
30-114 b
TRANSMISSION
12
6. Remove the gear e.
7.
Remove the spacer f and thrust washer g.
8.
Remove the spring pin h.
9.
Remove the gear i.
30-115 b
TRANSMISSION
12
10. Remove the roller bearings j and thrust washer 1).
11. Press down on the stop plate 1!.
13. Remove the stop plate 1! using two screwdrivers.
30-116 b
TRANSMISSION
12
14. Remove the belleville washer 1#, friction discs 1$ and separator
plates 1%.
15. Remove the spring pin 1^.
16. Lower the spring retainer. Remove the retainer ring 1&. Use tool
C9.
17. Remove the spring retainer 1* and spring 1(.
30-117 b
TRANSMISSION
12
18. Remove the clutch piston 2) by blowing in low pressure compressed air through the delivery port.
19. Remove the rotary seal 2!.
20. Remove the rotary seal 2@.
21. Remove the retaining ring 2# and washer 2$.
22. Remove bearing 2% using an extractor
30-118 b
TRANSMISSION
12
1ST, 3RD AND 4TH GEAR SHAFT
1.
30-119 b
TRANSMISSION
12
2. Remove the rotary seals a.
3.
Remove the retaining ring b.
4.
Remove the shims c.
5.
Using an extractor, remove the bearing d, speed wheel e and gear

f.
30-120 b
TRANSMISSION
12
6. Remove roller bearings g and pin h.
7.
Press the stop plate i.
8.
Remove the retaining ring j.
9.
Remove the pack including stop plate i, belleville washer 1), friction discs 1! and separator plates 1@.
30-121 b
TRANSMISSION
12
10. Remove the washer 1# and spring pin 1$.
11. Lower the spring retainer 1% and remove retaining ring 1^. Use tool
C9.
12. Remove the spring retainer 1%, spring 1&.

13. Remove the clutch piston 1* by blowing in low pressure compressed air through the delivery port. Remove the rotary seal 1(.
14. Remove the rotary seal 2).
30-122 b
TRANSMISSION
12
15. Using an extractor, remove 1st speed gear 2! and bearing 2@.
16. Lower the stop plate 2#.
18. Remove the stop plate 2# using two screwdrivers.
30-123 b
TRANSMISSION
12
20. Remove the belleville washer 2&.
21. Lower the spring retainer 2* to allow retaining ring 2( removal. Use
tool C9.
22. Remove the retaining ring 2(, spring retainer 2* and spring 3).
30-124 b
TRANSMISSION
12
23. Remove the clutch piston 3! by blowing in low pressure compressed air through the delivery port. Remove rotary seal 3@.
24. Remove the retaining ring 3#.
25. Remove the roller bearings 3$, bushings 3% and spacer 3^.
26. Remove the gear 3&.
30-125 b
TRANSMISSION
12
27. Remove the gear 3*.
28. Remove the roller bearings 3(.
29. Lower the stop plate 4).
30-126 b
TRANSMISSION
12
31. Remove the stop plate 4) using two screwdrivers.
32. Remove the belleville washer 4@, friction discs 4#, separator plates
4$ and thrust washer 4%.
33. Remove the spring pin 4^.
34. Lower spring retainer 4& and remove the retaining ring 4*, use tool
C9.
30-127 b
TRANSMISSION
12
35. Remove the spring 4(.
36. Remove the clutch piston 5) by blowing in low pressure compressed air through the delivery port. Remove the rotary seal 5!.
4WD DRIVE SHAFT

1.
2.
Remove the rotary seals a.
30-128 b
TRANSMISSION
12
3.
Compress the belleville washers b and remove the retaining ring

c. Use tool C9.
Take care not to damage the belleville washers.
4.
Remove the washers d and spacers e.
30-129 b
TRANSMISSION
12
5. Remove the spacer f and belleville washers b.
6.
Remove the clutch piston g from its seat. To remove the piston
blow low pressure compressed air into the shaft.
7.
Using an extractor, remove the clutch piston g.
8.
Remove the o-rings, inner h and outer i.
30-130 b
TRANSMISSION
12
9. Remove the three pins j and the relative o-rings 1).
11. Remove the bearing 1@ using an extractor.
12. Slightly press the stop plate 1#.
30-131 b
TRANSMISSION
12
14. Remove the stop plate 1#.
15. Remove the friction discs 1%, separator plates 1^ and the brake actuating disc 1&.
16. Remove the spacer 1*.
30-132 b
TRANSMISSION
12
17. Remove the bearing 1( using two levers.
18. Remove all the bearing 1( parts.
REASSEMBLY
4WD SHAFT
30-133 b
TRANSMISSION
12
1. Install the bearing a and retaining ring b. Use tool C12.
2.
Insert the inner c and outer d o-rings on the clutch piston e.
3.
Install the o-rings f on the relative pins g.
4.
Position the pins g on the clutch piston e in correspondence with

the holes on the output shaft. Install the clutch piston.
30-134 b
TRANSMISSION
12
5. Install the stop ring h, separator plates i, friction discs j and
brake actuator 1) on the gear hub 1!.
6.
Install the shaft 1@ on the gear 1!.
7.
Install the shaft 1@ using a rubber hammer.
8.
Install the retaining ring 1# after pulling up on the gear 1!.
30-135 b
TRANSMISSION
12
9. Make sure that the friction discs, separator plates and the piston are
correctly seated.
10. Preassemble the removed spacer 1$, washers 1% and retaining ring
1^.
11. Install the retaining ring 1^ to measure shim S thickness dimension

X.
Calculate the shim S with this formula:
S = X - (S1+S2)
S1 ................................................................Retaining Ring 1^
S2 ...........................................................Washer Thickness 1%
12. Insert belleville washers 1&, spacer 1$, washers 1% and shims 1*.
30-136 b
TRANSMISSION
12
13. Lower the belleville washers 1& and install the retaining ring 1^. Use
tool C9.
14. Apply 10 kg/cm with an oil pump to check the seal of rings c and
d. Use tool C13.
15. Install the rotary seals 1(.
16. Install the bearing 2). Use tool C14.
30-137 b
TRANSMISSION
12
17. Install the spacer 2!.
18. Using tool C11, lift the three shafts at the same time and install into the half housing.
1ST, 3RD AND 4TH GEAR SHAFT

1.
Install the rotary seal A on the clutch piston B.
2.
Apply a thin film of grease on the outer edge and in the inner part
of the clutch piston b.
30-138 b
TRANSMISSION
12
3.
Install the clutch piston b, spring c and spring retainer d.
30-139 b
TRANSMISSION
12
4. Lower the spring retainer d and install the retaining ring e. Use
tool C9.
5.
Install the stop plate f, belleville washer g, friction discs h and

separator plates i on gear j.
6.
Install the spring pin 1).
7.
Apply a thin film of grease under thrust washer 1! as an adherent.
30-140 b
TRANSMISSION
12
8. Align the friction discs h, separator plates i and stop plate f. Install the main shaft 1@.
9.
Insert the roller bearings 1#.
10. Install the retaining ring 1$.
11. Lift the retaining ring 1$ with a screwdriver to install into its seat.
30-141 b
TRANSMISSION
12
12. Install and hook the rotary seal 1% to the gear 1^.
13. Install and hook the rotary seal 1& on the clutch piston 1*.
14. Apply a thin film of grease on the outer edge and in the inner part
of the clutch piston 1*.
15. Install the clutch piston 1*, spring 1( and spring retainer 2).
30-142 b
TRANSMISSION
12
16. Lower the spring retainer 2) and install the retaining ring 2!. Use
tool C9.
17. Install the gear 2@, roller bearings 2#, bushings 2$ and spacer 2% on
the main shaft.
18. Install the stop plate 2^, friction discs 2&, separator plates 2* and
belleville washer 2( on the main shaft making sure they are all
aligned.
19. Install the gear 1^ on the main shaft.
30-143 b
TRANSMISSION
12
20. Install the retaining ring 3) making sure it is correctly seated.
21. Insert and hook the rotary seals 3!.
22. Install the bearing 3@. Use tool C8.
23. Insert and hook the rotary seal 3# on the clutch piston 3$.
30-144 b
TRANSMISSION
12
of the clutch piston 3$.
25. Install the clutch piston, spring 3% and spring retainer 3^.
26. Lower the spring retainer 3^ and install the retaining ring 3&. Use
tool C9.
27. Install the spring pin 3*.
30-145 b
TRANSMISSION
12
28. Apply a thin film of grease under the washer 3( to avoid its falling
when overturning the shaft.
29. Install the stop plate 4), belleville washer 4!, friction discs 4@ and
separator plates 4# on the gear 4$.
30. Install the roller bearings 4%.
31. Install the gear 4$ with the pack to the main shaft.
30-146 b
TRANSMISSION
12
32. Locate the pack using two screwdrivers. Lift the gear 4$ for retaining ring installation.
33. Install the retaining ring 4^ and gear.
34. Install the pin 4&.
35. Install the speed wheel 4*.
30-147 b
TRANSMISSION
12
36. Install the bearing 4(. Use tool C7.
37. Install the washer 5) and retaining ring 5!.
38. Install the rotary seals 5@.
39. Check for proper operation by blowing in low pressure compressed

air into the port.
30-148 b
TRANSMISSION
12
40. Lift the three shafts at the same time and insert into the half housing. Use tool C11.
2ND GEAR SHAFT
30-149 b
TRANSMISSION
12
1. Install the bearing a. Use tool C10.
2.
Install the washer b and retaining ring c.
3.
Install the and hook the rotary seal d.
4.
Install the rotary seal e on clutch piston f.
30-150 b
TRANSMISSION
12
of clutch piston f.retainer
6.
Install the clutch piston f, spring g and spring retainer h.
7.
Lower the spring retainer h and install the retaining ring i. Use
tool C9.
8.
Install the spring pin j.
9.
Install the washer 1) and roller bearings 1!.
30-151 b
TRANSMISSION
12
10. Install the friction discs 1@, separator plates 1#, belleville washer 1$
and stop washer 1% on gear 1^.
11. Install the assembly using two screwdrivers.
12. Install the retaining ring 1&.
13. Install the spring pin 1*.
30-152 b
TRANSMISSION
12
14. Install the washer 1(, spacer 2) and gear 2!.
15. Install the bearing 2@. Use tool C7.
16. Install the spacer 2# and retaining ring 2$.
17. Install the rotary seal 2%.
30-153 b
TRANSMISSION
12
air into the port.
19. Lift the three shafts at the same time and insert into the rear half
housing. Use tool C11.
FORWARD REVERSE SHAFT

1.
Install the rotary seal a.
2.
Install the rotary seal b on clutch piston c.
30-154 b
TRANSMISSION
12
3.
Apply a thin film of grease on the outer edge and in the inner part
of clutch piston c.
30-155 b
TRANSMISSION
12
4. Install the spring d, spring retainer e.
5.
Lower the spring retainer e and install the retaining ring f. Use
tool C9.
6.
Install the spring pin g, align the hole with the cover notch e.
7.
Install the washer h, roller bearings i and spacer j.
8.
Install the friction discs 1), separator plates 1! and stop plate 1@ on
the gear 1#.
30-156 b
TRANSMISSION
12
10. Lift gear 1# to allow the retaining ring 1$ assembly.
11. Install the spring pin 1%.
12. Install the thrust washer 1^, bearing 1& and insert the retaining ring
1*. Use tool C8.
30-157 b
TRANSMISSION
12
13. Install and hook the rotary seal 1(.
14. Install the rotating seal ring 2).
15. Install the rotary seal 2! on the clutch piston 2@.
of clutch piston 2@ and insert.
30-158 b
TRANSMISSION
12
17. Install the spring 2# and spring retainer 2$ and lower the spring retainer.
18. Install the retaining ring 2%. Use tool C9.
19. Install the spring pin 2^.
20. Install the washer 2& and roller bearings 2*.
21. Install the friction disc 2(, separator plates 3) and stop washer 3! on
gear 3@.
30-159 b
TRANSMISSION
12
23. Lift the gear 3@ to allow retaining ring 3# installation.
24. Install the spring pin 3$.
25. Install the washer 3%, spacer 3^ and bearing 3&. Use tool C8.
30-160 b
TRANSMISSION
12
26. Install the retaining ring 3*. Insert and close rotary seal 3(.

air into the port.
28. Install the shaft 4) bearings 4!. Use tool C10.
29. Reposition the reverse idler shaft 4@.
30-161 b
TRANSMISSION
12
30. Reposition the forward reverse shaft 4# and install.
HOUSING
1.
Install new o-rings a.
30-162 b
TRANSMISSION
12
2. Apply sealant on the rear housing b.
Rear housing sealant Loctite 510
3.
Using tool C6, locate front housing c on rear housing d.
4.
Install the rear housing bolts e.

Rear housing bolts 50 Nm
5.
Install the front housing bolts e.

Front housing bolts 50 Nm
30-163 b
TRANSMISSION
12
6. Install the bearing retaining ring f.
7.
Install the bearing g. Use tool C7.
8.
Install the seal ring h on cover i. Use tool C4.
9.
Install the o-ring j and cover i.
30-164 b
TRANSMISSION
12
10. Install the front cover bolts 1).
Front cover bolts 50 Nm
11. Install the flange 1!, o-ring 1@ and washer 1#.
12. Install the front flange bolt 1$. Use tool C3 to avoid flange rotation.
Front flange bolt 139 Nm
13. Install the rear lower bearing 1% with retaining ring 1^.
30-165 b
TRANSMISSION
12
14. Apply sealant to the rear flange cover face.
Rear flange cover face Loctite 510
15. Install the seal ring 1& to rear flange cover 1*. Use tool C4.
16. Install the cover and tighten the bolts 1(.

Rear flange cover bolts 50 Nm
17. Install the rear flange 2), o-ring 2! and washer 2@.
30-166 b
TRANSMISSION
12
18. Install the bolt 2#. Use tool C3 to avoid flange rotation.
Flange bolt 139 Nm
19. Using tool C8, install the bearing 2$.with the retaining ring 2%.
20. Apply sealant to the cover face.

Rear cover Loctite 510
21. Install the rear lower cover 2^ and tighten the bolts 2&.
Rear lower cover bolts 50 Nm
30-167 b
TRANSMISSION
12
22. Install the retaining ring 2* to the bearing.
23. Apply sealant.to the tri cover face.

Tri cover face Loctite 510
24. Install the tri cover 2( and tighten the bolts 3).
Tri cover bolts 50 Nm
25. Install the bearing 3! on the transmission shaft 3@.
30-168 b
TRANSMISSION
12
26. Install the retaining ring 3#.
27. Install the retaining ring 3$.
28. Install the transmission shaft 3@.
29. Install the o-ring 3% and apply a thin film of grease on the pump
flange inner diameter 3^.
30-169 b
TRANSMISSION
12
30. Install the pump flange 3^ and bolts 3&.
Pump flange bolts 50 Nm
CONTROL VALVE
1.
Install the solenoid valve spools a.
30-170 b
TRANSMISSION
12
2. Install the o-ring b, solenoid valve c, o-ring d and then tighten the
nut e by hand.
3.
Install the seal f on transmission.
4.
Install the control valve g.
5.
Install the bolts h and tighten in a cross sequence.
30-171 b
TRANSMISSION
12
6. Install the fittings of the delivery pipes connected with the control
valve.
TUBING AND SENSORS
1.
Install the 1st speed antishock valve a to the elbow b.

Make sure that arrow is directed towards clutch.
Anti shock valve 50 Nm
30-172 b
TRANSMISSION
12
2. Install the lower fitting c and 2nd speed antishock valve d.
3.
Install the 3rd speed antishock valve e.

4.
Install the 2nd speed tube f and tighten fitting g.

2nd speed tube 26 to 30 Nm
Fitting 40 Nm
5.
Install the 1st speed tube h and tighten fitting i.

1st speed tube 26 to 30 Nm
Fitting 40 Nm
30-173 b
TRANSMISSION
12
6. Install the 3rd speed tube j and tighten top fitting 1).
3rd speed tube 26 to 30 Nm
Fitting 40 Nm
7.
Install the Forward tube 1! and tighten fittings 1@.

Forward tube 26 to 30 Nm
Fitting 40 Nm
8.
Install the 4th speed tube 1# and tighten fittings 1$.

4th speed tube 26 to 30 Nm
Fitting 40 Nm
9.
Install the oil temperature sensor 1%.

Oil temperature sensor 23 Nm
30-174 b
TRANSMISSION
12
10. Install the 3rd speed pressure sensor 1^.
3rd speed pressure sensor 25 Nm
11. Install the 1st speed pressure sensor 1&.

1st speed pressure sensor 25 Nm
12. Install the pressure sensor 1*.

Pressure sensor 25 Nm
13. Install the 4th speed pressure sensor 1(.

4th speed pressure sensor 25 Nm
30-175 b
TRANSMISSION
12
14. Install the 2nd speed pressure sensor 2).
2nd speed pressure sensor 25 Nm
15. Install the o-ring 2! and sensor 2@ by centering it on its reference

pin.
16. Install the seal 2# and its sensor cover 2$.
17. Install the cover bolts 2%.

Cover bolts 23 Nm
30-176 b
TRANSMISSION
12
OIL PUMP
1.
Install the seal ring a on the oil pump b. Use tool C2.
2.
Install the o-ring c.
30-177 b
TRANSMISSION
12
3. Before assembling the oil pump, check that oil passage holes between the pump b and the case or the visual marks coincide.
4.
Apply a thin film of grease on the coupling seat with the front half
case.
5.
Install the oil pump b.
6.
Install the bolts d.

Make sure that the marks on the oil pump and the bell housing
are aligned.
Pump bolts 23 Nm
PLUGS AND FILTERS

1.
Install the filter a.
30-178 b
TRANSMISSION
12
2.
Install the plug b.

Filter plug 80 Nm
3.
Apply a thin film of grease on filter c seal and install. Tighten by

hand.
30-179 b
TRANSMISSION
12
4. Install the oil drain plugs d.
Drain plug 25 Nm
5.
Install the filler cap e.
CONVERTER GROUP
1.
Locate the seal a on the bell housing b.
2.
Install the bell housing b to the transmission.
30-180 b
TRANSMISSION
12
3.
Install the bell housing bolts c.

Bell housing bolts 170 Nm
4.
Install the converter d. Turn the torque converter until engaging

the relative splined shafts.
30-181 b
TORQUE CONVERTER
12
TORQUE CONVERTER

switch a.


down the drain, on to the ground or into a body of water, doing so is in violation of the law.
REMOVAL
1.
Lower all work equipment to the ground and turn the electrical supply off a. Release any pressure from the systems.
2.
Remove the piston pump, see PISTON PUMP. Remove the transmission, see TRANSMISSION.
3.
Carefully slide the converter b off the transmission c input shaft.
30-182 b
TORQUE CONVERTER
12
INSTALLATION
Engage the two shafts, primary and secondary, by slowly rotating

the body of the convertor.
When installing the converter on to the input shaft, rotate the
converter to the right then left while holding it square with the
shaft until it slides in place. Be sure it is seated in the flywheel
housing. Do not force the converter into the housing, damage
to the front pump may result. Once the converter is in place, retain it in place to keep it from falling out.
1.
Refill the tank with hydraulic oil to maximum level.

Hydraulic oil 92 l
Fill the pump body and the pump, bringing the tank up to pressure, see TESTING AND ADJUSTMENTS.
2.
Refill the transmission.

Transmission oil 16 l
3.
Start the engine to circulate the oil in all circuits. Check that there
are no leaks.
4.
AND ADJUSTMENTS.
5.
Stop the engine, check the levels and top them off.
30-183 b
STEERING VALVE
12
STEERING VALVE
switch a.

WARNING! Do not dump any system down the drain, on
to the ground or into a body of water, doing so is in violation of the law.
REMOVAL
1.
Lower all work equipment to the ground and release all residual hydraulic pressure from the system. Turn the battery disconnect
switch a to the off position.
2.
Position a suitable drain pan under the valve. Disconnect the lines
c at the steering valve b. Quickly cap or plug any openings.
Tag or mark line locations as they relate to the valve.
3.
Remove the lower instrument panel cover d.
4.
Raise the column boot e and separate the connectors f and g.
30-184 b
STEERING VALVE
12
5. Disconnect the relays h and i.
6.
Remove the steering column bolts j and remove the complete

steering unit 1).
INSTALLATION

Bleed the air from the Load Sensing circuit, see TESTING
AND ADJUSTMENTS.
Start the engine and perform several complete steering rotation
in both directions, to bleed the air out of the steering system.
30-185 b

12
COLUMN
COLUMN CONTROL SWITCHES
CONTROL SWITCHES

switch a.
REMOVAL
1.
Remove the bolts a and guard b.
2.
Lower the bellows boot c and detach the connectors d, e.
3.
Remove the bolts f, the lock nuts and the gearshift g and light
control h.
The controls have fixed orientation and position, defined by a
location pin.
30-186 b
COLUMN CONTROL SWITCHES
12
INSTALLATION
30-187 b
MASTER BRAKE CYLINDER
12

switch a.
REMOVAL
1.
Turn the battery disconnect switch a to the off position.
2.
Remove the cap b from the reservoir c and siphon the brake fluid.
3.
Disconnect the wiring d.
4.
Remove the reservoir c.
5.
Remove the retaining clip e that holds the brake lines f in place.
6.
Disconnect the lines f from the master cylinder g.
7.
Remove four mounting bolts h and carefully remove master cylinders (6).
If only one master cylinder is to be removed, disconnect pressure equalizing line i.
INSTALLATION

Bleed the air from the brake system, see TESTING AND ADJUSTMENTS.
Adjust pedal rods j to allow full return of the master cylinder
piston. Be sure the pedal adjustments 1) are set equally, see
TESTING AND ADJUSTMENTS.
30-188 b
12
Pipe fitting 20 Nm
30-189 b
LOADER CONTROL VALVE
12

switch a.

REMOVAL
1.
Lower all work equipment to the ground and release all residual hydraulic pressure from the system. Turn the battery disconnect
switch a to the off position.
2.
Remove floor mat B and slide lever boots C, D, and E up. Remove
bolts F and trim panel G.
3.
Disconnect control rod i from control valve h.
30-190 b
12
4. Disconnect the front equipment tubes j, control valve supply and
delivery lines 1), 1!, load sensing line 1@, and steering line 1#. Cap
or plug all openings.
Be sure to tag or mark the line locations and valve body locations for reassembly.
5.
Remove the four control valve retaining bolts. Remove the control
valve h.
INSTALLATION
1.
Start the engine to circulate the oil, and check that there are no
leaks.
2.
Bleed air from all circuits, see TESTING AND ADJUSTMENTS.
3.
Stop the engine and check the oil level in the tank.
30-191 b
FRONT AXLE
12
FRONT AXLE
REMOVAL
1.
Start the engine and use the front bucket to raise the machine and
front wheels. Place two stands a and some blocks beneath the
chassis. Slowly lower the machine onto the blocks, checking that
the wheels remain at least 5 cm above the ground. Engage the parking brake.
switch a.
Eliminate all residual pressures in all the circuits. For details, see TESTING AND ADJUSTMENTS.
2.
Remove the front wheels b.

Front wheel 65 kg
3.
Remove the front guard c, see COUNTERWEIGHT.
4.
Utilizing a suitable drain pan, disconnect the lines f from the steering cylinder and plug open ports.
5.
Disconnect the drive shaft e from the axle d.
6.
Disconnect the lube lines g for the axle oscillation pin h.
7.
Position a rolling floor jack and some blocks beneath the axle d.
Raise the jack until the blocks are under axle arms.
Lower the jack 10 cm in order to disengage axle from the pivot
support.
30-192 b
FRONT AXLE
12
8. Remove the retaining bolt i and nut of the axle pivot pin h. Install
an eyebolt into the hole of the pin and extract.
9.
Lower the jack until axle is free. Remove the entire axle.
Front axle 316 kg
INSTALLATION

Front wheel nuts 350 Nm
Front close bolts 300 Nm

Bleed the air from the Load Sensing circuit, see TESTING AND
ADJUSTMENT.
Axle pivot pin and bushing ASL800050

Check level in the tank and start the engine. Perform a few steering
turns in both directions to bleed air from the steering circuit.
DISASSEMBLY
STEERING CYLINDER
1.
Loosen the link arm b lock nut a until the pin threads are protected
in the lock nut. Tap on the nut A with a hammer in order to dislodge the link arm b from the swivel housing c.
Do not beat on the end of the pin threads. This is a destructive
operation for the nut.
2.
Remove the guide rod link b by unloosing the jam nut d, then
threading out from the swivel joint e.
3.
Remove the swivel joints e from the cylinder rod.
4.
Remove the cylinder g gland bolts f.
30-193 b
FRONT AXLE
12
5. Slide the gland h off the rod j. Remove the seals i from inside
the gland and discard.
6.
Pull the rod j out of the body 1). Remove the seals 1! from the rod
piston and discard.
7.
Remove the seals 1@ from inside the end of the body 1) and discard.
8.
Replace all the seals with the seal kit.
PLANETARY WHEEL HUB

1.
Position a suitable drain pan under the wheel hub. Place the wheel
hub b with the plug a up. Loosen it slowly to eliminate any internal pressure. Rotate the wheel hub over the drain pan. Remove the
plug.
Wheel hub 1.3 l each
Drain the oil completely.
2.
Remove both fastening screws c and stud bolts d from the cover
e. Remove the cover from the wheel hub. Remove and discard the
o-ring f.
3.
Remove the three snap rings g and thrust plate h.
4.
Remove the planetary gears i off the shafts.

Collect the needle bearings j (30 per shaft), check their conditions. With new planetary gears, is advisable to assemble new
needle bearings.
5.
Remove the thrust washers 1).
DO NOT remove the shafts from the cover 1!. DO NOT loose the
thrust button 1@ from the cover.
30-194 b

12
FRONT AXLE
Eliminate all residual pressures in all the circuit. For details, see TESTING AND ADJUSTMENTS.
6.
Remove the steel lock ring 1# from the axle shaft.
7.
Remove the sun gear 1$ and spacer 1% from the axle shaft.
8.
Remove the bolts 1^ from the wheel carrier 1&.
9.
Install two of the just removed bolts in the threaded extraction

holes of the wheel carrier. Extract and remove the carrier together
with the planetary ring gear.
10. Remove the steel lock ring 1* and the wheel carrier 1& from the
planetary ring gear 1(.
11. Only if necessary, remove the centering bushings 2) of the carrier
with tool D1.
30-195 b
FRONT AXLE
12
12. Remove the wheel hub 2! and collect the bearing cone 2@.
13. Place the hub on a flat surface and remove the seal ring 2#.
This is a destructive operation for the seal ring.
14. Remove the bearing cups out 2@ on both sides of the hub.
15. Remove the bearing cone 2@ from the steering knuckle.
STEERING KNUCKLE
1.
Remove the bolts a from the upper b and lower c king pin.
Before removing the king pins, sling the steering knuckle to a
support device.
2.
Remove the king pins b and c.
3.
Remove the steering knuckle d from the axle housing and from the
short shaft e.
30-196 b
FRONT AXLE
12
4. Place the steering knuckle d on a flat surface and remove the seal
ring f.
5.
Turn the steering knuckle over and remove the bushing g.
AXLE HOUSING
1.
Remove the U joint a from the axle housing.
2.
Remove the seal ring b from the axle housing.

3.
Remove the belleville washers c and d from the king pin mounts
in the axle housing.
4.
Remove spacer e from the upper part of axle housing.
5.
Remove the bushing f from the housing. Examine the bushing before the removal and replace it only if the wear conditions require
this.
6.
Take the upper g and lower h bushings out of the housing and out
of king pin.
7.
Remove the seal rings i from the pivot. If necessary, replace the
bushings j.
This is a destructive operation for the seal rings.
30-197 b
FRONT AXLE
12
DIFFERENTIAL CARRIER
1.
Remove the bolts a and the nuts b from the flange c. Use a screwdriver and unclamp the flange and remove.
2.
Using a lever to carefully pry out the oil seal cover d from the differential carrier.
3.
Remove the seal ring e and o-ring f from the oil seal cover. Discard the o-ring and seal ring.
4.
Rotate the axle so that the differential carrier g is facing up. Attach
a hoist to the carrier. Remove the bolts, then the differential carrier.
Install the differential carrier in an appropriate stand.
5.
Remove the bolts h and the ring nut retainers i.
30-198 b
FRONT AXLE
12
6. Mark the carrier halves j to the differential carrier g with reference marks to avoid incorrect assembly.
7.
Remove the adjuster ring nuts 1) using tool D2.
8.
Loosen and remove the bolts 1! and carrier halves j.
9.
Using a hoist, remove the differential case 1@.

Keep the cups with the bearings 1# they were removed with.
DO NOT mismatch the cups and cones bearings if they are not
to be replaced.
Check that the bushings 1$ remains in the housing.
30-199 b
FRONT AXLE
12
PINION GEAR
1.
Mount the differential carrier a in a vise.
2.
Remove the lock nut b using special tools D3 and D4.

This is a destructive operation for the ring nut.
3.
Remove the ring nut b and retaining washer c.
4.
Tap the shaft with a mallet to remove the pinion gear d.

Take care not to drop the pinion gear.
5.
Remove the washers e, the collapsible spacer f and the inner cone
of the tapered roller bearing g.
6.
Place the differential carrier on a flat surface and remove the outer
cups of the taper roller bearing g using a driver.
30-200 b
FRONT AXLE
12
7. Remove the inner cone of the tapered roller bearing g from the pinion gear d. Collect the bearing cone and the shim h.
8.
Check all pinion components for wear. The ring nut and compression spacer must be replaced.
DIFFERENTIAL
1.
Place the differential a in a vise. Remove the ring gear b bolts c.

This will make both differential halves free, so take care not to
drop the internal components.
2.
Remove the ring gear.
3.
Disassemble the differential halves d. Check the operating and

wear conditions of the components.
4.
Remove the bearing e from the differential halves d.
30-201 b
FRONT AXLE
12
REASSEMBLY
PINION GEAR
1.
Place the differential support a on a workbench. Install the outer

cups of the bearings b using the special tool D5.
2.
In order to measure the distance, use the kit consisting of the special tools called the false pinion gear D6 and false differential
halves D7 and D8.
3.
Insert the false pinion gear D6, together with its bearings b and
ring nut c. Using tools D3 and D4, tighten until the backlash is
eliminated.
4.
Install special tools D7 and D8 to the differential carrier and bolt

d in the carrier halves e.
5.
Use a depth gauge to take the measurement X. Write down the X

measurement.
30-202 b
FRONT AXLE
12
6. Make a note of the value V marked on the head of the pinion gear.
Calculate the shim thickness S to be installed beneath the pinion,
using the formula:
S = X - V, S is the thickness of the shim.
7.
Install the shim f onto the pinion gear g and press the inner bearing b using the tool D9.
The chamfer on the inner diameter of the shim must face the
gear teeth.
8.
Install to the pinion gear the first washer h, the new spacer i and
the second washer h.
9.
Install the pinion gear g into the differential carrier a, from the internal axle side, and the second bearing cone b into the pinion end,
from the opposite side.
In order to seat the second bearing into position, use the special
tool D9.
10. Install the ring nut washer j and new lock ring nut d on the pinion
gear end.
30-203 b
FRONT AXLE
12
11. Tighten ring nut, using the wrench for ring nut D3 and for pinion
gear D4.
The torque setting is given by the preloading measurement on
bearings. Tighten the ring nut gradually.
If the tightening is excessive, the elastic spacer must be replaced and the procedure repeated. When you check the preloading, it is advisable to bang slightly both pinion ends with a
soft hammer, so as to help seat the bearings.
12. Wrap a wire line around the pinion, uniformly and without overlapping. Connect it to a load meter and check the force P required to
rotate the shaft.
The force should be that needed for continual rotation. Do not
take into consideration the initial thrust force.
13. Using the wrenches, tighten the nut c taking load measurements at
intervals until force P has been obtained.
P force, maximum 92 to 137 N
If the max permissible value is exceeded, a new spacer must be
used and the preloading operations must be repeated.
DIFFERENTIAL
1.
Assemble the cones of the new taper roller bearings a on the carrier halves b, using the special tool D10.
2.
After cleaning and after checking operational conditions and wear,

assemble the differential parts.
30-204 b
FRONT AXLE
12
3. Position a carrier half on a workbench and assemble all its inner
components, sun gears, planetary gears, thrust washers pin and
discs. Join the two carrier halves c.
4.
Install the ring gear d and assemble with the bolts e.

Ring gear bolt Loctite 270
Ring gear bolt 95 Nm
DIFFERENTIAL CARRIER
1.
Install the differential box a, with outer bearing cups b on the differential carrier.
Take care not to invert the outer races of the tapered roller bearings and check that you are working on the right side of the ring gear.
2.
Install the two carrier halves c and bolts d in their seat. Check the
position with the reference marks. Position and snug the bolts.
30-205 b
FRONT AXLE
12
3. Install the two adjustment ring nuts e in the differential carrier
with tool D2, so as to preload the bearings slightly. Tap lightly with
a soft hammer in order to properly set the bearings in position. Take
care not to reverse the ring nuts.
4.
Position a magnetic base dial indicator A on the differential carrier,

so that the indicator feeler touches the surface of one tooth of the
ring gear at a 90 angle.
5.
Lock the pinion gear and move the ring gear alternatively and note
the pinion ring gear backlash, measured with the dial indicator. Repeat the operation on two or more points (teeth), rotating the ring
gear, to obtain an average value.
Permissible backlash 0.18 to 0.25 mm
6.
If the measured backlash is less than the given tolerance range,

screw in the ring nut from the side opposite to the ring gear and unscrew the opposite one the same amount.
If the measured backlash is higher than the given tolerance range,
screw in the ring nut from the side of the ring gear and unscrew the
opposite one of the same amount.
Before measuring the clearance, tap lightly on the bearing covers with a soft hammer to ensure that they are securely positioned.
7.
Tighten the bolts d.
30-206 b
FRONT AXLE
12
8. Using the same method employed to check the pinion gear force,
check the force T required to rotate the ring and pinion gears.
Force required:
(P+39 N) < T < (P+59 N)
P = the force found for the pinion gear
The force should be that of continual rotation. Do not take the
thrust force into consideration.
9.
If the force is not within the permissible limits:

Tighten each lock nut to the same extent to increase the force T.
Loosen each lock nut to the same extent to decrease the force T.
WARNING! The clearance between the ring gear and
the pinion gear must remain within the permissible limits.
10. Check the centering of the contact area using the following procedure:
1.
Coat both surfaces of the teeth of the ring gear with a marking
substance.
2.
Rotate the pinion gear.
If the contact area is excessive near to the edge of the teeth, the ring
gear must be brought closer to the pinion gear.
If the contact area is excessive on the inside of the teeth, the ring
gear must be moved away from the pinion gear.
11. Tighten the carrier half bolts d.

Carrier half bolts 266 Nm
30-207 b
FRONT AXLE
12
12. Once you have completed adjustment operations, fit the adjuster
nut f retainers bolts g.
Retainer bolts 13 Nm
13. Install the seal ring h in the pinion gear cover i with special tool
D11.
14. Install a new o-ring j onto the pinion gear cover i.
15. Assemble the pinion gear cover i with a suitable driver.

Do not damage the seal ring h o-ring j.
16. Clean the mating surfaces of the carrier and axle. Degrease and
clean with the appropriate cleaner. Apply Loctite on the contact
surface of the differential carrier.
Differential carrier surface Loctite 510
17. Place the differential carrier 1) on the axle housing. Install the
mounting bolts 1!.
Differential carrier bolts 169 Nm
30-208 b
FRONT AXLE
12
18. Insert the flange 1@ on the pinion gear end. Install the flange bolts 1#
with the relative nuts on the flange.
Flange bolts 56 Nm
AXLE HOUSING
1.
Assemble two new bushings A respectively, longer bushing from

the pinion gear side, and two new seal rings b in the central pivot
by using special tools D12 and D13.
2.
Install the king pin bushings c and d on the axle with the special
tool D14.
3.
Install the bushing e on the axle with the special tool D15.
4.
Install the seal ring f on the axle with the special tool D16.
Fill of the seal ring cavity with fresh grease.
30-209 b
FRONT AXLE
12
5. Lubricate the bushing e and the seal ring lip f. Insert the U joint g
inside the axle housing.
Be careful not to damage the seal.
STEERING KNUCKLE
1.
Drive the bushing a into the steering knuckle b with the special
tool D17.
2.
Assemble the seal ring c on the steering knuckle b with the special
tool D18.
Fill of the seal ring cavity with grease.
3.
Place the lower king pin d on a workbench and assemble the cone
of the spherical bearing e with the special tool D19 under a press.
Put the spacer f under the belleville washer on the upper part.
Liberally grease the king pin housings.
4.
Position the belleville washers G on the king pin housings.
5.
Secure the steering knuckle b with a hoist.
6.
Lubricate the seal ring lip and protect the splined end of the axle
shaft with a thin adhesive tape to avoid damage to the seal ring. After assembly, remove the adhesive tape. Assemble the steering
knuckle on the axle housing. Assemble the two king pins, the upper
H and the lower I, and tighten the retaining bolts J.
Retainer bolts 190 Nm
Make sure that the belleville washers remain in their position.
30-210 b
FRONT AXLE
12
WHEEL HUB
If the tapered roller bearings B have been replaced, verify that the
measure A, B and C are within the limits.
A measurement 17.950 to 18.000 mm
B measurement 64.275 to 64.325 mm
C measurement 23.070 to 23.172 mm
1.
Place the wheel hub A on a work bench and drive both cups of the
taper roller bearings b in place with special tool D20.
2.
Install the seal ring c into the wheel hub A with the special tool
D21.
3.
Install the taper roller bearing cone B on the steering knuckle end.
4.
Place the wheel hub on the steering knuckle and install the other
taper roller bearing cone B in place.
5.
Position the wheel carrier D on a bench and drive the bushings E

into the carrier surface level with the special tool D1.
At least two bushings, diametrically opposed, should be set
slightly higher than the carrier surface level to be used as dowels.
30-211 b
FRONT AXLE
12
6. Preassemble the wheel carrier F planetary gear G and with the
locking ring H.
7.
Install the wheel carrier F on the wheel hub using the two projecting bushings g as dowel pins. Install the bolts to secure the ring
gear with the wheel hub.
8.
Seat all the hub dowel bushings completely with the special tool
D1.
9.
Assemble the wheel carrier bolts i and tighten.

Wheel carrier bolts 230 Nm
10. Slide the spacer J onto the axle shaft, fit the sleeve 1) and install
the lock ring 1! to the end of the splined hub.
11. Repeat this procedure for the remaining side.
30-212 b
FRONT AXLE
12
PLANETARY CARRIER
1.
Place the planetary carrier a on a workbench. Install the outer

thrust washers b and planetary gears c the shafts.
2.
At each gear, install 30 needle rollers d between the gear and shaft.
Install the inner trust plate e and secure with the snap rings f to
the shafts.
3.
Install a new o-ring g to the carrier.
4.
Install planetary carrier to the wheel hub and secure with the fastening screws h. Coat the stud bolts i and install.
Fastening screws 80 Nm
Stud bolts Loctite 542
Stud bolts 70 Nm
5.
Repeat this procedure for the remaining side.
AXLE FILL
1.
Position the drain/fill hole up. Fill the wheel hub with clean lubricant. Install the drain plug A.
Wheel hub 1 l
Repeat for the remaining side.
2.
Fill the axle housing with clean lubricant. Install the drain plug b.
Axle housing 6.5 l
30-213 b
FRONT AXLE
12
STEERING CYLINDER
1.
Install a new seal kit a to the cylinder gland b, to the piston rod c
and to the cylinder body d.
2.
Slide the rod into the cylinder body.
3.
Fit the swivel joints e to the ends of the cylinder rod and tighten.
Swivel joint 300 Nm
4.
Install the steering cylinder to the central body and secure with the
bolts f.
Cylinder bolts 120 Nm
5.
Install the lock nut g loose and guide rod h to the swivel joint so
that the ball joint can be inserted into the steering knuckle.
6.
Insert the ball joint of the guide rod h into the steering knuckle.
30-214 b
FRONT AXLE
12
7. Install the lock nut i.
Lock nut 220 Nm
Screw in the lock nut g (previous page) of the guide rod h
only when the toe in adjustment has been carried out.
TOE IN ADJUSTMENT
1.
Put two 1 m linear bars A on the wheel sides and lock them with
two nuts on the wheel hub stud bolt. Align the two bars.
The two bars should be fixed on their center so that they are
perpendicular to the supporting surface and parallel to the
mounting pin axis.
2.
Measure the distance M between the bar ends with a tape line.
Keep the minimum value, swing the measurement point.
3.
Check that the difference of the measurements between the wheel

hubs diameters ends is within the tolerance range.
30-215 b
FRONT AXLE
12 The nominal toe in A value is referred to as the top to bottom

distance of the wheel hubs flange. The measured toe in value
M at the bar ends is the front to rear value of the bar and flange
distance.
A - Nominal toe in 0 to < 2 mm
M - Measured toe in 0 to < 5 mm
4.
If toe in is incorrect, use two wrenches on the swivel joints screwing in and out equally till the toe in is within the required tolerance.
5.
After adjusting, tighten the guide rod lock nuts.

Lock nuts 250 Nm
STEERING ANGLE ADJUSTMENT

1.
Use the same bars A assembled for the toe in adjustment and a long
bar over the machined part of the central body, so that the two bars
form an acute angle at the maximum steering.
2.
Adjust a inclinometer to a 50 angle and position it on the long bar.

Move a wheel side till it forms, with the two bars, the angle fixed
by the inclinometer.
30-216 b
FRONT AXLE
12
3. Adjust the steering mechanical retainer, screwing in or out the special bolts A on the steering knuckle, lock with the lock nut B.
Lock nut 150 Nm
Steer completely towards the other side and repeat the same
operations.
30-217 b
REAR AXLE
12
REAR AXLE
REMOVAL
1.
Lower the outriggers b to raise the rear wheels c about 5 cm.
2.
Position a safety stand a, 65 cm tall, beneath the backhoe chassis.

Retract the outriggers until the machine is resting on the stand.
3.
Stop the engine and remove the rear wheels c.

Rear wheel 163 kg
4.
For safety, rest the backhoe bucket with back resting on the ground,
keeping the arm vertical. Also lower front bucket on the ground.
5.
Stop engine and completely release any residual pressures from all
the circuits, see TESTING AND ADJUSTMENTS.
6.
Disconnect parking brake cable e and differential lock tube f

from rear axle d.
Plug and cap all openings to prevent entry of impurities.
7.
Disconnect rear drive shaft g from the rear axle.
8.
Disconnect brake hoses h and remove bolts i.
30-218 b
REAR AXLE
12
9. Partially loosen eight lock nuts j to facilitate removal.
Loosen lock nuts in a crisscross sequence.
10. Place the jacks and some blocks beneath the axle d. Raise the jack
until the blocks can be positioned under the axle.
Loosen the nuts j and plates 1) that secure the axle.
It should be possible to lower the jack by 20 cm.
11. Remove the lock nuts j, plates 1), and mounting bolts 1!. Lower
the jack until the axle d is clear of the chassis. Remove the axle.
INSTALLATION
Wheel nuts 500 9 Nm
Adjust stroke of the parking brake lever and bleed air from the
brake circuits. For details, see TESTING AND ADJUSTMENT.
Axle lock nuts 570 Nm

Tighten in two stages, using the crisscross method.
Check the oil level in the tank and start the engine.
DISASSEMBLY
PLANETARY GEARS
1.
Position a suitable drain pan under the wheel hub. Before draining
the oil, position the hub with the plug a on top. Loosen it in order
to relieve any residual pressure, then remove it completely. Rotate
the hub down, then drain the oil.
Wheel hub, each 1.5 l
2.
Remove the two fastening screws b of the planetary carrier c.
30-219 b
REAR AXLE
12
3. Remove the planetary carrier c from the wheel hub d.
4.
Remove and discard the o-ring e.
5.
Position the planetary carrier on a table and check its wear conditions.
6.
To replace the planetary gears f, remove the bolt g and relevant

washers h and i. Treat the pin j with care.
7.
Remove the planetary gear f from its seat, taking care not to lose
the two units of rollers 1) and thrust washer 1! and 1@ inside it.
8.
If the pins 1# of the pinion gears are in poor condition, replace the
entire planetary train with prefitted pins.
9.
If the thrust button 1$ is worn, replace the entire planetary carrier.
WHEEL HUB
WARNING! Before disassembling the hub, it is advisable
to secure it with a a hoist or any other supporting device to
avoid an accidental fall.
1.
Remove the sun gear shaft a with the coupling and snap ring.
30-220 b
REAR AXLE
12
2. Remove the bolts b from the wheel hub lock ring gear c.
3.
To remove the hub lock ring gear c from its housing, screw at least
two of the just removed bolts b in the threaded extraction holes A.
4.
Remove the hub lock ring gear c together with the planetary ring
gear d.
5.
Remove the steel stop ring e and disjoin the hub lock ring gear d
from the planetary ring gear c.
6.
If necessary, remove the centering bushings f of the hub lock ring

gear with special tool E1.
30-221 b
REAR AXLE
12
7. Remove the hub g. Collect the bearing cone h.
8.
Position the hub on a flat surface and remove the seal ring i.
9.
Remove the bearing cups h from both sides of the hub. Remove
the bearing cone h from the steering knuckle.
AXLE HOUSING AND BRAKE

1.
Drain oil from the axle, remove the breather first, to release the axle
inner pression, then loosen the plug A very carefully.
2.
Extract the seal ring b from the axle housing.

3.
In order to replace the bushing c inside the axle housing, it has to

be cut and destroyed with a chisel.
Do not ruin the bushing seat
30-222 b
REAR AXLE
12
4. Put alignment marks on the axle beam body and on the differential
supporting flanges, in order to identify the right side and the left
side with certainty.
5.
Position the axle on supports fitted to hold either the central body
or the two housings, even after the split, or secure the three groups
to a hoist.
6.
Remove the bolts d to disassemble the axle housings.
7.
Spread apart the axle housings. Once the axle housing has been removed, the brake disks are free.
8.
Remove the o-ring e from its seat and the oil passage hole and
check the conditions.
9.
Remove the long axle shaft f and the sleeve. Remove the snap ring
from the sleeve.
30-223 b
REAR AXLE
12
10. Remove the first brake drive plate G.
11. Remove the remaining brake disks h and drive plates i up to the
brake splined sleeve.
12. Remove the brake splined sleeve j, recording the indent position
compared to the brake group.
The brake splined sleeve should be reassembled in the same
position as the one before disassembling.
13. Remove the last brake plate 1).
30-224 b
REAR AXLE
12
14. Secure the brake flange to a hoist. Remove the lower bolt 1!. Remove the differential supporting flange 1@ from the central body, together with the ring gear backlash adjusting ring nut and the brake
control unit.
This operation frees the differential, and must supported.
15. Remove and discard the o-ring 1# from the housing.
16. Remove and discard the o-ring 1$ from the two oil pipe holes.
17. Remove the oil blow by tube 1% from the central body. Remove and
discard the o-rings 1^ from tube.
30-225 b
REAR AXLE
12
BRAKE CONTROLS
1.
Remove the brake group a and position it on a workbench.
2.
Remove the locknut b and adjusting screw on the support bracket

c. Remove the adjusting screw.
3.
Remove the lever fastening bolt d at the shaft end e.
4.
Remove the washer f.
5.
Put an alignment mark on the lever e and shaft g splines for use
during installation and to distinguish between right and left control,
i.e.: you can put two marks on the right and only one on the left.
30-226 b
REAR AXLE
12
6. Loosen the lever e to release the tension on the spring.
7.
Remove the lever e.
8.
Remove the spring h.
9.
Remove the washer i and the spacer j.
10. Remove the two bracket c fastening bolts 1).
30-227 b
REAR AXLE
12
11. Remove the bracket c.
12. Make an alignment mark on the cam 1! near the set screw 1@. Align
with the top of the roll pin, for use during assembly.
Distinguish between right and left sides.
13. Remove the set screw 1@ to free the cam.
14. Unscrew the shaft set screw 1#, being careful the steel ball 1$ (under
set screw) does not get lost.
30-228 b
REAR AXLE
12
15. Collect the steel ball 1$.
16. Remove the o-ring 1%, taking the shaft 1^ out.
17. Remove the shaft 1^ and collect the cam 1!.
18. Remove the upper bolts 1& of kit brake mechanism return and take
the springs 1* and the bushings out 1(.
30-229 b
REAR AXLE
12
19. Remove the lower self adjust kit screws 2) and take the bushings 2!
and the spacers 2@ out.
20. Remove the brake flange 2$ bleed screw 2#. Remove the piston 2%.
21. Using low pressure air, blow through the brake bleeder vent to
move the piston. Cover the port with a clean folded towel to prevent swift ejection of the piston.
22. Remove the o-rings 2^ and 2& from the piston 2% and check their
conditions.
23. Remove the fastening bolt 2* of the ring nut retainer 2(.
30-230 b
REAR AXLE
12
24. Remove the ring nut retainer 3).
25. Remove the ring nut 3! with E2 special tool.
26. Remove the bearing cup 3@.
DIFFERENTIAL
Place the differential a in a vise.
1.
Remove the bolts b of the ring gear c. This will make both differential halves free, so take care not to drop the internal components.
30-231 b
REAR AXLE
12
2. Disassemble the differential halves d complete with the relative
components.
Mark the two halves before splitting them, in order to reassemble them in the same position as the one before disassembling.
3.
Disassemble all the components and check the operating and wear
conditions of the components.
Remove the bearing e from each differential half.
PINION GEAR
1.
From the gear a, remove the snap ring b and slide out the input
flange c.
Collect the o-ring d and the shim e.
2.
Remove the seal ring f from the central housing.

3.
Place the central body on a work bench. Remove the ring nut g
with the special tools E3 and E4.
30-232 b
REAR AXLE
12
4. Once the ring nut washer h has been removed, take the pinion gear
i out of its housing.
5.
Collect the washers j, the elastic spacer 1) and the cones of the
taper roller bearing 1!.
When the elastic spacer is removed, it should be replaced by a
new one.
6.
Remove the bearing cone 1@ off the pinion gear.
7.
Remove the adjusting shim 1# placed under the bearing and check
its wear conditions.
8.
Remove the cups of the taper roller bearing out of the central body
1$.
30-233 b
REAR AXLE
12
DIFFERENTIAL LOCK
1.
Remove one of the cylinder support a bolts, the replace it with one
that is 25 mm longer. Carefully remove the remaining bolt allowing
the longer bolt to collect the spring tension
2.
Remove the o-rings and the piston b.
3.
Remove the snap ring c, holding the bushing d that is pushed outside by the spring e, remove the bushing and the spring from the
shaft f.
4.
Repeat Step 1 for the other cover g.
5.
Remove off the shaft h by with the o-ring, spring, spacer and snap
ring.
6.
Remove the differential lock fork i from the central body.
7.
Check the integrity of all components disassembled.
REASSEMBLY
PINION GEAR
1.
Position the central body a on a workbench.
2.
Install the cups of the taper roller bearings on their housings using
the special tools included in the kit E5.
3.
In order to measure the distance, the kit composed of the tools E6

false pinion and E7 false differential, is used.
4.
Insert the false pinion with E6, together with its bearings b and
ring nut c. Tighten without exceeding, till the backlash is eliminated.
30-234 b
REAR AXLE
12
5. Check the positioning of the right and left flanges, using the reference marks on them and on the central body. Install the each brake
flange d and affix them with two bolts e diametrically opposed.
Flange bolts 79 Nm
6.
Insert the false differential E7 into the central body to measure the
distance. Check that the false differential is inserted in both brake
flange housings.
7.
Carry out the measurement A with a depth gauge through the false
pinion hole and calculate the measurement X.
B measurement 100 mm
C measurement 50 mm
A+C-B=X
8.
Note of the value V marked on the head of the pinion gear. Calculate thickness S to be installed beneath the pinion gear, using the
formula:
S = X - V S is the shim thickness
30-235 b
REAR AXLE
12
9. Remove the false pinion gear, the bearings and the ring nut from
the central body. Disassemble the false differential from the flanges
and then remove the bolts and flanges.
10. Mount the shim f onto the pinion gear g and press the inner bearing b using the tool E8.
Always use a new elastic spacer.
11. Insert the pinion gear h into the central body housing and the second bearing b cone onto the pinion gear.
In order to seat the bearing into position use the special tool
E8.
12. Insert into the pinion shaft h a new ring nut washer i and the ring
nut c retainer.
13. Install the ring nut, using the wrench for ring nut E3 and for pinion
retainer E4.
The torque setting is given by the preloading measurement on
bearings.
Tighten the ring nut step by step.
If it is tightened too much, the elastic spacer should be replaced and the procedure repeated.
30-236 b
REAR AXLE
12
14. Carry out the preloading measurement P of the pinion taper roller
bearings, using a pull scale whose cord is wound on the diameter of
the pinion spline.
The adjustment is carried out by increasing the ring nut torque
setting gradually, being careful not to exceed.
All preloads should be measured without the seal ring.
Preload value 92 to 138 N
15. Once youve achieved the required preload value, stake the ring
nut.
DIFFERENTIAL
1.
Assemble the cones of the new taper roller bearings a on the differential halves b, using the special tool E9.
2.
Position a differential half b on a workbench and assemble all its

inner components; sun gears, planetary gears, thrust washers, pins,
discs and counterdiscs. Join the two differential halves, aligning the
reference marks made upon them.
3.
Position the ring gear c, and secure with the bolts d.

Ring gear bolts Loctite 270
Ring gear bolts 155 Nm
30-237 b
REAR AXLE
12
BRAKE FLANGE AND DIFFERENTIAL HOUSING
1.
Place the flange on a work bench and seat the cup of the taper roller
bearing a in position, using the special tool E10 with interchangeable handle E11.
2.
Install the elastic pin b into the brake piston c self adjust ports until they are leveled with the piston supporting inner surface.
3.
Install the o-rings d and e to the piston and lubricate the piston
flange with a light layer of fresh grease.
4.
Apply a light coat of fresh grease on the piston surfaces and especially on the o-rings already inserted, insert the piston c into the
brake flange f and position the special tool E12 on the piston and
with a lever anchored to an eyebolt, exert a pressure just enough to
insert the piston into the brake flange.
5.
Install the components of the self adjust kit to the piston c. Install
the bolts g of the two kits and tighten them.
Adjust kit bolts 10 Nm
30-238 b
REAR AXLE
12
6. Insert the new o-rings in their relative housings on the central body.
Before assembling, lubricate the o-rings h. Insert new o-rings i in
the oil tube hole housings. Grease the o-rings.
7.
Insert the oil blow by tube j. Insert the differential lock fork 1) in
the central body.
Do not invert the fork position.
8.
Insert a new o-ring 1! on the flange. Lubricate the o-ring. Assemble

the left flange on the central body. Tighten the brake cylinder bolts.
Brake cylinder bolts 79 Nm
Check that the reference marks made in the disassembly between flange and central body match.
9.
Before the adjustment of the ring gear bearings preload, fasten the
brake cylinders with two bolts.
Brake fastening bolts - M14x120 79 Nm
Once the adjustment is made, remove the bolts.
Notice the correct assembled side of the differential with its
relative components.
10. Turn over and position the flange central body on a work bench. Insert the differential.
11. Assemble the differential locking device as follows.
30-239 b
REAR AXLE
12
12. Once the snap ring 1# has been mounted on the shaft 1@ until about
20 mm from the knotched end, insert the shaft in the central body,
on the ring gear side, through the fork 1).
Do not put the snap ring in the housing.
13. Insert the spring 1$ and bushing 1% on the shaft 1@. Install into the
central body on the opposite side of the ring gear, then assemble the
snap ring 1^ in its housing.
14. Insert the piston 1* in the cylinder 2!, with new o-rings 1& and 1(.
Assemble a new o-ring 2) in the cylinder, and then insert, with the
piston, into the central body and secure with the bolts 2@.
Cylinder bolts 27.6 Nm
Before assembly, lubricate properly the seal rings and the contact surfaces.
15. Push the lock ring 1# into the housing in the differential locking device of the shaft 1#. Then let the ring slide along the shaft with a
pipe or a suitable tool. Insert the spacer 2# and spring 2$ on the
shaft. Install a new o-ring 2% in the cap 2^ and lubricate. Install the
cap to the central body at the flatted end of the shaft, tightening the
bolts 2&.
Cap bolts 27.6 Nm
30-240 b
REAR AXLE
12
16. Install the right brake flange. Tighten the brake flange bolts.
Brake flange bolts 79 Nm
Install the second brake flange on the opposite ring gear side. Insert
and screw the adjusting ring nuts of the pinion ring, using the
wrench with E2 till the bearing backlash is eliminated. Then measure the ring gear backlash.
17. Assemble the special tool E13 on the pinion end. Move the pinion
end alternatively and note the pinion gear backlash, measured with
a dial indicator, so that the feeler is in contact and at 90 with the
bracket surface on the special tool in correspondence with the reference mark. Check if the measured backlash value is within the request range.
Backlash 0.18 to 0.23 mm
Carry out the adjustment by operating on the two ring nuts with the
tool E2.
Adjust the ring nuts remembering that:
If the measured backlash is less than the given tolerance
range, screw the ring nut from the side opposite to the ring gear
and unscrew the opposite one of the same measure.
If the measured backlash is higher than the given tolerance
range, screw the ring nut from the side of the ring gear and unscrew the opposite one the same measure.
18. Once you have carried out the adjusting of the ring gear backlash,
check also that there is a minimum preload on the differential bearings.
Repeat the whole sequence of above events until the indicated conditions are reached.
19. Once the pinion gear backlash has been established, measure the total preload T of the ring gear bearings using a pull scale whose cord
is wound on the pinion gear shaft.
Force required:
P + 37.3 < T < P + 55.5 N
P = the force found for the pinion
The force should be that of continual rotation. Do not take the
initial thrust force into consideration.
30-241 b
REAR AXLE
12
20. If the force is not within permissible limits:
1.
Tighten both the lock nuts to the same extent to increase the
force T.
2.
Loosen both the lock nuts to the same extent to decrease the
force T.
The clearance between the ring gear and the pinion gear
must remain within the permissible limits.
21. Check the centering of the contact area using the following procedure:
1.
Coat both surfaces of the teeth of the ring gear with a marking
substance.
2.
Rotate the pinion.

If the contact area is excessive near to the edge of the teeth, the
ring gear must be brought closer to the pinion.
If the contact area is excessive on the side of the teeth, the ring
gear must be moved away from the pinion.
22. Insert the ring nut retainer 2* turning the ring nut slightly in order to
align it to the retainer. Screw in and tighten the bolt 2( of the ring
nut retainer.
Retainer bolt 13 Nm
23. Install the seal ring 3) into the central housing using seal driver
E14.
30-242 b
REAR AXLE
12
24. Coat the lip seal and o-ring 3! with oil. Install to the pinion gear the
shim 3@, o-ring and input flange 3#. Secure the assembled parts with
snap ring 3$.
BRAKE CONTROLS
1.
Insert the cam a and the shaft b, on the side you are operating, on
the brake flange c. They can be identified by the match marks previously left.
2.
When the shaft is inserted into the cam, align the reference mark
with the cam set screw d hole.
3.
Insert the cam set screw d.
30-243 b
REAR AXLE
12
4. Tighten the cam set screw d.
Set screw 10 Nm
5.
Insert the steel ball e that sets the shaft and the relative set screw
f.
6.
Tighten the shaft set screw f.

Shaft set screw SILASTIC
Shaft set screw 25 Nm
7.
Insert a new o-ring g on the shaft b.
30-244 b
REAR AXLE
12
8. Position the supporting bracket h and secure with bolts i.
9.
Tighten the bracket bolts i.

Bracket bolts 35 Nm
10. Install the spacer j washer 1) and spring 1! on the shaft end.
11. Install the brake control lever 1@, using the match marks.
30-245 b
REAR AXLE
12
BRAKE AND AXLE HOUSING
1.
Insert the odd shaped brake plate a, respecting the indicated position compared to the cam position.
2.
Check that the friction discs and the brake plates do not present any
sign of burning; replace as necessary. Check the friction disc wear
and if necessary replace them.
Friction disc thickness Min 4.03 mm
3.
Reassemble all the components of the brake group, friction discs b,

brake plates c and coupling d, inside the flange as per the sequence in the figure.
The coupling should be inserted after the first disc and positioned with the shortest spline against the differential.
If new brake discs are installed, before assembling, they should
be dipped in the suitable oil.
The friction discs and brake plates are free.
4.
Insert the axle shaft e into the housing f. Position the snap ring g
on the inner seat of sleeve h. Insert the sleeve on the axle shaft.
The sleeve must be inserted with the inner snap ring resting
against on the axle shaft.
5.
Before assembly, check the match marks for the correct positioning
of the axle housings.
30-246 b
REAR AXLE
12
6. Drive the bushing i in the seat on the axle housing by means of the
special tool E15.
7.
Assemble a new o-ring into the axle housing and into the two oil
blow by holes. Lubricate the o-rings. Assemble the housing on the
flange, being aware of bolt alignment. to the holes alignment.
Support the housings properly.
8.
Tighten the bolts j of the axle housing.

Housing bolts 176 Nm
Assemble the breather and adapter with the notch.
9.
Lubricate with care the lip of the new seal ring 1). Insert the new
seal ring in the seat on the axle housing with special tool E16.
10. Insert the short axle shaft 1! into the axle housing and coupling.
30-247 b
REAR AXLE
12
11. Set the brakes, putting the system under pressure.
Install a pump, with the required brake oil, with teed lines and
gauges at each brake port BP.
Required brake oil ATF
Brake set pressure 40 kg/cm
The brake system, piston, discs, self adjust kit and brake return
mechanism, should be set, before moving the brake control levers.
12. With the brakes set, install the control levers 1@, setting them at the
start of brake actuation position A.
Start of brake actuation position A 165.5 mm
Lever total range B 331 mm
The lever return springs should not be connected.
13. Measure the distance between the holes at the control lever ends
and check that it is within the lever total range B.
If the value is not within the range, correct the lever position:
take them off the shaft and reinstall them shifted one spline.
Repeat the checking and the further adjustment until the value
is reached.
14. Release the brake control levers, secure with bolts 1# and washers
1$.
15. Tighten the bolt of the control lever.

Control lever bolt 35 Nm
30-248 b
REAR AXLE
12
16. Hitch the return spring 1% to the brake control lever 1@.
Repeat the described operations for the other brake.
17. Check that, in released position C, the measurement between the

lever holes is higher.
Brake lever released position C 349 mm
18. Assemble the adjusting bolts 1^ on the brackets and thread in until
they contact the levers.
19. Thread in the two bolts equally to be within the brake lever released
position C:
Brake lever released position C 349 mm
About 3 mm between lever and bracket will remain.
30-249 b
REAR AXLE
12
20. If the bolt 1^ is not perpendicular to the side surface of the lever 1@,
adjust its position by moving the support bracket.
WHEEL HUB
1.
Place the wheel hub a on a work bench and seat the two cups of the
taper roller bearings b in position with special tool E17.
2.
Install the seal ring c into the wheel hub with special tool E18.
3.
Install the cone of the taper roller bearing b on the housing d end.
4.
Install the wheel hub a on the housing d and seat the other cone of
the taper roller bearing b in position.
5.
Place the wheel carrier e on a work bench and seat the bushings f
to the carrier surface flush with special tool E1.
At least two bushings, diametrically opposed, should be set
slightly higher than the carrier surface to be used as dowels.
30-250 b
REAR AXLE
12
6. Assemble the wheel carrier e, planetary ring gear g, with snap
ring h.
7.
Install the wheel carrier on the wheel hub a using the two projecting bushings f as dowel.
8.
Force the hub dowel bushings flush with special tool E1.
9.
Install the wheel carrier bolts i and tighten.

Wheel carrier bolts 230 Nm
10. If the bearings b were replaced, verify that the measurements A, B

and C are in the limits.
A measurement 17.950 to 18.000
B measurement 64.275 to 64.325
C measurement 23.070 to 23.172
30-251 b
REAR AXLE
12
PLANETARY GEAR
1.
Install the thrust button a to the planetary carrier.
2.
Place the planetary carrier on a work bench and install the planet
gears b and bottom washers c on the shafts. Insert two sets of rollers d into the planet gears b.
3.
Place the two thrust washers e and f and secure with the bolt g.
The first washer e must be aligned with the dowel pin h.
4.
Tighten the bolts g.

Planet gear bolts 79 Nm
5.
Insert a new o-ring on the wheel hub. Fit the planetary carrier to the
wheel hub i. Insert and tighten the screws j.
Hub screws 25 Nm
AXLE FILL
For fill procedure refer to the machine OPERATION AND MAINTENANCE MANUAL.
30-252 b
LOADER CYLINDERS
12
LOADER CYLINDERS
BOOM
REMOVAL
WARNING! Stop the machine on level ground, lower all
work equipment to the ground, and shut off the engine.
Then apply the parking brake and put blocks under the
wheels to prevent the machine from moving.
1.
Sling the cylinder a, insert blocks b between the boom c and the
lever spacer d.
2.
Remove the snap ring and the internal spacer for the rod end.
3.
Remove the pin e in order to free the rod f, but leave the lever d
attached.
4.
Start the engine and retract the rod. Secure the rod to the barrel with
wire and stop the engine
.
Loosen the oil filler cap slowly to release the pressure
inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in
the hydraulic lines.
WARNING! Cut off electrical supply by turning the battery
disconnect switch counterclockwise and remove the handle.
5.
Disconnect the hydraulic hoses g and h, then plug them to prevent

the entry of dirt.
6.
Remove the snap ring i and spacer j, then remove the cylinder a.
Boom cylinder 40 kg
INSTALLATION
WARNING! When aligning the position of the pin hole

use a bar. NEVER insert your fingers in the pin hole.
Start the engine and run at low idle, operate the control levers
and extend the rod to align the pin holes.
Internal bushing ASL800050
1.
Start the engine and bleed air from the cylinders, see TESTING
AND ADJUSTMENT.
After bleeding the cylinders, check the oil level
30-253 b
LOADER CYLINDERS
12
DISASSEMBLY
1.
Place the cylinder A in the tool A1.
2.
Using the wrench A4D, unscrew the cylinder gland b from the
cylinder barrel c.
3.
Remove the piston rod d from the cylinder. Remove the cylinder
barrel from the tool. Secure the piston rod d in the tool A1.
4.
Use the socket wrench A7, 55 mm across the flats, on the piston
nut e and remove. Slide the piston f off the rod. Remove and discard the piston seal g and wear ring h from the piston.
5.
From the cylinder gland 1), remove the following items and discard:
i
O-ring
Back up ring
1!
Buffer ring
1@
Rod seal
1#
Wiper seal
1$
O-ring
30-254 b
LOADER CYLINDERS
12
REASSEMBLY
1.
Mount the buffer ring a, rod seal b and wiper seal c in the cylinder gland d. Use tool A8 to mount the wiper seal.
Make sure that the lips are turned towards the inside of the cylinder for the rod seal b and outward for the wiper seal c.
2.
Install the o-ring e outside of the cylinder gland. Install the o-ring
f and the back up ring g on the outside of the cylinder gland.
3.
Using tool A9 with the appropriate diameter, Install the piston seal
h, external seal i and back up rings j into the piston 1). Install the
wear ring 1!.
4.
Gauge the external diameter of the seal h and i of the piston 1)

mounting the group under a press and use the tools A3 for the piston diameter.
5.
Using tools A1 and A2 with the appropriate diameter, insert the

bushing 1@ into the piston rod 1#
30-255 b
LOADER CYLINDERS
12
6. Mount tool A10 of the correct diameter onto the end of the rod 1#.
7.
Lubricate the cylinder gland seals and slide the assembly onto the
rod 1#.
Seal lube ASL800050
8.
Remove from the end of the piston rod 1#, the bushing A10.
9.
Install the piston 1) to the rod 1# and secure with the nut 1$.
Rod and nut threads Loctite 262
Piston nut 2900 Nm
10. Position the bushing 1% and mount it in the cylinder barrel 1^ using
tool A2 of the correct diameter.
Leave the cylinder in position for subsequent assembly.
11. Lubricate the threads of the first part of the cylinder barrel 1^.
Barrel threads ASL800050
12. Mount the two halves of the tool A11 with the appropriate diameter at the mouth of the cylinder barrel 1^. Install the piston and rod
in the cylinder up to tool A11. Guide the piston and center it tool.
Insert the piston slowly until inside the barrel. in order to calibrate
the guide rings without overheating them. Remove tool and thread
the cylinder gland into the barrel. Tighten the gland with upgraded
tool A4D.
30-256 b
LOADER CYLINDERS
12
13. Using upgraded tool A4D, nut welded to spanner wrench, tighten
the cylinder gland.
Apply applicable weld to the nut to sustain the following
torque valve.
Cylinder gland 980 Nm
R = T x L (L + C)
T - Torque required
980 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
C - Extension length
_ _ _ mm
EQUALS (=)
R - Reading on dial
_ _ _ Nm
BUCKET
REMOVAL
1.
Loosen the clamps a and remove the hose protector b.
2.
Disconnect the sensor C and remove the bucket position indicator

D.
30-257 b
LOADER CYLINDERS
12
3. Place a sling around the cylinder e and insert a block f between
the spacer g of the lever h and link i.
4.
Remove the snap ring and spacer of the rod pin j. Remove the pin.
Start the engine and retract the rod 1). Secure the rod to the barrel
with wire and shut off the engine.
WARNING! Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure
in the hydraulic lines.
WARNING! Cut off electrical supply by turning the battery
disconnect switch counterclockwise and remove the handle.
5.
Remove the bolt 1! and clamp 1@. Disconnect the hoses 1# and 1$,
and cap and plug the open ports.
6.
Remove the snap ring 1% and spacer 1^.
7.
Remove the cylinder e.

Bucket cylinder 45 kg
INSTALLATION
Install the hoses without twisting or interference.

and extend the cylinder rod to align the pin holes.
WARNING! When aligning the pin holes use a bar.
NEVER insert your fingers in the pin holes.

1.
Start the engine and bleed air from the cylinders. For details, see
30-258 b
LOADER CYLINDERS
12
DISASSEMBLY
1.
Place the cylinder A In the tool A1.
2.
Using the wrench A4C, unscrew the cylinder gland b from the
cylinder barrel c.
3.
4.
5.
i
O-ring
Back up ring
1!
Buffer ring
1@
Rod seal
1#
Wiper seal
1$
O-ring
30-259 b
LOADER CYLINDERS
12
REASSEMBLY
1.
2.
3.
Using tool A9 with the appropriate diameter, install the piston seal
wear ring 1!.
4.

5.

bushing 1@ into the piston rod 1#
30-260 b
LOADER CYLINDERS
12
6. Mount tool A10 of the correct diameter onto the tip of the piston
rod 1#.
7.
Lubricate the cylinder gland seals and slide the assembly onto the
piston rod 1#.
Seal lube ASL800050
8.
Remove from the tip of the piston rod 1#, the bushing A10.
9.
Install the piston 1) to the rod 1# and secure with the nut 1$.
Rod and nut threads Loctite 262
Piston nut 2900 Nm
10. Position the bushing 1% and mount it in the cylinder barrel 1^ using
11. Lubricate the threads of the first part of the cylinder barrel 1^.
12. Mount the two halves of the tool A11 with the appropriate diameter at the mouth of the cylinder barrel 1^. Install the piston and rod
in the cylinder up to tool A11. Guide the piston and center it in the
tool. Insert the piston slowly in until inside the barrel.order to calibrate the guide rings without overheating them. Remove tool and
thread the cylinder gland into the barrel. Tighten the gland with upgraded tool A4C.
30-261 b
LOADER CYLINDERS
12
13. Using upgraded tool A4C, nut welded to spanner wrench, tighten
the cylinder gland.
Apply applicable weld to the nut to maintain the following
torque valve.
Cylinder gland 950 Nm
R = T x L (L + C)
T - Torque required
950 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
_ _ _ Nm
MP BUCKET CYLINDER
REMOVAL
1.
Open the jaw b, and attach a hoist. Remove the lock pin c from
the rod pin. Attach the sling and hoist to the cylinder a.
2.
Remove the top rod pin d. Disconnect the hoses e, and cap and
plug the open ports.
3.
Remove the bottom pin f and cylinder a.
INSTALLATION

use a bar, NEVER use your fingers in the hole.
30-262 b
LOADER CYLINDERS
12
1. Start the engine and at low idle, extend the rod to align the pin
holes.
2.
AND ADJUSTMENT.
DISASSEMBLY
1.
30-263 b
LOADER CYLINDERS
12
2. Using the wrench A4A, unscrew the cylinder gland b from the
cylinder barrel c.
3.
4.
Remove the rear wear ring e. Drive out the slotted spring pin f.
Slide the piston g off the rod. Remove and discard the front wear
ring e, piston seal h with the back up rings i and o-ring j from
the piston.
5.
Slide the cylinder gland b off the rod. From the gland, remove and
discard the following items;
6.
1)
Wiper seal
1!
O-ring
1@
Back up ring
1#
Rod seal
if necessary, using tools A1 and A2 with the appropriate diameter,

49 mm, remove the bushing 1$ from the piston rod.
30-264 b
LOADER CYLINDERS
12
REASSEMBLY
1.
Mount the rod seal a and wiper seal b in the cylinder gland c. Use
tool A8 to mount the wiper seal.
Make sure that the lips are turned towards the inside of the cylinder for the rod seal a and outward for the wiper seal b.
2.
Install the o-ring d and the back up ring e on the outside of the
cylinder gland.
3.
Using tool A9 with the appropriate diameter, install the piston seal
f, back up rings g and FRONT wear ring h into the piston i. Install inner o-ring j.
4.
Gauge the external diameter of the piston seal f of the piston i

5.

bushing 1) into the piston rod 1!.
30-265 b
LOADER CYLINDERS
12
6. Mount tool A10 of the correct diameter onto the tip of the piston
rod 1@.
7.
Lubricate the cylinder gland seals and slide the assembly c onto
the piston rod 1@.
Seal lube ASL800050
8.
Remove from the tip of the piston rod, the bushing A10.
9.
Install the piston i to the rod 1@ and secure with the slotted pin 1#.
Install the remaining REAR wear ring h.
10. Lubricate the threads of the first part of the cylinder barrel 1$.
11. Mount the two halves of the tool A11 with the appropriate diameter at the mouth of the cylinder barrel 1$. Install the piston and rod
in the cylinder up to tool A11. Guide the piston and center it in the
tool. Insert the piston in slowly until its inside the barrel in order to
calibrate the guide rings without overheating them. Remove tool
and thread the cylinder gland into the barrel. Tighten the gland with
upgraded tool A4A.
12. Using upgraded tool A4A, nut welded to spanner wrench, tighten
the cylinder gland.
torque valve.
Cylinder gland ~ Nm
30-266 b
LOADER CYLINDERS
12
R = T x L (L + C)
~ Nm
T - Torque required
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
~
_ _ _ Nm
For wrench dimension and gland torque contact;
LESTER WHALEY @ 803-405-6512
30-267 b
FRONT EQUIPMENT
12
FRONT EQUIPMENT
WARNING! Position the machine on level ground. Lower
all work equipment a to the ground and shut off the engine. Apply the parking brake and put blocks under the
WARNING! Open the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate the controls several times to release the remaining pressure in the
lines.
BUCKET
REMOVAL
1.
Remove the bolts b and pins c and disconnect the lever d.

Rest the lever d on the boom.
2.
Remove the bolts e and pins f from the bucket.
3.
Start the engine, put the machine in reverse gear, and back up to
disengage the boom g.
INSTALLATION
WARNING! When aligning the pin holes use a bar.

NEVER insert your fingers in the pin holes.
30-268 b
FRONT EQUIPMENT
12
BOOM
REMOVAL
1.
Remove the bucket cylinders, see LOADER CYLINDERS.
2.
Disconnect the boom cylinder rod ends c from the boom b and
rest them on wood blocks a on the front axle.
3.
Open the front hood d and remove the bolts e that lock the pivot
pins to the boom b. Close the front hood.
4.
Sling the boom b, and attach to a hoist. Apply slight tension to the
sling.
5.
Using a puller, remove the boom pivot pins f.
6.
Start the engine and put the machine into reverse gear, back the machine up, until the boom is disengaged and clears.
7.
Place two stands in position and lower the boom.

Work equipment 960 kg
30-269 b
FRONT EQUIPMENT
12
BUSHING REPLACEMENT
Boom at Frame
1.
Uses a 57 mm driver to remove the bushing from the boom.
2.
Position new bushing, with tapered end in, into the outside boom
arm with the lube hole down and the split side up.
3.
Using a 60 mm driver with a 50 mm aligner, install the bushing

flush with the outer wall.
Boom at Bucket
1.
Uses a 52 mm driver to remove the bushing from the boom.
2.
arm.
3.

Boom at Cylinder
1.
Place the spacer tube between the boom ears. Using a 55 mm driver, remove each bushing into the tube spacer.
2.
Freeze the bushings. Place the spacer tube between the boom ears.
arm.
3.

Bucket Link
1.
At Cylinder:
Place the spacer tube between the boom ears. Using a 55 mm driver, remove each bushing into the tube spacer. Freeze the bushings.
Place the spacer tube between the boom ears. Position new bushing, with tapered end in, into the outside boom arm. Using a 55 mm
driver with a 45 mm aligner, install the bushing flush with the outer
wall.
2.
At Bucket:
Uses a 52 mm driver to remove the bushing from the boom. Position new bushing, with tapered end in, into the outside boom arm.
30-270 b
FRONT EQUIPMENT
12
INSTALLATION

and extend the cylinder ram to align the pin holes.
use a bar. NEVER insert your fingers into the pin hole.
After bleeding the cylinders, check the oil level.
30-271 b
12

BACKHOE CONTROL
REMOVAL
1.
Swing the backhoe a completely to the right of the machine, rotate

the boom approximately 45 to the right. Lower the outriggers to
the ground, open the bucket and rest the arm on a block, keeping it
perpendicular to the ground. Rest the bucket on the ground, release
the backhoe plate and shut the engine off.
Loosen the filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers
several times to release the remaining pressure in the
hydraulic lines
2.
Remove the lower window b from the cab, and completely raise
the upper window.
3.
Remove the grips c from the control levers of the outriggers.
4.
Raise the control lever boots d, remove the bolts e and cover f.
If any optional devises have been installed, disconnect the

spool tie rod g, pedal h, and support i.
30-272 b
12
5. Disconnect the lever command tie rods 1! from the control valve 1).
6.
Disconnect hydraulic hoses 1@, top and bottom lines, then cap and
plug the open ports.
Mark the hydraulic hoses 1@ before removing, in order to reassemble them in the same position as before.
7.
Sling the control valve 1), and attach to a hoist. Apply slight tension
to the sling.
8.
Remove the mounting bolts 1#, then remove the control valve 1).
6 spool control valve 47 kg
INSTALLATION
Start the engine and bleed air from the load sensing circuits and
from hydraulic circuits of all the actuators. For details, see TESTING AND ADJUSTMENT.
EXCAVATOR CONTROLS
REMOVAL
1.

hydraulic lines
30-273 b
12
2. Remove the lower window b from the cab, and completely raise
the upper window.
3.
Remove the rear mat c.
4.
Remove the screws d and remove the platform e.
5.
Disconnect the upper hoses g from the control valve f.

Ensure that all hoses are marked and note down bends and
routing pattern. Cap the hoses and the holes to prevent contamination.
Lay the hoses inside the cab to gain access to the feed and return hoses.
30-274 b
12
6. Disconnect the bottom hoses h from the control valve f.
Check that all the hoses are marked and note down the bends
and routing patterns. Cap the hoses and holes to prevent contamination.
Lay down the hoses in the cab to gain access to the feed and
exhaust hoses.
7.
Disconnect the hoses j from the control valve f.

Cap the hoses to prevent contamination.
Mark the hoses so as not to mix them up when reassembling.
8.
Attach the control valve to a hoist and slightly tension the rods.
9.
Remove the fastening screws and then the entire control valve f.
6 Spool control valve 47 kg
INSTALLATION
30-275 b
12
To install, reverse the removal procedure. For pilot hose connection
and routing, refer to diagrams.
30-276 b
PPC CONTROLS
12
PPC CONTROLS
PPC VALVE
REMOVAL
WARNING! The following procedure applies to either PPC
valves.
1.

hydraulic lines
2.
Remove the cab lower window and fully raise the upper window.
3.
Raise the top boot b. Loosen and remove the bolts c retaining the
PPC valve d and arm rest e.
4.
Raise the arm rest from the rear side and remove the screw f retaining the rear guard g.
5.
Cut the retaining clamp and lower the bottom boot h.
6.
Loosen and remove the screw i and remove the rear guard g.
7.
Detach the connector j.
8.
Ensure that the hoses are marked 1), then disconnect the hoses from
the PPC valve.
9.
Mark the hoses, if necessary. Cap the hoses to prevent contamination.
30-277 b
PPC CONTROLS
12
10. Remove the PPC valve 1!.
INSTALLATION

Carefully inspect the hoses for the proper position when connecting them.
SUPPORT RELEASE CABLES

REMOVAL
1.
Lower the outriggers and the mounted equipment a to the ground.

Stop the engine.
2.
Remove the rear mat b.
3.
Remove the bolts c and platform d.
30-278 b
PPC CONTROLS
12
4. Raise the boot e.
5.
Remove the bolts f retaining the PPC valve and the arm rest g.
6.
Raise the arm rest from the rear side and remove the bolt h retainer
the rear guard i.
7.
Cut the retaining clamp and release the lower boot j.
8.
Loosen and remove the bolt 1) and remove the rear guard h.
9.
Remove the bolts 1! and raise the boot 1@ and retaining edge 1#.
Raise until the lower lever and lock fully disengaged.
10. Remove the bolts 1$ from the lock actuating lever 1%.
11. Remove the complete lever 1%.
30-279 b
PPC CONTROLS
12
12. Loosen the nut 1^ and disengage the sheath 1* from the support 1&.
13. Disconnect the cable 2) from the lower lock lever 1(.
14. Loosen the nut 2! and tensioner 2@; disengage the control cable 2)
from the release control lever 1%.
INSTALLATION
1.
Using the tensioner 2@, adjust cable tension to obtain safe locking
and friction free unlocking of the column.
2.
Lock the nut while holding the tensioner into position 2!.
30-280 b

12
SUPPORT
PPC CONTROLS
RETURN GAS SPRING
REMOVAL
1.
Lower the outriggers and the mounted equipment a to the ground.

Stop the engine.
2.
Remove the rear mat b.
3.
Remove the bolts c and platform d.
4.
Fully loosen the stop knob e of the PPC valve support f you are
working on.
30-281 b
PPC CONTROLS
12
5. Raise the boot g.
6.
Remove the bolts h that retain the PPC valve and arm rest i.
7.
Raise the arm rest from the rear side and remove the bolt j retaining the rear guard 1).
8.
Cut the retaining clamp to disengage the lower enclosing boot 1!.
9.
Remove the bolt 1@ and remove the rear guard 1).
10. Remove the bolts 1# and raise the boot 1$ and the retaining edge 1%.
Raise until the gas spring 1( becomes fully disengaged.
11. Loosen the nut 1^ and remove the snap ring 1& and washer 1*.
12. Disconnect the gas spring 1( and remove it.
INSTALLATION
30-282 b

12
SOLENOID
PPC CONTROLS
VALVE
REMOVAL
1.
Move the backhoe to the right hand side. Lower the outriggers and
the equipment a to the ground; stop the engine.
Eliminate residual pressure in all circuits. For detail see
2.
Release the wire harness from the clamps. Detach the connectors c
from the solenoid valves b.
Ensure that the connectors are marked to avoid mixing them up
during installation.
3.
Disconnect the lower hoses e and the rear hoses f from the valve
d.
Mark the position of the hoses to avoid mixing them up during
installation.
4.
Remove the bolts g and valve d.
INSTALLATION
30-283 b

12
SERVO
PPC CONTROLS
CONTROL FEED VALVE
REMOVAL
1.
Position the machine over a pit, lower the outriggers and the equipment a to the ground. Stop the engine.
Eliminate residual pressure in all circuits. For detail see
2.
Mark the connectors b and detach them from the solenoid valves.
Gather the connectors together and place them in a clean area.
3.
Mark the hoses c with the abbreviations for the connections and
then disconnect them from the valve d.
Plug and cap the open ports.
4.
Loosen the bolts e and remove the valve d.
INSTALLATION
1.
Start the engine and repeat as many backhoe movements as possible several times to bleed air from the circuits.
If the valve is replaced or removed, perform the operating pressure calibration procedure, see TESTING AND ADJUSTMENTS.
30-284 b
BACKHOE CYLINDERS
12
BACKHOE CYLINDERS
BOOM
REMOVAL
1.
Remove the lube fitting and extension a.
2.
Extend the arm b completely and fully open the bucket c.

Lower the front equipment until the bucket is resting on the
ground, the arm on a block about 10 cm high, and the joint between the arm and boom d on a stand, about 70 cm high.
3.
Sling the boom cylinder e, and attach to a hoist. Apply slight tension to the sling.
4.
Remove the bolt f and pin g.
5.
Start the engine and retract the rod. Secure the cylinder rod.
6.
Disconnect the hoses h and i, then plug them to prevent entry of

impurities.
7.
Remove the bolt j and pin 1).
8.
Remove the cylinder e.

WB140-2N Cylinder 73 kg
WB150-2N Cylinder 78 kg
INSTALLATION


1.
TESTING AND ADJUSTMENT. After bleeding the cylinders,
check the oil level.
30-285 b
BACKHOE CYLINDERS
12
DISASSEMBLY
1.
2.
Using the wrench A5, unscrew the cylinder gland b from the cylinder barrel c.
3.
4.
Remove the set screw e. Use the socket wrench A7, 65 mm across
the flats, on the piston f and remove. Slide the piston off the rod.
Remove and discard the piston seal g, wear ring h and o-ring i
from the piston.
5.
Remove the balls j from the rod, then the piston cushion plunger
1).
6.
From the cylinder gland 1!, remove the following items and discard:
1@
O-ring
1#
Back up ring
1$
Buffer ring
1%
Rod seal
1^
Wiper seal
1&
O-ring
30-286 b
BACKHOE CYLINDERS
12
7. Remove the plug 1*, gasket 1(, spring 2) and load check poppet 2!
from cylinder barrel.
8.

56 mm, remove the bushing 2@ from the piston rod.
9.

56 mm, remove the bushing 2# from the barrel.
REASSEMBLY
1.
2.
30-287 b
BACKHOE CYLINDERS
12
3. Using tool A9 with the appropriate diameter, Install the piston seal
wear rings 1!.
4.
Install o-ring 1@ inside the piston.
5.

mounting the group under a press and use the tool A3 for the piston
diameter.
6.

bushing 1# into the piston rod.
7.
Install the cushion plunger 1$ into the rod. Drop the eleven balls 1%
into the rod to secure the plunger.
30-288 b
BACKHOE CYLINDERS
12
8. Mount tool A10 of the correct diameter onto the end of the rod 1^.
9.
Lubricate the cylinder gland d seals and slide the assembly onto
the rod.
Seal lube ASL800050
10. Remove from the end of the piston rod 1#, tool A10.
11. Install the piston 1# onto the rod and tighten - 65 mm socket.
Piston 1100 to 1300 Nm
12. Install the set screw 1& and tighten.

Set screw Loctite 262
Set screw 15 to 20 Nm
13. Position the bushing 1& and mount in the cylinder barrel using tool
A2 of the correct diameter.
30-289 b
BACKHOE CYLINDERS
12
14. Install the plug 1*, gasket 1(, spring 2) and load check poppet 2! into the cylinder barrel.
15. Lubricate the threads of the first part of the cylinder barrel.
16. Mount the two halves of the tool A11 with the appropriate diameter at the mouth of the cylinder barrel. Install the piston and rod in
the cylinder up to tool A11. Guide the piston and center in the tool.
Insert the piston slowly in until inside the barrel in order to calibrate the guide rings without overheating them. Remove tool and
thread the cylinder gland into the barrel. Tighten the gland with upgraded tool A5.
17. Using upgraded tool A5, nut welded to spanner wrench, tighten the
cylinder gland.
Apply weld to the nut to sustain the following torque valve.
Cylinder gland 900 to 1100 Nm
R = T x L (L + C)
T - Torque required
900 to 1100 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
30-290 b
_ _ _ Nm
BACKHOE CYLINDERS
12
ARM
REMOVAL
1.
Extend the arm a completely and fully open the bucket b.

Lower arm until the joint between the arm and boom c is resting on stand about 90 cm high, and the tip of arm is resting on
block about 10 cm high. Rest the bucket teeth on the ground.
2.
Sling the arm cylinder d, and attach to a hoist. Apply slight tension
to the sling.
3.
Remove the bolt e and pin f.
4.
Start the engine and retract the cylinder rod g.

Secure the piston rod with wire.
Stop the engine, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the
remaining pressure in the hydraulic lines.
5.
Disconnect the hydraulic hoses h and i, then plug them to prevent

6.
Remove the snap ring j and pin 1).
7.
Remove the cylinder d.

Arm cylinder 69 kg
INSTALLATION

1.
Start the engine and run at low idle, operate the control levers and
extend the rod to align the pin holes.

2.
AND ADJUSTMENT.
30-291 b
BACKHOE CYLINDERS
12
DISASSEMBLY
1.
2.
Using the wrench A4F, unscrew the cylinder gland b from the cylinder barrel c.
3.
4.
Use the socket wrench A7, 55 mm across the flats, on the nut e
and remove. Slide the piston f and spacer g off the rod. Remove
and discard the piston seal h and wear ring i from the piston.
5.
From the cylinder gland j, remove the following items and discard:
1)
O-ring
1!
Back up ring
1@
Buffer ring
1#
Rod seal
1$
Wiper seal
1%
O-ring
30-292 b
BACKHOE CYLINDERS
12
6. if necessary, using tools A1 and A2 with the appropriate diameter,
51 mm, remove the bushing 1^ from the piston rod.
7.

51 mm, remove the bushing 1& from the barrel.
REASSEMBLY
1.
2.
3.
wear rings 1!.
30-293 b
BACKHOE CYLINDERS
12
4. Gauge the external diameter of the seal h and i of the piston 1)
diameter.
5.

bushing 1@ into the piston rod.
6.
Mount tool A10 of the correct diameter onto the end of the rod 1^.
7.
the rod.
Seal lube ASL800050
8.
Remove from the end of the piston rod 1#, tool A10.
9.
Install the spacer 1#, piston 1) and nut 1$ onto the rod and tighten 55 mm socket.
Piston nut Loctite 262
Piston nut 2845 284 Nm
30-294 b
BACKHOE CYLINDERS
12
the cylinder up to tool A11. Guide the piston and center in tool. Insert the piston slowly inside the barrel in order to calibrate the
guide rings without overheating them. Remove tool and thread the
cylinder gland into the barrel. Tighten the gland with upgraded tool
A4F.
12. Using upgraded tool A4F, nut welded to spanner wrench, tighten
the cylinder gland.
torque valve.
Cylinder gland 970 97 Nm
R = T x L (L + C)
T - Torque required
970 97 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
_ _ _ Nm
BUCKET
REMOVAL
1.
Extend the arm a completely and fully open the bucket b.

Lower the arm untill the joint between the arm and boom c is
resting on a stand about 90 cm high, and the tip of the arm is
resting on a block about 10 cm high. Rest the bucket teeth on
the ground.
30-295 b
BACKHOE CYLINDERS
12
2. Stop the engine and release the pressure in the cylinder D by moving the control lever several times.
3.
Sling the arm cylinder D, and attach to a hoist. Apply a slight tension to the hoist and sling. Remove the lock nut E, washer, and pin
F.
4.
Start the engine and retract the cylinder rod G. Secure the cylinder
rod with wire.
Stop the engine, loosen the filler cap slowly to release
the pressure inside the hydraulic tank. Then operate
the control levers several times to release the remaining pressure in the hydraulic lines.
5.
Disconnect the hoses H and I, then cap and plug to prevent entry
of impurities. Remove the snap ring J and pin 1).
Machines equipped with a telescopic arm, loosen the nut 1!
and remove the pin 1@.
6.
Remove the cylinder D.

Cylinder 49 kg
INSTALLATION

use a bar. NEVER insert your fingers into the pin hole
Tighten locknut completely, then loosen it one half turn.

1.
DISASSEMBLY
1.
Place the cylinder A in the tool A1.
30-296 b
BACKHOE CYLINDERS
12
2. Using the wrench A4E, unscrew the cylinder gland b from the
cylinder barrel c.
3.
4.
5.
6.
O-ring
Back up ring
1!
Buffer ring
1@
Rod seal
1#
Wiper seal
1$
O-ring

51 mm, remove the bushing 1^ from the piston rod.
30-297 b
BACKHOE CYLINDERS
12
51 mm, remove the bushing 1& from the barrel.
REASSEMBLY
1.
2.
3.
wear rings 1!.
4.

diameter.
30-298 b
BACKHOE CYLINDERS
12
5. Using tools A1 and A2 with the appropriate diameter, insert the
6.
Mount tool A10 of the correct diameter onto the end of the rod 1#.
7.
the rod.
Seal lube ASL800050
8.
9.
Install the piston 1) and nut 1$ onto the rod and tighten - 55 mm
hex.
Piston nut Loctite 262
Piston nut 2845 284 Nm
10. Position the bushing 1% and mount it in the barrel c using tool A2
of the correct diameter.
30-299 b
BACKHOE CYLINDERS
12
the cylinder up to tool A11. Guide the piston and center it in tool.
Insert the piston slowly inside the barrel in order to calibrate the
A4E.
13. Using upgraded tool A4E, nut welded to spanner wrench, tighten
the cylinder gland.
torque valve.
R = T x L (L + C)
T - Torque required
1108 to 1245 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
_ _ _ Nm
TELESCOPIC ARM
REMOVAL
1.
Extend the arm b and rest it on a stand about 40 cm high. Extend

the telescopic arm c until it is resting on a block, and rest the bucket teeth on the ground.
2.
Stop the engine and release the cylinder a pressure by moving the
control several times.
30-300 b
BACKHOE CYLINDERS
12
3. Sling the arm cylinder a, and attach to a hoist. Apply slight tension
to the sling.
4.
Remove the snap ring d and pin e.
5.
Start the engine and retract the cylinder rod. Secure the cylinder rod
with wire.
Stop the engine, loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank.
Then operate the control levers several times to release the remaining pressure in the hydraulic lines.
6.
Remove the safety pin f.
7.
Disconnect the hydraulic hoses G, h, i, and j, then cap and plug

them to prevent entry of impurities.
8.
Remove the clamp 1).
9.
Remove the bolt 1! and pin 1@.
10. Remove the cylinder a.

Cylinder 69 kg
INSTALLATION


1.
DISASSEMBLY
1.
30-301 b
BACKHOE CYLINDERS
12
2. Using the wrench A4B, unscrew the cylinder gland b from the
cylinder barrel c.
3.
4.
Use the socket wrench A7, 56 mm across the flats, on the piston e
and remove off the rod. Remove and discard the piston seal f,
wear ring g and o-ring h from the piston.
5.
Remove from the cylinder gland 1), the following items and discard:
6.
O-ring
Back up ring
1!
Buffer ring
1@
Rod seal
1#
Wiper seal
1$
O-ring
If necessary, using tools A1 and A2 with the appropriate diameter,

46 mm, remove the bushing 1% from the piston rod.
30-302 b
BACKHOE CYLINDERS
12
46 mm, remove the bushing 1^ from the barrel.
REASSEMBLY
1.
2.
3.
Using tool A9 with the appropriate diameter, Install the o-ring h,

piston seal i and wear rings j into the piston 1). Install the internal
o-ring 1!.
4.
Gauge the external diameter of the seal i of the piston 1) mounting

the group under a press and use the tool A3 for the piston diameter.
30-303 b
BACKHOE CYLINDERS
12
5. Using tools A1 and A2 with the appropriate diameter, insert the
6.
Mount tool A10 of the correct diameter onto the end of the rod 1#.
7.
the rod.
Seal lube ASL800050
8.
9.
Install the piston 1) onto the rod 1# and tighten - 56 mm socket.

10. Position the bushing 1$ and mount it in the barrel using tool A2 of
the correct diameter.
30-304 b
BACKHOE CYLINDERS
12
A4B.
13. Using upgraded tool A4B, nut welded to spanner wrench, tighten
the cylinder gland.
torque valve.
R = T x L (L + C)
T - Torque required
960 to 980 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
_ _ _ Nm
OUTRIGGERS
REMOVAL
WARNING! Rest the back of the bucket on the ground,
keeping the arm vertical.
work equipment to the ground, and shut off the engine. Then
apply the parking brake and put blocks under the wheels to
prevent the machine from moving.
1.
Lower the outriggers to the ground and stop the engine.
30-305 b
BACKHOE CYLINDERS
12
2. Sling the outrigger cylinder a, and attach to a hoist. Apply slight
tension to the sling.
Leave hoses and tubes free.
3.
Remove the nut b and bolt c. Then draw out the pin d until the
rod e is disengaged.
4.
Start the engine and retract the rod e. Secure the piston rod with
wire.
Stop the engine, loosen the filler cap slowly to release the pressure inside the hydraulic tank. Then
operate the control levers several times to release
the remaining pressure in the hydraulic lines.
5.
Disconnect the hydraulic hoses f and g, then cap plug to prevent

6.
Remove the nut h, bolt i, and pin j, then the cylinder a.

Cylinder 69 kg
INSTALLATION


1.
DISASSEMBLY
1.
2.
Using the wrench A4F, unscrew the cylinder gland b from the cylinder barrel c.
3.
30-306 b
BACKHOE CYLINDERS
12
4. Remove the set screw e. Use the socket wrench A7, 65 mm across
the flats, on the piston f and remove. Slide the piston off the rod.
Remove and discard the piston seal g, wear ring h and o-ring i
from the piston.
5.
Remove the balls j from the rod, then the piston cushion plunger
1).
6.
From the cylinder gland 1!, remove the following items and discard:
1@
O-ring
1#
Back up ring
1$
Buffer ring
1%
Rod seal
1^
Wiper seal
1&
O-ring
7.

51 mm, remove the bushing 1* from the piston rod.
8.

51 mm, remove the bushing 1( from the barrel.
30-307 b
BACKHOE CYLINDERS
12
REASSEMBLY
1.
2.
3.
wear rings 1!.
4.
Install o-ring 1@ inside the piston.
5.

diameter.
6.

30-308 b
BACKHOE CYLINDERS
12
7. Install the cushion plunger 1$ into the rod. Drop the eleven balls 1%
into the rod to secure the plunger.
8.
Mount tool A10 of the correct diameter onto the end of the rod 1^.
9.
the rod.
Seal lube ASL800050
10. Remove from the end of the piston rod 1#, tool A10.
11. Install the piston 1# onto the rod and tighten - 65 mm socket.
12. Install the set screw 1& and tighten.

Set screw Loctite 262
Set screw 15 to 20 Nm
30-309 b
BACKHOE CYLINDERS
12
13. Position the bushing 1& and mount it in the cylinder barrel using
A4F.
16. Using upgraded tool A4F, nut welded to spanner wrench, tighten
the cylinder gland.
Apply an applicable weld to the nut to maintain the following
torque valve.
R = T x L (L + C)
T - Torque required
930 to 980 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
30-310 b
_ _ _ Nm
BACKHOE CYLINDERS
12
SWING
REMOVAL
WARNING! Position the backhoe a with the equipment
centered, arm vertical, and back of the bucket resting on
the ground.
1.
Stop the engine and release cylinder pressure by moving the control
several times.
2.
Remove the retaining bolts b out of the clamp c.
3.
Disconnect the hydraulic hoses e from the cylinder d, then cap and
plug to prevent entry of impurities.
4.
Remove the bolts f, then remove the upper support g of the cylinder mounting.
5.
Remove the bolts h and pin i.
6.
Rotate the cylinders to disengage rods from the swing bracket j,

then remove the cylinders d.
Cylinder 32.5 kg
INSTALLATION
1.
Mount the cylinders d and upper support g. Secure the support

with bolts f.
Support bolts Loctite 262

Support bolts 100 10 Nm
2.
Connect the four hydraulic hoses e to the cylinders d. Start the engine and swing the boom in order to center one of two pins i. Secure the first pin with bolt h. Repeat this step for the other pin.
WARNING! When aligning the position of the pin

hole, use a bar. NEVER insert your fingers into the pin
hole.

3.
TESTING AND ADJUSTMENT. After bleeding the cylinders,
check the oil level
30-311 b
BACKHOE CYLINDERS
12
DISASSEMBLY
1.
Position the cylinder in fixture A1. Engage the pivot pins into the
suitable support.
2.
Remove the set screw a for the gland and barrel.
3.
Using special wrench A6, loosen and extract the rod b, gland c
and piston d from the cylinder barrel e.
4.
Remove the brake cylinder f.
5.
Attach the cylinder rod to the fixture A1.
6.
Raise the part staked, then using special tool A7 remove the piston
d.
Carefully check the piston. If both staked areas show wear, the
piston must be replaced.
7.
Remove the snap ring g from the piston, then remove the collar h
and cushion ring i.
Make a note for order of assembly for ring.
8.
Using a puller, remove swing bushings from the cylinder pivot

pins.
9.
Disassemble the piston d and gland c by removing all the seals,

wear rings and o-rings.
Discard the seals, guard rings, and guide rings. They must be
replaced with new.
10. If necessary, using tools A1 and A2 with the appropriate diameter,

59 mm, remove the bushing j from the piston rod.
30-312 b
BACKHOE CYLINDERS
12
REASSEMBLY
Be extremely careful not to damage the seals and sliding surfaces.
Prepare each component before final assembly.
1.
Install the buffer ring a, rod seal b and wiper seal c into the piston
d.
Make sure the lips of the rod seal b are face inwards to the inside of the cylinder and the lips of the wiper seal c face outwards.
2.
Install the o-ring e, wear ring f, and the last o-ring g.
3.
Using tool A9 with the appropriate diameter, install the inner piston seal h and outer ring i into the piston j. Remove the tool A9
and install the back up rings 1).
4.
Install the wear ring 1!. Install the o-ring 1@ into the internal seat.
5.
Gauge the external diameter of the seals of the piston 1) mounting

the group under a press and use the tool A3 for the piston diameter.
6.

30-313 b
BACKHOE CYLINDERS
12
7. Install the cushion ring 1% into the rod.
Check the direction of assembly for the cushion ring.
8.
Insert the collar 1^ and secure with the snap ring 1&.
9.
Mount tool A10 of the correct diameter onto the end of the rod 1*.
10. Lubricate the gland seals and slide the assembly onto the rod.
Seal lube ASL800050
11. Remove from the end of the piston rod, tool A10.
12. Lubricate o-ring and thread the piston assembly onto the rod by
hand several turns.
O-ring ASL800050
13. With the rod in tool A1, tighten the piston 1) with tool A7 - 65 mm
socket.
14. Secure the barrel to fixture A1. Engage the pivot pins in the suitable support.
the cylinder up to tool A11. Guide the piston and center it in tool.
Insert the piston slowly inside the barrel in order to calibrate the
A6.
30-314 b
BACKHOE CYLINDERS
12
17. Using upgraded tool A6, nut welded to spanner wrench, tighten the
cylinder gland.
torque valve.
R = T x L (L + C)
T - Torque required
810 to 990 Nm
MULTIPLIED BY (x)
L - Wrench length
_ _ _ mm
DIVIDED BY ()
L - Wrench length
_ _ _ mm
PLUS (+)
_ _ _ mm
EQUALS (=)
R - Reading on dial
_ _ _ Nm
18. Install the brake cylinder 1( with a new o-ring 2) into the cylinder
barrel.
Brake cylinder Loctite 270
Brake cylinder 78 to 98 Nm
19. Remove the cylinder from fixture A1. Using a press and appropriate tool A2, mount the swing bushings.
BOOM LOCK
REMOVAL
WARNING! Center the backhoe a, rest the back of bucket
on the ground, keeping the arm vertical, lower the outriggers.
30-315 b
BACKHOE CYLINDERS
12
1. Make sure that the safety stop b is raised. Stop the engine and release the residual hydraulic pressure.
2.
Remove the cotter pins c, then remove the pin d.
3.
Disconnect the hydraulic hose e that feeds cylinder f, then cap

and plug to prevent entry of impurities.
4.
Remove the snap ring g, then remove cylinder f.
INSTALLATION
Pin seats ASL800050
Install new cotter pins.

1.
Start the engine and perform several lock and release manoeuvres
to fill the safety cylinder and bleed air from the unit. For details, see
DISASSEMBLY
1.
Remove the snap ring a.
2.
Pull the rod b out with the piston c and gland d.
3.
Slide the gland d off, then remove and discard the wiper seal e.
4.
Remove and discard the o-ring f from the piston.
REASSEMBLY
Reassemble the cylinder in reverse order of disassembly.
30-316 b
BACKHOE WORK EQUIPMENT
12

BOOM TO BUCKET
REMOVAL
1.
Extend the arm completely and fully open the bucket. Lower the
equipment until it rests on the ground. Remove the boom cylinder
a, see BACKHOE CYLINDERS.
WARNING! Stop the engine, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then
operate the control levers several times to release the remaining pressure in the hydraulic lines.
2.
Remove the bracket B located inside the boom. Disconnect the

hoses c from the arm cylinder, then cap and plug to prevent entry
of impurities.
Mark the hoses for ease of installation.
3.
Remove the bracket d.

Mark the hoses for ease of installation.
4.
Sling the work equipment e, and attach a hoist. Apply slight tension to the sling.
5.
Remove snap rings and pin f.
6.
Slowly remove work equipment e, checking that there is no interference.

Be very careful not to damage any hydraulic hoses.
Work Equipment 850 kg
30-317 b
12
INSTALLATION

1.
Pass the cylinder hoses through the inside of brackets g.
BUCKET
REMOVAL
WARNING! Place the bucket on a level surface, resting on
its back.
1.
Remove the safety pin a and connecting pin b between the bucket
c and linkage d.
2.
Remove the safety pin e then the pin f that attaches the bucket c
to the arm g.
INSTALLATION

Start the engine and run at low idle, operate the control levers and
extend the ram to align the pin holes.
30-318 b

12
STANDARD
ARM
REMOVAL
1.
Remove the bucket, see BUCKET.
2.
Remove the bucket cylinder a, see BACKHOE CYLINDERS.
3.
Remove the lever b. Remove the lock nut c with washers, pin d
and levers e.
4.
Start the engine and bring the arm into a vertical position, then lower it to the ground. Stop the engine and release the residual pressure
arm cylinder f.
5.
Sling the arm cylinder f to a hoist. Apply slight tension to the

sling. Remove the bolt g and pin h, then rest the cylinder on the
wood block 1!.
6.
Start the engine and retract the rod i completely.

Secure the piston rod with wire.
7.
Sling the arm j to a hoist. Apply slight tension to the sling. Remove the bolts and pin 1).
8.
Remove the arm j.

WB140PS-2 arm 213 kg
WB150PS-2 arm 245 kg
INSTALLATION


Tighten the lock nut c, then back off one half turn.
WARNING! Start the engine and run at low idle, operate the control levers and extend the rod to align the
pin holes. When aligning the position of the pin hole
30-319 b

12
TELESCOPIC
ARM
REMOVAL
1.
Remove the bucket, see BACKHOE WORK EQUIPMENT
2.
Remove the bucket cylinder a and link b, see BACKHOE CYLINDERS
3.
Remove the lock nut c with the washer, pin d, then the cylinder
link e.
4.
Disconnect the telescopic arm hoses F and G, the bucket cylinder

hoses H and I, then the auxiliary equipment hoses J and 1). Plug
and cap to prevent entry of impurities.
Mark the hydraulic hoses before separation, in order to reassemble them in the same position as before separation.
5.
Remove the clamp 1!.
6.
Remove the telescopic arm the same as the standard arm

Telescopic Arm 392 kg
INSTALLATION


Completely tighten lock nut c, then back off one half turn.
30-320 b

12
INNER
ARM
REMOVAL
1.
Remove the bucket a, see BACKHOE WORK EQUIPMENT
2.
Remove the bucket cylinder b and link c, see BACKHOE WORK

EQUIPMENT
3.
Remove the telescopic arm cylinder. see BACKHOE CYLINDERS

For safety, cap and plug all open ports to prevent entry of impurities.
4.
Remove the lock nut d with the washer, link pin e, and the arm
links f.
5.
Attach chains to the inner arm g, and attach to a hoist.

Attach chains to the bucket pin hole and the safety pin holes
6.
Start the engine, and maintaining constant tension on the section of

chain connected to the bucket coupling, slowly raise the boom until
both sections of chain are under slight tension.
7.
Stop engine and loosen the upper guide adjustment bolts, then the
lower guide adjustment dowel bolts by several turns.
Loosen the adjustment bolts on both sides.
8.
Slide inner arm g out.

Inner Arm 160 kg
INSTALLATION

Tighten the lock nut d, then back off turn.
30-321 b

12
INNER
ARM GUIDES
REMOVAL
1.
Remove the backhoe bucket, see BUCKET
2.
Partially extend the inner arm a.
3.
Rest the outer arm b on a stand 80 cm high.
4.
Loosen and remove the adjustment bolts c with lock washers d,

then remove the upper guides e.
5.
Attach chains to the inner arm a, and attach to hoist.

Attach the chains to the bucket pin hole and the safety pin
holes
6.
Slowly raise the inner arm b until it rests on the supporting surfaces of the upper guides e.
7.
Loosen the nuts f, then remove the lower guide adjustment dowel
bolts g.
8.
Raise the lower guides h and slide them out.
INSTALLATION
Upper and lower guides ASL800040

1.
Adjust the clearances, keeping the inner arm a aligned with the
outer arm b. For details, see TESTING AND ADJUSTING.
30-322 b
12
BOOM
REMOVAL
1.
Remove the backhoe arm, see BUCKET
2.
Remove the backhoe arm cylinder, see BACKHOE WORK

EQUIPMENT
3.
Start the engine, lower the boom and rest it on a wooden block on
the ground.
4.
Remove the backhoe boom cylinder, see BACKHOE CYLINDERS.
5.
Remove the bracket a. Disconnect the hydraulic hoses b, then cap

and plug to prevent entry of impurities.
Mark the hydraulic hoses b before separation, for ease of assembly.
6.
Sling the boom c, and attach to a hoist. Apply slight tension to the
sling.
7.
Remove the snap rings and pin d, then lift up and remove the boom
c.
Boom 323 kg
INSTALLATION
WARNING! When aligning the position of the pin and

hole use a bar. NEVER insert your fingers into the pin
hole.
Pass the cylinder hydraulic hoses inside the bracket e.

1.
30-323 b

12
SWING
BRACKET
REMOVAL
1.
Remove the backhoe work equipment, see BACKHOE WORK

EQUIPMENT
2.
Remove the bolts a and pins b that connect the swing cylinder c
rods.
3.
Remove the boom safety cylinder d, see BACKHOE WORK

EQUIPMENT
4.
Remove the snap e, pin f, and link g.
5.
Sling the swing bracket i, and attach to a hoist. Apply slight tension to the sling.
6.
Remove the bolts j and 1), then remove the swing bracket pivot
pins 1! and 1@.
7.
Remove the swing bracket, being careful not to lose or damage the
clearance adjustment shims 1#.
Swing Bracket 133 kg
INSTALLATION

hole.
Pin ASL800050
Insert the shims 1#.

1.
30-324 b
12
OUTRIGGERS
REMOVAL
WARNING! Position the backhoe a with the work equipment centered, with the arm vertical, and the back of the
bucket on the ground.
1.
Rest the outrigger on the ground and stop the engine.
2.
Sling the outrigger cylinder b, and attach to a hoist. Apply slight

tension to the sling.
3.
Remove the nut c, bolt d and pin e.
4.
Start the engine and retract the cylinder b rod. Raise the cylinder to
a vertical position and secure it in place with a strap.
5.
Sling the outrigger f, and attach to a hoist. Apply slight tension to

the sling.
6.
Remove the nut g, bolt h, and pin i.
30-325 b
12
7. With the hoist, raise the outrigger f until it is in a horizontal position. Remove the nut j, bolt 1), and pin 1!, then remove the outrigger.
8.
Repeat the same procedure for the other side.
INSTALLATION

hole.
30-326 b
90
OTHERS
HYDRAULIC CIRCUIT 90-3

BACKHOE STYLE CONTROLS FOR WB140PS-2N (1 OF 2) 90-3
EXCAVATOR STYLE CONTROLS FOR WB140PS-2N (1 OF 3) 90-11
ELECTRICAL CIRCUIT 90-23
CAB WIRING SCHEMATIC (1 OF 5) 90-23
LEGEND FOR CAB WIRING SCHEMATIC 90-33
CANOPY WIRING SCHEMATIC (1 OF 5) 90-35
LEGEND FOR CANOPY WIRING SCHEMATIC 90-45
TIER I ENGINE HARNESS 90-47
TIER II ENGINE HARNESS 90-49
LEGEND FOR TIER I AND II ENGINE HARNESS 90-51
FRONT HARNESS 90-53
LEGEND FOR FRONT HARNESS 90-55
LATERAL HARNESS AND SIDE DASHBOARD 90-57
TIER I ENGINE (1 OF 2) 90-57
TIER I ENGINE (2 OF 2) 90-59
LEGEND FOR TIER I ENGINE 90-61
90-1 b
OTHERS
TABLE OF CONTENTS
TIER II ENGINE (1 OF 2)
TIER II ENGINE (2 OF 2)
LEGEND FOR TIER II ENGINE
PPC FRAME AND SIDE DASH BOARD HARNESS
FRAME HARNESS
SIDE DASH BOARD HARNESS
LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS
WORK LIGHT HARNESS
TRANSMISSION HARNESS
LEGEND FOR TRANSMISSION HARNESS
FUSE AND RELAY PANEL
LEGEND FOR FUSE AND RELAY PANEL
90-2 b
90-63
90-65
90-67
90-69
90-69
90-71
90-73
90-75
90-77
90-79
90-81
90-81
OTHERS
HYDRAULIC CIRCUIT
12
HYDRAULIC
CIRCUIT
BACKHOE STYLE CONTROLS FOR WB140PS-2N (1 OF 2)
90-3 1
OTHERS
HYDRAULIC CIRCUIT
12
BACKHOE
STYLE CONTROLS FOR WB140PS-2N (2 OF 2)
90-5 1
OTHERS
HYDRAULIC CIRCUIT
12
BACKHOE
90-7 1
OTHERS
HYDRAULIC CIRCUIT
12
BACKHOE
90-9 1
OTHERS
HYDRAULIC CIRCUIT
12
EXCAVATOR
90-11 1
OTHERS
HYDRAULIC CIRCUIT
12
EXCAVATOR
90-13 1
OTHERS
HYDRAULIC CIRCUIT
12
EXCAVATOR
90-15 1
OTHERS
HYDRAULIC CIRCUIT
12
EXCAVATOR
90-17 1
OTHERS
HYDRAULIC CIRCUIT
12
EXCAVATOR
90-19 1
OTHERS
HYDRAULIC CIRCUIT
12
EXCAVATOR
90-21 1
OTHERS
ELECTRICAL CIRCUIT
12
ELECTRICAL
CIRCUIT
CAB WIRING SCHEMATIC (1 OF 5)
90-23 1
OTHERS
ELECTRICAL CIRCUIT
12
CAB
WIRING SCHEMATIC (2 OF 5)
90-25 1
OTHERS
ELECTRICAL CIRCUIT
12
CAB
90-27 1
OTHERS
ELECTRICAL CIRCUIT
12
CAB
90-29 1
OTHERS
ELECTRICAL CIRCUIT
12
CAB
90-31 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR CAB WIRING SCHEMATIC
ITEM
EV1
EV2
EV3
EV4
F1A
F1B
F1C
F2A
F2B
F2C
F3A
F3B
F3C
F4A
F4B
F4C
F5A
F5B
F5C
F6A
F6B
F6C
F7A
F7B
F7C
FUG1
FUG2
FUG3
FUG4
G1
G2
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
DESCRIPTION
MP Bucket Open Solenoid
MP Bucket Close Solenoid
Diff Lock Solenoid
Boom Lock Solenoid
Low Beam Fuse, 15A
Right Light Fuse, 3A
Left Light Fuse, 3A
Trans Power Supply Fuse, 10A
Cab Fuse, 15A
Hazard Fuse, 10A
Stp Seat DL Fuse, 7.5A
Instr. Warn RTD, 10A
MPB Declutch Fuse, 7.5A
4WD Ft Washer Fuse, 7.5A
F/R BUA Fuse, 10A
High Beam Fuse, 15A
Heater Relay Fuse, 10A
Rear Work Light, 15A
Front Work Light, 15A
Rear Wiper Front Horn, 15A
Light Sel Horn Relay, 7.5A
Direction Lights, 10A
Fuse, 7.5A Not Used
Front Horn Fuse, 10A
Fuel Shut Off Fuse, 7.5 A
Key Switch Fuse, 60A
Preheat Switch Fuse, 80A
FSO Power Fuse, 40A
Heater A/C Fuse, 40A
Battery
Alternator
Preheat Warn Light
Alternator Warn Light
Coolant Warn Light
Eng Oil Pressure Warn Light
Air Filter Warn Light
Hyd Oil Filter Warn Light
Opt Warn Light
Opt Warn Light
Coolant Warn Light
Converter Temp Warn Light
4WD Warn Light
Low Fuel Warn Light
Komatsu Logo Light
Komatsu Logo Light
Lighter Light
SHEET
5 of 5
5 of 5
5 of 5
5 of 5
1 of 5
2 of 5
2 of 5
2 of 5
3 of 5
2 of 5
2 of 5
2 of 5
1 of 5
2 of 5
1 of 5
1 of 5
3 of 5
3 of 5
2 of 5
3 of 5
1 of 5
2 of 5
1 of 5
1 of 5
2 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
1 of 5
1 of 5
1 of 5
1 of 5
1 of 5
1 of 5
3 of 5
ITEM
H16
H17
H18
H19
H20
H21
H22
H23
H24
H25
H28
H29
H36
H37
H38
H39
HA1
HA2
HA3
HA4
K01
K02
K03
K04
K05
K06
KC
K2
K3
K4
K5
K6
K8
K9
K10
K12
K13
K14
KT1
KT2
M1
M2
M3
M4
M5
M8
DESCRIPTION
Cab Light
Front Work Light
Front Work Light
Beacon Light
Rear Work Light
Rear Work Light
Indicators Warn Light
High Beam Warn Light
Brake Oil Warn Light
Diff Lock Warn Light
Right Front Light
Left Front Light
Rear Left Side Lights
Rear Right Side Lights
Courtesy Light
Plate Light
Horn
Buzzer
Rear Horn
Back Up Alarm
Starter Relay
Preheat Relay
Fuel Shut Off Relay
AC Blower Relay
Return to Dig Relay
Power ECO Unit
Load Fan Heater Relay
Reverse Direction Relay
4WD Relay
Neutral Position Relay
Low Beam Relay
Main Beam Relay
Front Horn Relay
Flasher Unit
Trans Power Relay
Seat Unit
Stop Light, Diff Lock Unit
Trans Diode Unit
Fuel Shut Off Timer
Preheater Timer
Starter Motor
Washer Pump
Windshield Wiper Motor
Blower Motor
Transfer Fuel Pump
Windshield Wiper Motor
SHEET
4 of 5
4 of 5
4 of 5
4 of 5
4 of 5
4 of 5
1 of 5
1 of 5
1 of 5
1 of 5
2 of 5
1 of 5
4 of 5
4 of 5
4 of 5
? of 5
5 of 5
2 of 5
3 of 5
3 of 5
5 of 5
5 of 5
5 of 5
3 of 5
2 of 5
5 of 5
3 of 5
1 of 5
1 of 5
2 of 5
1 of 5
1 of 5
1 of 5
1 of 5
? of 5
5 of 5
4 of 5
? of 5
5 of 5
5 of 5
5 of 5
2 of 5
5 of 5
3 of 5
5 of 5
1 of 5
ITEM
M9
P1
P2
P3
P4
R30
R31
R32
R33
S1
S2
S4
S6
S10
S13
S15
S16
S17
S18
S19
S21
S22
S23
S24
S27
S35
S37
S1A
S1L
S2A
S2L
S3A
S3L
S4A
S4L
S5L
SM2
SM3
SM4
SM5
SM6
Y0
Y1
Y6
Y7
Y8
DESCRIPTION
Fuel Pump
Tachometer
Hour Meter
Fuel Level Gauge
Coolant Temp Gauge
Heating Start
Fuel Level Sender
Coolant Temp Sender
Alternator
ECO Power Button
Boom Unlock Switch
Blower Motor Switch
Starting Switch
Declutch Button
Battery Cut Off Switch
Hand Brake Switch
Brake Oil Level Low Switch
Brake Pressure Switch
Seat Sensor
Coolant High Temp Switch
Air Filter Clogged Switch
Lo Eng Oil Pres Switch
Fuel Gauge
Return to Dig Sensor
Converter Hi Temp Switch
Rear Door Switch
4WD Switch
Rear Work Light Switch
Front Wiper/Washer Switch
Rear Wiper/Washer Switch
Front Work Light
Rotary Beacon Switch
Warning Switch
Horn Switch
Optional Switch
Power Button
MPB Grab Button
Converter Declutch Button
MPB Open Button
Differential Lock Button
Fuel Shutoff Solenoid Valve
Eco Power Solenoid Valve
Return to Dig Magnet
Forward Solenoid
Reverse Solenoid
SHEET
5 of 5
2 of 5
2 of 5
2 of 5
2 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
4 of 5
3 of 5
2 of 5
5 of 5
5 of 5
3 of 5
1 of 5
1 of 5
1 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
3 of 5
? of 5
3 of 5
1 of 5
3 of 5
1 of 5
3 of 5
1 of 5
3 of 5
1 of 5
3 of 5
3 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
3 of 5
? of 5
? of 5
ITEM
Y9
Y10
Y11
Y12
Y13
C1
XC1
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X10A
X11
X12
X16
X17
X18
X19
X20
X21
X22
X23
X24
X25
X26
X27
X28
X29
X30
X31
X32
X33
X34
X35
X39
X40
X43
X45
X46
X47
DESCRIPTION
SHEET
3rd Speed Solenoid
? of 5
1st Speed Solenoid
? of 5
2ndSpeed Solenoid
? of 5
4th Speed Solenoid
? of 5
4WD Solenoid
? of 5
A/C Magnetic Clutch
5 of 5
Lighter Socket
3 of 5
Engine Harness, 11 Pin
2 of 5
Lights and Gear Shift, 9 Pin 1 of 5
Front Line, 11 Pin
1 of 5
4WD Monitor, 11 Pin
? of 5
Cab Controls, 11 Pin
3 of 5
Trans Solenoids, 9 Pin
1 of 5
Not Used, 9 Pin
3 of 5
Side Dashboard, 17 Pins
2 of 5
Front Dashboard, 17 Pins
1 of 5
To Engine Harness, 13 Pin
4 of 5
Trans Interface, 4 Pin
? of 5
2 Way Power, 2 Pin
4 of 5
Front Cross Over, 2 Pin
4 of 5
AC Clutch, 2 Pin
5 of 5
Side Dashboard, 21 Pin
2 of 5
Front Cable, 5 Pin
2 of 5
Front Dashboard, 9 Pin
2 of 5
Blower Motor
3 of 5
Fuel Level Indicator, 3 Pin
5 of 5
Washer Pump, 2 Pin
2 of 5
Optional, 2 Pin
1 of 5
Front Wiper, 4 Pin
1 of 5
Blower Motor, 2 Pin
3 of 5
Rear Line, 8 Pin
4 of 5
Valve Lines, 6 Pin
5 of 5
Loader Lever, 12 Pin
5 of 5
Declutch Button, 2 Pin
5 of 5
Transfer Fuel Pump, 2 Pin
5 of 5
Cab, 5 Pin
4 of 5
Radio, 2 Pin
3 of 5
Wiper and Beacon, 7 Pin
3 of 5
Right Front Light, 6 Pin
2 of 5
Left Front Light, 6 Pin
1 of 5
Proximity, 3 Pin
3 of 5
Flasher Unit, 13 Pin
1 of 5
Power Relay, 7 Pin
3 of 5
Power ECO Unit, 5 Pin
5 of 5
Rear Wiper, 4 Pin
5 of 5
Beacon Light, 2 Pin
4 of 5
ITEM
X53
X59
X60
X63
X65
X66
X67
X69
X70
XA
XAM
XD1
XD2
XD3
XD4
XM9
XS
XT1
XT2
XK12
XK13
DESCRIPTION
SHEET
AC Interface, 1 Pin
3 of 5
Front Line Cross, 6 Pin
4 of 5
Optional, 1 Pin
1 of 5
Alternator Resistance, 2 Pin 5 of 5
Optional light
? of 5
Optional light
? of 5
Seat Sensor, 3 Pin
5 of 5
Trans Diode
? of 5
Trans Gear Unit
? of 5
Alternator, 2 Pin
5 of 5
Fuel Shutoff Valve, 3 Pin
5 of 5
Light Switch, 9 Pin
1 of 5
Gear Shift, 5 Pin
1 of 5
Light Switch, 12 Pin
? of 5
Gear Shift, 8 Pin
? of 5
Fuel Pump, 2 Pin
5 of 5
Instrument Panel, 6 Pin
2 of 5
Fuel Shutoff Timer, 4 Pin
5 of 5
Preheat Timer, 4 Pin
5 of 5
Seat Unit, 6 Pin
5 of 5
Stop Light Diff Lock, 6 Pin
4 of 5
90-33 1
OTHERS
ELECTRICAL CIRCUIT
12
CANOPY
90-35 1
OTHERS
ELECTRICAL CIRCUIT
12
CANOPY
90-37 1
OTHERS
ELECTRICAL CIRCUIT
12
CANOPY
90-39 1
OTHERS
ELECTRICAL CIRCUIT
12
CANOPY
90-41 1
OTHERS
ELECTRICAL CIRCUIT
12
CANOPY
90-43 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR CANOPY WIRING SCHEMATIC
ITEM
EV1
EV2
EV3
EV4
F1A
F1B
F1C
F2A
F2B
F2C
F3A
F3B
F3C
F4A
F4B
F4C
F5A
F5B
F5C
F6A
F6B
F6C
F7A
F7B
F7C
FUG1
FUG2
FUG3
FUG4
G1
G2
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
DESCRIPTION
MP Bucket Open Solenoid
MP Bucket Close Solenoid
Diff Lock Solenoid
Boom Lock Solenoid
Low Beam Fuse, 15A
Right Light Fuse, 3A
Left Light Fuse, 3A
Fuse, 10A Not Used
Canopy Fuse, 15A
Hazard Fuse, 10A
Stp Seat DL Fuse, 7.5A
Instr. Warn RTD, 10A
MPB Declutch Fuse, 7.5A
4WD Fuse, 7.5A
F/R BUA Fuse, 10A
High Beam Fuse, 15A
Fuse, 10A Not Used
Rear Work Light, 15A
Front Work Light, 15A
Rear Wiper Front Horn, 15A
Light Sel Horn Relay, 7.5A
Direction Lights, 10A
Fuse, 7.5A Not Used
Front Horn Fuse, 10A
Fuel Shut Off Fuse, 7.5 A
Key Switch Fuse, 60A
Preheat Switch Fuse, 80A
FSO Power Fuse, 40A
Fuse, 40A Not Used
Battery
Alternator
Preheat Warn Light
Alternator Warn Light
Coolant Warn Light
Eng Oil Pressure Warn Light
Air Filter Warn Light
Hyd Oil Filter Warn Light
Opt Warn Light
Opt Warn Light
Coolant Warn Light
Converter Temp Warn Light
4WD Warn Light
Low Fuel Warn Light
Komatsu Logo Light
Komatsu Logo Light
Lighter Light
SHEET
5 of 5
5 of 5
5 of 5
5 of 5
1 of 5
2 of 5
2 of 5
2 of 5
3 of 5
2 of 5
2 of 5
2 of 5
1 of 5
2 of 5
1 of 5
1 of 5
3 of 5
3 of 5
2 of 5
3 of 5
1 of 5
2 of 5
1 of 5
1 of 5
2 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
2 of 5
1 of 5
1 of 5
1 of 5
1 of 5
1 of 5
1 of 5
3 of 5
ITEM
H17
H18
H19
H20
H21
H22
H23
H24
H25
H28
H29
H36
H37
H38
HA1
HA2
HA3
HA4
K01
K02
K03
K05
K06
K1
K2
K3
K4
K5
K6
K7
K8
K9
K12
K13
KT1
KT2
M1
M5
M9
P1
P2
P3
P4
R30
R31
R32
DESCRIPTION
Front Work Light
Front Work Light
Beacon Light
Rear Work Light
Rear Work Light
Indicators Warn Light
High Beam Warn Light
Brake Oil Warn Light
Diff Lock Warn Light
Right Front Light
Left Front Light
Rear Left Side Lights
Rear Right Side Lights
Courtesy Light
Horn
Buzzer
Fuel Shut Off Relay
Back Up Alarm
Starter Relay
Preheat Relay
Fuel Shut Off Relay
Return to Dig Relay
Power ECO Unit
Forward Direction Relay
Reverse Direction Relay
4WD Relay
Neutral Position Relay
Low Beam Relay
Main Beam Relay
Gear Relay
Front Horn Relay
Flasher Unit
Seat Unit
Stop Light, Diff Lock Unit
Fuel Shut Off Timer
Preheater Timer
Starter Motor
Transfer Fuel Pump
Fuel Pump
Tachometer
Hour Meter
Fuel Level Gauge
Coolant Temp Gauge
Heating Start
Fuel Level Sender
Coolant Temp Sender
SHEET
4 of 5
4 of 5
4 of 5
4 of 5
4 of 5
1 of 5
1 of 5
1 of 5
1 of 5
2 of 5
1 of 5
4 of 5
4 of 5
4 of 5
5 of 5
2 of 5
3 of 5
3 of 5
5 of 5
5 of 5
5 of 5
2 of 5
5 of 5
1 of 5
1 of 5
1 of 5
2 of 5
1 of 5
1 of 5
1 of 5
1 of 5
1 of 5
5 of 5
4 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
2 of 5
2 of 5
2 of 5
2 of 5
5 of 5
5 of 5
5 of 5
ITEM
R33
S1
S2
S6
S10
S13
S15
S16
S17
S18
S19
S21
S22
S23
S24
S26
S27
S1A
S1L
S3A
S3L
S4A
S4L
S5L
SM2
SM3
SM4
SM5
SM6
Y0
Y1
Y2
Y4
Y5
Y6
XC1
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
DESCRIPTION
Alternator
ECO Power Button
Boom Unlock Switch
Starting Switch
Declutch Button
Battery Cut Off Switch
Hand Brake Switch
Brake Oil Level Low Switch
Seat Sensor
Coolant High Temp Switch
Lo Eng Oil Pres Switch
Fuel Gauge
Trans Oil Temp Switch
4WD Switch
Rear Work Light Switch
Front Work Light
Rotary Beacon Switch
Warning Switch
Horn Switch
Optional Switch
Power Button
MPB Grab Button
Converter Declutch Button
MPB Open Button
Differential Lock Button
Fuel Shutoff Solenoid Valve
Eco Power Solenoid Valve
4WD Solenoid
Forward Solenoid
Reverse Solenoid
Return to Dig Magnet
Lighter Socket
Engine Harness, 11 Pin
Lights and Gear Shift, 9 Pin
Front Line, 11 Pin
Not Used, 11 Pin
Canopy Controls, 11 Pin
Trans Solenoids, 9 Pin
Not Used, 9 Pin
Side Dashboard, 17 Pins
Front Dashboard, 17 Pins
To Engine Harness, 13 Pin
SHEET
5 of 5
5 of 5
4 of 5
2 of 5
5 of 5
5 of 5
3 of 5
1 of 5
1 of 5
1 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
3 of 5
3 of 5
1 of 5
3 of 5
1 of 5
3 of 5
1 of 5
3 of 5
3 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
5 of 5
1 of 5
1 of 5
1 of 5
3 of 5
3 of 5
2 of 5
1 of 5
1 of 5
1 of 5
3 of 5
1 of 5
3 of 5
2 of 5
1 of 5
4 of 5
ITEM
X11
X12
X17
X18
X19
X21
X23
X26
X27
X28
X29
X30
X31
X33
X34
X35
X38
X39
X40
X41
X43
X45
X47
X59
X60
X63
X65
X66
X67
XA
XAM
XD1
XD2
XM9
XS
XT1
XT2
XK12
XK13
DESCRIPTION
2 Way Power, 2 Pin
Front Cross Over, 2 Pin
Side Dashboard, 21 Pin
Front Cable, 5 Pin
Front Dashboard, 9 Pin
Fuel Level Indicator, 3 Pin
Optional, 2 Pin
Rear Line, 8 Pin
Valve Lines, 6 Pin
Loader Lever, 12 Pin
Declutch Button, 2 Pin
Transfer Fuel Pump, 2 Pin
Canopy, 5 Pin
Beacon, 7 Pin
Right Front Light, 6 Pin
Left Front Light, 6 Pin
F and R Solenoids, 4 Pin
Proximity, 3 Pin
Flasher Unit, 13 Pin
4WD Solenoid, 2 Pins
Power Relay, 7 Pin
Power ECO Unit, 5 Pin
Beacon Light, 2 Pin
Front Line Cross, 6 Pin
Optional, 1 Pin
Alternator Resistance, 2 Pin
Optional Light, 1 Pin
Optional Light, 1 Pin
Seat Sensor, 3 Pin
Alternator, 2 Pin
Fuel Shutoff Valve, 3 Pin
Light Switch, 9 Pin
Gear Shift, 5 Pin
Fuel Pump, 2 Pin
Instrument Panel, 6 Pin
Fuel Shutoff Timer, 4 Pin
Preheat Timer, 4 Pin
Seat Unit, 6 Pin
Stop Light Diff Lock, 6 Pin
SHEET
4 of 5
4 of 5
2 of 5
2 of 5
2 of 5
5 of 5
1 of 5
4 of 5
5 of 5
5 of 5
5 of 5
5 of 5
4 of 5
3 of 5
2 of 5
1 of 5
1 of 5
3 of 5
1 of 5
1 of 5
3 of 5
5 of 5
4 of 5
4 of 5
1 of 5
5 of 5
2 of 5
3 of 5
5 of 5
5 of 5
5 of 5
1 of 5
1 of 5
5 of 5
2 of 5
5 of 5
5 of 5
5 of 5
4 of 5
90-45 1
OTHERS
ELECTRICAL CIRCUIT
12
TIER
I ENGINE HARNESS
90-47 1
OTHERS
ELECTRICAL CIRCUIT
12
TIER
II ENGINE HARNESS
90-49 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR TIER I AND II ENGINE HARNESS
TIER I ENGINE
No. Connector
Description
To Front Line
A X10
b
c
d
e
f
g
h
i
j
1)
1!
1@
1#
1$
1%
1^
1&
1*
1(
2)
2!
2@
2#
2$
2%
2^
2&
2*
2(
3)
3!
3@
3#
3$
3%
3^
3&
3*
3(
4(
X13
To Front Line
XAD
Coolant Temperature with Diode

Ground
X11
+30 +50
Ground
Ground
Ground
S23
Oil Temperature
XAM
Fuel Shut Off
+30
Starter Motor
+50
Starter Motor
RPM (Tachometer) Indicator
XA
Alternator
B+
S21
Coolant Temperature
S22
S22
R32
Coolant Temperature
X16
AC Magnetic Clutch
HA1
Horn
HA1
Horn
R30
Preheat Grid Block
K02
Preheat Relay
K02
Preheat Relay
K02
Preheat Relay
XT2
Preheat Timer Excitation
XT1
Fuel Shut Off Timer

80A Fuse
30A Fuse
60A Fuse
30A Fuse
Fuse Ground
Matcher
12V 70A Relay
Timer
Timer
Relay
Control Box
K03
Fuel Shut Off Relay
K01
Starting Relay
TIER II ENGINE
No. Connector
Description
Fuel Shut Off Relay
A K03
b
c
d
e
f
g
h
i
j
1)
1!
1@
1#
1$
1%
1^
1&
1*
1(
2)
2!
2@
2#
2$
2%
2^
2&
2*
2(
3)
3!
3@
3#
3$
3%
3^
3&
3*
3(
X61
Safety Relays
X10
To Front Line
X02
X63
X11
+30 +50
Ground
Ground
Ground
S23
Oil Temperature
XAM
Fuel Shut Off
M9
Fuel Pump
+50 +50
+30 +30
+30 +30
Tachometer
XA
Alternator
S21
Coolant Temperature
S22
R32
Coolant Temperature
X16
AC Magnetic Clutch
HA1
Horn
R30
Preheat Grid Block
GND2
Ground
KT2
Preheat Relay
X64
Preheat Start Relay
XT2
Preheat Timer Excitation
XT1
Fuel Shut Off Timer

80A Fuse
40A Fuse
60A Fuse
30A Fuse
Fuse Ground
Matcher
12V 70A Relay
Timer
Timer
Relay
Control Box
Power ZZBox
90-51 1
OTHERS
ELECTRICAL CIRCUIT
12
FRONT
HARNESS
90-53 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR FRONT HARNESS
TIER I ENGINE
No. Connector
Description
Power Box
A X18
B
C
D
E
F
G
H
I
J
1)
1!
1@
1#
1$
1%
1^
X12
Power +30 +50
X59
To Platform Cable
X23
Optional
X35
Front Left Light
X10
To Engine Harness
X11
Power +30 +50
GND
Ground
S18
Stop Light Switch
S17
Stop Light Switch
S16
Brake Oil Level Switch
X22
Washer Pump
X34
Front Right Light
X1
Electronic Board
X3
Electronic Board
X60
Optional
+30
Electronic Board
90-55 1
OTHERS
ELECTRICAL CIRCUIT
12
LATERAL
HARNESS AND SIDE DASHBOARD
TIER I ENGINE (1 OF 2)
90-57 1
OTHERS
ELECTRICAL CIRCUIT
12
TIER
I ENGINE (2 OF 2)
\
90-59 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR TIER I ENGINE
No. Connector Description

To Front Dash Board
A X19
b
c
d
e
f
g
h
i
j
1)
1!
1@
1#
1$
1%
1^
1&
1*
1(
2)
2!
2@
2#
2$
2%
2^
2&
2*
2(
3)
3!
3@
3#
3$
3%
3^
3&
3*
3(
4)
+15
Electronic Board
X8
Electronic Board
X5
Electronic Board
X27
Solenoid Valves
X28
Loader Control Lever
X39
Return Sender
Return Valve
Ground
X25
Electric Bridge
K04
Heater Motor Relay
K05
Return Relay
K06
Power EC Relay
S4
Heater
X31
Cab/Canopy
AC Kit
X17
Side Dash Board
X15
Starting Switch
S3
Not Used
S2
Relay Valve Switch
S1
Economy Power Button
X32
Radio
X26
Rear Light Cable
TIER I ENGINE
Connectors
4!
4@
4#
4$
4%
4^
4&
4*
4(
5)
5!
5@
5#
5$
5%
5^
5&
5*
5(
6)
Battery Warning Light

Preheat Warning Light
Engine Oil Pressure Warning Light
Engine Air Filter Warning Light
Tachometer/Hour Meter
Fuel Level Gauge
Engine Coolant Temperature Gauge
Buzzer
Optional Warning Light
Engine Coolant Temp Warning Light
Hydraulic Oil Filter Warning Light
Starting Switch
S3
Beacon Lamp Switch

Connectors
S2
Optional Switch
Connectors
S1
Work Light Switch

Connectors
To Platform Cable
Lighter
Parking Brake Switch

Rear Horn
Not Used
Back Up Alarm
X20
Heater Motor
X29
Converter Detach - 2nd Button

Economy Power with Diode
X30
Fuel Pump
X21
Fuel Float
X12
To Front Cable
X14
To Front Cable
X43
Wiring Gear Switch

To Platform Cable
Wiper Switch
Optional Switch
Connectors
Rear Horn Switch
90-61 1
OTHERS
ELECTRICAL CIRCUIT
12
TIER
II ENGINE (1 OF 2)
90-63 1
OTHERS
ELECTRICAL CIRCUIT
12
TIER
II ENGINE (2 OF 2)
90-65 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR TIER II ENGINE

To Front Dash Board
A X19
b
c
d
e
f
g
h
i
j
1)
1!
1@
1#
1$
1%
1^
1&
1*
1(
2)
2!
2@
2#
2$
2%
2^
2&
2*
2(
3)
3!
3@
3#
3$
3%
3^
3&
3*
X5
Electronic Board
X8
Electronic Board
X27
Solenoid Valves
X28
Loader Control Lever
X39
Y6
RTD Valve
Ground
X25
Electronic Bridge
K04
3 Speed Fan Relay - AC
K05
RTD Relay
KC
Load Fan Relay
K12
Seat Relay
K06
Power Economy Unit
K13
Relay
S4
Heater
X53
AC Kit
X31
Cab/Canopy
X17
Side Dash Board
S6
Starting Switch
S3
Not Used
S2
Boom Unlock Switch
S1
Economy Power Switch
XC1
Lighter
X32
Radio
X26
Rear Work Light
X67
Not Used
S15
Parking Brake Switch
HA3
Rear Horn
Y3
Not Used
HA4
Back Up Alarm
X20
Heater Motor
X29
Converter Detach - 2nd Button
Y1
Economy Power
X30
Fuel Pump
X21
Fuel Float
X43
To 4th Gear Relay
X12
Power Supply
X59
Front Wiring Interface
TIER II ENGINE
+15 Electronic Board
3( X15
4)
4!
4@
4#
4$
4%
4^
4&
4*
4(
5)
5!
5@
5#
5$
5%
5^
5&
5*
5(
X17
To Platform Harness
Light
S3L
Beacon Light Switch
S2L
Front Wiper Switch
S1L
Work Light Switch
HA
Lamp
Lamp
Lamp
Fuel Gauge
Battery Warning Light
Preheater Warning Light
Light
Engine Air Filter Warning Light
Engine Oil Pressure Warning Light
S4L
Switch
S5L
Switch
+15
X33
Cab/Canopy
X65
Rear Work Light
X66
Rear Work Light
90-67 1
OTHERS
ELECTRICAL CIRCUIT
12
PPC
FRAME AND SIDE DASH BOARD HARNESS
FRAME HARNESS
90-69 1
OTHERS
ELECTRICAL CIRCUIT
12
SIDE
DASH BOARD HARNESS
90-71 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR PPC FRAME AND SIDE DASH BOARD HARNESS
To Cab/Canopy Wiring
A X55
b
c
d
e
f
g
h
i
j
1)
1!
1@
1#
1$
1%
1^
1&
1*
1(
2)
2!
2@
2#
2$
2%
2^
2&
2*
2(
3)
3!
3@
3#
Y25
Arm Block Solenoid Valve
GND
Ground
Y14
PPC Solenoid Valve
Y15
Left Outrigger Down Solenoid Valve
Y16
Right Outrigger Up Solenoid Valve
Y22
Telescopic Extend
Y21
Telescopic Retract
Y20
Hammer Solenoid Valve
S43
Hammer Foot Switch
Y18
Left Turn Solenoid Valve
Y17
Right Turn Solenoid Valve
X57
Left Lever
HA3
Horn
HA4
Horn
Y19
Not Used
X58
Right Lever
Y23
Right Outrigger Down Solenoid Valve
Y24
Left Outrigger Up Solenoid Valve
X55
From Platform Harness
X1
Seat Swivel Switch
X3
Backhoe Lock Out Switch
X2
Boom Lock Switch
X42c
Power Right Outrigger Switch
X42b
Up Right Outrigger Switch
X42a
Down Right Outrigger Switch
X41c
Power Left Outrigger Switch
X41b
Up Left Outrigger Switch
X41a
Down Left Outrigger Switch
X40
Power Economy Switch
X10
Telephone Exchange Relay
X11
Relay
X9
15A Fuse
X4
Power from Key Switch
90-73 1
OTHERS
ELECTRICAL CIRCUIT
12
WORK
LIGHT HARNESS
Ground
A
B
C
D
E
F
G
H
Front Work Light

Front Work Light
Rear Work Light
Rear Work Light
Rear Relay
Front Relay
25A Fuse
90-75 1
OTHERS
ELECTRICAL CIRCUIT
12
TRANSMISSION
HARNESS
90-77 1
OTHERS
ELECTRICAL CIRCUIT
12
LEGEND
FOR TRANSMISSION HARNESS
Gear Control
A X24
b
c
d
e
f
g
h
i
j
1)
1!
1@
1#
1$
1%
X7
Fuse Box
C23
1st Speed Solenoid Valve
C25
3rd Speed Solenoid Valve
C22
Forward Gear Solenoid Valve
C21
Reverse Gear Solenoid Valve
C26
4th Speed Solenoid Valve
C27
4WD Solenoid Valve
C24
2nd Speed Solenoid Valve
GND
Ground
C16
Converter Oil Temperature Sensor
XC
Transmission Diode
X10
Fuse Box Interface
XA
Shfiter Switch
XZ
Light Column Switch
XD1
To Old Light Column Switch
90-79 1
OTHERS
ELECTRICAL CIRCUIT
12
FUSE
AND RELAY PANEL
LEGEND FOR FUSE AND RELAY PANEL

Position
F1 A
F1 B
F1 C
F2 A
F2 B
F2 C
F3 A
F3 B
F3 C
F4 A
F4 B
F4 C
F5 A
F5 B
F5 C
F6 A
F6 B
F6 C
F7 A
F7 B
F7 C
K3
K4
K5
K6
K7
K8
K9
K10
TIER I ENGINE
Description
15A Light Blue for Low Beam
3A Violet for Parking Lights
3A Violet for Parking Lights
10A Red for Lighter
7.5A Brown for Dome Light Radio
10A Red for Emergency Power Supply
7.5A Brown for Start Enable
7.5A Brown for Instruments Switch Lights
7.5A Brown for OPT Solenoid
7.5A Brown for Diff Lock Solenoid Valve
10A Red for Direction Selector
15A Light Blue for High Beam
15A Light Blue for Heater
15A Light Blue for Rear Work Light
15A Light Blue for Front Work Light
15A Light Blue for Wiper and Beacon
7.5A Brown for Dimmer Switch Horn Relay
10A Red for Directional Indicators
7.5A Brown for Monitor
10A Red for Horn
7.5A Brown for Alt Excitation Stop Solenoid
Four Wheel Drive Relay

Start Relay
Low Beam Relay
High Beam Relay
Transmission Power Supply Relay
Horn Relay
Turn Indicator Relay
Flasher Relay
Position
F1 A
F1 B
F1 C
F2 A
F2 B
F2 C
F3 A
F3 B
F3 C
F4 A
F4 B
F4 C
F5 A
F5 B
F5 C
F6 A
F6 B
F6 C
F7 A
F7 B
F7 C
K3
K4
K5
K6
K7
K8
K9
TIER II ENGINE
Description
15A Light Blue for Low Beam
3A Violet for Right Parking Lights
3A Violet for Left Parking Lights
10A Red Trans Power Supply
15A Light Blue for Cab Features
10A Red for Emergency Power Supply
7.5A Brown for Stop Lights Differential Lock
7.5A Brown for Instruments Lights RTD
7.5A Brown for Opt Solenoid Trans Disengage
7.5A Brown for 4WD Front Wiper
10A Red for Direction Selector
15A Light Blue for High Beam
10A Red for Heater Motor Power Econ Unit
15A Light Blue for Rear Work Light
15A Light Blue for Front Work Light
15A Light Blue for Rear Horn Rear Wiper
7.5A Brown for Dimmer Switch Horn Relay
10A Red for Directional Indicators
7.5A Brown
10A Red for Front Horn
7.5A Brown for Engine Stop Solenoid
Four Wheel Drive Relay

Start Relay
Low Beam Relay
High Beam Relay
Transmission Power Supply Relay
Front Horn Relay
Turn Indicator Relay
90-81 1

Wb140ps-2n Serie A40034 Up (Ing)

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Wb140ps-2n Serie A40034 Up (Ing)

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CEBM012801

WB140PS-2N A40034 and up

Copyright 2010 Komatsu

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

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

The affected pages are indicated by using the following

New page to be added

IMPORTANT SAFETY NOTICE

Mistakes in operation are extremely dangerous. Read the

Always wear safety glasses when hitting parts with a

Always wear safety glasses when grinding parts with a

If welding repairs are needed, always have a trained,

PREPARATIONS FOR WORK

When disassembling or assembling, support the

PRECAUTIONS DURING WORK

Before adding oil or making repairs, park the machine

When installing hoses and wires, be sure that they will

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

Shop manuals are issued as a guide to carrying out repairs.

DISTRIBUTION AND UPDATING

So that the shop manual can be of ample practical use,

Special safety precautions are

Special technical precautions or

Weight of parts or systems. Caution necessary when selecting

Places that require special attention for tightening torque during

Places to be coated with adhesives and lubricants etc.

Places where oil, water or fuel

Places where oil or water must

Any additions, amendments or other changes will be sent to

REVISED EDITION MARK

When a manual is revised, an edition mark (bcd) is

Revised pages are shown at the LIST OF REVISED PAGES

can result. Hooks have maximum strength at the middle

WARNING! Heavy parts (25 kg or

If a part cannot be smoothly removed from the machine

WARNING! Slinging with one rope may

Use adequate ropes depending on the weight of parts to

Do not sling a heavy load with ropes forming a wide

The allowable load value is estimated to be 1/6 or 1/7 of

QUICK DISCONNECT COUPLER

QUICK DISCONNECT COUPLER

WARNING! Before carrying out the following work,

WARNING! Even if the residual pressure is released

QUICK DISCONNECT COUPLER

QUICK DISCONNECT COUPLER

Main applications, features

Used to prevent rubber gaskets, rubber

Used in places requiring an immediately

Used as adhesive or sealant for metal, glass

Used as sealant for machined holes.

Used as heat-resisting sealant for repairing

Quick hardening type adhesive.

Features: Resistance to heat, chemicals

Features: Resistance to heat

Quick hardening type adhesive.

Features: Resistance to heat, chemicals

Main applications, features

400 g (10 per

Features: Resistance to water, oil

Used as heat-resisting sealant for repairing

Used as lubricant for sliding parts (to prevent squeaking).