WEBMPW9500

SHOP MANUAL

PW95-1
HYDRAULIC EXCAVATOR
SERIAL NUMBER
0000007 and up
 CONTENTS

No. of page

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

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

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

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

00-1
00-2
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to table
below.
C Page to be newly Add

c Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

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

00-1 10-26 20-1 20-41 20-81

00-2 10-27 20-2 20-42 20-82
00-2-1 10-28 20-3 20-43 20-83
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 Time of Time of Time of Time of Time of
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30-46 30-102 30-158

00-2-2
 IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by FKI and describe in this manual are both effective
and safe methods of operation. Some of these operations require the use of tools specially designed by
FKI for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this man-
ual. The cautions accompanying these symbols should always be carefully followed. If any danger arises
or may possibly arise, first consider safety, and take necessary steps to face.

SAFETY
GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions written on the decals which
are suck on 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.
4. 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.
5. Keep all tools in good condition and learn the cor-
rect way to use them.
6. 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.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chine on hard, level ground, and block the wheels
to prevent the machine from moving.
8. Before starting work, lower ourigger, bucket or
any other work equipment to the ground. If this
is not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
to lock all the control levers and hang warning
sign on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before start-
ing work.
10. 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
11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
cuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.

00-3
13. Before starting work, remove the leads from the 24. Take sure when removing or installing tracks of in
battery. Always remove the lead from the negative particular rubber tracks. When removing the
( ± ) terminal first. track, the track separates suddenly, so never let
anyone stand at either end of the wheel.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
. When installing hoses and wires, be sure that
they will not be damaged by conctat with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.

00-4
 FOREWORD

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-
curate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into
the following sections.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, dissassembling or assembling
each component, as well as precautions to be taken for these operations.

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

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your FKI distributor for the latest information.

00-5
HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out re- In order to make the shop manual greatly chelpful,
pairs. These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.

Symbol Item Remarks

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

Example Weight of parts or systems.

10 - 3 Caution necessary when selecting
Weight hoisting wire, or when working
posture is important, etc.
Numero dell'articolo (10. Struttura e
funzionamento) Parts that require special attention
Tightening for the tightening torque during as-
torque
Numero di pagina progressivo per sembly.
ogni articolo
Parts to be coated with adhesives
Coat and lubricants etc.
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num- Places where oil, water or fuel
Oil, water must be added, and their quantity.
ber.
Fle as in the example.
Places where oil or water must be
Example:
Drain drained, and quantity to be
10-4
drained.
10-4-1
10-4-2
] Added pages
10-5

REVISED EDITION MARK

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

REVISIONS
Revised pages are shown on the LIST OF RE-
VISED PAGES between the title page and SAFETY
page.

00-6
HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

ing, and a serious accident can result.

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

1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
. Check for removal of all bolts fastening the part
to the relative parts.
. Check for any part causing interference with
the part to be removed.
2. Wire ropes
1) Use adequate ropes depending on the weight
of parts to be hoisted, referring to the table be-
low:
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
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
cause dangerous accidents.

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

The allowable load value is estimated to be

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

2) Sling wire ropes from the middle portion of the

hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during hoist-

00-7
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

The following charts give the stardard tightening torques of bolts and nuts. Exceptions are given in sections of «Dis-
assembly and Assembly».

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

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

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

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

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

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

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

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

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

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

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

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

27 3 41 19 96w10 945w100 135w15 1329w140

30 3.5 46 22 131w14 1287w140 184w20 1810w190

33 3.5 50 24 177w20 1740w200 250w27 2455w270

36 4 55 27 230w25 2250w250 320w35 3150w350

39 4 60 Ð 295w33 2900w330 410w45 4050w450

This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
. Nm (Newton meter): 1 Nm = 0.102 kgm

00-8
STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

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

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

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

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

Nomenclature Code Applications

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-mettalic parts when a fast, strong
ASL800020 seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270 bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573 dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601 only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675 and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
ASL800060 tings in hydraulic circuits of less than 50 mm in diameter.
Gasket sealant
Used by itself on mounting suface on the final drive and transmission cases.
ASL800070 (Thickness after tightening :0.07-0.08 mm).
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent stick-
(Lubricant inclunding ASL800040 ing, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
(Lithium grease) ASL800050 facilitation of assembling work.
Vaseline ± Used for protecting battery electrode terminals from corrosion.

00-9
ELECTRIC WIRE CODE

ELECTRIC ELECTRIC WIRE CODE

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: R -N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
Number ù of strands Cross section Applcable circuit
number (mm) (A)
strands (mm) (mm2)
0.35 11 0.20 0.35 1.55 3.5 Proximity sensor
0.5 16 0.20 0.50 2.40 6 Instrument
0.8 11 0.30 0.78 2.80 8 Instrument - transmitter
1 14 0.30 0.99 2.80 11 Lighting - signal etc.
1.5 21 0.30 1.48 3.35 14 Working light - solenoid valve etc.
2.5 35 0.30 2.47 3.80 20 Control panel - Ignition switch etc.
4 56 0.30 3.95 4.60 28 Alternator - preheating etc.
6 84 0.30 5.93 5.20 37 Starter motor fuses
50 399 0.40 50.11 14 160 Ground - starter motor

CLASSIFICATION BY COLOUR AND CODE

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

COMPOSITION OF THE COLOURS

The coloration of two-colour wires is indicated by the composition of the symbols listed.
Example: G-V = Yellow-Green with longitudinal colouring.
G/V = Yellow-Green with transversal colouring.

00-10
 WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model PW95-1

From serial no. 0000007
Engine assembly 492
Radiator - exchanger 41
Hydraulic tank (without hydraulic oil) 76
Fuel tank (without fuel) 104
Revolving frame 1092
Counter weight 1150
Swing circle 130
Swing machinery assembly 65
Main hydraulic pump 60
Auxiliary pump 16.5
Operator's cab 250
Operator's seat 32
Operator's seat support 9
Platform 55
Control valve 60
Track frame assembly 860
Front axle 403
Rear axle 410
Transmission assembly 72
Wheel assembly 79
Center swivel joint 97
Axle locking cylinder cylinder 30.5
Swing bracket 36
Engine hood (movable) 60
Engine hood (fixed) 83
Control valve hood 16
Boom 358
1st boom 272
nd
2 boom 195
Arm (L=1850) 156
Arm (L=1600) 134
Outrigger 76
Bracket 29
Outrigger support 140
Blade 192

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

SAE 10W
Lubricating oil
SAE 20W-20 11.5 11.5
sump OIL
. API CD-SG SAE 30 1 1
Engine oil filter . MIL-L-2104 E
. CCMC D4-G4 SAE 40

Hydraulic system SAE 10W 148 82

Front axle: 7.8 7.8

. differential
. planetary (each) OIL 0.9 0.9
Rear axle: . UTTO FLUID
7.8 7.8
. differential
. planetary (each) 0.9 0.9
Transmission OIL 1.9 1.9
Swing . API GL5 SAE 80W/90
. MIL-L-2105 D 4 4
machinery

Fuel
tank
DIESEL FUEL * ASTM D975 N. 2
140 ÐÐ

WATER+
20 ÐÐ
ANTI-FREEZE

Cooling system WATER 20 ÐÐ

PERMANENT
20 ÐÐ
LIQUID

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

SAE: Society of Automotive Engineers

API: American Petroleum Institute
MIL: USA Military Specification
CCMC: Common Market Constructors Committe
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

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

00-12
GROUP 10
 STRUCTURE AND FUNCTION

P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 2 Servocontrol feed unit . . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-40

Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 3 R.H. PPC valve . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-42
Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 4 L.H. PPC valve . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-43
Front axle - differential. . . . . . . .. . . . . .. . . . .. . . . . .. . . 10- 6 Accumulators . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-44
Rear axle - differential . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 7 Swing motor braking circuit selector valve.. . . . . 10-45
Planetary.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 8 Travel PPC valve .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-46
Axles . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 9 2nd boom PPC valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-47
Parking brake and cylinder. . .. . . . . .. . . . .. . . . . .. . . 10-10 Boom swing PPC valve . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-48
Steering system . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-12 Outrigger and blade PPC valve .. . . . . .. . . . . .. . . . . 10-49
Steering unit . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-16 Outrigger and blade safety valve . . . . .. . . . . .. . . . . 10-50
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-17 Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-51
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-18 Axle locking valve . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-52
Check valve and oil cooler safety by-pass. . .. . . 10-19 Solenoid valves. . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-53
Hydraulic circuit diagram . . . . .. . . . . .. . . . .. . . . . .. . . 10-20 Electrical circuit diagrams:
Main hydraulic pump . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-21 1 - Starting and engine line . . . . .. . . . . .. . . . . .. . . . . 10-59
Pump drive . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-22 2 - Beams, direction indicator horn and
Summation horsepower control. . . .. . . . .. . . . . .. . . 10-23 fan line . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-61
3 circuit control valve . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-26 3 - Column steering switch, R.H. dashboard
switch, mechanical travel speed change
Mode-System . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-28 relay and rotary and cutting shovel switch
Auxiliary pump . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-29 line .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-63
Priority valve. . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-30 4 - Mode System, relief servocontrol and L.H.
Control valve (valve) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-31 dashboard switch line . .. . . . .. . . . . .. . . . . .. . . . . 10-65
Control valve (ports) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-32 5 - Steering emergency switch steering
Swing motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-34 selection switch and upper slip ring
Swing motor relief valve .. . . . .. . . . . .. . . . .. . . . . .. . . 10-35 collector line . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-67
Center swivel joint .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-36 6 - Track frame solenoid valve and steering
relay box line .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-69
Travel motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-37
7 - Main box and track frame relay box
Displacement automatic control high
disposition . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-71
pressure related . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-38
Travel motor brake valves. . . .. . . . . .. . . . .. . . . . .. . . 10-39

10-1
P.T.O.

2 1 3 4

A
5

6
15

14 7

13 8

12

11
9

10
A Section A - A

D0400002

1. Connecting plate 10. Screw

2. Crown wheel 11. Flywheel
3. Flywheel housing 12. Washer
4. Centering ring 13. Screw
5. Screw 14. Nut
6. Screw 15. Loose piece
7. Screw
8. Hub
9. Pump plate

10-2
POWER TRAIN

REDUCTION RATIO

Transmission Differential Planetary Axle Total

High speed 1.96 26.82
3.22 4.25 13.68
Low speed 6.062 82.92

Front of machine

Z=39 8 Z=29 10

Z=12

Z=13

5
Z=9

7
Z=29
Z=51
6

Z=29
4

Z=49 Z=51 3
Z=25
2
7
1
Z=9

Z=12

Z=13

9 Z=29 Z=39

11

D0400003

1. Engine 7. Propeller shaft

2. Pump 8. Front axle
3. Control valve 9. Rear axle
4. Swivel joint 10. Front wheel
5. Travel motor 11. Rear wheel
6. Transmission

10-3
TRANSMISSION

7 6 9

A A 5

1 3 2 4

a b

Section A - A

D0400004

1. Front coupling a. A port (From EV3 - A2 port)

2. Rear coupling b. B port (From EV3 - A3 port)
3. Oil drain plug
4. Refilling plug
5. Oil level
6. Safety switch
7. Neutral manual control
8. Speed surveyor
9. Vent plug

10-4
 1 2 3 4 5 6 7 8 9 10

11
12
13
14
15
16
17

18
29 28 27 26
19

20

25 24
21
23

22 D0400153

1. Neutral manual control shaft 19. Output shaft

2. Ball 20. Rear coupling
3. Spring 21. Roller bearing
4. Piston (slow drive control) 22. Protection
5. Piston 23. Low speed idle gear
6. Piston (high drive control) 24. Bearing
7. Input gear 25. Front coupling
8. Shifting fork 26. Bearing
9. Shifting (dog) gear 27. Roller bearing
10. Low speed driven gear 28. Flange
11. Gear (coupling internal gear) 29. Coupling
12. Output drive gear
13. Bearing Low speed
14. Input shaft Reduction ratio: 1 : 6.0617
15. Roller bearing High speed
16. Ring gear Reduction ratio: 1 : 1.96
17. Output driven gear
18. Bearing
Amount of oil: 1.9 ,

10-5
 FRONT AXLE - DIFFERENTIAL

10 1

3 12 2 3

4 4

5 5

Front of machine
8 11 9
7 6

19 19
18
14
17 16 15 D0400006

1. Central housing 12. Union brake pump

2. Brake bleading screw 13. Differential bearing
3. Service brake piston 14. Pinion bearing
4. Braking group 15. Coupling
5. Drive shaft 16. Nut
6. Pin 17. Seal ring
7. Drain plug 18. Bevel pinion
8. Differential gear 19. Refilling plug
9 Bevel gear
Amount of oil: 7.8 ,
10. Grease nipple
11. Ring bevel gear

10-6
REAR AXLE - DIFFERENTIAL

1 2 6 3 13 8 9

10 10

11 11

12 4 5 15 14 16

24 7

Front of machine

17

23 18
22
19
D0400007

21 20

1. Adjustment screw 14. Central housing

2. Cylinder fulcrum lever 15. Ring bevel gear
3. Parking brake cylinder 16. Service brake piston
4. Differential brake 17. Pin
5. Bevel gear 18. Pinion bearing
6. Brake bleading screw 19. Seal ring
7. Right lever 20. Nut
8. Adjustment screw 21. Coupling
9. Push rod 22. Bevel pinion
10. Braking group 23. Refilling plug
24. Left lever
11. Drive shaft
12. Drain plug Amount of oil: 7.8 ,
13. Union brake pump

10-7
PLANETARY

22 1 2 3 4 5 6 7 8 9

10

11

12
Section A - A

13

14

15
25 21 20 2 19 18 17 16

A A

23 24
Section B - B

B B D0400008

1. Drive shaft 15. Ring gear

2. Bearing 16. Ring gear support
3. Knuckle pin 17. Screw
4. Seal ring 18. Seal ring
5. Bearing 19. Steering knuckle
6. Wheel hub 20. Bushing
7. Stud bolt 21. Bearing
8. Nut 22. Screw
9. Bearing 23. Nut
10. Planetary carrier 24. Cotter pin
11. Bevel gear 25. Ball-and-socket joint
12. Bevel gear pin Amount of oil: 0.9 ,
13. Pinion
14. Plug

10-8
AXLES

Front of machine
°
28

28°
b 3 a
Front axle

c 3 d
28°

28°
Rear axle

D0400009

1. Adjustment screw
2. Nut
3. Sensor

FRONT AXLE
a. A Port - From EV9-EV10 group (T Port)
b. B Port - From swivel joint (9a Port)

REAR AXLE
c. C Port - From EV9 - EV10 Port (A Port)
d. D Port - From EV9 - EV10 Port (B Port)

10-9
PARKING BRAKE AND CYLINDER

13 3 4 5 6 7 8 9

2
10

14

12
11

15 16

D0400010

1. Screw 12. Bushing

2. Nut 13. Screw
3. Cylinder fulcrum pin 14. Bracket
4. Cylinder 15. Cylinder fulcrum lever
5. Gasket 16. Piston fulcrum lever
6. Spring a. From EV1 - A Port
7. Piston
8. Filter SPECIFICATIONS
9. Piston fulcrum pin . Minimum unlocking pressure: 20 bar
10. Ball joint
. Required oil volume: 47 cm3
11. Scraper ring

10-10
 17 4 10 1 18 19

20
16

D0400011

17. Lever SYSTEM DESCRIPTION

18. Push rod The parking brake is of the «negative» type, e.i. it pro-
19. Push disk vides full mechanical braking in the absence of pres-
20. Brake disks sure in the circuits that make the machine safe to
drive.
b 4 6 7 OPERATION
When the engine is started up the auxiliary pump (P3)
connected to it sends oil to the brake pump and the
servocontrol circuit and pressurizes the system to
B C which the solenoid valve EV2 is connected when the
machine is idle.
15 16 When push-button is pushed EV2 is energized and al-
17 lows oil to flow into chamber b of the cylinder (4); when
A D the pressure exceeds the loading on the spring (6) it is
20 20 compressed and the piston (7) moves, thus lengthen-
ing side B-C of the parallelogram A-B-C-D formed by
the swing centers of the levers (15) and (16), the cylin-
der fulcrum B (4) and the fulcrum C of the lever (16)
connected to the piston (7).
19 18 18 19 The swing of levers (15) and (16), coupled directly to
lever (17), cancels out the action on the push rods
(18) joined to the push disks (19).
The limit of the swing and the distribution of the load
EV2 generated by the pressure in the cylinder (4) are gov-
P3 erned by adjustable screws (1) that act directly on le-
vers (15) and (16).
Servocontrol Brake
When the engine stops, EV2 is de-energized, and re-
feed unit pump
leases pressure in the circuit. As pressure drops the
spring (6) commences the thrusting action that rotates
the levers (15) and (16). The force of the spring is
Engine
transferred to the push rods of the push disks (19)
D0400155 which act on the brake disks (20) on the rear axle.

10-11
STEERING SYSTEM

4 1

3
11
10 T P
a d
5
A 2 (P4) D

12 13
6
B C

(EV9) (EV10)
b 7 c
R L

8 9

D0400013

DESCRIPTION
. The steering system is completely hydraulic. The
oil required, supplied by the pump (2) driven by
the motor (1), is sent to the priority valve (4) which
functions by Load Sensing, and sends the neces-
sary quantity of oil to the steering system (5), even
when other oleodynamic components supplied by
the same circuit are in operation. The oil passes
from this group (5) into the swivel joint (7) and from
there into the steering cylinders (10) and (11).
1. Engine Two solenoid valves (8) and (9) can switch the oil
2. Pump (P4) flow to provide three types of steering:
3. Tank 1 - 2 wheels steering
4 Priority valve Steering condition in which the rear axle is ex-
cluded.
5. Steering unit
6. Steering wheel 2 - 2 wheels steering and 2 wheels countersteer-
ing. Steering condition in which rear steering is
7. Swivel joint
activated and the direction of the rear wheels is
8. Elettrovalvola EV9 esclusione sterzatura ponte contrary to that of the front wheels.
posteriore
3 - 4 wheels steering in the same direction.
9. Elettrovalvola EV10 inversione senso sterzatura
Steering condition in which rear axle steering is
ponte posteriore
activated and the direction of the rear wheels
10. Cilindro di sterzatura ponte anteriore agrees with that of the front wheels.
11. Cilindro di sterzatura ponte posteriore . The hydraulic power supplied by the pump (2) is
12. Pistone cilindro ponte anteriore transferred to cylinders (10) and (11) and trans-
13. Pistone cilindro ponte posteriore formed into mechanical steering power.

10-12
OPERATION
1 - Steering with front wheels only.
(Selector 60 in position 0, EV9 and EV10 DE-ENERGIZED)

b 12 a 10 b 10 12 a

B A B A

h e R T
h e R T

g 5 3 g 5 3
L P L P

f 4 f 4
7 7
6 2 6 2
(P4) (P4)
EV9 EV9

EV10 EV10

D0400014 D0400015

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (6) clockwise causes rota-
tion of the steering metering group (5) and prepares
the control valve (port R) to send oil through line e to
EV9 and thence through line g, into chamber a of
the cylinder (10); the pressurized oil moves the piston
(12) which then steers the wheels.
The oil in chamber b of cylinder (10) is impelled into
line h and thence into line f which is coupled to the
control valve of the steering group (5) (port L); from
the control valve the oil passes out of port T and drains
into the tank (3).
Turning the steering wheel (8) anti-clockwise causes
rotation of the steering metering group (5) and pre-
pares the control valve (port L) to send oil through
lines f and h directly into chamber b of the cylinder
(10); the pressurized oil moves the piston (12) which
then steers the wheels.
The oil in chamber a of cylinder (10) is impelled into
line g of EV9 and thence into line e which is coupled
to the control valve of the steering group (5) (port R);
from the control valve the oil passes out of port T
and drains into the tank (3).

10-13
2 - Steering with 2 wheels steering and 2 wheels countersteering.
(Selector 60 in position 1, EV9 ENERGIZED - EV10 DE-ENERGIZED)

b 12 a 10 b 10 12 a

B A B A

h e R T
h e R T

g 5 3 g 5 3
L P L P

f 4 f 4
7 7
6 2 6 2
(P4) (P4)
EV9 EV9

EV10 EV10

m m
n
n
C D C D

c 13 11 d c 13 11 d
D0400016

D0400017

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (6) clockwise causes rota-
tion of the steering metering group (5) and prepares
the control valve (port R) to send oil (through line e)
to EV9 energized and EV10 de-energized and thence
through line m into chamber d of cylinder (11).
The pressurized oil moves the piston (13) of the cylin-
der (11) that steers the wheels and at the same time
impels the oil in chamber c (at the same pressure as
chamber d), through lines n and g into chamber a of
cylinder (10).
The oil in chamber b of cylinder (10) is impelled
through lines h and f to the control valve of the steer-
ing group (5) (port L), from which it passes (port T) to
drain into the tank (3).
Turning the steering wheel (6) anti-clockwise causes
rotation of the steering metering group (5) and pre-
pares the control valve (port L) to send oil through line
f directly to chamber b of cylinder (10).
The pressurized oil moves the piston (12) of cylinder
(10) which in turn steers the wheels while simulta-
neously impelling the oil in chamber a (at the same
pressure as chamber b), through lines g - n into cham-
ber c of cylinder (11).
The oil in chamber d of cylinder (11) is impelled
through lines m and e to the control valve of the steer-
ing group (port R) from which it passes (port T) to drain
into the tank (3).

10-14
3 - Steering with 4 wheels steering in the same direction.
(Selector 60 in position 2, EV9 and EV10 ENERGIZED)

b 12 a 10 b 10 12 a

B A B A

h e R T h e R T

g 5 3 g 5 3
L P L P

f 4 f 4
7 7
6 2 6 2
(P4) (P4)
EV9 EV9

EV10 EV10
m m
n n

C D C D

c 13 11 d c 13 11 d
D0400019

D0400018

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (6) clockwise causes rota-
tion of the steering metering group (5) and prepares
the control valve (port R) to send oil (through line e)
to EV9 and EV10 (both energized) and thence through
line m into chamber c of cylinder (11).
The pressurized oil moves the piston (13) of the cylin-
der (11) that steers the wheels while simultaneously
impelling the oil in chamber d (at the same pressure
as chamber c) through lines m and g into chamber a
of the cylinder (10).
The oil in chamber b of cylinder (10) is sent through
lines h and f to the control valve of the steering group
(5) (port L) from which the oil passes (port T) to drain
into the tank (3).
Turning the steering wheel (6) anti-clockwise causes
rotation of the steering metering group (5) and pre-
pares the control valve (port L) to send oil through
lines f and h into chamber b of cylinder (10).
The pressurized oil moves the piston (12) of cylinder
(10) which in turn steers the wheels while simulta-
neously impelling the oil in chamber a (at the same
pressure as chamber b) through lines g and m into
chamber d of cylinder (11).
The oil in chamber c of cylinder (11) is impelled
through lines n and e to the control valve of the steer-
ing group (5) (port R) from which it passes (port T) to
drain into the tank (3).

10-15
STEERING UNIT

a e b

D0400020

c d

a. L Port - To swivel joint (9A Port) SPECIFICATIONS

b. R Port - To swivel joint (5A Port) Steering unit type: OSPC200LS
c. T Port - To tank Rated discharge: 20 ,/min
d. P Port - From priority valve (CF Port)
e. LS Port - From priority valve (LS Port)

OPERATION
. The steering unit consists of a control valve and a
rotating oil dispenser and functions hydrostatically.
. When the steering wheel is moved, the control
valve sends oil from pump P4 (through the rotating
oil dispenser) to one or other of the chambers of the
steering cylinder. The rotating oil dispenser en-
sures that the amount of oil supplied to the cylinder
is proportional to the rotation angle of the steering
wheel.
. If the steering unit pump malfunctions the oil dis-
penser functions automatically like a hand-pump
to ensure emergency steering.

10-16
SWING CIRCLE

1 6

3 2 5
5
Section A - A

Detail A
B
A

8
A

Detail B

A
B D0400021

1. Swing circle outer race SPECIFICATIONS

2. Swing circle inner race Reduction ratio: 81
Ð = 7.36
3. Ball bearing 11
4. Pin Amount of grease: 18 kg
5. Screw
6. Screw
7. Nut
8. Grease nipple

10-17
SWING MACHINERY

11 12

10
13

9
a

8
14

7
15
6

16
5

17
4

18
3

19
2

1 D0400022
18

1. Swing pinion (11 teeth) 15. No. 1 planetary gear (31 teeth)
2. Case 16. No. 2 sun gear (18 teeth)
3. No. 2 planetary carrier 17. No. 2 planetary gear (29 teeth)
4. Drive gear (78 teeth) 18. Bearing
5. No. 1 planetary carrier 19. Drain plug
6. Brake disks
7. Piston guide a. C Port - From circuit selector valve (B Port)
8. Piston
9. Refilling and level plug SPECIFICATIONS
10. Spring Reduction ratio: 1 : 33
11. Coupling
Nominal tightening torque: 300 daNm
12. Support
Amount of oil: 4,
13. Breather
14. No. 1 sun gear (15 teeth)

10-18
CHECK VALVE AND OIL COOLER SAFETY BY-PASS

8 A
a

2
7

3
1

b
A B
B
6
Oil cooler

Hydraulic tank
4

5 Control valve

c
C T

D0400023

1. Valve body SPECIFICATIONS

2. Spring centering
. Check valve (4): 2 bar
3. By-pass valve
. By-pass valve (3): 3 bar
4. Check valve
5. Check valve seat
6. Check valve spring
7. By-pass valve spring

a. A Port - To tank
b. B Port - To oil cooler (A Port)
c. C Port - From control valve (T Port) and
swing motor (S Port)

10-19
HYDRAULIC CIRCUIT DIAGRAM
Swing machinery
with hydraulic motor 2-piece boom Boom cylinder Bucket cylinder Boom swing Arm cylinder Travel motor T1
L.H. outrigger R.H. outrigger Theoretical displacement: 33 cc/rev cylinder cylinder Min. displacement: 36 cc/rev
cylinder cylinder Max. displacement: 80 cc/rev
Check valve rated pressure: 350 bar B

350 bar
S
Blade
cylinders
A1
EV6 C T
B1

350 bar
A2

190/160 bar

190/160 bar
A
EV7
B2
C2 C1 C2 C1 C2 C1
C1 V1
A3 B X4 X5 A 12A 12a T
EV8
B3
C2 V2 11A 11a
V2 V1 V2 V1 V2 V1

T P

B9 B6
10a 10A
7a
6a 6A
M3 a10 A10 B10 a9 A9 C M2 a8 A8 B8 a7 A7 B7 a6 A6 C6 a5 A5 B5 C a4 B3 A3 a3 C7 B2 A2 a2 B1 A1 a1 M1
7A

P3

350 bar

350 bar

320 bar

220 bar

320 bar

320 bar

320 bar

320 bar

320 bar

320 bar
280/350 bar

280/350 bar
Priority valve

200 bar
LS

EF
P
b10 b9 P2 x b8 b7 b6 b5 T b4 b3 b2 b1 x1 P1
CF

Servocontrol feed unit

0
LS T P Relief valve: 45 -4,5 bar
0
Reducing valve: 35 -3,5 bar

P3 T BV
EV4

Steering unit
Rated discharge: 20 l/1'
EV5

2A
140 bar 140 bar
P1 P2 PV PR a5 b5 a1 b1
2a 7a 7A Reduction gear box
V=0.35 l

P T T P
A EV12 X4 a10 b10 X5
R L EV1 A B B A
P3
P4 B A
A1
Relief valve EV2 EV11
A3

P T
A4

Engine: Rated pressure: 200 bar a3 b3 a8 b8 a7 b7 a6 b6 a2 a4 b2 a9 b9

9A 5A Perkins 1004.4 A2 B
EV3
M3 X2 X3 R1 C
A3 C A
S1 A2
9a 5a 2 bar
DIESEL 1 2 2 1 3 1 4 2 A 1 3 4 2 1 2
T P 3 bar
EV9
P2 A B
A
EV10 B
A B P T P T P T P T P T P T
Boom Bucket Arm Swing
P1
A B C D A1
Boom swing 2nd boom R.H. PPC valve Travel PPC valve L.H. PPC valve Outrigger and blade
S PPC valve PPC valve PPC valve
Front axle Rear axle G R2
Main hydraulic pump
Max. discharge: 2x74 l/1'
V=0.7 l

V=0.7 l

Max. unitary displacement: 28 cc/rev

F R1 R2

T'2 PN RV
3A 3a
P T2 Front axle B A

B L
T'1
EV13
Rear axle
T1 1A 1a

Brake pump R.H. axle locking L.H. axle locking

Feed pressure: 65480 bar cylinder cylinder

Parking brake
cylinder

10-20
MAIN HYDRAULIC PUMP

b
b c
4

a d
e 5
D0400024

1. Drive SPECIFICATIONS
2. Pump case Max. unitary displacement: 28 cc/rev
3. Power control Max. power at 2000 rpm: 44 kW
4. 3 circuit control valve Max. pressure 350 bar
5. Mode-system Max. delivery: 2x74 ,/min

a. S Port - From tank

b. A2 Port - To control valve (P2 Port) and to
servocontrol feed unit (P1 Port)
c. A1 Port - To control valve (P1 Port) and to circuit
servocontrol feed unit (P3 Port)
d. X3 Port - From P3 pump (A3 Port)
e. X2 Port - From servocontrol feed unit (PR Port)

10-21
PUMP DRIVE

11

5
6
4

2
A
1

12

10

Transmission diagram
View A
14 13
8 7 D0400025

1. Drive shaft Pump gear ratio: 1 : 1.354

2. Seal ring
3. Snap ring
4. O-Ring
5. Bearing
6. Auxiliary drive
7. Bearing
8. Bearing
9 Ring nut
10. Snap ring
11. P3 - P4 pump gear (z=48)
12. Inlet gear (z=65)
13. P1 pump gear (z=48)
14. P2 pump gear(z=48)

10-22
SUMMATION HORSEPOWER CONTROL

4
5

2
3

6
7
8

1 2
15 9

14 10

13 11

12
P1 P2
Section A - A

D0400026

FUNCTION
. The automatic governor at power addition is a reg-
ulatory device that comes into action in function of
the working pressure that continuously positions
the two mechanically coupled pumps P1 and P2,
in order to vary displacement between a minimum
1. Pressure averaging valve and a maximum value.
2. Control piston Delivery varies in function of the system pressures
3. Lever fulcrum to ensure that a constant torque is obtained from
the main engine.
4. Calibration spring
5. Min. displacement stop
P (bar)
6. Piston return spring
350
7. Lever
8. Bearing 300

9. Control piston 250

10. Swivel fork 200

11. Positioning piston 150
12. Max. displacement stop
100
13. Mode-system group
50
14. 3 circuit control valve
15. Push rod 25 50 75 100 Q (l/min)
D0400027

10-23
OPERATION
1 - Operation when an increase of pressure is required.

A
R1 R2 2
4 h 5 A2 A3

2 A1 c
3
c

6
7
Z

15 10 a P1 b P2
Section A - A

e d 9

14 11

g
13
12

Detail Z D0400028

. The delivery pressures of pumps P1 and P2 are
transmitted to two separate chambers, a and b,
and act on a floating control piston (2) with two
equal surfaces A1 and A2 and a third, A3, that cor-
responds to the sum of the first two, according to
the relation: A1 + A2=A3 .
Pressure differences between the two pumps, and
therefore in the two chambers a and b which are
in direct communication with surfaces A1 and A2,
creates a pressure signal corresponding to the ar-
ithmetic mean of the two pressures according to
the relation:
P1+P2
ÐÐÐÐ = Pm
2 on the lever (7).
NOTE - The following example considers an in-
crease in pressure in pump P1; the same example
remains valid for a pressure increase for pump P2
(check valve R2).
. If the pressure value in chamber c is less than Pm,
the control rod (2) moves and the check valve R1 of
chamber a which has a higher pressure, opens to
pressurize the control circuit until this pressure
equals the circuit pressure at a value Pm; once
pressure has been stabilized the check valve R1
closes in order to allow passage of the amount of
oil drained through the clearance h existing be-
tween the positioning piston (11) and its slideway
and guide.
. The oil passing through the check valve R1 into
chamber c, also pressurizes line d within which is
housed the control piston (9) that presses down
Pressure generates a force on the surface of the
control piston (9) causing it to move and push
against the calibration spring (4).

10-24
. The movement of the control piston (9) opens pas-
sage e thus pressurizing the lower chamber g of
the positioning piston (11) and forcing it to rise. This
reduces the angle of the pump cylinder blocks and
therefore also reduces the delivery.
The movement of the positioning piston (11) also
moves the control piston (9) so that its position
changes with respect to the fulcrum of the lever (7).
. The positioning piston ends its stroke when parity
has been re-established between the moments
generated by the force of the spring (4) and the
2 - Operation when pressure is reduced
force generated by the pressure on the control pis-
ton (9).
. Once equilibrium between the moments has been
reached the control piston (9) closes the passage
that communicates with the lower chamber of the
positioning cylinder.
. Equilibrium is maintained until a positive or nega-
tive variation occurs in the pressure required from
one or both pumps.

A
h R1 R2 2
4 A2 A3
5

2 A1 c
3
c

d
7
6

X
15 a P1 b P2
10 Section A - A
8 9
e
14
11

g
13
12 e

NOTE - The example considers a reduction in pres-
sure in pump P1 and assumes a condition of equili-
brium throughout the control system.
. When the pump is asked to provide lower pressure
and pressure drops in chamber a, the measuring
piston (2) moves to the left, pushed by the action
of the mean pressure Pm on surface A3.
. Delivery to chamber c and line d is reduced and
pressure therefore decreases due to a steady leak-
age of oil through clearance h between the position-
ing piston (11) and its guide.
. The control piston (9) is moved by the thrust exerted
by the spring (4) on the lever (7). This movement
D0400029
Detail X
opens the line e thus releasing pressure and, due
to the thrust exerted by the spring (6), also withdra-
wal of the oil present in the lower chamber g of the
positioning piston (11).
. The descent of the piston and the resulting increase
in pump displacement continues until the equili-
brium between the pressures acting on the control
rod (2) has been fully recovered, i.e. until re-estab-
lishment of the mean pressure Pm and the equili-
brium of the moments acting on the lever (7).

10-25
3 CIRCUIT CONTROL VALVE

2 6

4
1

D0400030

1 3 circuit control valve piston FUNCTION

2. Push rod
. The 3 circuit valve limits the pre-established maxi-
3. Calibration spring mum torque of the endothermic motor when, in ad-
4. Positioning piston dition to the torque required from pumps P1 and
5. Lever P2, a pressure increase is also demanded of the
6. Control piston auxiliary pump P3 which provides for cabin rota-
tion, the servocontrol powering group, the stabilizer
group and the blade.
a. X3 Port - From P3 pump (A3 Port)
. The pressure signal that causes a reduction in the
displacement of pumps P1 and P2 in function of
the pressure needed by the devices powered by
pump P3, is taken directly from the circuit.

10-26
OPERATION

5 d

6
2
e

h 4

g
1 P (bar)

350

300

250
D0400032
200

150

100

50

25 50 75 100 Q (l/min)
D0400031

NOTE - This example describes the influence ex-
erted by cabin rotation because it is the most sig-
nificant, but the concept is also valid for the other
circuits coupled to pump P3.
. Activation of the command for cabin rotation de-
mands maximum pressure from the auxiliary pump
P3 because the hydraulic rotation motor needs the
maximum torque to overcome inertia.
The pressure signal is transmitted to chamber h
and acts on the piston (1) through the push rod
(2), acting directly on the lever (5) which is subject
to counterpressure from the calibration spring. (3).
Rotation of the lever (5) interrupts the equilibrium of
the moments and the pressure present in line d
moves the control piston (6). This movement frees
passage e and oil flows into the lower chamber g
of the positioning piston (4), giving rise to a se-
quence of reduced delivery from pumps P1 and
P2 and therefore also a reduction of their absorbed
power.
Once cabin inertia has been overcome, the pres-
sure required for rotation diminishes, the loading
on the calibration spring (3) lessens, and a new
constant modulation of the delivery of pumps P1
and P2 commences, until the system has returned
to a state of equilibrium.
. The return to rest of the control piston (6) and the
push rod (2) corresponds to the termination of ca-
bin rotation.

10-27
MODE-SYSTEM

P (bar)

350

300
4
250

200

150
j
100

50
3
25 50 75 100 Q (l/min)
D0400033
D0400034
8 1 2

1. Mode-system piston SPECIFICATIONS

2. Limit stop Calibration power: 70% engine nominal
3. Spring horsepower (30.8 kW)
4. 3 circuit control valve piston
5. Push rod OPERATION
6. Calibration spring When the operator selects this mode of operation he
7. Lever activates the EV5 with a switch; the oil (at the same
8 Locking nut pressure as the servocontrols) enters chamber j and
pushes the control piston (1) down to its limit stop (2).
This movement compresses the spring (3) which in
a. X4 Port - From servocontrol feed turn pushes up the piston (4) containing the seating
unit (EV5) - (PR Port). of the push rod (5) that compresses the calibration
spring (6) of the control system for the power absorbed
FUNCTION by pumps P1 and P2.
. This group reduces the absorbed power of pumps Compression of the calibration spring (6) causes the
P1 and P2, in a set manner, independently of the lever (7) to rotate and this torque gives rise to the se-
required working pressure. quence of movements that coordinate the power lim-
itation.
. The pressure signal needed to reduce power is in-
The mode-system group can be regulated to reach the
terpreted by a switch-activated solenoid valve EV5
percentage of power absorbed by pumps P1 and P2
belonging to the servocontrol power group.
by acting on a lock-nut (8) that calibrates the spring
(3).

10-28
AUXILIARY PUMP

1 2 3 4

a b

D0400035

1. Drive shaft SPECIFICATIONS

2. P3 pump body Theoretic displacement: 22.9+12.7 cm3/rev.
3. P4 pump body Discharge at 2000 rpm: 58+38.7 ,/min
4. Cover Nominal pressure: 200 bar
Max. pressure: 245 bar
a. A3 Port - To braking group (P Port)
- To 3 circuit control valve (X3 Port)
- To servocontrol feed unit (P2 Port)
b. A4 Port - To priority valve (P Port)
c. S1 Port - From tank

10-29
PRIORITY VALVE

d c

D0400036

a. P Port - From P4 pump (A4 Port) OPERATION

b. LS Port - To steering unit (LS Port)
. The oil from the pump is distributed through the
c. CF Port - To steering unit (P Port) priority valve to the steering unit (Port CF) and to
d. EF Port - To by-pass valve (C Port) the other hydraulic components (Port EF).
. Distribution is determined by the position of the
SPECIFICATIONS priority valve slider in function of:
Type: OLS40 a - the Load Sensing signal coming from the steer-
ing unit (Port LS);
b - the pump oil delivery;
c - the pressure in the steering system;
d - the pressure in the connected hydraulic circuit.
. The slider position is such as to ensure that deliv-
ery to the steering unit always corresponds to the
actual requirements.

10-30
CONTROL VALVE (Valve)

10 6 2 4 2 5 6

9 5 2 5 7 1
7

9 5 10 8
3 1 6 2 9

D0400037
2 9

1. Relief/anti-cavitation valve 6. Anti-cavitation valve

(double-calibration) (280/350 bar) 7. Anti-cavitation valve
2. Relief/anti-cavitation valve (320 bar) 8. Anti-cavitation valve
3. Relief/anti-cavitation valve (200 bar) 9. Anti-cavitation valve
4. Relief/anti-cavitation valve (220 bar) 10. Check valve
5. Plug

10-31
CONTROL VALVE (Ports)

a b c d e f

g h i j k l
ff m n o p q r s t

ee dd a cc bb aa z y x w v f
gg hh ii jj kk ll

pp oo n mm
qq rr ss tt

D0400038

10-32
a. x Port - From travel PPC valve (A Port)
b. b4 Port - From R.H. PPC valve (1 Port)
c. b3 Port - From swing PPC valve (2 Port)
d. b2 Port - From L.H. PPC valve (3 Port)
e. b1 Port - From EV11 (B Port)
f. x1 Port - From travel PPC valve (A Port)
g. b10 Port - From L.H. PPC valve (2 Port)
h. b9 Port - From outrigger PPC valve (2 Port)
i. b8 Port - From 2nd boom PPC valve (1 Port)
j. b7 Port - From R.H. PPC valve(1 Port)
k. b6 Port - From R.H. PPC valve (2 Port)
l. b5 Port - From EV12 (P Port)
m. A9 Port - To center swivel joint (6A Port)
n. A8 Port - To 2nd boom cylinder bottom side
o. A7 Port - To boom cylinder bottom side and control valve (C Port)
p. A6 Port - To bucket cylinder bottom side
q. A5 Port - To center swivel joint (12A Port)
r. A3 Port - To swing cylinder head side
s. A2 Port - To arm cylinder head side
t. A1 Port - To center swivel joint (12A Port)
v. B1 Port - To center swivel joint (11A Port)
w. B2 Port - To arm cylinder bottom side
x. B3 Port - To swing cylinder bottom side
y. C Port - To boom cylinder bottom side and control valve (A7 Port)
z. B5 Port - To center swivel joint (11A Port)
aa. B6 Port - To bucket cylinder head side
bb. B7 Port - To boom cylinder head side
cc. B8 Port - To 2nd boom cylinder head side
dd. B9 Port - To center swivel joint (10A Port)
ee. B10 Port - To swing motor (A Port)
ff. A10 Port - To swing motor (B Port)
gg. a10 Port - From L.H. PPC valve (4 Port)
hh. a9 Port - From outrigger PPC valve (1 Port)
ii. a8 Port - From 2nd boom PPC valve (2 Port)
jj. a7 Port - From R.H. PPC valve (3 Port)
kk. a6 Port - From R.H. PPC valve (4 Port)
ll. a5 Port - From EV12 (T Port)
mm. a1 Port - From EV11 (A Port)
nn. a2 Port - From L.H. PPC valve (1 Port)
oo. a3 Port - From boom swing PPC valve (1Port)
pp. a4 Port - From L.H. PPC valve (3 Port)
qq. P3 Port - From brake pump (B Port)
rr. P2 Port - From main hydraulic pump (A2 Port)
ss. T Port - To check and by-pass valve (C Port)
tt. P1 Port - From main hydraulic pump (A1 Port)

10-33
SWING MOTOR

e 1

c d X f

2 2 b

a
D0400039

1. Motor SPECIFICATIONS
2. Relief valve Theoretical displacement: 32 cc/rev
Swing motor relief valve:
a. A Port - From control valve (B10 Port) Rated pressure: 160-190 bar at 50 ,/min
b. B Port - From control valve (A10 Port)
c. X4 Port - From L.H. PPC valve (4 Port)
d. X5 Port - From L.H. PPC valve (2 Port)
e. T Port - To tank
f. S Port - To check valve (C Port)

10-34
SWING MOTOR RELIEF VALVE

1. Piston
2. Plunger
1
3. Spring
4. Pilot valve
5. Main valve
2 6. Orifice
7. Spring

4
Measured at V=41 mm2/s and t=50°C

7 10

Pressure difference (Dp bar)

5 8

6 6

D0400040
0
0 20 40 60 80 100
Flow Q (l / min)
FUNCTION AND OPERATION D0400152

The function of these valves is to protect the engine

from pressure peaks and extreme pressure drops
due to sudden interruptions in cabin rotation. Protec-
tion consists of transferring amongst the various lines
either the amount of oil that has caused a pressure
peak, or the amount of oil required to prevent the ca-
vitation phenomenon.
1

Function of the safety valve

. In normal conditions valves (4) and (5) are closed.
When the pressure of line b (higher than the cali-
brated value) is transferred to chamber a through
a nozzle (6), the pilot valve (4) opens to allow the
pressurized oil to flow through a hole c. The pres- 3
sure in line b acts on the main valve (5) which
opens to allow passage of the oil-flow in line b to c
line d.
4
Function of the anti-cavitation valve
. When there is pressure in line d and a vacuum in a
line b the pressure in line d acts on the main valve 5
(5) which is opened to allow communication be-
tween lines b and d.
d 6
. The pilot system pressure that acts on the control
valve shuttling that governs cabin rotation is also
transmitted to the piston (1). When the piston
moves it increases the load on the spring (3) of b
the pilot valve in proportion to the pressure needed D0400041
for rotation.

10-35
CENTER SWIVEL JOINT

Front of machine

Inlet axis
3 1 1a 12a 2A-6A-10A
2a
2
8a 5a

10 6a
10a

8 Inlet axis
4A-8A-12A Inlet axis
3A-7A-11A
12A 7a
11A 9a
3a
9 10A 4a 11a Inlet axis
1A-5A-9A
9A
8A View X
7A
1. 20 slip ring collector
6A
4A 2. Screw
5A 3. Collector support
3A 4. O-Ring seal
4
5. Rotor
2A
6. Body
8 1A 7. Guard ring
8. Anti-friction ring
5
7 9. Seal
10. Screw

D0400043
X

1A. From braking pump (T1 Port)
2A. From servocontrol feed unit (PV Port)
3A. From braking pump (T2 Port)
4A. Available
5A. From steering unit (R Port)
6A. From control valve (A9 Port)
7A. To tank
8A. Available
9A. From steering unit (L Port)
10A. From control valve (B9 Port)
11A. From control valve (B1 - B5 Port)
12A. From control valve (A1 - A5 Port)
1a. To front axle brake
2a. To EV1 - EV2 - EV3 (P Port)
3a. To rear axle brake
4a. Available
5a. To EV steering block (P Port)
6a. To EV6 - EV7 - EV8 block (P Port)
7a. From travel motor (T Port) and EV1 - EV2 - EV3
block (T Port)
8a. Avalaible
9a. To front steering cylinder (B Port)
10a. From EV6 - EV7 - EV8 block (T Port)
11a. To travel motor (B Port)
12a. To travel motor (A Port)

10-36
TRAVEL MOTOR

4 X
4

View X

a b D0400044

1. Motor SPECIFICATIONS
2. Brake valve Min. displacement: 36 cc/rev
3. Displacement automatic control Max. displacement: 80 cc/rev
4. Relief/anti-cavitation Check valve rated pressure: 350 bar

a. A Port - To center swivel joint (12a Port)

b. B Port - To center swivel joint (11a Port)
c. T1 Port - From suspension locking valve
(L Port)
d. T Port - To center swivel joint (7a Port)

10-37
DISPLACEMENT AUTOMATIC CONTROL HIGH PRESSURE
RELATED
1 1
4 X
a 7
5 4
Detail X
FUNCTION
. This device automatically varies the displacement
in function of the working pressure.
A displacement increase leads to a reduction in the
engine shaft rpm and an increase in the torque.
OPERATION
. The pressurized oil coming from the control valve
arrives through the check valves (1) on the smaller
surface of the positioning piston (2), thus pushing it
towards the minimum displacement limit stop.
The smaller surface is connected hydraulically to
the pilot system bushing (4), which contains a mea-
suring piston with two different surfaces. The avail-
able pressure therefore acts in a differential man-
ner and, with the spring (6), causes the piston (5)
to perform the function of governing the pressure
flows.
. When delivery line pressure increases the mea-
surement piston (5) moves, compresses the spring
(6), and allows oil to pass through line a into cham-
ber b of the larger surface of the positioning piston
(2).
10-38
a
c
6
5
D0400045
. The pressure moves the positioning piston (2)
which, because it is connected mechanically to
the engine cylinder, causes this to move and in-
crease the displacement.
The movement of the positioning piston (2) con-
tinues until equilibrium has been reached between
the delivery pressure acting on the smaller surface
of the piston and the pressure acting on the larger
surface. Once equilibrium has been reached the
spring (6) returns the measuring piston (5) to its
neutral position.
Maximum displacement is determined by the me-
chanical limit stop (7).
. When delivery line pressure diminishes there is no
longer equilibrium between the forces acting on the
positioning piston; the measuring piston moves,
and opens passage c to release the existing pres-
sure in chamber b.
Under this new pressure the positioning piston (2)
gradually returns to the minimum displacement po-
sition. The movement stops when a new equili-
brium is reached between the forces acting on
the measurement piston (5) and the positioning pis-
ton (2).
TRAVEL MOTOR BRAKE VALVES
8 9 10 11 f 11
5
6
7 c
b a
FUNCTION
. The brake valves control loading in order to prevent
the cavitation phenomenon which occurs when the
rotation speed of the hydraulic motor exceeds the
speed determined by pump delivery through the
control valve.
. The brake valves are not a substitute for the ma-
chine duty brakes.
OPERATION
. Pressurized oil from the control valve enters line a
causing valve (1) to open, and acts through the pilot
system channel c the ring chamber d and valve (2)
to feed the piston motor.
The pilot system oil acts on the surface of piston (3)
and causes it to move to compress the spring (4)
while the throttles (5) control the passages to obtain
slow and regular piston movement.
The piston movement (3) releases a progressive
throttling action (6) and allows the oil drained out
of the motor to return to the tank through the valve
opening (7).
10 9 2
5
3
4
D0400046
. When the pressure in line a drops due to loading
changes or due to the movement of the controls,
there is an immediate reduction of pressure in the
spring housing e; pressure from the spring (4)
and residual pressure from the drainage lines
cause the piston (3) to return, leading to a reduction
in the amount of oil draining through the throttle (6),
and thus provoking an automatic braking action.
. Valves (2) and (8) protect the engine against both
pressure peaks and the cavitation phenomenon.
. When the pressure in line f exceeds the calibration
value of the spring (9), the pilot valve (10) opens to
eliminate pressure inside the main valves (11). The
pressure in line d acts on the outside of the main
valves (11) which causes them to open and allow
communication between their lines of delivery a
and drainage b.
10-39
 SERVOCONTROL FEED UNIT

1
C
b
a

A A

d c

2
3 4 C
D0400047

e f

1. Relief servocontrol solenoid valve (EV4)

2. Mode-system solenoid valve (EV5)
3. Relief valve
4. Reducing valve B B
5. Accumulator

a. P2 Port - From P3 pump (A3 Port) SPECIFICATIONS

b. PR Port - To mode-system (X4 Port) Relief valve (3):
0
45 ± 4.5 bar
c. BV Port - To PPC valve (P Port) Reducing valve (4):
0
35 ± 3.5 bar
d. T Port - To tank
e. PV Port - To center swivel joint (2A Port) and
travel PPC valve (P Port)
f. P1 Port - From P3 pump (A3 Port)

10-40
 10 7

11

Section C - C
8 9 12 D0400048

1
Section B - B

Section A - A

7. Selector valve OPERATION

8. Relief valve The pressurized oil coming from pumps P1, P2, P3 to
9. Relief valve spring the ports P1 and P2 feeds the servocontrols and the
auxiliary services through the circuit selection valve
10. Check valve
(6).
11. Reducing valve The high pump pressure is reduced to the operating
12. Reducing valve spring pressures of the servocontrols by the fixed calibration
reducing valve (4) that charges the accumulator (5)
through check valve (9) and supplies the solenoid
valves EV4 and EV5 with the oil delivery required to
allow the servocontrols and the auxiliary circuits to
function.
The circuits supplied by this group are protected by
the overpressures of the safety valve (3).

10-41
R.H. PPC VALVE

4
Front of machine
a c b
1

f e d
View Z

Operating curve c port

3
bar

P.C.

+3
19,5 0

+0
5,8 -0,7

0
0,9 6,4 7,5560,3 PLUNGER
Z MOUVEMENT (mm)

D0400052 D0400140

Operating curve e port Operating curve d -f ports

bar bar

P.C. P.C.

+3 +2,5
25 0 25 0

0
7 -1
0
6 -0,7
0 0
0,975 6,475 7,5560,3 PLUNGER 0,975 6,475 7,5560,3 PLUNGER
MOUVEMENT (mm) MOUVEMENT (mm)

D0400148 D0400149

1. Control lever
2. Rubber jacket
3. Body
4. Electrical conctat

a. P Port - From servocontrol feed unit (BV Port) d. 4 Port - To bucket control valve (a6 Port)
b. T Port - To tank e. 3 Port - To boom control (a7 Port)
c. 1 Port - To boom control valve (b4-b7 Port) f. 2 Port - To bucket control valve (b6 Port)

10-42
L.H. PPC VALVE

1
Front of machine

a c b

3 f e d
View Z

Z
D0400139

Operating curve c - e ports Operating curve d - f ports

bar bar

P.C.
+3
24 0
+2,5
25 0

0 +0,3
6 -0,7 5,5 -0,3

0 0
0,975 6,475 7,5560,3 PLUNGER 0,975 6,475 PLUNGER
MOUVEMENT (mm) MOUVEMENT (mm)

D0400149 D0400150

1. Control lever
2. Rubber jacket
3. Body

a. P Port - From servocontrol feed unit (BV Port) d. 2 Port - To swing control valve (b10 Port)
b. T Port - To tank e. 3 Port - To arm control valve (a4 - b2 Port)
c. 1 Port - To arm control valve unit (a2 Port) f. 4 Port - To swing control valve (a10 Port)

10-43
ACCUMULATORS

D0400051

FUNCTION
TECHNICAL DATA . A rubber bag (1) containing nitrogen gas is used in
the accumulator. Its function is to maintain oil pres-
Servocontrol feed group
sure in the circuit to which the accumulator is con-
Nominal volume: 0.35 , nected.
0
Pre-set pressure: 12 + 1 bar
Working pressure: 35345 bar OPERATION

Braking system . When the engine is running, the chamber A of the

rubber bag (1) (containing nitrogen) is compressed
Nominal volume: 0.70 , by the pressurized oil from line B.
Pre-set pressure: 70 bar . If the oil pressure in line B falls below the maximum
Working pressure: 653150 bar calibration pressure (even after intensive use), the
rubber bag (1) will expand due to the pressure of
the nitrogen inside it.

10-44
SWING MOTOR BRAKING CIRCUIT SELECTOR VALVE

2 3 1 2
A
c a

A
b D0400050
Section A - A

1. Body
2. Valve seat
3. Ball

a. A Port - From L.H. PPC valve (4 Port)

b. B Port - To swing machinery brake (C Port)
c. C Port - From L.H. PPC valve (2 Port)

10-45
TRAVEL PPC VALVE

25
°
a
4
6 2 3
1
1

2
b
a 5

3
4

Z c

ANGLE ADJUSTABLE

Hole a
1 25ë
2 30ë
3 35ë D0400054
4 40ë View Z

1. Pedal
2. Pedal adjustment
3. Adjustable stop
4. Control unit
5. Support
6. Rubber jacket

a. P Port - From servocontrol feed unit (PV Port)

b. T Port - To tank
c. A Port - To EV11 (P Port)

10-46
2nd BOOM PPC VALVE

c d
°
12

1
12°

4
5

b 2

a 3

D0400055

1. Pedal
bar
2. Support
3. Control unit P.C.

4. Adjustable stop 19
+3
0

5. Rubber jacket

a. P Port - From servocontrol feed unit (BV Port) +0

5,8 -0,7
b. T Port - To tank
0
c. 1 Port - To 2nd boom control valve (b8 Port) 0,9560,22 4,9560,32 5,860,25 PLUNGER
d. 2 Port - To 2nd boom control valve (a8 Port) 0
MOUVEMENT (mm)

2° 10° 12° PEDAL

DEFLECTION (degree)

D0400141

10-47
BOOM SWING PPC VALVE

c d

4
12° 12°

b 2

a 3

D0400057

1. Pedal
bar
2. Support
3. Control unit P.C.

4. Adjustable stop 19
+3
0

5. Rubber jacket

a. P Port - From servocontrol feed unit (BV Port) +0

5,8 -0,7
b. T Port - To tank
0
c. 1 Port - To boom swing control valve (a3 Port) 0,9560,22 4,9560,32 5,860,25 PLUNGER
d. 2 Port - To boom swing control valve (b3 Port) 0
MOUVEMENT (mm)

2° 10° 12° PEDAL

DEFLECTION (degree)

D0400141

10-48
OUTRIGGER AND BLADE PPC VALVE

a b

c
20°

d
20°

2 1
D0400058

1. Operating rocker lever bar

2. Control unit P.C.

a. P Port - From servocontrol feed unit (BV Port)

b. T Port - To tank 19
+3
0

c. 1 Port - To outrigger control valve (a9 Port)

+0

d. 2 Port - To outrigger control valve (b9 Port) 5,8 -0,7

0
0,9 5,1 6 PLUNGER
MOUVEMENT (mm)
0
3°15' 21°24' 25° ROCKER LEVER
DEFLECTION (degree)

D0400142

10-49
OUTRIGGER AND BLADE SAFETY VALVE

a b

c d

D0400060

a. V2 Port SPECIFICATIONS
R.H. outrigger: from EV7 (B2 Port) Start opening: 8 bar
L.H. outrigger: from EV8 (B3 Port)
Blade: from EV6 (B1 Port) 16
Pressure difference (Dp bar)

b. V1 Port 14

R.H. outrigger: from EV7 (A2 Port) 12

10
L.H. outrigger: from EV8 (A3 Port) 2
8 ➔C
Blade: from EV6 (A1 Port) 6
V2
V2
➔
C2
c. C2 Port - To cylinder bottom side 4
2
d. C1 Port - To cylinder head side 0
0 6 12 18 24 30
Flow Q (l / min)

D0400143

10-50
BRAKE PUMP

2
b c d
5

4
i h 3
g f a
e

D0400062

View A

1. Pedal CARATTERISTICHE
2. Pedal angle adjustment Feed pressure: 65380 bar
3. Pump Unitary displacement: 70 cc
4. Service brake locking solenoid valve (EV13)
5. Pedal movement adjustment

a. P Port - From P3 pump(A3 Port)

b. N Port - To tank
c. T1 Port - Brake light pressure switch port
d. F Port - Accumulator pressure switch port
e. B Port - To control valve (P3 Port)
f. R1 Port - To A1 accumulator
g. R2 Port - To A2 accumulator
h. T2 Port - To center swivel joint (3A Port)
i. T1 Port - To center swivel joint (1A Port)

10-51
AXLE LOCKING VALVE

a b

RV

PN

d c

A
e

D0400049

a. RV Port - To EV2 (A1 Port) SPECIFICATIONS

b. PN Port - To EV2 (A1 Port) Pilot pressure: 3 bar
c. A Port - To L.H. axle stabilizer cylinder
d. B Port - To R.H. axle stabilizer cylinder
e. L Port - From travel motor (T1 Port)

10-52
SOLENOID VALVES

FOR STEERING

a b
1 2

T A

P B

c 3 d

D0400063

Measured at V=41 mm2/s and t=50°C Measured at V=41 mm2/s and t=50°C
5 3 6 9
Pressure difference (Dp bar)

10 10
Pressure difference (Dp bar)

8 8

6 6

4 4

2
2

0 0
0 20 40 60 80 0 20 40 60 80
Flow Q (l / min) Flow Q (l / min)

Curve 3 is valid for flow AnT e BnT D0400145 Curve 6 is valid for flow PnB e PnA D0400147
Curve 5 is valid for flow PnA e PnB Curve 9 is valid for flow AnT e BnT

1. Exclusion rear axle steering solenoid valve (EV9)

2. Checking rear steering solenoid valve (EV10)
3. Block

a. T Port - To front steering cylinder (A Port)

b. A Port - To rear steering cylinder (C Port)
c. P Port - From center swivel joint (5a Port)
d. B Port - To rear steering cylinder (D Port)

10-53
FOR SELECTION OF DIRECTION OF MOVEMENT

a b

d c

D0400066

a. P Port - From travel PPC valve (A Port) Measured at V=41 mm2/s and t=50°C 1 2

b. B Port - To EV12 (A Port) and control valve 10

(a1 Port)
Pressure difference (Dp bar)

8
c. T Port - To tank
d. A Port - To EV12 (B Port) and control valve 6
(b1 Port)
4

0
0 20 40 60 80
Flow Q (l / min)
D0400146

Curve 1 is valid for flow PnA - PnB e BnT

Curve 2 is valid for flow AnT

10-54
FOR TRAVEL ACCELERATION (EV12)

a b

d c

D0400068

a. P Port - To control valve (b5 Port) Measured at V=41 mm2/s and t=50°C 6 9
Pressure difference (Dp bar)

b. B Port - From EV11 (A Port) 10

c. T Port - To control valve (a5 Port)
8
d. A Port - From EV11 (B Port)
6

0
0 20 40 60 80
Flow Q (l / min)
D0400147
Curve 6 is valid for flow PnA e PnB
Curve 9 is valid for flow BnT e AnT

10-55
FOR LOCKING FRONT AXLE, PARKING BRAKE, SELECTION TRAVEL SPEED

4 3 2

f 1

b a D0400070

1. Block
2. EV1 Parking brake
3. EV2 Axle lock
4. EV3 Selection travel speed

a. A Port - To parking brake cylinder

b. A1 Port - To locking axle control valve
(PN - RV Port)
c. A2 Port - To transmission (A Port)
d. A3 Port - To transmission (B Port)
e. T Port - To center swivel joint (7a Port)
f. P Port - From center swivel joint (2a Port)

10-56
FOR R.H. - L.H. REAR OUTRIGGER AND BLADE

1 g

2 3 4

a e

c d

b f
D0400071

1. Block g. P Port - From center swivel joint (6a Port)

2. EV6 - For blade (if mounted) h. T Port - To center swivel joint (10a Port)
3. EV7 - For R.H. rear outrigger
4. EV8 - For L.H. rear outrigger
EV6
a. A1 Port - To blade cylinder safety valve (V1 Port)
Measured at V=41 mm2/s and t=50°C
1
b. B1 Port - To blade cylinder safety valve (V2 Port) 3
Pressure difference (Dp bar)

10
EV7
c. A2 Port - To R.H. and L.H. rear outrigger cylinders 8

safety valves (V1 Port)

6
d. B2 Port - To R.H. rear outrigger cylinder safety
valve (V2 Port) 4

EV8 2
e. A3 Port - To R.H. and L.H. rear outrigger cylinders
0
safety valves (V1 Port) 0 20 40 60 80
f. B3 Port - To L.H. rear outrigger cylinder safety Flow Q (l / min)

valve (V2 Port) Curve 3 is valid for flow PnA e PnB D0400144
Curve 1 is valid for flow BnT e AnT

10-57
10-58
ELECTRICAL CIRCUIT DIAGRAM

1 - STARTING AND ENGINE LINE

L-N2,5
13 D

G4
L-N2,5
R2,5
15 ACC. BR R2 C

FS11
FS 8

FS 4

FS 2
OFF ACC
14 15

Fi 4
R1 ST

1 2 3 4 1 2 3 4 5 6 1 2 1 2 3 4 8
XN B 11

L4
R/N1
L-N0,8

B/N1
Z1,5
L-N2,5

L-N2,5
L-N2,5

L-N0,8
H1

Z-B0,8
10

R2,5

R2,5

V-N0,8
G/N1
B/N1
A/V1

Z/B1
R4

N1
V4

L4
S1

V1
1
XK
XE XM XY
XE 1 V-N0,8
5
M0,5
3
15 11 10
See line 5 A/V1 H-N0,8 H0,5 0000000h
3 8
Z-B0,8 Z-B0,5
7 2
Xi V1
12
V0,5
5
7 V-B0,8 V-B0,5
See line 3 B-N0,5 B-N0,5 4 14 6 7
A-G0,8 A-G0,8 A-G0,8 G0,5
11 10 12
OP. B-N0,8 B-N0,5
Xi XE

B-N0,5
A/V1

H-N0,8

B-N0,8
V-B0,8
G/N1

Z/B1
H1

S1

V1
S1

Z1
G4
R4
86 87 87b 1 2 3 1 2 3 5 6 7
XA 12 XC XY 9
XO
85 30

H-N0,8
V-B0,8
G/N1

G/N1
G2,5

Z/B1

Z/B1
R4

H1

V1
S1

Z1
Z1,5
OFF

N1
LO
OFF
HI 1

XB
V4 V4
R4 R4
R4
R4
F50A

F80A

96 97

B-N0,8
N1
R50
1 3

H-N0,8

A-G0,8
V-B0,8
B4
L6

Z/B1
G2,5

H1
B4

V4

V1

S1
Z1
+

30 50
B+
W P 33
D+
-

O
1 2 3 4 5 6 7 8 9 32
N1,5
N50

N1

N1

N1

N1

N1
N6

N1
COMPONENTS CONNECTOR FUSES A: FS2 - Preheater
1 - Battery XA - 2-ways connector starting switch FS4 - Stop motor
2 - Starter motor XB - 2-ways connector supply and pre-heater FS8 - Mechanical travel speed relay
3 - Alternator XC - 3-ways connector engine - relay-box line FS11- Buzzer, + 15 operator's cab
4 - Pre-heater XE - 17-ways connector main box - R.H. dashboard
5 - Stop motor XY - 7-ways connector engine - R.H. dashboard FUSES B: Fi4 - +15 preheater, L.H. switch
6 - Air filter clogging sensor Xi - 21-ways connector service and indicator light line
7 - Engine oil low pressure sensor XK - 1-way connector R.H. dashboard
8 - Coolant high temperature sensor XM - 13-ways connector control panel
9 - Coolant temperature sensor XN - 17-ways connector supply
11 - Starter switch XO - 17-ways connector beam line
12 - Inserted reverse speed relay XY - Connector control panel
13 - R.H. dashboard diodes connector
14 - Buzzer
15 - Pre-heater box
32 - Brake pressure sensor
33 - Fuel level sensor
96 - Fuse 50A
97 - Fuse 80A
10-59
ELECTRICAL CIRCUIT DIAGRAM

2 - BEAMS, DIRECTION INDICATOR HORN AND FAN LINE

L-N2,5

A-G1,5
DX 57/58 SX DX WARNING DRIV. BEAM

A/N1
0

M2,5

B2,5
N1

N1

Fi 6

Fi 7
Fi 8
Fi 5
Fi 2
L-N2,5
R2,5
SX
15 ACC. BR R2 C 56a 56b 30 L - 2 1 0 2 1 0

Fi 11
49

FS 1
OFF ACC R

OFF
86 87 87b 86 87 87b

ON
R1 ST

FS 9
Fi 9
1 2 3 4 3A
XN B 85 30 85 30
29 30

49a
H-N1

H-R1
B-N1

A-N1
A-N1
V-N1

S0.5

B0.5
90 31

A1

A1
26 27

L1

Z/N1
15 30 L
11

B-G0,8
L-N1,5

L-N1,5

XQ
L-N2,5

L-N2,5
L-N2,5
A F E B C A F E B C
XDa

M1
R2,5

R2,5

G-R0,8
R4

B0,75
M1,5

B1,5

A2,5
G1
G 5 4 3 2 11 7 10 6 1 8 9

H-R1,5

H-R1,5
A-B0,8
-

Z/N1

L/N1
1A

A1
5

C-B1,5

C-V1,5
L + P

L-R1,5
G-R1,5
G.R0,8

B-N1,5
M-B1,5
C-B1,5

R1
N1
B-G0,8

A-N1,5

A-B0,8

G/R1
B0,75

A/N1
G1,5
L/N1

A2,5

N1

Z/N1
M1

N1

XQ
A1
A-G1,5
A-V0,8
XR

L/N1

N1
6 4
A/N1
XF
4
11
A-G1,5
8
A-B0,8
2
See line 3 A1
3

B-R0,5
L/N1

13
G-R0,8 G-R0,5
1
N1 N0,5
1 8
R1 R0,5
4
A-V0,5 A-V0,5
XR
R4
2
G/R1 G1

XA XM 13 15 6 14 16
C-B1,5
3
16
C-B1,5 XY
R4

L-R1,5 L-R1,5
12
C-V1,5 C-V1,5
8
B-N1,5 B-N1,5
13
A-V0,8 A-V0,5

G-R1,5
G-R1,5
B-G0,8

A-B0,8
M1,5
G1,5
L/N1

R0,5
A2,5

B1,5
See

M1
XE

G1
A1

A1
line 4
See line 3
XE

B-R0,5

B-G1,5
B-G1,5
R1,5

B-N1,5
G-R0,8

A-N1,5
A-B0,8
9 1

M1,5
A-V1.5

R1,5
B1,5
3 17 2 13 14 20 10 9 16 15 6

G1
A1
6A -
2

H-G1.5
B-G1,5
+

0000000h
XB Xi XO

G-R0,8
12 10 13 6 5 3 4 8 86 87 87b 86 87 87b 21 11
Xi XO

B-G0,8
R4 R4

A-B0,8
M1,5
G1,5
L/N1

R0,5
A2,5

B1,5
M1

G1
A1
85 30 85 30 14 2 1
4

G-R0,8
R4
R4

A-N1,5
A-B0,8
91 92

M1,5
B1,5
XY

G1
A1

M-B1,5
C-B1,5

H-G1.5
B-G1,5

A-V1.5
R0,5

N1
G-R0,8
F50A

G-R0,8

C-V1,5
L-R1,5

B-G 1.5
N1,5

H-G1.5
N1

A-V1.5
N1.5
R50 OFF

G-R0,8

A-B0,8
A-N1,5

G-R0,8

A-B0,8
M1,5

M1,5
B1,5

R0,5
B1,5
1 2 6 LO

G1
A1

G1
R1

R1
A1
L6

1 2 3 4 2 1 3 4
XF
+

OFF
HI 1

N2,5
30 50
2
M P
-

22 23 24 25 95
94 16 17 18 19 20 21 10
N1

1 2
N1,5

N1,5

N1,5
N1,5
N50

N1

N1

N1

N1

N1

N1
N1

N1
N1
N6

COMPONENTS CONNECTOR FUSES A: FS1 - +15 Turning indicator lights

1 - Battery 29 - Working beam switch XA - 2-ways connector starting switch FS9 - Stop, heater, working mode,
2 - Starter motor 31 - Emergency switch XB - 2-ways connector supply and pre-heater R.H. switch, control panel
10 - Control panel 90 - Flashing light relay XDa - 13-ways connector column steering switch
11 - Starter switch 91 - Stop beam relay XE - 17-ways connector main box - R.H. dashboard FUSES B: Fi2 - Turning indicator lights
16 - L.H. beam 92 - Working beam relay XF - 7-ways connector L.H. dashboard Fi5 - Front R.H. and rear L.H. parking light
17 - L.H. travel direction indicator beam 94 - Horn XY - 7-ways connector engine - R.H. dashboard Fi6 - Front L.H. and rear R.H. parking light
18 - R.H. travel direction indicator beam 95 - Overload pressure sensor Xi - 21-ways connector service and indicator light line Fi7 - Lower beam
19 - R.H. beam XM - 13-ways connector control panel Fi8 - Driving beam
20 - Rear L.H. beam XN - 17-ways connector supply Fi9 - Working lamp
21 - Rear R.H. beam XO - 17-ways connector beam line Fi11 - +30 emergency warning lights
22 - Brake switch XQ - 9-ways connector L.H. dashboard
23 - Registration number beam XR - 5-ways connector main box - column travel switch line
24 - Heating fan motor
25 - Working beam (optional)
26 - Lower beam relay
27 - Driving beam relay

10-61
ELECTRICAL CIRCUIT DIAGRAM

3 - COLUMN STEERING SWITCH, R.H. DASHBOARD SWITCH, MECHANICAL TRAVEL SPEED CHANGE RELAY AND ROTARY AND CUTTING SHOVEL SWITCH LINE

CMV MI MA ML MV HIGH SLOW

48

L-N2,5
MI 0 MA
MV
28

L-N2,5
ML

R2,5
15 ACC. BR R2 C + + -
OFF ACC
D P

FS 10

Fi 10
FS 6
FS 5

FS 7

FS 9
XN R1 ST

1 2 3 4
B 44

R-N1

H-N1
B-N1
A-N1

V-N1
N0.5
11

C1

H1
A1
Z1

Z1

C-B1,5

B-R1,5
45

A-R1,5
R2,5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 A B C D + -

H1,5
L-N2,5

L-N2,5
L-N2,5
XDb XP

R4
R2,5
1 2 3 4 5 6 7 8

M-N0,8
M-N1.5
B/R1

M-N0,8
M-N1.5

M-N0,8
M-N0,8
G-N0,8

H-G1.5
13 12 9 1 5 2 3 7 11 8 6

A-G0,5

B-R0,5
L-G0,5

V-R0,5

B-L0,5

A-G0,5
L-G0,5

V-R0,5
B/R1

G0,5

L/G1

G0,5
XE

G1

R1
N1
A-R1,5

Z-B0,5
N1

S1

B1

H-G1,5
H-R0,8
A-R1,5
A-R0,8

B-N0,5
S-N1,5
3

Z-B0,5

H1
S1
B1
XR XR Xi
See line 2
6
V-R0,5
2 7 10
Z-B0,5 Z-B0,5 G0,5
3 12 4
S1 S1 L-G0,5
4 2
B1 B1 A-G0,5

XE

H-G1,5
5

H-R0,8
S/N1
Xi

S-N1,5
B-L0,5
R4

86 87 86 87 87b

85 30 85 30
XA See line 5
46 47 XH

N1

N1
A-R1,5
R4

N1
17
S/N1
14
B1
V0,5
11
S1
B-N0,5 6
See line 1 L/G1
13
G1
See line 2 B-R0,5

XB
R4 R4
R4
R4
F50A

XS XR
8
Xi XL 10 Xi 15
2 1 4 3 5 9 8
XO
15 17 16

M-B1,5
C-N1,5

Z-G1,5
V-N1,5
3A

M-N1,5
M-B1,5
R50

M-N1,5

Z-G1,5
H1,5
G-N0,8

V-N1,5
B-R1,5
OPZ.

H-G1,5
H-R0,8
3 1 2

H1
L6
+

30 50
1A 1A 1A 1A 1A 1A 1A
0 1 2 3 1 2 3
-

34 35 36 37 38 39 40 41 42 43
1 2

N1,5

N1,5

N1,5
N50

N1

N1

N1

N1

N1

N1

N1

N1
N6

N1

COMPONENTS CONNECTOR FUSES A: FS5 - Direction indicator lamp, low and high
1 - Battery 43 - Bucket L.H. rotation solenoid valve (optional) XA - 2-ways connector starting switch speed travel
2 - Starter motor (EV15) XB - 2-ways connector supply and pre-heater FS6 - Relay box
11 - Starter switch 44 - Mechanical travel speed change relay XDb - 11-ways connector column travel switch FS7 - R.H. switch relay box
28 - Column steering switch 45 - R.H. switch relay box XE - 17-ways connector main box - R.H. dashboard FS9 - Stop, heater, working mode,
34 - Forward travel solenoid valve (EV11) 46 - Forward travel control relay XH - 21-ways connector slip ring collector R.H. switch, control panel
35 - Reverse travel solenoid valve (EV11) 47 - Mechanical travel speed control relay Xi - 21-ways connector service and indicator light line FS10- Servocontrol, hammer and rotating and
36 - Hydraulic high speed solenoid valve (EV12) 48 - R.H. switch XL - 13-ways connector L.H. dashboard cutting shovel
37 - Working brake solenoid valve (EV13) XN - 17-ways connector supply
38 - Electric socket XO - 17-ways connector beam line FUSES B: Fi10 - +30 Operator's cab, electric socket
39 - Rotary and cutting shovel switch XR - 5-ways connector main box - column travel switch line
40 - Hammer switch (optional) XS - 7-ways connector main box - dashboard
41 - Hammer solenoid valve (optional) (EV14)
42 - Bucket R.H. rotation solenoid valve (optional)
(EV15)

10-63
ELECTRICAL CIRCUIT DIAGRAM

4 - MODE SYSTEM, RELIEF SERVOCONTROL AND L.H. DASHBOARD SWITCH LINE

Z-N1,5
L-N2,5
54

N1
FS 6
Fi 4

Fi 3
L-N2,5
R2,5
15 ACC. BR R2 C 1 0 1 9 15 30 L

OFF
ON

FS 11
OFF ACC

FS 10

Fi 10
FS 9
R1 ST
XN

Fi 1
1 2 3 4 5 10
B
53 49 30b R
11

S-N1,5

C-B1,5
L-N2,5

L-N2,5
L-N2,5
55 56

H/R1

B/R1

A/R1
R2,5

R2,5
A B C D + - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

B-R0,8

Z-N1,5
XPa

R4
A F E B

B-R1,5

C1,5
G-V1
C/N1

H/R1
A/B1
L/R1

S0,5
R1

N1

N1

S-N0,8
G-V1
C/N1
B/R1

A/R1
A/R1

A/R1
A/R1
A/B1

S0,5
C1

Z1
L1
3
3 7
XQ
XE XE

R1
See line 2

B-R0,8
C1,5
9 3 1 2
XL X
XL
7

B-G1.5
B-G1,5
B-R0,8

B-R1,5
H/R1 H/R1

N2,5

C1,5
5
S0,5 S0,5
R4

1 2 3 6 4 7
XA XT
XF
R4

XH
5 12
C/N1 C/N1 L1
10 15
A/B1 A/B1 C1
9 16
G-V1 G-V1 N1,5
19
Z1
20
S-N0,8

XB
R4 R4
R4
R4

S-N1,5

L/R1
F50A

1 7 2 18
XO Xi
S-G1,5
S-N1,5

L/R1

R50
L6
+

S-G1,5

30 50

5 4
-

1A 1A

51 52
1 2
N1,5

50

N2,5

N2,5
N50

N1

N1
N1
N6

N1
COMPONENTS CONNECTOR FUSES A: FS6 - Relay box
1 - Battery XA - 2-ways connector starting switch FS9 - Stop, heater, working mode,
2 - Starter motor XB - 2-ways connector supply and pre-heater R.H. switch, control panel
11 - Starter switch XE - 17-ways connector main box - R.H. dashboard FS10- Servocontrol, hammer and rotating and
50 - Relief servocontrol switch XF - 7-ways connector L.H. dashboard cutting shovel
51 - Relief servocontrol solenoid valve (EV4) XH - 21-ways connector slip ring collector FS11- Buzzer, + 15 operator's cab
52 - Mode System solenoid valve (EV5) Xi - 21-ways connector service and indicator light line
53 - Mode System switch XL - 13-ways connector L.H. dashboard FUSES B: Fi1 - Rotary beam
54 - L.H. switch XN - 17-ways connector supply Fi3 - Upper relay box supply
55 - L.H. switch relay box XO - 17-ways connector beam line Fi4 - +15 Pre-heater, L.H. switch
56 - Rotary beam switch XPa - 17-ways connector L.H. switch relay box Fi10 - +30 Operator's cab, electric socket
XQ - 9-ways connector L.H. dashboard
XT - 11-ways connector operator's cab
X - 1-way connector main box - indicator light line

10-65
ELECTRICAL CIRCUIT DIAGRAM

5 - STEERING EMERGENCY SWITCH STEERING SELECTION SWITCH AND UPPER SLIP RING COLLECTOR LINE

R-N0,8

L-N2,5
R-V0,8

M/N1

M/N1
G/R1
R/N1

N1

N1

N1
V1,5
L-N2,5
1 0 2 63 64

C1
R2,5

FS3
OFF ACC
15 ACC. BR R2 C
R1 ST
15 30 L 86 87 87b 86 87 87b 86 87 87b

OFF
ON
1 2 3 4
XN B 60 85 30 85 30 85 30
58
11 61 93 62

R-N0,8
L-N2,5

L-N2,5
L-N2,5
49 30b R 1

V0,5
R2,5
R-N0,8

G-R0,8
G/R1
A B C D E F

V1,5
R2,5
1 2 4 4

R4
59

R1
2
V/B1

G-R1,5
R-N1,5
R1,5

G-R0,8
G-R1,5

R-N0,8
R-V0,8
3

V/B1
G/R1
G-R0,8

N1
N1
1A

V1
N1
V1
4
R-V0,8
5
R1,5
7 1 2 1 6
XF XF L/G1

XQ
7
V1
8
G/R1
9
XH A/V1
R/N1 10
1 11
R-N0,8 R-N0,8 S1
4 12
R-V0,8 R-V0,8 L1
8 13
G/R1 G/R1 G1
10 14
R/N1 R/N1 B1
14 15
V0,5 C1
16
See line 3 B1 N1,5
7 17
V1 V1 S/N1
18 18
R1 R1 R1
19
R-N1,5 Z1
3 20
G-R0,8 G-R0,8 S-N0,8
R4

2
V/B1 V/B1

G-R1,5
G-R0,8
R-N0,8
R-V0,8

G/R1
R/N1
5
R1,5 R1,5
6
L/G1 L/G1
XA S1 11
S1
13
XL
R4

G1 G1
2 8 1 6 4 11 See line 3 14
B1 B1

G-R1,5
G-R0,8
R-N0,8
R-V0,8
V0,5

G/R1
R/N1
17
S/N1 S/N1
12
L1 L1
15
C1 C1
16
See line 4 N1,5 N1,5
19
Z1 Z1
20
S-N0,8 S-N0,8
9
See line 1 A/V1 A/V1
XB
R4 R4
R4
R4
F50A

M/N1
220 ohm
R50
L6
+

30 50
-

57
1 2
N50

N6

N1

N1
N1

N1

COMPONENTS CONNECTOR FUSES A: FS3 - Under-carriage relay box supply

1 Battery - XA - 2-ways connector starting switch
2 -
Starter motor XB - 2-ways connector supply and pre-heater
11 -
Starter switch XF - 7-ways connector L.H. dashboard
57 -
Steering buzzer XH - 21-ways connector slip ring collector
58 -
Slip ring collector XL - 13-ways connector L.H. dashboard
59 -
Steering emergency switch XN - 17-ways connector supply
60 -
Steering selection switch XQ - 9-ways connector L.H. dashboard
61 -
Buzzer relay
62 -
Fast speed and crab steering acoustic
alarm relay
63 - Rear axle light
64 - Front axle light
93 - Signal rear axle sensor inversion relay

10-67
ELECTRICAL CIRCUIT DIAGRAM

6 - TRACK FRAME SOLENOID VALVE AND STEERING RELAY BOX LINE

G-R0,8
H-R0,8

H-R1,5

H-N1,5
V-B0,8

H/N1

H/R1

V/B1

V/B1

L/R1
N1

N1

H1

H1

N1
86 87 87b 86 87 87b 86 87 87b 86 87 87b 86 87 87b 86 87 87b 86 8 87

85 30 85 30 85 30 85 30 85 30 85 30 85 3
81 82 83 84 85 86 87

G-R0,8
R-N0,8

R-N1,5

R-N1,5
R-V0,8
Z-B0,8

L-N0,5
H-N1

G/R1
R/N1

N1

N1

N1

N1
X1
1
R-N0,8
2
V/B1
3
G-R0,8
58 4
R-V0,8
5
1
N1 R-N1,5
2
N2
3
4
N3 X2
N4 1
5
N5 L/G1
2
6
N6 V1,5
3
7
8
N7 4
G/R1
A/V1
89
N8 5 1
9
N9 R/N1 H-R1,5 A
2
10
N10 3 B
11
12
N11 X3 G-R0,8
H1 4
C
N12 1 5
13 S1 Z-B0,8
N13 2 6 D
14 L1
N14 3 7
15 G1 G/N1
N15 4 8 E
16 B1 V1
N16 5 9 F
17 C1 V1,5
N17 10
18 V-B0,8
N18 11 G
19
20
N19 X4 H-N1
H-N1,5 12
H
N20 1 13
N1,5 H-R0,8

R-N1,5
L-N0,5
G/N1

H/R1

H/N1
A/V1
L/G1
L/R1
2

H1
V1
S/N1
3
R-N1,5
4 1
Z1 R1
5 2
S-N0,8
XU 11 3 5 6 1 7 2 8 9 4
B-N0,5
R1 3 88
4
S/N1 D

R-N1,5
N0,35
G/N1

G/N1

H/R1

H/N1
A/V1
L/G1
L/R1

H1

R1
V1
5
N1,5
6
L0,5
7
8

L/R1

R1
N1
A B C

S-N0,8

B-N0,8
M0,35

M0,35
N0,35

N0,35
L0,35

L0,35
H/R1

H/N1
L/G1

A/V1

L0,5
G1

C1

H1
S1

B1

V1
Z1
L1

6 10 7 5 9 11 12 1 8 3 2 4
75
65 66 67 68 69 70 71 72 73 74 76 77 78 79 80
N1,5

N1,5
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
COMPONENTS CONNECTOR
58 - Slip ring collector 79 - Front axle steering sensor XU - 5-ways connector solenoid valve line
65 - Low mechanical speed solenoid valve (EV3) 80 - Sensor for inhibition gear box X1 - 5-ways connector slip ring collector - solenoid valve line
66 - Front L.H. outrigger solenoid valve (EV8) 81 - Double steering manteining relay X2 - 5-ways connector slip ring collector - solenoid valve line
67 - Locking axle sonenoid valve (EV2) 82 - Steering clear and front steering relay X3 - 5-ways connector slip ring collector - solenoid valve line
68 - High mechanical speed solenoid valve (EV3) 83 - Lateral and crab steering control relay X4 - 16-ways connector slip ring collector - solenoid valve line
69 - Front L.H. outrigger solenoid valve (EV7) 84 - Circle steering control relay
70 - Blade solenoid valve (optional) (EV6) 85 - Front and rear straight wheels control relay
71 - Outrigger solenoid valve (optional) (EV16) 86 - Front straight wheels control relay
72 - Normal steering solenoid valve (EV9) 87 - Rear straight wheels control relay
73 - Parking brake solenoid valve (EV1) 88 - Mechanical speed control box
74 - Circle steering solenoid valve (EV9) 89 - Diodes box
75 - Inserted travel speed switch
76 - Double steering solenoid valve (EV10)
77 - Lateral steering solenoid valve (EV10)
78 - Rear axle steering sensor

10-69
ELECTRICAL CIRCUIT DIAGRAM

7 - MAIN BOX AND TRACK FRAME RELAY BOX DISPOSITION

MAIN RELAY BOX
UPPER VIEW

FUSES "B"

93 61 91 15 55
11 6 1

FUSES "A" 12 62 26 92
10 8 5
44 45
46 90 27 47
9 7 4 3

TRACK FRAME RELAY BOX

82 81 85 83 DIODE BOX
1 2 3 4
A-DIODE 3A
86 87 84 B-DIODE 3A
7 6 5 C D B C-DIODE 1A
H
D-DIODE 1A
G E-DIODE 3A
A
F-DIODE 3A
E F
89 G-DIODE 1A
H-DIODE 1A

88

NOTE : NUMBER INDICATETED IN THE UPPER RELAY'S SIDE

AND IN A MOST EVIDENT WAY REFERS TO THE LEGEND

COMPONENTS
12 - Inserted reverse speed relay 55 - L.H. switch relay box 86 - Front straight wheels control relay
15 - Pre-heater box 61 - Acoustic allarm relay 87 - Rear straight wheels control relay
26 - Lower beam relay 62 - Fast speed and crab steering acoustic alarm relay 88 - Mechanical speed control box
27 - Driving beam relay 81 - Double steering manteining relay 89 - Diodes box
44 - Mechanical travel speed change 82 - Steering clear and front steering relay 90 - Flashing lights relay
45 - R.H. switch relay box 83 - Lateral and steering control relay 91 - Stop beam relay
46 - Forward travel control relay 84 - Circle steering control relay 92 - Working beam relay (optional)
47 - Mechanical travel speed control relay 85 - Front and rear straight wheels control relay 93 - Signal rear axle sensor inversion relay

10-71
GROUP 20
 TESTING AND ADJUSTMENTS
Normal or standard technical data . . . . . . . . . . . . . . . . . . . . . 2
Equipment for testing, adjusting and
identifying faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Measuring the engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Measurement of compression pressure . . . . . . . . . . . . . . . 23
Checking and tightening the fan-belt . . . . . . . . . . . . . . . . . . 24
Adjusting the stroke of the accelerator lever . . . . . . . . . . 25
Adjusting PPC valves clearance. . . . . . . . . . . . . . . . . . . . . . . 26
Adjusting the safety microswitch . . . . . . . . . . . . . . . . . . . . . . 28
Centering the stroke of the blade and the
outriggers control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Measuring the swing circle axial clearance . . . . . . . . . . . 29
Bleeding air from pumps (P1 and P2) . . . . . . . . . . . . . . . . . 30
Bleeding air from the PPC valves circuit . . . . . . . . . . . . . . 30
Bleeding air from the Load Sensing circuit . . . . . . . . . . . 30
Bleeding air from the cylinders . . . . . . . . . . . . . . . . . . . . . . . . 31
Releasing residual pressure from the circuits. . . . . . . . . 31
Releasing residual pressure from the
brake line accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checking and regulating pressure
in the hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Checking the intervention point of the summation
horsepower control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Checking the initial horsepower
control point for the 3-circuit control valve . . . . . . . . . . . . 41
Checking and adjusting pressures in the
servocontrol supply units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adjusting the main safety valve of pump P4 . . . . . . . . . . 43
Measuring pump delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Checking that the priority valve
is functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Checking and regulating the pressure
of the steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking leakages in the steering cylinders . . . . . . . . . . 47
Checking the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Checking wear in the brake disks . . . . . . . . . . . . . . . . . . . . . 53
Bleeding air from the brake lines . . . . . . . . . . . . . . . . . . . . . . 54
When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level
ground. Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine
is undergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed
while the liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
Adjusting the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking the hydraulic travel system . . . . . . . . . . . . . . . . . 56
Checking and adjusting the safety valves
of the travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Checking and adjusting the automatic
displacement control system
of the travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking for leakages in the travel motor. . . . . . . . . . . . . 60
Checking and adjusting the speed
of the travel propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Adjustment of the speed surveyor . . . . . . . . . . . . . . . . . . . . . 62
Adjusting boom and arm safety valves . . . . . . . . . . . . . . . . 63
Adjusting 2nd boom safety valves. . . . . . . . . . . . . . . . . . . . . . 64
Measuring the initial intervention point
of the overload sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Adjusting the valve that controls
the closing speed of the 2nd boom . . . . . . . . . . . . . . . . . . . . 66
Measurement of internal oil leakages
in the swing motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Checking for leakages inside the swivel joint . . . . . . . . . 68
Analysis of the causes of hydraulic drifts. . . . . . . . . . . . . . 70
1. Boom test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2. Arm test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3. Testing the functionality of the boom
and arm safety valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4. 2nd boom test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5. Testing the functionality of the
2nd boom safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6. Bucket test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7. Boom swing test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8. Test for the outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9. Blade test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10. Swing motor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11. Checking the travel motor . . . . . . . . . . . . . . . . . . . . . . . . . 78
12. Test for the axle-locking valve. . . . . . . . . . . . . . . . . . . . . 79
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
20-1
NORMAL OR STANDARD TECHNICAL DATA
. FOR ENGINE
Machine model PW95-1

Engine 1004-4

Check item Test Conditions Unit Standard Permissible

value value

High idling rpm 2160w50 Ð

Engine speed Low idling rpm 1000 50 Ð
(no-load)
Set speed rpm 2050 50 Ð

Sudden acceleration Index Ð Ð

Exhaust gas colour Bosch
At high idling speed Ð Ð

Intake valve (20ëC) 0.20

Valve clearance mm Ð
Exhaust valve (20ëC) 0.45

Water temperature in operating range

Blow-by pressure ,/min Ð 60
At high idling speed SAE 30 oil

Min. engine oil Water temperature in operating range

kg/cm2 3.4v4 2.1
pressure At high idling speed

Oil temperature Entire speed range ëC 85ëC Max. 120

Fuel injection timing B.T.D.C. degrees 16.5 Ð

Fan-belt tension Slack when pushed with finger mm 10 Ð

force of 4.5 kg

20-2
. FOR MACHINE
All tests, if not otherwise specified, should be performed with WORKING MODE in position P

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Engine speed with

pump P1 at 2100w50 Min. 2000
max. pressure
. Hydraulic oil temp.: 45v55ëC
Engine speed with . Engine oil pressure: in correct range
pumps P1 and P2 . Cooling water temp.: in correct range 2100w50 Min. 2000
at max. pressure . Swing lock pin inserted
Engine

. Max. pressure P1: with arm rpm

Engine speed with
pumps P1-P2-P3 . Max. pressure P1-P2: with arm 2050w50 Min. 1950
at max. pressure and bucket
. Max. pressure P1-P2-P3 with
Engine speed when pumps arm, bucket and swing
P1-P2 are at max. pressure 2150w50 Min. 2050
and the WORKING MODE
selector is in pos. E

Boom control valve a b a b

Arm control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5

Bucket control valve a

9w0.5 9w0.5 8.7w0.5 9.3w0.5
b

Swing control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5

Spool travel

Blade - outriggers 9w0.5 9w0.5 8.7w0.5 9.3w0.5

control valve
mm
Boom swing control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5

2nd boom control valve D0400173 9w0.5 9w0.5 8.7w0.5 9.3w0.5

Travel control valve 8w0.5 8w0.5 7.7w0.5 8.3w0.5

Rapid travel control valve 8w0.5 8w0.5 7.7w0.5 8.3w0.5

Boom and arm speed 8w0.5 8w0.5 7.7w0.5 8.3w0.5
redoubling control valve
. At centre of Raise
Boom control lever lever knob
Neutral Lower 80w8 72v88
. Reading at end
of travel Extended
Arm control lever Neutral Retracted 80w8 72v88
. Engine stopped
. Equipment on
the ground Open
Bucket control lever Neutral Curled 80w8 72v88
Travel of levers and pedals

Swing R.H.
Swing control lever Neutral Swing L.H. 80w8 72v88

Blade - outriggers Neutral

Raise
50w5 45v55
control lever Lower
mm
Fuel control lever Min. Max. 150w15 135v165

Swing R.H.
Boom swing pedal Neutral Swing L.H. 20w2 18v22

Open
2nd boom pedal Neutral Curled 30w3 27v33

Travel pedal Stop Max. 60w6 54v66

. A 150 mm
from fulcrum
Brake pedal Zero Max. 30w3 27v33

20-3
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Raise boom 2.6w0.3 Max. 3.5

. Engine speed: high idling
Operating force for control of levers and pedals

Lower boom . Oil temperature: 45v55ëC 2.6w0.3 Max. 3.5

. Instrument coupling at centre
Bucket curled-open of control lever knob 2.0w0.3 Max. 2.7
. Instrument coupling on outside
edge of pedal control
Arm open-close 2.6w0.3 Max. 3.5

Swing (R.H.-L.H.) 2.0w0.3 Max. 2.7

Blade control and outriggers kg 2.0w0.3 Max. 2.7

Fuel control lever 3.0w0.3 2.7v3.3

Boom swing pedal 9.0w2 7.0v11.0

2nd boom pedal 8w2 6.0v10.0

Travel pedal 4w0.5 3.5v4.5

. A 150 mm
from fulcrum
Brake pedal 50 2 50 2

1st Section 280/350 5 280/350 +15

± 10
Main valve

2nd Section 280/350 ± 10

pressure

5 280/350 +15
bar
3rd Section 200w5 200w15
+ 0
Servocontrols (safety) 45 ± 4.5 35v40

Raise 320w5 320w15

Boom
Lower 220w5 220w15

Arm 320w5 320w15

Hydraulic pressure (Reducing valve)

. Engine speed: high idling

Bucket 320w5 320w15
. Oil temperature: 45v55ëC
. Check one circuit at a time
Swing control valve 190/160w5 190/160w15

Blade - outriggers 200w5 200w15

bar
Boom swing control valve 320w5 320w15

2nd boom control valve 350w5 350w15

Travel 350w5 350w15

+ 0
Servocontrols 35 ± 3.5 30v35

Steering 140 5 135v150

. Engine speed : low idling

Braking 70 1 68v75
. Oil temperature 45v55ëC

20-4
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Work equipment at max. reach

Braking angle D0400410 Degrees Max. 60ë Max. 80ë

(mm) (400) (540)
. Load in the bucket: 540 kg
. Engine speed: high idling.
. Oil temperature: 45v55ëC
. Make centring marks on the outer swing
circle rings. Rotate the upper turret 360ë
and stop. Measure the difference between
the marks after stopping.

Working equipment at max. reach

90ë Ð Ð

Time taken to start swing sec

D0400410

. Engine speed: high idling 180ë 4.3w0.4 Max. 5.1

. Oil temperature: 45v55ëC
. Time taken also from starting posi-
tion at 90ë and 180ë.
Swing

Working equipment at max. reach

Time taken to swing sec Max. 35 34v41

D0400410
. Engine speed: high idling
. Oil temperature: 45v55ëC
. Make one turn to settle machine.
. Measure the time taken to make 5 full
swings.

15°

Hydraulic drift of swing . Load in the bucket: 540 kg

D0400210 Degrees 0 Ð
. Engine switched off (mm)
. Oil temperature: 45v55ëC
. Brake disengaged (with specific tool)
. Park the machine on a 15ë slope and set
the boom at 90ë with respect to the ground
surface
. On the outer swing circle, mark the position
between turret and track frame.
. After 15 minutes measure the drift.

20-5
. FOR MACHINE

PW95-1
Machine model

Classifi- Standard Permissible

cation Check item Test conditions Unit value value

. Engine speed: high idling

Swing

Internal leakage from swing . Oil temperature: 45v55ëC

motor . Swing block: engaged
,/min 0.608 Max. 1.3
. Measure the leakage

20-6
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Measuring posture

Normal
2050 Min. 1950

Travel motor swing D0400414

rpm
speed (1) (no-load)

For TUV approval

. Engine speed: 2000 rpm
. Oil temperature: 45v55ëC
. Axle blocked 1500 Min. 1400
. Rest the front work equipment on
the ground and push it down to rai-
se the machine
. Measure the speed of the propeller
shaft in 2nd fast gear

Measuring posture

45° Normal

6.6 8.0
Travel

Travel speed (2) D0400411 sec

For TUV approval

. On road travel configuration

. Engine speed: high idling
. Oil temperature: 45v55ëC 9.0 11.0
. On flat ground
. Travel for at least 20 metres and
then check on the time needed to
cover 50 metres.

Hydraulic drift mm 0 Ð
of travel motor 15°

D0400210

. Engine: switched off

. Ignition key in position I
. Oil temperature:: 45v55ëC
. After 1 minute, mark the position; measure
drift for next 5 minutes

20-7
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
. Measuring posture
Travel

Leakage from
travel motor ,/min Max. Ð

. Engine speed: 2000 rpm

. Oil temperature: 45v55ëC
. Working brakes: engaged
. 2nd fast gear engaged
. After 30 seconds start to measure for full
minute

20-8
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible
cation value value
Measuring posture
Boom
A Max. 700 Max. 1140

Total work equipment

(Standard boom) Boom
(Downward movement B Max. 700 Max. 1200
bucket teeth tips) A
B
C Boom
C Max. 700 Max. 1320

D0400412
Boom
A Max. 8 Max. 15

Boom cylinder Boom

(Retraction) . In this position, measure extension B Max. 10 Max. 18
or retraction of each cylinder, and mm
any leakages occurring when a
load is applied to the tips of the Boom
C Max. 13 Max. 25
bucket teeth.
. Horizontal levelled ground
. Bucket: rated load (540 kg) Boom
A Max. 56 Max. 100
. Levers: neutral
. Engine: switched off
Hydraulic drift of working equipment

Arm cylinder . Oil temperature: 45v55ëC Boom

(Extension) . Safety valve disengaged B Max. 60 Max. 110
. Take measurements as soon as
the engine stops
Boom
. Measure the variations every 5 mi-
C Max. 65 Max. 125
nutes and check the total variation
after 15 mins.
Bucket cylinder Max. 18 Max. 30
(Retraction)
Measuring posture Boom
Max. 700 Max. 1250
Total work equipment A
(Downward movement Boom
Max. 700 Max. 1300
of tips of bucket teeth) B
(2-piece boom) Boom
C Max. 700 Max. 1450
A Boom
B
A Max. 10 Max. 18
C
Boom
Boom cylinder Max. 13 Max. 25
(Retraction) D0400413 B
Boom
C Max. 18 Max. 35

. In this position, measure extension Boom

A mm Max. 46 Max. 90
and retraction of each cylinder,
and any leakages when a load is ap- Boom
2nd boom cylinders plied to the tips of the bucket teeth. Max. 50 Max. 95
(Retraction) B
. Horizontal levelled ground Boom
. Bucket: rated load (540 kg) C Max. 55 Max. 100
. Levers: neutral
Boom
. Engine: switched off
A Max. 56 Max. 100
. Oil temperature: 45v55ëC
Boom
Arm cylinder . Safety valve disengaged Max. 60 Max. 110
(Extension) B
. Take measurements as soon as the
engine stops Boom
C Max. 65 Max. 125
. Measure the variations every 5 mi-
Bucket cylinder nutes and check the total variation
(Retraction) after 15 mins. Max. 45 Max. 80

20-9
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible
cation value value
Boom
A Max. 16 Max. 30

Boom swing Boom

(Standard boom) B Max. 18 Max. 35

Boom
15°
C Max. 22 Max. 40
D0400273 mm
Boom
. Engine: switched off A Max. 19 Max. 35
. Oil temperature: 45v55ëC
Boom swing . In the same position as above, park Boom
(boom and 2-piece boom) the machine on a 15ë slope and B Max. 21 Max. 40
bring the turret round to 90ë. Mea-
sure the extension and retraction of Boom
the cylinder after 15 mins. C Max. 25 Max. 48
Hydraulic drift of working equipment

Outriggers D0400415 mm Max. 5 Max. 8

. Engine speed: high idling
. Oil temperature: 45v55ëC
. Safety valve cut out
. Bring the outriggers to half stroke and mea-
sure their height from the ground.
Measure the downward after 15 mins.

Blade
(measure the downward D0400427
mm Max. 5 Max. 8
movement of the edge of
the blade) . Engine: switched off
. Oil temperature: 45v55ëC
. Safety valve disengaged
. Raise the blade and measure the height of
the edge from the ground.
Measure the downward after 15 mins.
H Check one cylinder at a time

Boom Max. 3.3 Max. 13.5

Internal cylinder leankage

2nd boom (2 cylinders) Max. 2.0 Max. 8.0

(each cylinder)
. Engine speed: high idling
Arm . Oil temperature: 45v55ëC Max. 2.4 Max. 9.6
. Check leakages: on the cylinder on the side
cc/
Bucket oppsite to the one under pressure Max. 2.0 Max. 8.0
min
H Check one cylinder at a time
Boom swing H For the 2-piece boom check the two cylin- Max. 2.4 Max. 9.6
ders individually but simultaneously.
Blade - outriggers Max. 3.3 Max. 13.5
(each cylinder)

Steering Max. 2.0 Max. 8.0

(each cylinder)

20-10
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
. Measuring posture
Boom

Raise
2.0w0.1 Max. 2.4
Bucket teeth on the ground

D0400416

Lower
Cylinder completely 2.3w0.1 Max. 2.8
extended
. Engine speed: high idling
. Oil temperature: 45v55ëC

. Measuring posture
2nd boom

Closed
5.0w0.3 Max. 6.0
Cylinders completely
retracted

Inout
Cylinders completely
D0400417 5.4w0.3 Max. 6.5
extended . Engine speed: high idling
. Oil temperature: 45v55ëC

. Measuring posture
Arm
Closed

3.1w0.2 Max. 3.7

Work equipment

Cylinder completely
retracted
Speed

sec
Inout

Cylinders completely
D0400418
3.8w0.2 Max. 4.5
extended . Engine speed: high idling
. Oil temperature: 45v55ëC

. Measuring posture
Bucket
Curled

4.1w0.2 Max. 5.0

Cylinder completely
retracted
Dump

Cylinder completely
D0400419
2.5w0.1 Max. 3.0
extended . Engine speed: high idling
. Oil temperature: 45v55ëC

. Measuring posture
Boom swing
L.H.

5.9w0.3 Max. 7.0

Cylinder completely
retracted

D0400430
R.H.

Cylinder completely 5.9w0.3 Max. 7.0

extended . Engine speed: high idling
. Oil temperature: 45v55ëC

20-11
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
. Measuring posture

Raise
Outriggers
Max. 2.5
2.1w0.3
Resting on ground

Lower
D0400420
Work equipment

Fully raised 1.6w0.2 Max. 2.0

. Engine speed: high idling
Speed

. Oil temperature: 45v55ëC

sec
. Measuring posture

Raise
Blade
2.2w0.3 Max. 2.6
Blade on the ground

D0400428
Lower
Blade raised to max. 1.5w0.2 Max. 1.8
height
. Engine speed: high idling
. Oil temperature: 45v55ëC

20-12
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Measuring posture

Boom Max. 2 Max. 3

(Standard)

D0400421

. Engine speed: low idling

. Oil temperature: 45v55ëC
. Retract fully the cylinders of the arm and
bucket.
Lower bucket to ground and measure time
taken for chassis to rise from ground.

Measuring posture
Work equipment

Boom
(2-piece boom) Max. 2 Max. 3
Time lags

sec
D0400422
. Engine speed: low idling
. Oil temperature: 45v55ëC
. Retract fully the cylinders of the arm and
bucket.
Extend the 2nd boom fully.
Lower bucket to ground and measure time
taken for chassis to rise from ground.

Measuring posture

2nd boom Max. 2 Max. 3

D0400423

. Engine speed: low idling

. Oil temperature: 45v55ëC
0
. Valvola strozzatore: 60+ 5
. Retract fully the cylinders of the arm and
bucket. Extend the 2nd boom fully. Bring
the boom into a vertical position. Close
completely the 2nd boom and measure the
time taken to increase the pressure.

20-13
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Measuring posture

Arm D0400424 Max. 2 Max. 3

. Engine speed: low idling

. Oil temperature: 45v55ëC
. Bring the boom into a horizontal position.
Retract the cylinder of the arm completely
and then extend it.
Amount of time when arm stops for a mo-
ment.

Measuring posture
Work equipment

Time lags

Bucket Max. 2 Max. 3

D0400425 sec

. Engine speed: low idling

. Oil temperature: 45v55ëC
. Bring the arm into a horizontal position.
Retract the bucket cylinder completely, then
extend it.
Measure the time that elapses between the
bucket stopping at dead centre and then
starting to move again.

Measuring posture

Outriggers D0400426 Max. 0.5 Max. 1

. Engine: low idling

. Oil temperature: 45v55ëC
. Raise the outriggers to their max. height
and then lower them. Measure the time it ta-
kes for the front of the machine to be lifted
off the ground, starting from the time the ou-
triggers contacts the ground.

20-14
. FOR MACHINE

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Measuring posture
Work equipment

Time lags

Blade D0400429 sec Max. 1 Max. 2

. Engine speed: low idling

. Oil temperature: 45v55ëC
. Raise the blade to its max. height, then lo-
wer it.
Measure the time it takes for the rear of the
machine to be lifted off the ground, starting
from the time the blade contacts the
ground.

Machine model PW95-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Engine: 2000 rpm

50 bar 16.8 Min. 15.1
Gear pump P3 . Oil temperature: 45v55ëC
100 bar 16.7 Min. 15.0
(22.9 cc/rev) . Measure the delivery at
50-100-200 bar
200 bar 16.6 Min. 14.9

. Engine: 2000 rpm 50 bar 7.4 Min. 6.7

. Oil temperature: 45v55ëC
Gear pump P4
(12.7 cc/rev) . Valve calibration to MAX: 200 bar 100 bar 7.4 Min. 6.7
. Measure the delivery at
Pumps

50-100-200 bar 200 bar ,/min 7.4 Min. 6.7

. Engine: 2000 rpm
. Oil temperature: 45v55ëC
. Measure (for each pump) the delivery at
50-100-200-300 e 350 bar
Piston pumps (P1 and P2) . Measure the deliveries for See following pages
WORKING MODE in position P
and in position E
. Measure the deliveries for
WORKING MODE in position P
and with the 3-circuit valve functioning

20-15
 Machine model PW95-1

Classifi- . Delivery of individual piston pumps, P1 and P2

cation
. WORKING MODE selector: position P.
. Pump speed: 2000 rpm
P(bar)

350

300

250

STANDARD PUMP
RANGE POMPE
DELIVERY
STANDARD RANGE
200
Pump characteristics

PUMP
LIMITEDELIVERY
DI PORTATA
LOWER
MINIMALIMIT
AMMESSA
150

100

50

0
10 25 50 75 Q (l /min)
D0400177

H When measuring the deliveries with the pumps mounted on the machine, it becomes difficult to use
the accelerator to set the number of engine rpm corresponding to the test speed prescribed for the
pump.
Measure the delivery with the engine set to 2000 rpm, and perform a proportional calculation to find
the delivery value required for the test.
H Engine/pump gear ratio: 1:1.354.

20-16
 Machine model PW95-1

Classifi- . Delivery of individual piston pumps, P1 and P2

cation
. WORKING MODE selector: position E (Mode System).
. Pump speed: 2000 rpm
P(bar)

350

300

250

200
STANDARD PUMP
RANGE POMPE
Pump characteristics

DELIVERY
STANDARD RANGE

150
PUMP DELIVERY
LIMITE DI PORTATA
LOWER
MINIMALIMIT
AMMESSA

100

50

0
10 25 50 75 Q (l /min)
D0400178

H When measuring the deliveries with the pumps mounted on the machine, it becomes difficult to use
the accelerator to set the number of engine rpm corresponding to the test speed prescribed for the
pump.
Measure the delivery with the engine set to 2000 rpm, and perform a proportional calculation to find
the delivery value required for the test.
H Engine/pump gear ratio: 1:1.354.

20-17
 Machine model PW95-1

Classifi- . Delivery of individual piston pumps, P1 and P2

cation
. WORKING MODE selector: position P (3-circuit valve operation)
. Pump speed: 2000 rpm
P(bar)

350

300

250

200
Pump characteristics

STANDARD PUMP
RANGE POMPE
DELIVERY
STANDARD RANGE

150

PUMP DELIVERY
LIMITE DI PORTATA
LOWER LIMIT
MINIMA AMMESSA
100

50

0
10 25 50 75 Q (l /min)
D0400179

H When measuring the deliveries with the pumps mounted on the machine, it becomes difficult to use
the accelerator to set the number of engine rpm corresponding to the test speed prescribed for the
pump.
Measure the delivery with the engine set to 2000 rpm, and perform a proportional calculation to find
the delivery value required for the test.
H Engine/pump gear ratio: 1:1.3\54.

20-18
EQUIPMENT FOR TESTING, ADJUSTING, AND IDENTIFYING FAULTS

Measurement check points Symbol Code Name Q.ty Remarks

Valve clearance A 1 Commercially Feeler gauge 1 Ð

available

1 ATR800090 Compression gauge 1 0-70 kg/cm2

Compression pressure B
2 ATR800130 Adapter 1 Ð

1 ATR800070 Multi-scale tachometer 1 20 - 4000 rpm

Engine speed and propeller C
shaft rotation speed
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm

Commercially Digital temperature

Water and oil temperature D 1 available gauge 1 ± 50 - 1200 ëC

1 ATR800010 Pressure gauge 2 Full scale 600 bar

2 ATR800140 Pressure gauge 1 Full scale 400 bar

E 3 ATR800150 Pressure gauge 1 Full scale 250 bar

Hydraulic pressures and
deliveries
4 ATR800160 Pressure gauge 1 Full scale 100 bar

5 ATR800170 Pressure gauge 1 Full scale 60 bar

F 1 ATR800120 Flowmeter 1 Ð

Thickness of brake disks G 1 ATR500930 Feeler gauge 1 4.5/4.3 (T23 CK)

Drift Test H 1 ATR200380 Tool for checking 1 Ð

drifts and brake line

Parking brake L 1 Commercially Dynamometer 1 Full scale 20 kg

available

20-19
20-20
TESTING AND ADJUSTMENTS MEASURING THE ENGINE SPEED

MEASURING THE ENGINE SPEED

When measuring the speed (rpm) of the engine, do

not touch heated parts and take care not to become
entangled in rotating elements.
C1
H Do not start to measure engine speed until the follow-
ing conditions have been met:
. Engine cooling water temperature: 68v80ëC
. Hydraulic system oil temperature: 45v55ëC
1 - Install and connect the tachometer C1.
H If a stroboscopic tachometer C2 is used, make a
distinct mark on the motor pulley to facilitate the
reading. F0400001

2 - Start the engine and check:

. Low idling without load (accelerator lever in «mini- MIN MAX
mum» position).
. High idling without load (accelerator lever in
«maximum» position).
H Low idling 1000 50 rpm
H High idling 2160w50 rpm

H If the minimum and maximum engine speeds

without load do not fall within the correct range,
check the position stops of the accelerator lever
and the accelerator cable sheathing (See «AC-
CELERATOR LEVER ADJUSTMENT») before F0400002

performing the stress tests.

. Engine rpm with the pumps working.

H Max. speed when working: 2050 50 rpm

H If the efficiency is not within the permissible limits,

call the Authorised Repair Shop to come and give
the engine a diagnostic check.

20-21
TESTING AND ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT

VALVE CLEARANCE ADJUSTMENT

H Adjust the clearance between the valves and the rock-

er arms to the following values: 6
Unit: mm 1
Intake valves Exhaust valves
Engine cold
0.20 0.45

H Adjust (following the ignition order) cylinders 1-3-4-2.

H Normal direction of rotation: COUNTERCLOCKWISE,
as seen from the flywheel.

F0400003

. Locating the cylinders

1 - Remove the valve cover (1).
2 - Rotate the crankshaft in the normal direction until
the intake valve of cylinder no. 4 is about to open
and the exhaust valve of the same cylinder is IN EX EX IN IN EX EX IN

about to close.
Check the clearance of the valves of cylinder no. 1
and adjust them.
3 - With the valves of cylinder number 2 prepared as
Cylinder
Cilindro 1 2 3 4
described for cylinder no. 4 check/adjust the clear-
ance between the valves of cylinder no. 3. D0400215

4 - Having prepared the valves of cylinder no. 1

check/adjust the clearance of the valves of cylin-
der no. 4.
5 - Having prepared the valves of cylinder no. 3
check/adjust the clearance of the valves of cylin- 3
der no. 2. 2

. Adjustment method
Adjust the clearance by inserting the feeler gauge (2)
between the valve and the rocker arm (3) to be ad-
justed. Turn the valve tappet (4) until it touches the
feeler gauge (2). Block the tappet (4) with the nut (5).
D0400216
H Lock the nut and then check the clearance once
again.

. Replacing the valve cover

Clearance
Gioco 4 5
1 - Check the condition of the valve cover seal and
the retaining washers. Clean the sealing surface
of the cylinder head.
2 - Position the valve cover (1) and the lateral protec-
tion. Mount the seals and the flanged nuts (6).
Flanged nuts on the valve cover: (20 Nm)
2.1 kgm

D0400217

20-22
TESTING AND ADJUSTMENTS MEASUREMENT OF COMPRESSION PRESSURE

MEASUREMENT OF COMPRESSION PRESSURE

When measuring the compression, be careful not to

get caught up in the cooling fan, the alternator belt or 1
any other rotating parts.
2
H Test conditions:
. Engine: at running temperature
. Hydraulic oil: 45v55ëC
. Battery: fully charged
. Valve clearance: adjusted (See «VALVE CLEAR-
ANCE ADJUSTMENT»)
1 - Disconnect the high pressure tubes (1).
2 - Remove the nozzle holder (2) of the cylinder to be F0400004

checked.
3 - Install the adapter B2 and connect the pressure
gauge B1.
B1
B2

F0400005

4 - Disconnect the cables (3) from the solenoid valve (4)

that stops the engine.
5 - Turn the engine using the starting motor and measure
3
the compression.
H Compression value:
normal 24v26 kg/cm2 4
minimum permissible 20 kg/cm2
H Measure the compression value once the pres-
sure gauge has stabilised.

F0400006

6 - After measuring the pressure, replace the nozzle

holder and reconnect the high pressure and flow-back
tube.
Nozzle holder retaining screws:
12 Nm (1.2 kgm)
High pressure connector: 19 Nm (1.9 kgm)

H Check all the cylinders.

20-23
TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE FAN-BELT

CHECKING AND TIGHTENING THE FAN-BELT

1. Measuring the tension
1 - Press the belt (1) at the mid-point of the longest
free length and measure the sag.
At a pressure of 4.5 kg, the sag should be 10 mm.
If this value is not found, adjust the tension of the 1
belt. 10 mm

4,5 kg

F0400007

2. Adjusting belt tension

2 1
1 - Unscrew the screws (2) of the alternator (3) and 3
thescrews (4) of the fan-belt stretcher stop.
2 - Turn the alternator (3) to obtain the correct belt
tension (1) and tighten the screws (2) and (4).
3 - Measure the belt tension (1) again.
H If a new belt has been fitted, measure the tension 4
once again after about 20 hours of operation.

F0400008

20-24
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR LEVER

ADJUSTING THE STROKE OF THE ACCELERATOR LEVER

H Test conditions:
. Engine: Switched off, but at working temperature.
. Low idling: within correct range.
. Hydraulic oil: 45v55ëC
. Accelerator lever (8) at the mid-point of its stroke.
1 - Use the stretcher (2) to eliminate clearance in the
jacket (1). 2
2 - Raise the right-hand cover in order to reach the
1
screws (3) and (4).
3 - Unscrew the nuts (5) and (6) and tighten the screws F0400009
(3) and (4) in the support (7).

4 - Move the accelerator lever (8) slowly towards low id-

ling position. Stop this movement when the lever (9) 8 3 8
on the cover of the injection pump comes into contact
6
with the low idling adjustment screw (10).
7
5 - Adjust the screw (3) until it is 0.1 mm from the lever (8)
and lock it in this position with the nut (5). 7
6 - Move the lever (8) towards the high idling position. 5
Stop this movement when the lever (9) on the cover 4
of the injection pump rests against the lead-sealed
high idling adjustment screw (11).
7 - Adjust the screw (4) to 0.1 mm from the lever (8) and
D0400227
lock it in this position with the nut (6).
H After adjustment, replace the right-hand cover
and check that the aperture does not impede
the movement of the lever (8) towards its extreme
positions.
10 9

11

F0400056

20-25
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE

ADJUSTING PPC VALVES CLEARANCE

Adjust PPC valve levers clearance as follows.

Rest the work equipment on the ground and stop the

engine.
Turn the ignition key to position «I» and move the
control levers in all directions to relieve all pressure
in the hydraulic circuits.
Turn the ignition key to position «O» (OFF) and re-
move it.
Put the safety device lever in its «ENGAGED» posi-
tion.
Slowly unscrew the filling-cap of the oil-tank to re- 1
lease any residual pressure.
2
1. Front equipment and swing PPC valves 3
3
1 - Unscrew the retaining nut (1) of the disk (2).
2 - Screw the disk (2) down until it comes into light
contact with the four plungers (3). Tighten it for an-
other 1/8th of a turn (45ë).
H During this adjustment, take care not to acti-
vate the plungers (3).
3 - Secure the position with the retaining nut, tigh-
tened to the specific torque.
Retaining nut: 30w3 Nm

D0400197

2. Blade and outriggers PPC valves

1 - Remove the command PPC valve coupling from
the PPC valve.
1 2
2 - Unscrew the nuts (1) that block the adjustment
3
screws (2).
3 - Tighten the adjustment screws (2) until any clear-
ance has been eliminated. Tighten for a further
quarter of a turn (90ë).
H During this adjustment, take care not to acti-
vate the plungers (3).
4 - Secure the retaining nuts with the specific torque.
Retaining nut: 8w1 Nm

D0400198

20-26
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE

3. 2nd boom and boom swing PPC valves

1 - Unscrew the nuts (1) that block the adjustment
screws (2).
2 - Tighten the adjustment screws (2) until all clear-
ance is eliminated. Tighten for a further quarter
of a turn (90ë). 1
H During this adjustment, take care not to acti-
vate the plungers (3). 2
3 - Secure the adjustment screws with the retaining
nuts, tightened to the specific torque. 3
Retaining nuts: 8w1 Nm

D0400199

4. Travel PPC valve

1 - Tighten the screw (1) until all clearances are elimi-
nated. Tighten a further quarter of a turn (90ë).
H While making this adjustment, take care not to
activate the plunger (2).
2 - Check that the pedal stroke is 25ë. To adjust this
stroke, act on the end-of-stroke screw (3), after
having loosened the nut (4).
25
°

3 - Block the set position by tightening the nut (4) to

the specified torque.
Retaining screws: 8w1 Nm 2
4

3
1

D0400431

20-27
 ADJUSTING THE SAFETY MICROSWITCH - CENTERING THE
TESTING AND ADJUSTMENTS STROKE OF THE BLADE AND THE OUTRIGGERS CONTROL LEVER

ADJUSTING THE SAFETY MICROSWITCH

H Test conditions:
. Engine: switched off but at working temperature.
. Hydraulic oil: 45v50ëC 2
1 - Unscrew the nut (1) that secures the microswitch (2).
2 - Tighten or unscrew the microswitch (2) to the extent
indicated.
H Projection of microswitch: 16 1 mm
3 - Secure it in position with the nut (1).
1

F0400010

2
1

16 0+1

D0400218

CENTERING THE STROKE OF THE BLADE AND THE OUTRIGGERS

CONTROL LEVER

H Test conditions:
. Engine: switched off but at working temperature.
. Hydraulic oil: 45v50ëC
1 - Check that the lever returns to the NEUTRAL position.
2 - Check the state of the springs (1).
3 - Unscrew the nuts (2).
4 - Unscrew the tie-rod (3) in order to move the lever for-
wards, or tighten it in order to move the lever towards
the rear of the machine.
5 - Lock the nuts (2). 1

2
3

F0400011

20-28
TESTING AND ADJUSTMENTS MEASURING THE SWING CIRCLE AXIAL CLEARANCE

MEASURING THE SWING CIRCLE AXIAL CLEARANCE

1. Test procedure
1 - Park the machine on firm, flat ground, and align
the revolving frame with the wheels.
2 - Extend the boom, the arm and the bucket, in such
a way that they cover the maximum radius of ac-
tion when the teeth of the bucket are at the same
height as the lower platform of the revolving
frame.
3 - Use the working brakes to block the machine.

D0400432

4 - Attach a comparator with a magnetic base (1) to

the rear surface of the under carriage (2), and rest 3
1
the tracer on the part machined to support the
swing circle (3).
H Place the tracer as close as possible to the
swing circle.
5 - Preload the comparator by about 1 mm and set
this measurement to zero.

2
F0400253

6 - Close the bucket, position the arm perpendicular Worked zone

Zona lavorata
to the ground and rest the back of the bucket on
the ground.
7 - Force the boom down until the front of the ma-
chine rises, in order to transfer the weight of the
under carriage onto the rear wheels.
8 - Check the movement of the comparator (1) in 1
these conditions. The value read corresponds to
the value of the swing circle axial clearance.
While the machine is raised, take care not to D0400434
place hands or feet beneath the wheels.

9 - Return the machine to phase 2 conditions and

check that the comparator returns to «zero». If it
does not, repeat the test, starting at phase 4.

150 ÷ 200 mm

D0400433

20-29
TESTING AND ADJUSTMENTS BLEEDING AIR - RELEASING RESIDUAL PRESSURE

BLEEDING AIR - RELEASING RESIDUAL PRESSURE

Bleeding air from pumps P1 and P2

H When the hydraulic oil tank is drained, or when the
main pumps are removed for revision or replacement, 2 1
air must be bled from the intake circuit as follows:
1 - Remove the plug (1) of the pump body (2).
2 - Fill the tank with oil up to the level of the hole in
the plug (1).
3 - Replace the plug (1).
Cap: 30 Nm
4 - Continue to fill the tank until the maximum level is F0400016

reached.

Bleeding air from the PPC

valves circuit
1
H When tubing or PPC valves circuit components are
moved, air must be bled, as follows:
1 - With the engine set to minimum, operate the PPC
valves to bring the upper chamber of each spool
to maximum pressure.
2 - While maintaining this situation, slowly loosen the
bleeder plug (1) to let all the air out of the control
circuit of the control valve spool.
F0400017

3 - When oil leaks from the bleeder vent without a

trace of air, tighten the plug once more (1).
Plug: 9 Nm
H Repeat this bleeding process for each control.
H To bleed the speed-redoubling spool for
boom-raising and arm-closing, loosen the
plug of the redoubling spool while raising
the boom or closing the arm.

Bleeding air from the Load Sensing circuit

H When removing the priority valve or the steering unit
on starting up the machine, air must be bled from
the Load Sensing circuit. The procedure is as follows:
1 - Start the engine and leave it running at low idling
speed.
2 - Loosen the outgoing union (1) of the steering unit
(2).
3 - Start turning the steering wheel slowly, and con-
tinue until oil runs out of the union (1) without a
trace of air. 1
4 - Stop turning the steering wheel and tighten the
union (1).
H After the bleeding operation and before start- 2
ing to travel, execute a complete steering ac-
tion with both axles. F0400677

20-30
TESTING AND ADJUSTMENTS BLEEDING AIR - RELEASING RESIDUAL PRESSURE

Bleeding air from the cylinders

H Once the hydraulic cylinders or the tubes connected
to them have been removed, the air must be bled as
follows:
1 - Start the engine and let it run at high idling speed
for about 5 minutes.
2 - Reduce engine speed to low idling, and raise and
lower the boom 4-5 times.
H Lower and raise the boom piston to about 100
mm from the ends-of-stroke.
3 - Increase engine speed to high idling and repeat
the operations described at point 2. Reduce en-
gine speed to low idling and take the piston
through its entire stroke until the hydraulic pump
has reached maximum pressure.
4 - Repeat the operations (starting from point 2) for
the cylinders of the 2nd boom, the arm and the
bucket.

Releasing residual pressure from the circuits

1 - Rest the work equipment on the ground and stop the
engine.
2 - Put the ignition key at position «I» and move the con-
trol lever in all directions to relieve all pressure in the
main hydraulic circuits and the PPC valves.
3 - Turn the ignition key to position «O» (OFF) and re-
move it.
4 - Put the lever of the safety device into the «LOCKED»
position.
5 - Slowly loosen the oil-tank filler-cap to release any re-
sidual pressure. D0400184

Releasing residual pressure from the brake line accumulators

1 - Rest the work equipment on the ground and stop the
engine.
2 - Turn the ignition key to position «I».
3 - Push the button that engages the working brakes sev-
eral times until the accumulators are completely emp-
tied. This condition has been achieved when the
brake pedal will no longer move.
4 - Return the ignition key to position «O» (OFF).

20-31
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

CHECKING AND REGULATING PRESSURE

IN THE HYDRAULIC CIRCUITS
INTRODUCTION
. The control valve is divided into three normally inde-
pendent sections, supplied by pumps P1-P2-P3 re-
spectively.
. Each section is protected against overpressures by a
main (or primary).
The safety valves of sections 1 and 2 can be re-set by
a hydraulic pilot system, whereas the section 3 valve
has a fixed setting and must be lead-sealed after
every re-adjustment.
CONTROL VALVE
DISTRIBUTORE

SEZ. 3 SEZ. 2 SEZ.1

M2

M3 M1

MAIN RELIEF
VALVOLA VALVE
GENERALE
SECTION
SEZIONE 33

MAIN RELIEF
VALVOLA VALVE
GENERALE MAIN RELIEF VALVE
SECTION
SEZIONE 22 VALVOLA
SECTION
GENERALE
SEZIONE 11

P3 BRAKE
P4 POMPA
PUMP
FRENI

A2

DIESEL

P2

P1 A1

D0400435

. The sections consist of the spools that govern:

Sec- Control Ports

tion

Slow travel (Forward-Backward) A1-B1 10 9 8 7 6 5 3 2 1

Arm (Open-Close) A2-B2
1
Boom swing A3-B3 PORTS
UTILIZZI
Boom speed increment C A
Rapid travel (Forward-Backward) A5-B5
B
Bucket (Curl-Dump) A6-B6
2
Boom (Raise-Lower) A7-B7
2nd boom (Raise-Lower) A8-B8

Blade - Outriggers (Lower-Raise) A9-B9 10 9 8 7 6 5 C 3 2 1

3 D0400436
Swing (Left-Right) A10-B10

20-32
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

. The movements of the work equipment (boom, 2nd 1 1

boom, arm, bucket and boom swing) are all protected 2
by independently adjusted safety and anticavitation
valves (1), mounted on sections 1 and 2 of the control
valve.
. Blade and outriggers movements are protected by an-
ticavitation valves (2) mounted on section 3 of the con-
trol valve.

2 1
1
F0400254

. Travel movements are protected by safety/anticavita-

tion valves (3) mounted on the travel motor (4).

3
3

4 4
F0400255

. Revolving frame swing movements are protected by

safety and anticavitation valves (5) that can be re-ad-
justed with a hydraulic pilot system, mounted directly
on the swing motor (6). 5

5
6

F0400292

20-33
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

CHECKING ADJUSTMENT OF VALVES

IN THE CONTROL VALVE

1. Main or primary valves in the three sections of

the control valve.
H Test conditions:
. Engine: at working temperature
. MIN. and MAX. motor speeds: within permis-
sible limits.
. Hydraulic oil: 45v55ëC
. WORKING MODE selector: position P
. Working brakes: engaged.

1 - Connect the pressure gauge E1 (600 bar) to the

adapters M1-M2 and pressure gauge E2 (400
bar) to adapter M3. E1
2 - Start the engine and put the accelerator into the
high idling position.
3 - Check the general pressure for each of the three
sections by means of the following operations: M1
Section 1 - Move the arm to its open or closed
end-of-stroke and check that the pres-
sure gauge connected to the adapter
M1 shows a pressure of 280w5 bar. M2
Section 2 - Bring the bucket to its open or closed F0400256

end-of-stroke and check that the pres-

sure gauge connected to the adapter
M2 shows a pressure of 280w5 bar. E2
Section 3 - Raise the blade to the end of its stroke
and check that the pressure gauge
connected to the adapter M3 shows
a pressure of 200w5 bar.
4 - Check the re-adjustment pressure of the safety
valves of sections 1 and 2 using the following pro-
cedures:
1 - Select the 2nd slow gear and a travel direction, M3
then press the travel pedal down completely.
F0400257
Check that the pressure gauge connected to
the socket M1 shows a pressure of 350w5 bar.
2 - Select the 2nd fast gear and the same travel di-
rection, and press the travel pedal down com-
pletely. Check that the pressure gauge con-
nected to the socket M2 shows a pressure of
350w5 bar.
If the opening pressures of the valves do not corre-
spond to the values indicated, they must be adjusted.
(See «1. Re-adjustable Main relief valves» and «2.
Valves with a Fixed Setting»).

20-34
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

2. Secondary valves: Boom - 2nd boom - Arm -

Bucket - Boom swing E1
H Test conditions:
. Engine: at working temperature
. MIN. and MAX. engine speed: within correct
range
. Hydraulic oil: 45v55ëC M1
. WORKING MODE selector: position P
. Travel brakes engaged.

1 - Connect two pressure gauges E1 (600 bar) to the

adapters M1-M2. M2
2 - Start the engine and put the accelerator into the
F0400256

MAX position.
3 - Adjust the main safety valves of sections 1 and 2
to a pressure of 370 w 5 bar.
4 - Executing one movement at a time, bring the pis- M2 9 7 5
ton to the end of its stroke in both directions. Use
the pressure gauge to check the maximum pres-
sure of the secondary valve corresponding to the
movement executed.
H The settings of the secondary valves are:

Cylinder Setting of the secondary valves

Left (1) 320w5 bar
Boom swing
Right (2) 320w5 bar
Open (3) 320w5 bar 10 8 6 2 4 M1
Arm
Closed (4) 320w5 bar
Closed (5) 320w5 bar 1 3
Bucket
Open (6) 320w5 bar
Raise (7) 320w5 bar
Boom
Lower (8) 220w5 bar
Open (9) 350w5 bar
2nd boom
Closed (10) 350w5 bar

H If the opening pressures of the valves do not

correspond to the values indicated, they must
be adjusted. (See «Valve Adjustment»). D0400437

20-35
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

VALVE ADJUSTMENT
E1
1. Re-adjustable main relief valves for sections 1-2.
H Always set the maximum pressure first, and then
the working pressure.
H Check one section at a time.

1 - Disconnect the pilot system tubes (1) from the two M1

valves and seal them securely.
2 - Connect two pressure gauges E1 (600 bar) to the
adapters M1-M2.
3 - Loosen the nut (2) of the main relief valve of sec-
M2
tion 1 and completely screw down the cartridge (3) F0400256

of the piston. Secure this position with the nut (2).

4 - Start the engine and put it into low idling speed.
5 - Loosen the nut (4) of the cartridge (5).
6 - Select a first gear (forward or backward) and
slowly press the travel pedal down as far as it will
go.
7 - With the pedal fully depressed, rotate the car-
tridge (5) to regulate the maximum pressure of
section 1 of the control valve.
H Pressure setting: 350w5 bar
. To INCREASE pressure turn in a CLOCK- 1
WISE direction.
. To DECREASE pressure, turn in a COUN- F0400258

TERCLOCKWISE direction.
8 - Use the nut (4) to secure this position.
Lock nut: 10w1 Nm 3
9 - Loosen the nut (2) and, still with the pedal fully de- 10 6 1 Nm
pressed, loosen the cartridge (3) in order to set the 2
normal working pressure.
H Pressure setting: 280w5 bar
. To INCREASE pressure turn in a CLOCK-
5
WISE direction. 10 6 1 Nm
. To DECREASE pressure, turn in a COUN- 4
TERCLOCKWISE direction.
10 - Use the nut (2) to secure this position.
Lock nut: 10w1 Nm
11 - Repeat these operations from point 3 to point 9 for
the main relief valve of section 2 of the control
valve.
H The second rapid gear must be used for this
calibration.
12 - Release any residual pressures in the servocon-
trols.
13 - Reconnect the tubes (1).

D0400438

20-36
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

2. Valves with a fixed setting

H This setting is valid for:
. Main relief valve of section 3 of the control 3
valve. 2
. Secondary valves of the boom cylinder 1
. Secondary valves of the 2nd boom cylinder
. Secondary valves of the arm cylinder
. Secondary valves of the bucket cylinder
. Secondary valves of the boom swing cylinder
. For these valve adjustments the machine
should be prepared in the same way as for
the pressure tests.
. Before adjusting pressures for the 2nd
boom, set the safety valve of section 2 of
the control valve to a pressure of 370w5 bar.
1 - Unscrew the locknut (1).
2 - Adjust pressure with the adjusting screw (2).
. To INCREASE pressure, turn in a CLOCK-
WISE direction.
. To DECREASE pressure, turn in a COUN-
TERCLOCKWISE direction.
3 - Block the position with the nut (1).
Locknut: 10w1 Nm
D0400204
On completion of the adjustment, attach seals
(3) to protect against any unauthorised tamper-
ing.
. Restore the maximum pressure of section 2
of the control valve.

20-37
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

3. Safety valves for the swing motor

H Test conditions:
. Engine: at working temperature
. Hydraulic oil: 45v55ëC
. Main safety valve of the 3rd section: set to the
permissible values.
. WORKING MODE selector: position P
1
. Revolving frame: swing lock pin inserted.

3
F0400259

Preparation
1 - Disconnect the servocontrol hoses (1) and (2) of 6
4 5
element (3) of the swing, and plug them to prevent
entry of impurities.
2 - Disconnect the tubes (4) and (5) from the selection
valve (6) and cap the inputs a and c.
3 - Connect two extension tubes (7) and (8) of the
same section to tubes (4) and (5).
H Length of the extensions: approx. 700 mm.
4 - Connect the ends of the extension tubes to the el-
bow on the swing element. F0400023

H Connect: tube 7 to elbow a10

tube 8 to elbow b10
5 - Disconnect the tubes (2-9) and (1-10) from the tee
(11) and (12) in order to adjust the safety valves.
7
H Cap the tubes and elbows to prevent entry of
impurities.
H Mark the tubes to facilitate subsequent reas- 8
sembly of the hydraulic circuit.

4
a
a10 6

7 5
c

11
1
3
10
8 9
12

2 b10 D0400219

20-38
 CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

Setting
H First set the maximum pressure and then the working E2
pressure.
H Check one valve at a time.
1 - Connect the pressure gauge E2 (400 bar) to the adap-
ter M3 of the 3rd section of the control valve.
2 - Unscrew the nut (1) of the valve to be tested and tight-
en the cartridge (2) of the adjustment piston as much
as possible. Secure the position with the nut (1).
3 - Start the motor and bring it up to low idling speed. M3
4 - Unscrew the locknut (3). F0400257

5 - Swing the revolving frame to the side of the valve

being adjusted.
2
6 - With the swing control lever at the end of its stroke, 10 6 1 Nm
turn the cartridge (4) to regulate the maximum pres-
sure. 1
. To INCREASE pressure, turn in a CLOCKWISE
direction. 4
. To DECREASE pressure, turn in a COUNTER- 10 6 1 Nm
CLOCKWISE direction. 3
H Adjustment pressure: 190w5 bar.
7 - Secure the position of the cartridge (4) with the nut (3).
Locknut: 10w1 Nm
8 - Unscrew the nut (1) and, with the swing control lever
still at the end of its stroke, unscrew the cartridge (2)
until the working pressure can be read on the pres-
sure gauge.
H Working pressure: 160w5 bar.
. To DECREASE pressure, turn in an COUNTER-
CLOCKWISE direction.
. To INCREASE pressure, turn in a clockwise direc-
tion.
9 - Secure the position of the cartridge (2) with the nut (1).
Locknut: 10w1 Nm
10 - Repeat the same operations on the other valve.
11 - Switch off the motor and release any residual pres-
D0400185
sures as indicated at the beginning of the paragraph.
12 - Re-assemble the hydraulic circuit.

20-39
 CHECKING THE INTERVENTION POINT OF THE
TESTING AND ADJUSTMENTS SUMMATION HORSEPOWER CONTROL

CHECKING THE INTERVENTION POINT OF THE SUMMATION

HORSEPOWER CONTROL
H Test conditions:
E1
. Engine: at working temperature.
. Hydraulic oil: 45v55ëC
. WORKING MODE selector: position P.

Relieve the residual pressures from the circuits (See

«RELEASING RESIDUAL PRESSURES FROM THE M1
CIRCUITS»).

1 - Disconnect the hoses (1) and (2) from the ports X2

and X3 and cap them. M2
2 - Connect the two pressure gauges E1 (600 bar) to the F0400256

adapters M1 and M2 of the control valve (1st and 2nd

section).
3 - Connect the pressure gauge E3 (250 bar) to the port G
of the pump.
4 - Start the engine and bring it up to high idling speed.
5 - Raise the boom completely and close the arm comple-
tely.
G
6 - Operate the control levers of the boom and arm simul-
taneously to pressurise the pumps.
H The pumps should be pressurised slowly and si-
multaneously. 2
7 - Check at which point the pressure gauge E3 (250 bar) 1 F0400024

starts to indicate pressure (intervention point).

H Intervention point: 155w5 bar
H If the intervention is early or delayed, adjust it with
the screw (3) after having loosened the nut (4).
. To BRING FORWARD the intervention point,
turn in a COUNTERCLOCKWISE direction. 3
. To DELAY the intervention point, turn in a
CLOCKWISE direction. 4
On completion of the adjustment, apply the seal-
ing cap to protect against tampering.

8 - Stop the engine, release any residual pressures and

re-assemble the hydraulic circuit.
F0400025

20-40
 CHECKING THE INITIAL HORSEPOWER CONTROL
TESTING AND ADJUSTMENTS POINT FOR THE 3-CIRCUIT CONTROL VALVE

CHECKING THE INITIAL HORSEPOWER CONTROL POINT

FOR THE 3-CIRCUIT CONTROL VALVE

H Test conditions: E3 G
. Engine: at working temperature
. Hydraulic oil: 45v55ëC
. WORKING MODE selector: position E
. Revolving frame:swing lock pin inserted

Release any residual pressure from the circuits (See

«RELEASING RESIDUAL PRESSURES FROM THE
CIRCUITS»).
1
1 - Disconnect the hose (1) from the port X2 and cap it. F0400026

2 - Connect the two pressure gauges E1 (600 bar) to the

adapters M1 and M2 of the control valve (1st and 2nd
section). E1
3 - Connect the pressure gauge E3 (250 bar) to the port G
of the pump.
4 - Start the engine and bring it up to high idling speed.
5 - Raise the boom completely and close the arm comple- M1
tely.
6 - Move the swing control lever to the end of its stroke in
one direction or another. At the same time, slowly
move the arm-closing lever and activate the boom- M2
raising lever in order to pressurise the pumps.
F0400256

H The pumps should come up to pressure slowly

and simultaneously.
7 - Check at which point the pressure gauge E3 (250 bar)
starts the pressure-indicating movement (intervention
G
point).

H If the intervention is early or delayed, adjust it with

the cartridge (1) after having loosened the nut (2).
. To BRING FORWARD the intervention point,
2
turn in a CLOCKWISE direction.
. To DELAY the intervention point, turn in an
COUNTERCLOCKWISE direction.
1
H Intervention point: 110w5 bar.
8 - Stop the engine, release any residual pressures, and F0400027

re-assemble the hydraulic circuit.

20-41
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING PRESSURES
IN THE SERVOCONTROL SUPPLY UNITS

CHECKING AND ADJUSTING PRESSURES IN THE

SERVOCONTROL SUPPLY UNITS

H Test conditions: 1
. Engine: at working temperature
. Hydraulic oil: 45v55ëC

Release any residual pressures from the circuits

(See «RELEASING RESIDUAL PRESSURES FROM
THE CIRCUITS»).

1. Reduction valve
1 - Connect the pressure gauge E4 (100 bar) to the
adapter (1). F0400435

2 - Start the engine and move the accelerator into its

minimum position.
E4
3 - Put the lever of the safety device in its working po-
sition, (UNLOCKED). 1
4 - Bring a servocontrol circuit up to pressure by op-
erating the work equipment. Check the working
pressure on the pressure gauge E4.
H Working pressure: 35 3.5 bar.
H If the working pressure is lower that the per-
missible value, insert a shim (2) underneath
the spring (3) of the reduction valve.
H The 1 mm shim changes the pressure by 1.8 F0400029

bar.

2. Safety valve
1 - Remove the reduction valve and place a 7 mm
shim (2) underneath the spring (3), to increase
the working pressure for the purpose of checking
the safety valve.
2 - Replace the reduction valve.
3 - Start up the engine and move the accelerator into
its minimum position.
4 - Move the lever of the safety device into its working
position (UNLOCKED).
5 - Bring a servocontrol circuit up to pressure by op-
erating the work equipment. Check the working
pressure on the pressure gauge. This value will
correspond to the pressure at which the safety
valve intervenes.
H Working pressure: 45 4.5 bar. 5
H If the working pressure is lower that the per-
missible value, insert a shim (4) underneath
the spring (5). 4
H The 1 mm shim changes the pressure by 7.1
bar. Safety
Valvola di 3
6 - Release any residual pressures and remove the valve
sicurezza
shim (2) in order to return the reduction valve to 2
its working pressure. Reducing
Valvola
valve
riduttrice
7 - Seal the valve against tampering. D0400225

20-42
TESTING AND ADJUSTMENTS ADJUSTING THE MAIN SAFETY VALVE OF PUMP P4

ADJUSTING THE MAIN SAFETY VALVE OF PUMP P4

H Test conditions:
. Engine: at working temperature
E2
. MIN. and MAX. swing speed: within the correct
range
. Hydraulic oil 45v55ëC
. WORKING MODE selector: position P
. Machine: with safety devices engaged on all work
equipment.

Test M4
1 - Set the main safety valve of section 3 of the control F0400302

valve to a value of 220w5 bar (See «2. Valves with a

fixed setting»).
2 - Release any residual pressures from the circuits (See
«RELEASING RESIDUAL PRESSURES FROM THE
CIRCUITS»). E2
3 - Disconnect the supplementary equipment from the
hydraulic system. Cap the equipment tubes to prevent
entry of impurities.
4 - Cap the tubes of the hydraulic system of the machine.
5 - Connect the pressure gauge E2 (400 bar) to the adap-
ter M4 of the priority valve. M4
6 - Start the engine and put the accelerator into its high F0400260
idling position.
7 - Operate the pedal control of the hammer, or the dual-
control push-button mounted on the right-hand lever.
Check the pressure reading on the gauge. A
H Normal pressure: 200w5 bar.

Adjustment
1 - If the pressure is not within the normal range, set the
valve (1) by turning the adjusting screw (2).
. To INCREASE the pressure, turn in a CLOCK-
WISE direction.
. To DECREASE the pressure, turn in an COUN-
TER-CLOCKWISE direction. F0400032

2 - Secure this position with the nut (3).

3 - Bring the adjustment of the main valve of section 3 of A
the control valve back to a normal value of 200w5 bar. 1 2
4 - Stop the engine and release any residual pressures in
the equipment circuits by repeatedly operating the
concrete breaker pedal button or the dual-control but-
ton on the right-hand lever.

3
D0400201

20-43
TESTING AND ADJUSTMENTS MEASURING PUMP DELIVERY

MEASURING PUMP DELIVERY

H Test conditions:
. Engine: at working temperature.
. Hydraulic oil: 45v55ëC
. WORKING MODE selector: position P.
. Work equipment on the ground and made safety.

1. Connecting the flowmeter

1 - Disconnect the delivery tube of the pump to be
checked.
ToAll'utilizzo
utilization
2 - Connect the delivery outlet of the pump to the inlet
port of the flowmeter F1.
3 - Connect the discharge port of the flowmeter to the 1
tube disconnected in phase 1.
From pompa
Dalla pump
4 - Mount a rev. counter to measure that the delivery
from the tested pump is within the tolerances al-
lowed for the rated engine rpm.
F1
H If an electronic pressure-transducer type rev.
counter is installed on a diesel supply tube
D0400220
to the nozzle, make sure that it is mounted
at a distance from the hose-clamps.

2. Measurement for pumps P1 - P2

1 - Start the engine and bring it up to a speed of 2000
rpm.
2 - Adjust the delivery pressure with the flowmeter
knob (1) and measure the effective delivery of
the pump.
H Perform this test several times, varying the
pressure to cover the entire duty range
(max. 350 bar).
3 - Stop the engine, release any residual pressures
and repeat the same operations for pump P2.
4 - Check the delivery/pressure values against the
values in the diagram given in the «TECHNICAL F1
1
DATA». If the measured values differ by more than
7% from the nominal values, the pumps need an F0400033

overhaul.

3. Measurement for pumps P3 and P4

1 - Start the engine and bring it up to a speed of 2000
rpm. F1
2 - Check on the no-load delivery, and then on deliv- 1
ery at pressures of 50. 100 and 200 bar.
3 - Stop the engine and release any residual pres-
sures.

If the measured values differ from the minimum

permissible values, overhaul the pumps. F0400034

20-44
 CHECKING THAT THE PRIORITY VALVE
TESTING AND ADJUSTMENTS IS FUNCTIONING CORRECTLY

CHECKING THAT THE PRIORITY VALVE IS FUNCTIONING

CORRECTLY
H Test conditions:
. Engine: at working temperature.
. Hydraulic oil: 45v55ëC E3
. Working brakes: engaged.

1. Checking the Load Sensing signal

1 - Connect pressure gauge E3 (250 bar) to the adap-
ter M4.
2 - Start the engine and put it into swing speed of M4
2000 rpm.
F0400293

3 - Use the pressure gauge E3 to check the pressure

value when the steering wheel is not moving.
4 - Start to turn the wheel very slightly and see
whether the pressure increases.
5 - Complete the steering action and check that the
pressure increases up to the normal value
(140 5 bar) when force is applied to the steering
wheel.
H If the pressure as measured by the pressure
gauge shows no variation when the steering 1
wheel is turned, or if excessive effort is re-
quired on the steering wheel to execute the
steering movement, check that the priority F0400261
valve (1) is functioning correctly.

2. Checking that the priority valve is functioning 2

correctly 3
1 - Remove the priority valve (1).
(See «30. DISASSEMBLY AND ASSEMBLY»).
2 - Remove the cap (2) of the «PP» port and check (by
pushing with a rod) that the spool (3) moves freely
along the entire length of the stroke. 4
3 - Check that the nozzle (4) inside the spool is free of
obstructions. 1
4 - Re-assemble the priority valve (1). D0400460

5 - Start the engine and bleed the Load Sensing cir-

cuit. (See «BLEEDING AIR FROM THE LOAD
SENSING CIRCUIT»).
6 - Execute several steering operations and, if the dif-
ficulty persists, overhaul or replace the steering
unit.

20-45
 CHECKING AND REGULATING THE PRESSURE
TESTING AND ADJUSTMENTS OF THE STEERING SYSTEM

CHECKING AND REGULATING THE PRESSURE OF THE

STEERING SYSTEM
H Test conditions:
. Engine: at working temperature
. Hydraulic oil: 45v55ëC E3
Test
1 - Connect pressure gauge E3 (250 bar) to the adapter
M4.
2 - Start the engine and put it into high idling and turn the
steering wheel as far as it will go.
M4
3 - Apply extra force to the steering wheel in its fully
turned position. F0400293

H Normal pressure: 140 5 bar

4 - Repeat this check while steering in the other direction.
3

Adjustment 5
If the pressure is not within permissible limits, it can be ad- 4
justed from the safety valve (1) of the steering unit (2).
1 - Remove the cap (3).
1
2 - Using a 4 mm screw wrench, adjust the maximum
pressure through the screw (4).
. To INCREASE pressure turn in a CLOCKWISE di- 2
rection. D0400445
F0400262

. To DECREASE pressure, turn in a COUNTER-

CLOCKWISE direction.
3 - Stop the engine and replace the cap (3), making sure
that the washer (5) is properly seated.
Cap: 50w10 Nm

20-46
TESTING AND ADJUSTMENTS CHECKING LEAKAGES IN THE STEERING CYLINDERS

CHECKING LEAKAGES IN THE STEERING CYLINDERS

H Test conditions:
. Engine: at working temperature. 1
. Hydraulic oil: 45v55ëC
. Working brakes: engaged.
. Maximum steering pressure: within permissible
limits.
H First check the front axle cylinder and then the rear
axle cylinder.
3
2
1 - Start the engine and execute a full steering movement
in one of the two directions.
F0400263
2 - Stop the engine.
3 - Disconnect the supply hose (2) from the cylinder (1)
on the side of the fully extended piston rod (3). Seal
the hose securely.
4 - Connect a provisional hose to the cylinder (1) to col-
lect any leaking oil.
5 - Start the engine and put it into high idling.
6 - Apply maximum force to the steering wheel and hold
that position for 30 seconds; measure any oil lea-
kages for another full minute.
7 - Release the steering wheel, bring the engine back to
low idling, then switch off.
8 - Check whether the amount of leakage is normal (See
«NORMAL OR STANDARD TECHNICAL DATA»).
H Check the cylinder for one side only, since just
one seal separates the two chambers.
9 - Re-assemble the hydraulic connections and execute
several full steering movements in both directions to
release air from the circuit.
10 - Use the same procedure to check the rear axle cylin-
der after having selected one of the two types of steer-
ing.

20-47
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

CHECKING THE BRAKING SYSTEM

H Test conditions:
. Engine: at working temperature 2
. Hydraulic oil: 45v55ëC

1. Checking accumulator recharging pressure

1 - Connect pressure gauge E2 (400 bar) to the adap-
ter (1) of the accumulator line (2).
2 - Start the engine and put it into low idling.
1
3 - Depress the brake pedal completely to fully re- E2
charge the accumulators. Check that the maxi- F0400264

mum accumulator recharging pressure corre-

sponds to the normal value (150w5 bar).
4 - Using the push-button that engages the working
brakes, perform several braking actions to check
whether or not the accumulators start to recharge
when the normal minimum pressure is reached
(120 5 bar).

Adjustment
If the pressures are not within normal values, proceed
as follows:
3
Pressure at which to start recharging the accumu-
lators
This setting also causes variation in the maxi-
mum recharging pressure of the accumulators.
It will therefore also be necessary to perform
the adjustment described in the next paragraph.

1 - Loosen and remove the protective cap (3) and the

washer (4). 4
F0400265
2 - Depress the brake pedal several times to reduce
pressure in the accumulators and then measure
the pressure at which the recharging operation
will start.
3 - Loosen the nut (5) and adjust the initial recharging
pressure using the adjustment screw (6).
H Initial recharging pressure: 120 5 bar.
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCK-
WISE direction.
5 6
4 - Secure the adjustment screw (6) with the nut (5).
F0400266

20-48
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

Maximum accumulator recharging pressure

1 - Loosen the nut (7) and adjust the pressure by
screwing or unscrewing the screw (8). 7
H Maximum pressure: 150w5 bar.
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCK-
WISE direction.
8
2 - Secure the screw (8) with the nut (7).
3 - Re-assemble the washer (4) and the cap (3). F0400294

2. Checking the braking pressure

1 - Connect the pressure gauge E3 (250 bar) to the E3
adapter of the brake line (9).
2 - Start the engine and put it into low idling.
3 - Recharge the accumulators.
4 - Completely depress the brake pedal and check
9
whether or not the pressure is normal (70 1 bar).

F0400267

Adjustment of braking pressure

If the pressure is not within normal values, proceed as
follows:
1 - Raise the rubber sleeve (10) and loosen the nut 12
(11) that secures the end-of-stroke screw (12).
2 - With the pedal fully depressed, adjust the braking
pressure using the screw (12).
H Braking pressure: 70 1 bar.
. To INCREASE pressure turn in a CLOCK-
WISE direction. 11 10
. To DECREASE pressure, turn in a COUN- F0400268

TERCLOCKWISE direction.
3 - Secure the position of the screw (12) with the nut
(11).
Lock nut: 45w4 Nm 12

F0400269

20-49
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

3. Check the leaktightness of the hydraulic braking

circuit
1 - Connect the pressure gauge E2 (400 bar) to the
adapter of the braking line.
2 - Start the engine and put it into low idling.
3 - Execute several braking actions to empty the ac-
cumulators and then recharge them completely
(150 5 bar). E2

4 - Stop the engine and return the ignition key to po-

sition «I» in order to supply voltage to the electric
F0400295
circuits.
5 - Use the working brake engagement button to exe-
cute a braking action.
6 - Watch the pressure shown by pressure gauge E2
for two minutes. During this period the pressure
value should not vary with respect to the first read-
ing.
H If variations in the braking pressure are observed,
verify in the following sequence:
1 - Any visible leakages in the system.
2 - Internal leakages in the swivel joint (For de-
tails, see «MEASUREMENT OF INTERNAL
OIL LEAKAGES IN THE SWIVEL JOINT»).
3 - The leaktightness of the brake groups (For de-
tails, see «4. Checking the leaktightness of the
brake groups»).

4. Checking the leaktightness of the brake groups

This test envisages two phases:
1 - Identification of the defective axle.
2 - Identification of the defective brake group.

Identification of the defective axle

We shall describe here the procedure for the front
axle only, since the procedure for the rear axles is
identical.
1 - Release all residual pressure in the accumulators.
2 - Disconnect the flexible hose (14), leading out of
the swivel joint (branch 1), from the rigid front axle
supply tube (13) (on the LH side of the lower E3
frame). 14
15
3 - Insert apparatus H1 between the two tubes, con-
necting it in such a way that the cut-off cock (15)
is connected to the flexible hose leading out of 13
the swivel joint.
H1
F0400270

20-50
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

4 - Attach the pressure gauge E3 (250 bar) to the

adapter and open the cock (15) of apparatus H1.
5 - Start the engine and put it into low idling.
6 - Push the working brake engagement button to re-
charge the accumulators.
7 - Check that the braking pressure indicated by the
pressure gauge E3 is 70 1 bar.
8 - Close the cock (15) of apparatus H1 in order to
maintain pressure in the branch under examina-
tion, then stop the engine.
9 - Watch the pressure indicated by pressure gauge
E3 for 2 minutes.
. If the pressure value goes down, it means that
at least one piston in one of the two brake
groups under examination is defective. Test
the defective group, following the procedure
described in the next paragraph.
. If the pressure value remains constant, the
leakages are occurring in the rear axle.

Identification of the defective brake group

1 - Insert apparatus H1, complete with the pressure
gauge E3, into the supply line of the defective
axle.
2 - Disconnect the supply tube (17) of one of the two
brake groups from the Tee (16). Seal the free side 16
of the Tee (16) securely.
3 - Following the same procedure indicated for identi-
fication of the defective axle (from point 5 to point 17
8), pressurise the brake group that is still con-
nected and close the cock (15).
4 - Watch the pressure indicated by the pressure
gauge E3 for two minutes.
. If the pressure value goes down, it means that
at least one brake piston is defective.
. If the pressure value remains constant, the F0400271

other brake group is defective.

1 - Further confirmation of the leakage of one or

more brake pistons can also be found
through an increase in the level of oil in the
central body of the axle, or in the planetary.
2 - If such an oil increase, and hence mixing of
oils, are found as a result of brake piston
leakage, change all sealing rings between
axle sections and carry out a complete
change of the lubrication oil.

20-51
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

5. Checking the alarm pressure switch setting for

insufficient braking pressure
2
Before performing this test, first verify that there are
no leakages in the brake lines.
1 - Connect pressure gauge E2 (400 bar) to the adap-
ter (1) of the accumulator line (2).
2 - Start the engine and put it into low idling.
3 - Execute several braking actions with the pedal un-
til the accumulators are completely recharged 1
(150 5 bar). E2
F0400264
4 - Stop the engine and return the ignition key to po-
sition «I», in order to supply voltage to the electri-
cal circuits.
5 - Using the working brake engagement button, exe-
cute several braking actions (count them) while
keeping a check on both the warning light that in-
dicates insufficient braking pressure and the pres-
sure gauge E2.
The warning light should come on when the fol-
lowing conditions have been reached:
18
. residual pressure: 90 2 bar. 19
. minimal number of braking actions: 15.

Adjustment F0400278

If the warning light comes on at values higher or lower

than 90 2 bar, adjust the intervention setting of the
pressure switch (18) that causes the warning lamp
to light up.
The setting is obtained by turning the screw (19).

. Switching pressure: 90 2 bar

. To INCREASE pressure turn in a CLOCKWISE di-
rection.
. To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction.

20-52
TESTING AND ADJUSTMENTS CHECKING WEAR IN THE BRAKE DISKS

CHECKING WEAR IN THE BRAKE DISKS

1 - Start the engine and put it into low idling.

2 - Execute several braking actions with the working
brakes, until the braking system accumulators are 1
completely recharged.
3 - Stop the engine.
4 - Return the ignition key to the «I» position and press
the button that engages the working brakes.
5 - Remove the filling cap (1) and use the tool G1 to
check the thickness «S».
H Minimum thickness «S»: 4.5 mm
F0400272

6 - Following the same procedure, check all the brake

groups.
1 - If the thickness «S» of one of the two brake
groups of an axle is equal to or less than
the minimum permissible thickness, change
the disks on both brake groups.
2 - After changing the brake disks, bleed air
from the brake line.
(See «BLEEDING AIR FROM THE BRAKE G1
LINES»).

F0400273 D0400461

20-53
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE BRAKE LINES

BLEEDING AIR FROM THE BRAKE LINES

H Bleed air from both axles.

1 - Start the engine and put it into low idling.
2 - Engage and release the working brakes several times, 2
until the accumulators of the brake line are completely
recharged.
3 - Stop the engine.
4 - Return the ignition key to position «I» and press the
button that engages the working brakes.
1
5 - Attach a transparent flexible hose (1) to the bleeding
screws (2) in order to collect the oil. F0400274

6 - Slowly loosen by a half turn the bleeding screw (2) of

one brake group until oil runs out of the screw without
any trace of air.
7 - Tighten the screw (2).
8 - Repeat the bleeding operation for the other brake 2
group. 1
H If the level in the accumulators drops during the
bleeding operation, and the warning light for low
brake oil pressure comes on, interrupt the bleed-
ing operation and recharge the accumulators.
H Once the bleeding operation is concluded, re-
place the protective caps over the screws (2).
F0400275

20-54
TESTING AND ADJUSTMENTS ADJUSTING THE PARKING BRAKE

ADJUSTING THE PARKING BRAKE

H Conditions for the adjustment:

. Engine at working temperature
. Hydraulic oil: 45v55ëC
3 2
While carrying out this adjustment, the engine
must be running to maintain pressure in the
parking brake line. Rest the work equipment,
the blade and, if necessary, the outriggers on
the ground.
Place safety wedges beneath the wheels.

1 - Remove the cover (1) from the under carriage. D0400549

2 - Disconnect the support (2) complete with the diode

box (3). It must be removed completely to give access
to the group to be adjusted.
9 10 8 13
3 - Start the engine and put it into low idling.
4 - Press the button that releases the parking brake in or- 13
der to bring the circuit up to pressure.
5 - Disconnect the cylinder (10) from the levers (4-5), re-
moving in sequence the lock nut (6), the nut (7), the
screw (8), and finally the pin (9) of the cylinder fulcrum
(10). 7
H Check the positions of the washer (13). 13
13 6
6 - Move the cylinder (10) to a position that allows access
to the cylinder coupling lever. D0400439

7 - Using tool L1, pull the lever (4) towards the centre of
the axle with a force of 10 kg.
8 - Adjust the register (11) until a distance of 1.75 mm
has been obtained between the lever (4) and the reg- 11 4
ister (11). Secure this position with the nut (12). 5
10
Nut: 25 3 Nm
9 - Mount the cylinder (10) between the levers (4-5), mak-
ing sure that the levers rest lightly on both the register
screws.
H Position the washers (13) correctly.
Pin fulcrum: 73 3 Nm 12
9 8
Nut for piston rod coupling screw: 49 4 Nm F0400277

Lock nut: 30 2 Nm
10 - Stop the engine.
11 - Reposition the diode box (3) and the cover (1).

D0400462

20-55
TESTING AND ADJUSTMENTS CHECKING THE HYDRAULIC TRAVEL SYSTEM

CHECKING THE HYDRAULIC TRAVEL SYSTEM

H Test conditions:
. Engine: at working temperature.
. Hydraulic oil: 45v55ëC
. Working brakes: engaged.

The test must be divided into two parts in order to identify

accurately which element is defective or required adjust-
ment.
Some preliminary checks must be carried out before start-
ing work on the circuit or any elements connected with it.

For the upper part of the system

. Check that the pressure of the servocontrols is within
normal limits. (For details, see «CHECKING AND AD-
JUSTING PRESSURES IN THE SERVOCONTROL
SUPPLY UNIT»). 5 1
. Check whether the servocontrol pressure (35 3.5 bar)
reaches the control valve spools. PORTS
UTILIZZI
. Check that the control valve spools involved in travel
A
(A1-B1-A5-B5) are executing their full stroke (see
«TECHNICAL DATA»).
B
For the lower part of the system
. Check that there are no leakages inside the swivel
joint.
For details, see «CHECKING LEAKAGES INSIDE 5 1
THE SWIVEL JOINT». D0400440

1. Checking the upper part of the system

1 - Disconnect the two travel tubes (1-2) leading out
of the control valve. 1

2 - Securely plug both the control valve couplings (3- 3

4) and the tubes (1-2).
3 - Connect two pressure gauges E1 (600 bar) to the 2
4
adapters M1 and M2.
4 - Start the engine and put it into maximum swing
speed.
5 - Check the adjustment of the main relief valves.
(For details, see «VALVE ADJUSTMENT»); if ne-
F0400279

cessary, re-adjust.
. If normal pressures have not been obtained in
spite of adjustment, it means that the pumps E1
P1 and P2 are defective and require overhaul-
ing or replacement.
. If the pressures are within normal limits, pro-
ceded with a check on the lower part of the
system.
M1
6 - Stop the engine, release residual hydraulic pres-
sures and re-assemble the tube connections.

M2
F0400256

20-56
TESTING AND ADJUSTMENTS CHECKING THE HYDRAULIC TRAVEL SYSTEM

2. Checking the lower part of the system

1 - Start the engine and check in sequence:
. The adjustment of the safety valves (1) of the
travel motor (2).
For details, see «CHECKING AND ADJUST- 1
ING THE SAFETY VALVES OF THE TRAVEL
MOTOR». 1
. The intervention point of the automatic displa-
cement control system (3) of the travel motor
(2).
For details, see «CHECKING AND ADJUST- 2 2
ING THE AUTOMATIC DISPLACEMENT
CONTROL SYSTEM OF THE TRAVEL MO-
F0400303

TOR».
. Leakages in the travel motor (2).
For details, see «CHECKING FOR LEA-
3
KAGES IN THE TRAVEL MOTOR».

F0400678

20-57
 CHECKING AND ADJUSTING THE SAFETY
TESTING AND ADJUSTMENTS VALVES OF THE TRAVEL MOTOR

CHECKING AND ADJUSTING THE SAFETY VALVES OF THE TRAVEL

MOTOR
H Test conditions:
E1
. Engine at working temperature.
. Hydraulic oil: 45v55ëC
. Working brakes: engaged.

Test
M1
1 - Connect the pressure gauges E1 (600 bar) to the con-
trol valve adapters M1 and M2.
2 - Start the engine and adjust the safety valves of sec-
tions 1 and 2 of the control valve to a pressure of M2
370w5 bar. (For details, see «VALVE ADJUST- F0400256

MENT»).
3 - Select the 2nd fast forward gear.
4 - Bring the engine up to high idling.
5 - Press the travel pedal slowly down to the end of its
stroke.
6 - Holding the pedal in this position, check whether the
opening pressure of the safety valve (1) indicated by
the pressure gauges E1 is normal (350w5 bar). 1
7 - Bring the engine back to low idling.
8 - Select the 2nd fast reverse gear and repeat these tests
for the valve (2).
F0400281

Adjustment
1 - Loosen the nut (3) of the valve to be adjusted.
2 - Regulate the pressure using the screw (4).
H Setting pressure: 350w5 bar.
. To INCREASE pressure turn in a CLOCKWISE di-
rection
. To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction 2
3 - Secure the position of the screw (4) with the nut (3).
Lock nut: 20 Nm

. Once the adjustment is completed, apply lead F0400282

seals (5) to protect against unauthorised tamper-
ing.
. Re-adjust the settings of sections 1 and 2 of the 5 4
control valve.
3

D0400441

20-58
 CHECKING AND ADJUSTING THE AUTOMATIC
TESTING AND ADJUSTMENTS DISPLACEMENT CONTROL SYSTEM OF THE TRAVEL MOTOR

CHECKING AND ADJUSTING THE AUTOMATIC DISPLACEMENT

CONTROL SYSTEM OF THE TRAVEL MOTOR
H Test conditions:
. Engine at working temperature
. Hydraulic oil: 45v55ëC
. Working brakes: engaged E1

Test
M2
1 - Connect the adapter M2 of section 2 of the control
valve to the pressure gauge E1 (600 bar).
2 - Take off the cap and connect pressure gauge E2 (400
bar) to the automatic displacement control system (1).
3 - Select the 2nd fast forward gear.
F0400283

4 - Bring the engine up to a speed of 2000 rpm.

5 - Press lightly on the travel pedal and watch whether
the pressure gauge E2 connected to the control sys-
tem starts to move when the pressure gauge E1 con-
nected to the control valve indicates a pressure of
200 10 bar.
1
Adjustment
1 - Take off the safety cap (2).
2 - Loosen the nut (3).
E2
3 - Adjust the intervention point with the screw (4).
F0400284
H Intervention point: 200 10 bar
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction
. To DECREASE pressure, turn in a CLOCKWISE
direction 2
4 - Secure the position of the screw (4) with the nut (3).
Lock nut: 10 Nm
5 - Replace the cap of the control system (1).
Cap: 30 Nm
6 - Replace the safety cap (2) to protect against un-
authorised tampering.

F0400643

D0400442

20-59
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR

CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR

Before carrying out this control, check the efficiency

of the working brakes.
H Test conditions: 1
. Engine at working temperature
. Hydraulic oil: 45v55ëC
. Selector in WORKING MODE: position P
. Working brakes: engaged
1 - Disconnect the drainage tube (1) from the lower union
(2) of the motor (3) and plug it. 3
2 - Attach a provisional tube to collect the draining oil.
2
F0400296

3 - Start the engine and bring it up to 2000 rpm.

4 - Select the 2nd fast forward gear and press the travel
pedal slowly to the end of its stroke.
5 - Hold the travel pedal in this position for 30 seconds
and then measure the oil drainage from the motor
for the next minute.
6 - Check whether the amounts of drainage oil are normal
(see «NORMAL OR STANDARD TECHNICAL
DATA»).
7 - Stop the engine and re-assemble the hydraulic con-
nections.

20-60
 CHECKING AND ADJUSTING THE SPEED
TESTING AND ADJUSTMENTS OF THE TRAVEL PROPELLER SHAFT

CHECKING AND ADJUSTING THE SPEED OF THE TRAVEL

PROPELLER SHAFT
H Test conditions:
. Engine at working temperature
. Hydraulic oil: 45v55ëC
. Machine: completely raised
BLOCK BLOCK
BLOCCO
. Front axle: blocked BLOCCO

Test
H Make a distinct mark (1) on the propeller shaft to facil-
itate the reading of the speed indicator C2.
1 - Position the machine with the arm vertical and the 10 cm
back of the bucket resting on the ground.
F0400285

2 - Push down the boom and the rear outriggers until the
machine is completely raised.
If the blade is mounted on the machine, rest it on
the ground after the machine has been raised.

3 - Place safety blocks, height 10 cm, beneath the centre

of the axles to prevent the machine from dropping ac-
cidentally.
After having lowered the axles gently onto the
blocks, check that the wheels are raised approxi-
mately 10 cm above the ground.
4 - Use blocks to stop the front axle from turning.
5 - Select the 2nd fast forward gear. C2 1
6 - Bring the engine up to 2000 rpm, measuring it with in- F0400286

strument C1.
7 - Press the travel pedal down to the end of its stroke.
8 - Use the speed indicator C2 to check the rev. speed of
the propeller shaft.
Unit: rpm

Normal speed: 2050 100

Speed for TUV approval: 1500 100

2
Adjustment
1 - Take off the safety cap (2).
2 - Loosen the nut (3).
F0400282
3 - Regulate the speed with the minimum displacement
adjustment screw (4).
. To INCREASE the speed turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE the speed, turn in a CLOCKWISE
direction.
4 - Secure this position with the nut (3).
Lock nut: 69 Nm
5 - Apply a new safety cap (2) to protect against un-
authorised tampering.

3 4
D0400443

20-61
TESTING AND ADJUSTMENTS ADJUSTMENT OF THE SPEED SURVEYOR

ADJUSTMENT OF THE SPEED SURVEYOR

When dismantling or substituting the speed surveyor, pro- 0

ceed as follows for the final positioning: 0,5 + 0,2
1 2 3
1 - Screw the sealing washer (2) onto the sensor (1) and 4
screw the sensor (1) into the casing of the transmis-
sion (3) by hand until it rests on the toothed wheel (4).
H Check the condition of the sealing washer (2) with
care.
2 - Unscrew the sensor (1) until a space of 0.5 0.2 mm is
obtained between the sensor and the toothed wheel
(4) (0.5v0.6 turns).
5
3 - Secure the sensor with the nut (5). D0400444
Lock nut: 22w2 Nm
4 - Connect the electric cabling and mount the protective
rubber sleeve (6).
Turn the protective sleeve (6) so that the cable
opening points towards the ground, in order to
prevent accumulations of water or condensates.

F0400287

20-62
TESTING AND ADJUSTMENTS ADJUSTING BOOM AND ARM SAFETY VALVES

ADJUSTING BOOM AND ARM SAFETY VALVES

H Test conditions Boom

. Engine: at working temperature 1
. Hydraulic oil: 45v55ëC
. WORKING MODE selector: position P
. Main safety valves: set to 370w5 bar V2
. Secondary valves: set to normal values.
(See «2. Valves with a fixed setting»)
1 - Rest the work equipment on the ground, stop the en-
gine and release any residual pressures (See «RE- C2
LEASING RESIDUAL PRESSURES FROM THE CIR- 2
CUITS»).
F0400039

2 - Disconnect the pipe (1) from the coupling V2 and the

pipe (2) from coupling C2.
H Disconnect the safety valve from the arm cylinder. Arm
1
3 - Cap the pipe (2) to prevent entry of impurities.
H For the arm, cap the cylinder. V2
4 - Connect the tube (1) to the coupling C2, using a tube
with equal section.
H For the arm, connect the flange V2 to the coupling
C2.
5 - Unscrew the nut (6) and remove the threaded rod (5)
and the nut (4).
6 - Start the engine and bring it up to high idling speed. C2
F0400040

7 - Bring the boom cylinder bottom side or the arm cylin-

der head side slowly up to maximum pressure (320
bar), checking that no oil leaks out of the valve.
5
8 - Maintaining pressure, adjust the valve with the screw
(3), until a slight leakage of oil (just a few drops every 6 10
minute) is seen coming from the flange V2. 70 Nm 4
3
. To INCREASE pressure, turn in a CLOCKWISE
140 Nm
direction.
. To DECREASE pressure, turn in an COUNTER-
7
CLOCKWISE direction.
H Every turn of the screw (3) changes the pressure
by 110 bar. V2
9 - Block the screw (3) in position with the nut (4).
Locknut: 70 Nm
10 - Screw the rod in (5) until it comes into contact with the
retaining element (7) and then turn it back for 5-6 C2
turns. Secure it in position with the nut (6).
11 - Rest the equipment on the ground, stop the engine,
and release any residual pressures.
T
12 - Re-assemble the valve connections.
13 - Readjust the setting of the main safety valves.
(See «1. Re-adjustable main relief valves»).
P

D0400202

20-63
TESTING AND ADJUSTMENTS ADJUSTING 2nd BOOM SAFETY VALVES

ADJUSTING 2nd BOOM SAFETY VALVES

H Test conditions:
. Engine: at working temperature 4
. Hydraulic oil: 45v55ëC 6
. WORKING MODE selector: position P 5
. Main safety valve of the 2nd section of the control 2
valve: set to 370w5 bar 3
. Secondary valves: set to normal values. 8
(See «2. Valves with a fixed setting»).
1
1 - Rest the work equipment on the ground, stop the en-
gine and release any residual pressures (See «RE- 7
LEASING RESIDUAL PRESSURES FROM THE CIR-
F0400046

CUITS»).
H Adjust the valves of one cylinder at a time.
2 - Disconnect the pipes (1), (2), (3) and (4).
3 - Use hoses of equal section to connect up the pipes in
10 9
the following manner:
pipe (1) port (5).
pipe (2) port (6)
4 - Cap pipes (3) and (4) to prevent entry of any impuri-
ties.
5 - Remove the access caps (9) to the adjustment screws 13
(10-11). 7
6 - Start the engine and bring it up to high idling speed.
7 - Move the 2nd boom pedal to the end of its opening
stroke.
5
8 - Using the screw (11) adjust the valve (12) until a slight
leakage of oil can be seen from the flange (8).
. To INCREASE pressure, turn in a CLOCKWISE
direction.
. To DECREASE pressure, turn in an COUNTER-
CLOCKWISE direction.
H Every turn of the screw changes the pressure by
165 bar.
9 - Move the 2nd boom pedal to the end of its closing
stroke.
10 - Using the procedure indicated in point 8 adjust the
6
valve (13) until a slight leakage of oil is visible from
the port (7).
11 - Stop the engine and release any residual pressures. 8 12
12 - Replace the caps (9) and re-assemble the hydraulic
circuits.
Locknut 20 Nm
13 - Repeat the same regulation operations for the valves
of the other cylinder.

11 9

D0400203

20-64
 MEASURING THE INITIAL INTERVENTION POINT
TESTING AND ADJUSTMENTS OF THE OVERLOAD SENSOR

MEASURING THE INITIAL INTERVENTION POINT

OF THE OVERLOAD SENSOR

H Test conditions:
. Engine: at working temperature
. Hydraulic oil: 45v55ëC E1
. Boom safety valve: set to normal values

Test M2
1 - Connect the pressure gaugeto the adapter M2 of the
2nd section of the control valve E1 (600 bar).
2 - Start the engine and bring it up to 2000 rpm.
F0400283
3 - Set the overload alarm to «ON» (push-button illumi-
nated).
4 - Raise the boom to the end of its raising stroke.
5 3
5 - Bring the boom-raising cylinder slowly up to pressure, 4
checking at which pressure-value the overload signal
is triggered.
H Normal intervention pressure: 155w10 bar.

Adjustment
If the intervention pressure point is not within normal lim-
its, adjust the pressure switch as follows: P
1 - Unscrew and remove the protective cap (1).
2 - Pressurise the boom-raising cylinder up to a normal F0400042

intervention pressure.
3 - Turn the adjustment screw (2) until the acoustic over-
load signal is triggered. P
. To INCREASE pressure, turn in an COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCKWISE
direction.
H Every turn of the screw (2) changes the pressure
by about 80 bar.
4 - Relieve pressure and repeat the test several times to
check that the interventions occur within normal lim- 1
its.
2
5 - Replace the protective cap (1). D0400221

If the setting is found to be unstable or impossible,

install a new overload sensor.
5 4
When a setting is made in these conditions, the inter-
vention points with the boom and arm extended are 6
automatically set by the cam profile (3).

Before removing the overload sensor (4) or the cam 3

(3), rotate and use a screw (6) to secure the activat-
ing lever (5) in its safety position.

F0400043

20-65
 ADJUSTING THE VALVE THAT CONTROLS
TESTING AND ADJUSTMENTS THE CLOSING SPEED OF THE 2nd BOOM

ADJUSTING THE VALVE THAT CONTROLS THE CLOSING SPEED

OF THE 2nd BOOM

H Test conditions: E2
. Engine: at working temperature.
. Olio idaulico: 45v55ëC
. WORKING MODE selector: position P

1 - Connect the pressure gauge E2 (400 bar) to the adap- M2

ter M2 of the 2nd section of the control valve.
2 - Start the engine and completely extend the arm and
bucket.
3 - Raise the boom and open the 2nd boom as far as it will F0400288

go.
4 - Use the control pedal of the 2nd boom to close it to the
end of its downward stroke, and check the pressure
on the pressure gauge E2.
H Closing pressure: 60 5 bar
+
. To INCREASE pressure (i.e. to slow down the --
descent) turn the knob in a CLOCKWISE direc-
tion.
. To DECREASE pressure, turn the knob in an
COUNTERCLOCKWISE direction.

F0400045

20-66
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

MEASUREMENT OF INTERNAL OIL LEAKAGES

IN THE SWING MOTOR

H Test conditions: 2
. Engine: at working temperature
. Hydraulic oil: 45v55ëC
. WORKING MODE selector: position P 1
. Revolving frame: secured by the rotation-blocking
pin.
1 - Disconnect the drainage hose (1) of the motor (2).
2 - Attach a provisional hose to collect the drainage oil.
3 - Start the engine and bring it up to high idling speed. F0400047

4 - Push the swing control lever as far as it will go.

5 - Hold it in this position for 30 seconds and then mea-
sure the oil leakage for the next minute.
6 - Reduce motor speed to low idling, swing the revolving
frame 180ë and repeat the measurement.
7 - Check that the average between the two measure-
ments falls within the normal range. (See «TECHNI-
CAL DATA»).
8 - Re-assemble the hydraulic drainage circuit.

20-67
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT

CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT

H Test conditions:
12
. Engine: at working temperature.
11 Travel motor (forward)
. Hydraulic oil: 45v55ëC
. WORKING MODE selector: position P. 10 Travel motor (backward)

1. Functionality test 9 Blade-outriggers command (rise)

1 - When one of the lower-level tools (travel motor, 8 Front steering to the left
brakes, outriggers, steering) is found to be defec- 7 Unused
tive, one of the causes of the failure may be the 6 Discharge travel motor
swivel joint. 5 Blade-outriggers command (descent)
2 - To confirm the defect it is sufficient to by-pass the 4 Front steering to the right
joint by connecting (using an additional length of
3 Rear axle braking
tubing) the input and output hoses of the joint of
the branch to be checked. 2 Unused
If the defect disappears, it is certainly due to the 1 EV for transmission, parking brake, axle locking
swivel joint. Front axle braking
If the defect remains, it can be due to other
causes, but not to the swivel joint.
2. Identification of defective seal
These tests should be performed on those
branches subjected to working pressures. Tests
on unstressed or unused branches are therefore
excluded.
The test method consists in pressurising the branch
under examination and measuring any leakage from
adjacent branches, as set out in the following table:

Në Branch to be tested (under pressure) Adjacent parts (Leakages) Në

External leakage, (visible) ±
12 Travel motor (forward)
Travel motor (backward) 11
Travel motor (forward) 12
11 Travel motor (backward)
Blade-outriggers command (rise) 10
Travel motor (backward) 11
10 Blade-outriggers command
Front steering to the left 9
Blade-outriggers command (rise) 10
9 Front steering to the left
Unused 8
Discharge travel motor 7
6 Blade-outriggers command
Front steering to the right 5
Bland-outriggers (descent) 6
5 Front steering to the right
Unused 4
Unused 4
3 Rear axle braking
Solenoid transmission, parking brake, axle locking 2
Rear axle braking 3
2 Solenoid transmission, parking, axle laking
Front axle braking 1
Solenoid transmission, parking brake, axle locking 2
1 Front axle braking
External leakage (visible) ±

The numbers correspond to the numbers stamped on the input and output ports of the swivel joint.

20-68
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT

Preparation for testing:

. Travel motor 2 1
. Axle braking
. Axle steering
. Transmission, parking brake, axle locking
1 - Relieve all residual hydraulic pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR- 3
CUITS»).
2 - Identify the branch involved in the test (1).
3 - Disconnect the hoses (2) from the branches adjacent
to the part to be tested and cap them tightly.
Make sure that the detached tubes are securely D0400553
sealed, to prevent jets of high-pressure oil es-
caping if circuits that are not undergoing tests
should accidentally become pressurised.
H The tubes of the adjacent branches must be dis-
connected from the upper parts of the swivel
joint.
4 - Provisional hoses (3) for collecting any oil leakages
should be connected to the inlets of the branches ad-
jacent to the one being tested.
Preparation for testing outriggers or blade 3
1 - Relieve all residual hydraulic pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR-
CUITS»).
2 - Identify the branch involved in the test.
3 - Disconnect the tube corresponding to the branch to
be tested from the safety valve input and cap it. 1
Make sure that the detached tubes are securely
sealed, to prevent the escape of jets of oil at high
pressure.
4 - Cap the valve to prevent entry of impurities.
5 - Disconnect from the swivel joint the hoses (2) of the
branches adjacent to the branch to be tested, and
cap them tightly.
Make sure that the detached hoses are securely 3
sealed, to prevent jets of high-pressure oil es-
caping if the circuits that are not undergoing
tests should accidentally become pressurised.
H The tubes of adjacent branches must be discon- D0400552
nected from the upper parts of the swivel joint.
6 - Provisional hoses (3) to collect any leaking oil should
be connected to the inlets of the branches adjacent to
the one being tested.
Test
1 - Start the engine and bring it up to the test speed spe-
cified for every test.
2 - Pressurise the branch to be tested.
3 - After 30 seconds, watch for another minute if there
are any leakages.
H If oil leaks out of one of the two provisional hoses,
it means that there is a leakage in the intermedi-
ate gasket between the branch connected to the
provisional hose and the pressurised branch.

20-69
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

H If hydraulic drift occurs in the work equipment, a

check must be carried out to see if the cause is due
to a cylinder gasket or to the control valve.
H Conditions for all checks:
. Engine: at working temperature.
. Hydraulic oil: 45v55ëC
. Removal and connection of tubes only after relief
of residual pressures. (See «RELEASING RESI-
DUAL PRESSURES FROM THE CIRCUITS»).

1. Boom test D0400446

1 - Position the machine with the arm vertical and the

bucket on the ground, resting on its back.
2 - Stop the engine and release any residual hydrau-
lic pressure.
2
3 - Disconnect the hose (1) that feeds the cylinder on
the head side.
4 - Remove the pipe (2) that connects the safety valve
(port C2) to the cylinder on the bottom side.
5 - Cap the two tubes to prevent entry of impurities.
6 - Cap the cylinder hole (3) on the bottom side. 3
F0400048

7 - Start up the motor and extend the arm completely.

8 - Stop the engine and check the position of the
boom for 5 minutes.
. If the boom drops, the drift is due to the cylin-
der gasket.
. If the boom does not drop, the drift is due to
the control valve.

1
F0400049

2. Arm test
1 - Position the machine with the arm completely ex-
tended and the bucket teeth on the ground.
2 - Stop the engine and release any residual hydrau-
lic pressure.

D0400447

20-70
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

3 - Disconnect the pipes (1) and (2) from the arm cy-
linder and cap them to prevent entry of impurities. 2
H If a safety valve has been installed, remove it.
4 - Cap the arm cylinder hole on the head side and at- 1
tach a provisional hose on the bottom side to col-
lect any leaking oil.

F0400057

5 - Start the engine and raise the boom.

6 - Stop the engine and check the position of the arm
for 5 minutes.
. If the arm drops, the drift is due to the cylinder
gasket.
. If the arm does not drop, the drift is due to the
control valve.

3. Testing the functionality of the boom and arm

safety valve.

H This test should be carried out after having

checked that the drift is not due to the cylinder
gaskets (See «BOOM TEST» and «ARM TEST»),
and after having checked the valve settings
(See «ADJUSTING BOOM AND ARM SAFETY
VALVES»).
1 - Depending upon which valve is to be checked, po-
1
sition the machine as for the «Boom test» or for the
«Arm test».
2 - Disconnect the hose (1) that supplies the valve F0400050

(port V2).
3 - Disconnect:
For the boom, the head side pipe. 1
For the arm, the bottom side pipe.
4 - Start the engine and extend the arm completely
for the «Boom test», or raise the boom for the
«Arm test».
5 - Stop the engine and check for leakages from the
valve for 5 minutes.
. If there is any leakage, the valve is defective.

F0400051

20-71
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

4. 2nd boom test

1 - Position the machine with the arm and the 2nd
boom completely extended. Rest the bucket teeth
on the ground.
2 - Stop the engine and release any residual hydrau-
lic pressures.

D0400448

3 - Disconnect the two pipes (1) and (2) and cap them
to prevent entry of impurities.
H If a safety valve has been installed, remove it.
4 - Cap the cylinder couplings on the bottom side and 1
attach provisional hoses on the head side to col-
lect any leaking oil.

2
F0400058

5 - Start the engine and raise the boom.

6 - Stop the engine and check the position of the 2nd
boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
cylinder gasket.
. If the 2nd boom does not close, the drift is due 50 cm
to the control valve.
To check one cylinder at a time, proceed as follows:
7 - Rest the bucket on the ground and release any re-
sidual hydraulic pressures.
8 - From one cylinder remove the cap mounted on the D0400449

bottom side during phase 4.

9 - Start the engine, raise the boom and then stop the
engine.
10 - Check the position of the 2nd boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
gaskets of the cylinder that has been capped.
11 - Repeat the operation from phase 8 to phase 10 to
test the other cylinder.

20-72
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

5. Testing the functionality of the 2nd boom safety

valves

H This test should be performed after having ascer- V2

tained that the drift is not due to the cylinders.
(See «2nd BOOM TEST») and after having checked
the adjustment of the safety valves (See «AD- V1
JUSTING 2nd BOOM SAFETY VALVES»).
1 - Position the machine with the arm and 2nd boom
fully extended. Rest the bucket teeth on the
ground.
2 - Stop the engine and relieve any residual hydraulic F0400052

pressures.
3 - Disconnect the connecting tubes of the safety
valves (two pipes of ports V1 and V2 for each
valve).
4 - Start the engine and raise the boom.
5 - Stop the engine and check the position of the 2nd
boom for 5 minutes. 50 cm
. If the 2nd boom tends to close, both safety
valves are defective.

D0400449

6. Bucket test
1 - Position the machine with the arm vertical and the
bucket horizontal and resting on the ground. Put a
weight in the bucket, or fill it with earth.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the pipes (1 and 2) of the bucket cylin-
der and cap them to prevent entry of impurities.
4 - Cap the hole in the bucket cylinder on the bottom
side and attach a provisional hose on the head
side to collect any oil leakages.
D0400450

F0400053

20-73
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

5 - Start the engine and raise the boom.

6 - Stop the engine and check the position of the
bucket for 5 minutes.
. If the bucket tends to open, the drift is due to
the cylinder gasket.
. If the bucket does not tend to open, the drift is
due to the control valve. 50 cm

D0400451

7. Boom swing test

1 - Position the machine with the boom, arm and
bucket raised and with the revolving frame turned
90ë to the right.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the pipes (1 and 2) of the boom swing
cylinder and cap them. 15°

4 - Cap the hole in the boom swing cylinder on the

bottom side and attach a provisional hose to the
head side to collect any oil leakages. D0400213

5 - Start the engine and move the machine onto a 15ë

slope.
6 - Stop the engine and check the position of the
boom for 5 minutes.
. If the boom tends to swing, the drift is due to
the cylinder gasket.
. If the boom does not tend to swing, the drift is
due to the control valve.
1 2

F0400436

8. Test for the outriggers

H Test one outriggers at a time.
1 - Swing the revolving frame to bring the work equip-
ment to the same side as the outriggers. Position
the machine with the arm vertical and the back of
the bucket resting on the ground.
2 - Lower the outriggers to be tested to about half its
possible stroke and support it on a block of height
25 cm
25 cm.
3 - Stop the engine and release all residual hydraulic
pressures. D0400452

20-74
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

4 - Disconnect the tubes (2) and (3) that connect the

safety valves (1) to the cylinder (4). Plug the valves 2
to prevent entry of any impurities.
2
5 - Plug the tube (3) of the cylinder (4) on the head
side and attach a provisional tube on the base 3
side to collect any leakages. 3
6 - Start the engine, push down with the boom to 1 4
raise the machine and remove the supporting 4
block from beneath the outriggers.
7 - Lower the machine and stop the engine.
F0400289

8 - Check the position of the outriggers for 5 minutes.

. If the outriggers drops, the drift is due to the
cylinder (4).
. If the outriggers does not drop, the drift is due
to the safety valve (1).
H To discover whether the drift is due to the swi-
vel joint, see «CHECKING FOR LEAKAGES
INSIDE THE SWIVEL JOINT - CIRCUITS
FOR OUTRIGGERS AND BLADE».

D0400453

20-75
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

9. Blade test
1 - Position the machine with the arm vertical and
resting on the ground, and with the bucket resting
on its back.
2 - Bring the blade to roughly half its potential stroke
and support it on a block, height 28 cm, placed in
the centre.
28 cm
3 - Stop the engine and release any residual hydrau-
lic pressure.
4 - Disconnect both safety valves (1) and the tubes (2) D0400454
and (3) that connect them to the cylinder (4). Plug
the valves to prevent entry of any impurities.
5 - Plug the tube (3) on the head side of just one cy- 2
linder (4) and attach a provisional tube on the
base side of the same cylinder to collect any lea- 2
kages.
H The second cylinder should be left completely
free. 3
6 - Start the engine, push down with the boom to 1
3
raise the machine in order to remove the block 4
on which the blade is resting.
4
7 - Lower the machine and stop the engine.
F0400290

8 - Check the position of the blade for 5 minutes.

. If the blade tends to sink, the drift is due to the
cylinder (4).
. If the blade does not tend to sink, the drift is
due to the safety valve group (1).
H To discover whether or not the drift is due to
the swivel joint, see «CHECKING FOR LEA-
KAGES INSIDE THE SWIVEL JOINT - CIR-
CUITS FOR OUTRIGGERS AND BLADE».
9 - To test the other cylinder repeat these operations,
starting from point 5.

D0400456

20-76
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

10. Swing motor test

1 - Position the machine with boom, arm and bucket
raised as in the figure, and with the revolving
frame turned 90ë.
2 - Stop the engine and release any residual hydrau-
lic pressure.

D0400455

3 - Disconnect the hoses (1 and 2) from the motor

and cap them to prevent entry of impurities. At-
tach some provisional hoses to the motor to col-
lect any oil leakages. 1

F0400055

4 - Disconnect the hose of the swing brake from the

selector valve and install the test equipment H1
between the choke valve (3) and the hose (4). At-
tach the pressure gauge E5 (60 bar) to the adapter E5
of the apparatus H1 to measure the brake release
pressure for the entire duration of the test.
5 - Keeping the test equipment cock open, start the
engine and swing the revolving frame round sev-
eral times. 3
6 - With the braking circuit pressurised (35 3.5 bar), 4
close the test equipment cock to maintain pres- H1
sure and thus cancel out the braking action.
D0400223
7 - Let the machine travel onto a 15ë slope, and stop
the engine.
8 - Mark the position between revolving frame and
track frame on the swing circle. Check on any
swinging movement of the revolving frame for 5
minutes.
. If the revolving frame tends to swing, the drift
is due to the swing motor.
. If the revolving frame does not tend to swing,
the drift is due to the control valve 15°
H During this test, the pressure indicated on the
pressure gauge E5 should not drop below the
limit value of 10 bar.
D0400463

20-77
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

11. Checking the travel motor

1 - Position the machine with the arm vertical and the
back of the bucket resting on the ground. Stop the
engine.
2 - Disconnect the supply tube (2) from the parking
brake (1).
3 - Insert apparatus H1 between the brake (1) and the
tube (2). Attach the pressure gauge E5 (60 bar) to
the adapter of apparatus H1 to keep a check on
the parking brake release pressure throughout
the test. D0400457

4 - With the cock (3) of test apparatus H1 open, start

the engine and engage and release the parking
brake several times. 1 2

5 - Raise the front work equipment and travel the ma-

chine over a surface with a 15ë slope.
H The articulated axle should be facing towards
the lower part of the slope.
H1

6 - Using the working brakes to hold the machine in

position, close the cock of apparatus H1 in order
3
to maintain pressure (35 3.5 bar) and thus to keep
the parking brake released. Stop the engine.
E5
7 - After 5 minutes, mark the position of the machine. F0400437

8 - Check whether or not the machine has moved

every 5 minutes for a total of 15 minutes.
H During this test the pressure indicated on the
pressure gauge E5 should not drop below a
minimum limit of 22 bar.

15°

D0400214

20-78
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

12. Test for the axle-locking valve

H Use the same method to check both cylinders.
1 - Start the engine and lock the axle.
2 - Fully extend the entire front work equipment and
lower it to approx. 70 cm above the ground.
3 - Swing the frame approx. 45ë to bring the work
70 cm
equipment over the axle-locking cylinder (1-3)
being tested.
4 - Stop the engine and check to see whether the
work equipment has dropped at all. D0400458
H If the RH cylinder (1) has dropped, and there
are no visible leakages, the drift is due to
the axle-locking valve (2).
H If the LH cylinder (3) has dropped, and there
are no visible leakages, the drift may be due
either to the axle-locking valve (2) or the check 1
valve (4).
In order to establish which of these valves is de-
fective, it is sufficient to exclude the check valve 3
(4) from the circuit with a provisional tube, and
to repeat the test under with a loading.
H If the dropping effect persists, the drift is due
to the axle-locking valve.
H If no dropping effect is observed, the drift is D0400459

due to the check valve (4).

2
4

F0400291

20-79
20-80
 TROUBLESHOOTING

Procedures to follow while troubleshooting . . . . . . . . . . . 82

Rules to observed when working on
hydraulic circuits or equipment . . . . . . . . . . . . . . . . . . . . . . . . 83
Rules to observed when working on
electrical circuits or equipment . . . . . . . . . . . . . . . . . . . . . . . . 84
Table of failure modes and causes tests
to be carried out before troubleshooting . . . . . . . . . . . . . . 87
Troubleshooting the electrical system . . . . . . . . . . . . . . . . . 89
Troubleshooting the hydraulic system. . . . . . . . . . . . . . . . 107

20-81
TROUBLESHOOTING PROCEDURES TO FOLLOW WHILE TROUBLESHOOTING

PROCEDURES TO FOLLOW WHILE TROUBLESHOOTING

Park the machine on firm, flat ground. Always make sure that the swing-blocking safety pin is in place, that the
boom swing control pedal lock is engaged, and that the safety devices of the work equipment are in their
locked position.
. When more than one person is involved in the operation, keep scrupulously to agreed signals and phrases. Do
not allow any unauthorised person into the working area.
. Take care not to touch heated parts, or to become entangled in rotating elements.
If electrical wiring is to be disconnected, first disconnect the negative clamp (-) from the battery.

Always release residual pressures before removing caps, or loosening hydraulic or coolant circuit tubes. When
mounting measurement instruments or other special testing equipment, make sure that they are connected
correctly.
The purpose of troubleshooting is to diagnose the original cause of the fault, to carry out repairs quickly, and to
prevent repetition of the damage.
Before one can do this, however, one must be familiar with the machine, its component parts and how they
function.
One method that may shorten the time needed for trouble-shooting is to ask the operator a few questions. His
replies may help to direct the search to possible causes that have given rise to the fault.

1. When trouble-shooting, do not immediately take
components to pieces. If components are re-
moved and taken apart immediately after a defect
has been noticed, and without any preliminary
analysis, there is a risk of:
. dismantling parts that are only apparently in-
volved in the fault;
. unnecessarily dismantling parts not required
for achieving a repair;
. frequently making it impossible to find the ori-
ginal cause of the defect.
This behaviour causes loss of time and unneces-
sary use of tools and products (oil, grease, etc.)
but, worse still, it leads to loss of faith on the part
of the user or the operator.
For these reasons, when trouble-shooting, one
must first obtain information, and then follow es-
tablished procedures while searching for the fault.
2. Questions to put to the operator:
1 - Are there any other problems, in addition to
the one notified?
2 - Did you notice anything unusual before the
fault occurred?
3 - Did this fault occur unexpectedly, or has the
machine been suffering from other problems
previously
4 - Under what precise conditions did the fault oc-
cur?
5 - Have other repairs been carried out before the
fault occurred?
6 - Have similar faults ever occurred previously?
3. Tests to be performed before starting any trouble-
shooting operations.
1 - Check the oil level in the tank.
2 - Check that there are no external oil leakages
from hoses, pipes, or hydraulic equipment.
3 - Check that the levers for each individual com-
mand pass through their entire stroke.
4 - Check all other components that are subject to
regular maintenance. If deemed useful, carry
out normal maintenance.
4. Confirmation of the defect.
. Personally check out the nature of the trouble
to make sure that it is a true fault, or whether
or not it may have been caused by the way in
which the machine was used, or by other
causes.
H When the machine is started up to identify
any symptoms which might determine or
direct attention to the identification of a
fault, avoid taking measurements or hand-
ling the machine in such a way as to wor-
sen the problem.
5. Fault-diagnosis
. Use the results obtained from points 2 and 4
to approach the cause of the fault or failure
and then use the search table to identify the
defective part more precisely.
H The basic procedure for troubleshooting is
as follows:
1 - Start with the simpler faults.
2 - Start from the most likely points.
3 - Look for other related components and
pertinent information.
6. Methods for the removal of the cause that gave
rise to the fault.
. If the fault is repaired, but the cause that gave
rise to it is not dealt with, the same fault may
occur again. To avoid such repetition, look for
the cause of the problem and deal with that as
well.

20-82

TROUBLESHOOTING
RULES TO BE OBSERVED WHEN WORKING ON HYDRAULIC
CIRCUITS OR EQUIPMENT
1 - Do not add hydraulic oil, change filters or carry out in-
ternal inspections of the hydraulic equipment in condi-
tions of dust, rain or wind.
2 - During inspection or dismantling of hydraulic equip-
ment, observe scrupulous cleanliness in order to pre-
vent entry of foreign bodies or dust.
3 - If an emergency intervention is unavoidable in the
area where work is in progress, take all possible pre-
cautions to prevent penetration of dust or foreign
bodies into the tubes or components.
If necessary remove the defective hydraulic equip-
ment to the workshop where repairs are normally car-
ried out.
4 - Before reinstalling hydraulic equipment that has been
repaired or substituted because of failure, test its per-
formance using the appropriate test equipment.
5 - After removing pipes, cap the holes or pipes with
caps, adhesive cocke or plastic covers.
Never seal them with rags because if there is even a
minimal leakage of oil, impermeability to dust cannot
be guaranteed. Furthermore, the area around the plug
may become impregnated with dirt that could prove
difficult to remove.
RULES TO BE OBSERVED WHEN WORKING
ON HYDRAULIC CIRCUITS OR EQUIPMENT
6 - Do not let the oil drain out onto the ground, but
collect it in containers that can be disposed of
as industrial waste.
7 - When changing oil and/or filters, make sure that
the fillers and the surrounding area are clean.
8 - Drain the hydraulic oil and engine oil while they
are still hot, but not hot enough to cause burns
(max. 50ëC).
This method ensures removal of suspended par-
ticles of metal and sludge. Drain only through
the proper drainage outlets.
9 - When refilling the hydraulic oil, use only clean
containers and decanting pumps. If possible
start the engine, perform a few movements with
all the equipment and then filter the oil through
appropriate apparatus for filtering out ultra-fine
particles (about 3 m).
10 - If hydraulic hoses are to be substituted, flush
them all out at high pressure in order to remove
all impurities before installation.
20-83

TROUBLESHOOTING
RULES TO BE OBSERVED WHEN WORKING ON ELECTRICAL
CIRCUITS OR EQUIPMENT
PRECAUTIONS TO BE TAKEN DURING
MAINTENANCE WORK
To keep the machine in a state of perfect efficiency and to
avoid breakdowns or malfunctions, maintenance, inspec-
tions, troubleshooting and repairs must be carried out in
good time and in the correct manner.
This section will deal in particular with the correct proce-
dures for the repair of electromechanical parts, and its
aim is to improve the quality of the repairs carried out.
1. PRECAUTIONS TO BE OBSERVED WHEN
ELECTRICAL EQUIPMENT IS DAMAGED
1 - Electrical wiring assemblies and jacks
The wiring assemblies contain coils of cables that
connect the various electrical components and are
composed of electrical wires, jacks used to connect
and disconnect wires or pieces of equipment, and fi-
nally, sheaths whose purpose is to protect the wires
or jacks.
When compared with electrical components installed
on switchboards or panels, these wiring assemblies
are more exposed to the direct effects of rain, water
used to wash the machine, condensates, heat and vi-
brations.
Since the wiring assemblies are subject to repeated
movements during inspections and repairs, they are
very likely to suffer distortion and damage. For this
reason great care must be taken when handling them.
The principle defects to which the wiring assemblies
are liable
1 - Defective contact between jacks (defective contact
between the male and female terminals).
Problems of defective contact can occur when: the
male jack is not correctly inserted into the female jack,
one or both the jacks is distorted, the position is not
aligned, or the contact surfaces are corroded or
rusted.
2 - Defective compression or soldering of the jacks.
The contact pins are joined to the wiring by soldering
or compression of the stranded copper wire and by
the compression fitting of the insulating sheath.
If the connections are subjected to excessive pulling
force, the cables may come apart or break, even only
partially, but sufficient to cause a loss of conductivity.
3 - Disconnected cables.
If the cable is held in the hands and the jack pulled
out, if elements are removed with the cables still con-
nected, or if some heavy object strikes the cable or
jack, continuity may be interrupted due damaged sol-
dering, loosened compression fitting or to a ruptured
cable.
20-84
RULES TO BE OBSERVED WHEN WORKING
ON ELECTRICAL CIRCUITS OR EQUIPMENT
4 - Penetration of water at high pressure into the
jacks.
The jacks are designed to prevent easy penetra-
tion of water (water-proof structure). Neverthe-
less, water may still penetrate if sprayed directly
onto the jack at high pressure.
Given the structure of the jack, once water has
penetrated it will not be able to run back out
on its own, and will therefore create short cir-
cuits between the pins.
Before passing current through the jacks after
washing the machine at high pressure, dry the
jacks and check the insulation.
5 - Oil, grease or dirt in the jacks.
If grease or oil mixed with dust has deposited on
the male and female terminals, this will obstruct
a normal passage of current. A defective or false
contact may thus occur
Remove every trace of dirt or grease with a
clean, dry cloth, using rust-removing products,
or with dry compressed air containing no trace
of lubricating oil.
H When cleaning the contact points of a jack,
take care not to use excessive force which
could distort the pins.
2 - Removal, installation and drying of the jacks
and wiring assemblies
Disconnecting the jacks
1 - Hold the jacks themselves when disconnecting.
When disconnecting the jacks, apply pulling
force to the bodies of the jacks and not to the
cables.
For jacks fitted with safety locks, press the locks
with the fingers and pull the body of the jack out-
wards.
2 - Action to be taken after having disconnected the
jacks.
After having disconnected any type of jack, pro-
tect the terminals with waterproof plastic bags in
order to avoid contamination by dust, oil, grease
or water.
Connecting the jacks
1 - Visual check of the jack:
a - Check that there are no traces of water, oil,
grease or dirt on the contact areas.
b - Check that the jack pins are not distorted or
corroded, in such a way as to create defec-
tive contacts.

TROUBLESHOOTING
c - Check that the bodies of the jacks are undamaged
and free of cracks or dents.
H If there are traces of water, oil or dirt on the
jack, clean it with a dry soft cloth.
If water has penetrated into the jack, try to
evaporate it by heating up the inside of the
sheath with a heater. Care must be taken
not to apply excessive heat it, which could da-
mage the cable sheathing and thus cause
short circuits.
H If there is any sign of damage or rupture, fit a
new jack
2 - Connect the jacks correctly.
Before using force to connect the jacks, make sure
that they are in the correct position.
For jacks fitted with safety locks, fully engage the
male and female jacks, making sure that the locking
devices have clicked into place.
3 - Correct any lack of alignment in the wiring assem-
blies.
After having connected the jacks, check the alignment
of the wiring assemblies, acting if necessary on the
clamps.
If the jacks are provided with dust-protection devices,
make sure that they match perfectly.
Drying the wiring assemblies
If the wiring assemblies are dirty or oily, clean them with a
dry, clean cloth. Avoid washing them with water or steam.
If a wash is absolutely necessary, do not aim the high
pressure stream of water or steam directly onto the jack.
If water hits a jack accidentally, take the following steps:
RULES TO BE OBSERVED WHEN WORKING
ON ELECTRICAL CIRCUITS OR EQUIPMENT
1 - Disconnect the jack and dry the water with a dry
cloth.
H If the jack is blown dry with air, there is a
danger that any oil in suspension may cause
a defective contact. Therefore avoid the use
of compressed air.
2 - Dry the inside of the jack with a dryer.
If water penetrates a jack, use a dryer to dry it
out.
H Take care not to heat the jack or its relative
parts excessively. Excessive heating may
cause distortions and render the jack unusa-
ble.
3 - Perform a continuity test on the jack.
After having dried it, and before reconnecting
the wiring assembly, perform a continuity test
to find out if short circuits occur between the
pins.
H After having completely dried the jack, treat
it with a rust-removing product to be sure
that the contacts are in perfect condition.
20-85
20-86
 TABLE OF FAILURE MODES AND CAUSES TESTS TO
TESTING AND ADJUSTMENTS BE CARRIED OUT BEFORE TROUBLESHOOTING

TABLE OF FAILURE MODES AND CAUSES TESTS

TO BE CARRIED OUT BEFORE TROUBLESHOOTING
Standard
Operations values Remedy

Ð
1 - Check the fuel level Fill up

2 - Check for dirt or water Ð

in the fuel tank Clean or drain
Lubricants, cooling, fuel

Ð
3 - Check the level of the hydraulic oil Fill up
Ð
4 - Check the hydraulic oil filter Substitute
Ð
5 - Check the oil level in the final drive Fill up
Ð
6 - Check the oil level in the swing machinery Fill up
Ð
7 - Check the engine oil level Fill up

8 - Check the cooling liquid level of the engine Ð Fill up

9 - Check the engine air filter Clean or substitute

Ð

1 - Check the tightening and condition of Ð Tighten or substitute

Electrical circuit

the accumulator clamps

2 - Check the tightening and condition of

the alternator clamps Ð Tighten or substitute

3 - Check the tightening and condition of

the starting motor clamps Ð Tighten or substitute
Hydraulic circuit

1 - Check any unusual noises or smells Ð Repair

2 - Check any oil leakages Ð Repair

3 - Bleed air from the circuits Ð Bleed

1 - Check the accumulator voltage 10-14 V

(engine stopped) Substitute

2 - Check the electrolyte level Ð Fill up

3 - Check the electrical wiring Ð

(burnt through or damaged insulation) Substitute
Electrical components

4 - Check terminal blocks and cable attachments Ð Repair

5 - Check the cable attachment in the connectors Disconnect and

and look for any presence of water Ð dry

6 - Check that the fuses are in good condition and

not corroded Ð Substitute

7 - Check the alternator voltage 14 V

(engine at about 1500 rpm) Substitute

8 - Check that there is no noise when the ignition Ð Substitute the

key is turned to position I noisy part

20-87
20-88
TROUBLESHOOTING THE ELECTRICAL SYSTEM

E1 - The transmission does not change up

from the 1st to the 2nd gear . . . . . . . . . . . . . . . . . . . . . . 90
E2 - The transmission does not change down
from the 2nd to the 1st gear . . . . . . . . . . . . . . . . . . . . . . 92
E3 - The gear-change inhibitor does not function
when the wheels are moving
with the reverser disengaged . . . . . . . . . . . . . . . . . . . . 94
E4 - The gear-change inhibitor does not function
when the wheels are moving
with the reverser engaged . . . . . . . . . . . . . . . . . . . . . . 94
E5 - Failed selection of the type of steering
a. Tests for the upper system . . . . . . . . . . . . . . . . . . . 96
E6 - Failed selection of the type of steering
b. Tests for the lower system . . . . . . . . . . . . . . . . . . . . 97
E7 - The 2-wheel steering does not function
and the acoustic alarm does not sound . . . . . . . . . 98
E8 - The acoustic alarm is continually active
when the wheels are centred and 2-wheel
steering has been selected . . . . . . . . . . . . . . . . . . . . . . 99
E9 - Failed selection of 4-wheel steering . . . . . . . . . . . . 100
E10 - Failed selection of sideways
(crab-wise) steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
E11 - The warning lamps for axle alignment
do not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
E12 - The rear axle does not align
(does not stop on the sensor). . . . . . . . . . . . . . . . . . 106

20-89
TROUBLESHOOTING

E1 - The transmission does not change up

from the 1st to the 2nd gear

YES

1 YES

Check that vol-

tage is reaching
the coil of EV3 5
(lower coil 65) YES Check that relay
47 is functioning
Voltage: 12V
4
YES Check that step-
by-step relay 44
NO
3 is functioning
Check that the
YES push-button of
the reverser le-
ver is function- NO
2 ing
Check that fuse
F5 is unda-
NO maged NO

(Fuse box A)

NO

20-90
TROUBLESHOOTING

Cause Remedy

Coil defective Substitute

YES Speed surveyor

7 80 defective Substitute
Check that
there is conti-
YES nuity between
the accessory
6 control box (88)
and speed sur-
Check that ac- veyor 80
cessory control No continuity Restore
box (88) is func- NO
tioning

Accessory
control box defective Substitute
NO

Relay 47 defective Substitute

Relay defective Substitute

Push-button
defective Substitute

Fuse Substitute

20-91
TROUBLESHOOTING

E2 - The transmission does not change down

from the 2nd to the 1st gear

YES

1 YES

Check that vol-

tage is reaching
the coil of EV3 5
(upper coil 68) YES Check that relay
47 is functioning
Voltage: 12V
4
YES Check that step-
by-step relay 44
NO
3 is functioning
Check that the
YES push-button of
the reverser le-
ver is function- NO
2 ing
Check that fuse
FS is unda-
NO maged NO

(Fuse box A)

NO

20-92
TROUBLESHOOTING

Cause Remedy

Coil defective Substitute

YES Speed surveyor

7 Substitute
80 defective
Check that
there is conti-
nuity between
YES accessory con-
trol box (88) and
6 transmission
speed surveyor
Check that ac- 80
cessory control No continuity Restore
box (88) is func- NO
tioning

Accessory control
box (88) defective Substitute
NO

Relay 47 defective Substitute

Relay defective Substitute

Push-button defective Substitute

Fuse Substitute

20-93
TROUBLESHOOTING

E3 - The gear-change inhibitor does not function when the wheels

are moving with the reverser disengaged

YES

YES
5
Check that
1 there is conti-
nuity between
YES speed surveyor
Check that vol-
tage is reaching 80 and the gear-
the coil of relay
4 change inhibit-
47 (both for for- ing accessory
Check that the control box
ward and back- YES voltage of the
ward gears) 3 speed surveyor NO
is normal
Normal voltage: 12V Check that there
. Machine: raised is continuity be- Voltage: 1.8v2 V
from the ground YES tween joint (track
. Axle locked 2 17) and jack 3 NO
. Engine: high idling (Pos. 2) of the
. Gear: 2nd fast Check that there relay box
. Bring the wheels up is continuity be-
to maximum speed
and then put the
tween the sliding
gear lever into neu- joint (track 17) NO
tral and the coil of
. Perform this test for relay 47
both directions of
wheel rotation NO
NO

E4 - The gear-change inhibitor does not function when the wheels

are moving with the reverser engaged
Cause Remedy

YES Relay coil Substitute

defective relay
1
Check that vol-
tage is reaching
the coil of relay
47

Normal voltage: 12V

. Machine: raised Diodes defective Substitute
from the ground NO
. Axle locked
. Engine: low idling
. Gear: 1st slow
. Perform this test for
both directions of
wheel rotation

20-94
TROUBLESHOOTING

Cause Remedy

Relay coil Substitute

defective relay

Accessory control
box (88) defective Substitute

No continuity Restore

Sensor defective Substitute

No continuity Restore

No continuity Restore

20-95
TROUBLESHOOTING

E5 - Failed selection of the type of steering

a. Tests for the upper system

Cause Remedy

YES
See E4
3
Check (using
YES push-button 59)
2 that all diodes
are functioning
Check (machine correctly
stationary) if the
YES same defect is Diodes defective Substitute
encountered NO
with all selec-
tions
1
Selector defective Substitute
Check for the NO
presence of vol-
tage on selector
60 YES No continuity between
FS3 and selector Restore

4
Check that fuse
FS3 is unda-
NO maged
(Fuse box A)

Fuse Substitute
NO

20-96
TROUBLESHOOTING

E6 - Failed selection of the type of steering

b. Tests for the lower system

Cause Remedy

YES Repair or
EV9 defective
substitute
4
Check that
YES there is conti-
nuity between
relay 87 and
EV9
3
YES Check that relay No continuity Restore
87 is functioning NO
2
Check (with the
YES wheels centered) Relay defective Substitute
that rear sensor NO
78 is functioning

1 Sensor defective Substitute

NO
Check that front
sensor 79 is
functioning
YES
Sensor failed Substitute
5
Check that vol-
tage is reaching YES
6 Relay 81 defective Substitute
NO the sensor
(wire M) Check that
there is conti-
nuity in the slid-
ing joint (pos. 5-
NO 18) and jack 1
(pos. 5-4-3) of
the relay box
No continuity Restore
NO

20-97
TROUBLESHOOTING

E7 - The 2-wheel steering does not function

and the acoustic alarm does not sound

Cause Remedy

YES
Sensor 78 defective Substitute

3
YES Check that the
relays are all
2 functioning
Check that relay
YES 93 remains en-
ergised and re- Relay 87 defective Substitute
lay 61 remains NO
1 de-energised
Check that the
buzzer of the Normal condition:
93= Open Relay 93 defective Substitute
acoustic alarm NO
is functioning 61= Close

Buzzer defective Substitute

NO

20-98
TROUBLESHOOTING

E8 - The acoustic alarm is continually active when the wheels

are centred and 2-wheel steering has been selected

Cause Remedy

YES
Sensor 78 defective Substitute

1 YES
Relay 93 defective Substitute
Check that vol- 3
tage (+ and -) is
reaching rear Check that
sensor 78 YES there is conti-
nuity between
2 relay 87 and re-
lay 93
Check that
there is conti- No continuity in the joint
nuity between (tracks 3-18) Restore
NO rear sensor 78 NO
and relay 87

No continuity Restore
NO

20-99
TROUBLESHOOTING

E9 - Failed selection of 4-wheel steering

YES

5
YES Check that relay
4
81 is functioning
Check that
there is conti-
nuity in the slid-
YES ing joint (pos. 4)
between the NO
3 selector and
jack 1 (pos. 4) of
Check that the the relay box
YES diodes are
functioning with NO
2 push-button 59
Check (machine
YES stationary) that
the selector 60 is NO
switching

1
Check that NO
voltage is
reaching
selector 60 YES

8
Check that fuse
FS3 is unda-
NO maged
(Fuse box A)

NO

20-100
TROUBLESHOOTING

Cause Remedy

YES Repair or
EV10 defective
Substitute
7
YES Check that vol-
tage is reaching
solenoid 10
6
Check that relay No continuity Restore
84 is functioning NO

Relay 84 defective Substitute

NO

Relay 81 defective Substitute

No continuity Restore

Diodes defective Substitute

Selector 60 defective Substitute

No continuity between
selector 60 and FS3 Restore

Fuse Substitute

20-101
TROUBLESHOOTING

E10 - Failed selection of sideways (crab-wise) steering

YES

5
YES Check that relay
4
81 is functioning
Check that
there is conti-
nuity in the slid-
YES ing joint (pos. 1)
between the se- NO
3 lector and jack 1
(pos. 1) of the
Check that the relay box
YES diodes are
functioning with NO
2 push-button 59
Check (machine
YES stationary) that
selector 60 is NO
switching

1
NO
Check that vol-
tage is reaching
selector 60
YES

8
Check that fuse
FS3 is unda-
NO maged
(Fuse box A)

NO

20-102
TROUBLESHOOTING

Cause Remedy

YES Repair or
EV10 defective
Substitute
7

YES Check that vol-

tage is reaching
EV10
6
Check that relay No continuity Restore
83 is functioning NO

Relay 83 defective Substitute

NO

EV9 defective Repair or

Substitute

Relay 81 defective Substitute

Diodes defective Substitute

Selector 60 defective Substitute

No continuity between
selector 60 and FS3 Restore

Fuse Substitute

20-103
TROUBLESHOOTING

E11 - The warning lamps for axle alignment do not light up

H Check if the selector 60 functioning

YES

YES

5
Check that
1 YES there is conti-
nuity between
Check that vol- sensor and re-
tage (+ and -) is 4 lay
reaching the
warning lamps YES Check that the Sensor:
relays are func- Front axle =79
Rear axle =78 NO
Front axle warning 3 tioning
lamp = 64
Rear axle warning Check that there Front axle =86
lamp = 63 YES is continuity be- Rear axle =87
tween the joint
NO
2 and jack 1 of the
relay box
Check that
there is conti- Joint tracks:
nuity between Front axle =2
NO warning lamps Rear axle =3 NO
and joint Jack:
Front axle =pos. 2
Joint tracks: Rear axle =pos. 3
Front axle =2
Rear axle =3 NO

20-104
TROUBLESHOOTING

Cause Remedy

Warning lamp defective Substitute

Sensor defective Substitute

No continuity Restore

Relay defective Substitute

No continuity Restore

No continuity Restore

20-105
TROUBLESHOOTING

E12 - The rear axle does not align (does not stop on the sensor)

Cause Remedy

YES
3 Relay defective Substitute

Check continuity
in the sliding
YES joint (pos. 8) be-
tween selector
2 60 and jack 2
(pos. 3) of the
Check that relay box.
YES steering selec- No continuity Restore
tor 60 is func- NO
tioning
1
Check that rear Selector defective Substitute
sensor 78 is NO
functioning
(warning light
63 when wheels YES Repair or
are centered) EV9 defective
Substitute

4
Check that relay
NO 82 is functioning

Relay 82 defective Substitute

NO

1 2 3 1 2 3

4 5 4 5

1 2 3 1 2 3

4 5 4 5

20-106
TROUBLESHOOTING THE HYDRAULIC SYSTEM

H1 - Work equipment, revolving frame H13 - Power failure while travelling in both forward
swing and travel mechanisms and backward directions
function intermittently . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 (Tests for the lower circuits) . . . . . . . . . . . . . . . . . . 122
H2 - The revolving frame swing speed is slow H14 - The engine is running but
in both directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 the machine will not travel . . . . . . . . . . . . . . . . . . . . 122
H3 - The revolving frame swing speed is slow H15 - The fast travel gears (1st and 2nd)
in one direction and does not brake cannot be selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
properly on that side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 H16 - The 2nd travel gear cannot
H4 - Difficulties with raising be selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
or lowering the boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 H17 - Front axle steering defective
H5 - Excessive response time for boom, or lacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
arm and bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 H18 - Rear axle steering lacking . . . . . . . . . . . . . . . . . . . . 126
H6 - Boom slow to rise H19 - The steering wheel vibrates when
Arm slow to close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 turned as far as it will go. . . . . . . . . . . . . . . . . . . . . . 126
H7 - The servocontrol supply group H20 - The steering wheel moves jerkily . . . . . . . . . . . . . 127
does not function or the pressure H21 - Total lack of braking power . . . . . . . . . . . . . . . . . . . 127
is unstable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 H22 - Braking power weak or partial . . . . . . . . . . . . . . . . 128
H8 - The control levers move, H23 - The front axle cannot be locked . . . . . . . . . . . . . . 128
but equipment movements are incomplete
H24 - The front axle cannot be unlocked . . . . . . . . . . . 129
or have no effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
H9 - Speeds do not change H25 - The axle-locking pistons will not remain
if the working mode selector in position (when the axle is unlocked
is positioned on E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 this creates a vacuum in the cylinder). . . . . . . . 129
H10 - Abnormal noises in the pumps . . . . . . . . . . . . . . . . 118
H11 - Engine loses power or
stalls during work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
H12 - Power failure while travelling
in both forward and backward directions
(Tests for the upper circuits). . . . . . . . . . . . . . . . . . . 120

20-107
TROUBLESHOOTING

H1 - Work equipment, revolving frame swing and travel mechanisms

function intermittently

Cause Remedy

YES Defective control valve

2 spools Substitute

Check whether
or not the con-
YES trol valve spools
of the individual
movements
have seized up

Air in the servocontrol Bleed air

NO circuits
1
Check that the Not function- Check the
pressure of the YES ing or func- servocontrol Adjust
servocontrols is tioning alter- safety or substitute
constant 4 nately microswitch

Pressures: 35 3.5 bar Check that the

YES solenoid EV4 is
functioning cor-
3 rectly
Check whether
the pre-loading EV4 solenoid valve
of the servocon- Not function- Substitute
NO NO ing defective
trol accumulator
is normal

Pre-set pressures: Recharge or

12 1 bar Accumulator substitute
NO

20-108
TROUBLESHOOTING

H2 - The revolving frame swing speed is slow in both directions

Cause Remedy

YES Swing machinery

brake defective Substitute
4
Check that the
YES adjustments of
3 the secondary
valves are nor-
Check that the mal
servocontrol Adjustment:
YES pressure Secondary valves
190/160w5 bar Regulate
reaches the NO incorrectly regulated
2 swing machin-
Check whether ery brake
YES the oil leakages Choke valves or selection Clean or
in the swing valves defective substitute
motor are nor- NO
mal
1
Check that the MAX. 1300 cc/min.
main safety Swing motor defective Substitute
NO
valve of the 3rd
section of the
control valve is
regulated to YES Main safety valve Regulate
normal values wrongly adjusted
5
Main safety valve:
200w5 bar Check whether YES
or not it is possi- Main safety valve Substitute
NO ble to set the 6 defective
main safety valve
Check whether
or not the trouble
can be elimi- 7 YES
NO nated by chan-
Pump P3 defective Substitute
Check whether
ging the main or not the trou-
safety valve. ble can be
eliminated by
inverting the
NO deliveries of
pumps P2 and
P3 on the con-
trol valve.
Control valve defective Substitute
NO

20-109
TROUBLESHOOTING

H3 - The revolving frame swing speed is slow in one direction, and

does not brake properly on that side

Cause Remedy

YES Repair or
2 Control valve defective substitute
Check whether
or not the defect
YES remains when
the anticavita-
tion valves are
inverted on the
control valve.
Anticavitation valves Substitute
1 NO defective

Check whether
or not the defect Repair or
can be inverted YES
Swing motor defective substitute
by inverting the
tubes on the 4
control valve. Check that the
YES setting of the
secondary
3 valves on the
motor is normal
Check that the Adjustment:
swing motor 190/160w5 bar Valves incorrectly
NO drainage is nor- Regulate
NO regulated
mal

Max. 1300 cc/min.

Repair or
Swing motor defective substitute
NO

20-110
TROUBLESHOOTING

H4 - Difficulties with raising or lowering the boom

Cause Remedy

YES Repair or
Control valve defective substitute
3
Check that the
YES pressure of the
servocontrols is
2 normal
Check that the Pressure: 35 3.5 bar
YES setting of the Repair or
Cylinder defective substitute
secondary valve NO
is normal

Adjustment:
320 w 5 bar
Adjust
NO

Raising

YES
Defect of cylinder gasket Substitute
4
Check that the
intermediate cy-
NO linder leakages
are normal 5 YES Pumps P1 - P2 Repair or
Max. 13.5 cc/min. Check that the defective substitute
1 regulation of the
Check that the NO main safety
other equipment valve is normal. Valves incorrectly
Adjust
is working at NO regulated
normal speed
YES Dismantle
7 Defective valve and check
Check that the
YES pilot pressure is
reaching the
6 boom safety
valve.
Check that the
control valve Check the supply line
YES NO
spool passes
through its en-
tire stroke

Repair or
Control valve defective substitute
Lowering NO

Servocontrol pressure Adjust

NO

20-111
TROUBLESHOOTING

H5 - Excessive response time for the boom, arm and bucket

H When travel and boom swing are normal

. WORKING MODE selector: position P
. Engine: low idling speed

YES

3
YES Check that the YES
working speeds
are normal 5
Check that the
YES deliveries of
pumps P1 and
2 P2 are normal
4
Check that the
YES pressure of the Check that the
servocontrols is engine is run-
normal and NO ning normally NO
stable
Pressure: 35 3.5 bar
1
NO
Check whether
or not this phe-
nomenon is oc-
curring with all
the equipment NO
(boom, arm and
bucket)
6 YES

Check whether
or not the defect
can be elimi-
nated by invert- YES
NO ing the second-
ary valves of the 7
faulty equip- Check that the
ment. pressure of the
servocontrols is
NO normal and
stable
Pressure: 35 3.5 bar
NO

20-112
TROUBLESHOOTING

Cause Remedy

Anticavitation valves Substitute

defective

Spool defective Substitute

Repair or
Pumps defective substitute

See
Engine engine
manual

Supply to the
servocontrols Regulate
defective

Secondary valves
defective Substitute

Incomplete spool stroke Substitute

spool

Supply to the
servocontrols Regulate
defective

20-113
TROUBLESHOOTING

H6 - Boom slow to rise

Arm slow to close

Cause Remedy

YES
Choke nozzle clogged Clean
2
Check that the
YES rest of the
1 equipment is
working at nor-
Check that the mal speed
servocontrol
pressure is
reaching the Servocontrol pressure Adjust
choke valve of NO
the speed re-
doubling spool.
Supply line interrupted Check
NO

20-114
TROUBLESHOOTING

H7 - The servocontrol supply group does not function or

the pressure is unstable

Cause Remedy

4
YES The pressure
value at the PV Reduction valve Regulate
3 port is low.

Check whether
YES the pressure at
2 the PV port is
Check whether low.
the pressure re-
mains stable Reduction valve Repair or
while the work defective substitute
equipment exe- NO
YES cutes several
movements, or
whether it tends YES
to drop below Filtering element Substitute
the minimum
permissible va- 5
lues.
1 Check whether
Pressure: 35 3.5 bar or not the filter is
Check whether NO
or not there is clogged
pressure at the
output of the
group Recharge or
Accumulator flat substitute
NO
Pressure: 35 3.5 bar

6 YES P3 pump entrainment Repair

Check that the defective
EV4 solenoid
NO valve is ener-
gised. EV4 solenoid valve or Repair or
NO relative circuit defective substitute

20-115
TROUBLESHOOTING

H8 - The control levers move, but equipment movements are

incomplete or have no effect
H WORKING MODE selector: position P

YES

4
Check the sta-
YES bility of the ser- YES
vocontrol sys-
tem pressure 5

3 Check that the

Pressure: 35 3.5 bar safety micro-
Check that the NO switch is func-
YES deliveries of tioning normally
pumps P1-P2-
P3 are normal
NO
2
Check that the
YES diesel engine is
functioning nor- NO
1 mally
Check that the
level of hydrau-
lic oil in the tank NO
is within correct
limits

NO

20-116
TROUBLESHOOTING

Cause Remedy

Air in the circuit Bleed the

spools

EV4 solenoid defective Repair or

substitute

Switch defective Adjust or

substitute

Pumps defective Repair or

substitute

See
Engine engine
manual

Hydraulic oil level Top up

20-117
TROUBLESHOOTING

H9 - Speeds do not change if the working mode selector is

positioned on E

Cause Remedy

YES Mode System piston Overhaul

defective the group
2
Check that
YES pressure is
reaching the
1 Mode System
device
Check that
pressure to the EV5 solenoid valve or Substitute or
servocontrols is relative command
NO
circuit defective repair
normal

Pressure: 35 3.5 bar

Servocontrols feed unit Adjust
NO

H10 - Abnormal noises in the pumps

Cause Remedy

YES Pumps defective Substitute

3
Check that there
YES are no metallic
particles in the
2 filter of the hy-
draulic system
Check that the Move the equipment
YES suction hose is a few times and check Repeat the
completely air- NO whether or not the noise inspections
1 tight persists or changes

Check that the

hydraulic oil le- Air infiltrations Eliminate
vel is within NO
normal limits

Oil level Top up

NO

20-118
TROUBLESHOOTING

H11 - Engine loses power or stalls during work

Cause Remedy

YES
2 Summation horsepower Repair or
control defective substitute
Check whether
or not the defect
YES occurs only YES 3-circuit valve Repair or
when the work 3 defective substitute
equipment is in
use. Check whether
or not the defect
1 occurs in com-
NO bination with a
Check whether swing opera-
or not the pump tion.
goes into self- 3-circuit valve and
regulation. Repair or
summation horsepower substitute
(Summation NO control defective
horsepower
control function-
ing)

Overhaul or
Pump defective substitute
NO

20-119
TROUBLESHOOTING

H12 - Power failure while travelling in both forward and

backward directions
Tests for the upper circuits
H For test details, see «TESTING AND ADJUSTING»

YES

5
Check that the
YES setting of the
valves of the
control valve is
normal
Pressure: 350w5 bar
NO
4
Check that the
YES stroke of the YES
travel spools is
normal 6
Check that the
servocontrol
pressure is
NO
3 reaching the
spools
Check that
YES there is pres-
sure at the
adapters M1 - NO
2 M2
Check that the Pressure: 280w5 bar
YES PPC valve is (Use arm closure)
executing its full NO
1 stroke
Check that the
pressure of the
servocontrols is NO
normal

Pressure: 35 3.5 bar

NO

20-120
TROUBLESHOOTING

Cause Remedy

Proceed with
the lower cir-
cuit tests

Valves unset Re-set or

or defective substitute

Proceed with
the lower cir-
cuit tests

Circuit obstructed or
servocontrol filter Check or
clogged substitute

Pumps defective Repair or

substitute

Pedal defective Adjust or

substitute

Reducing valve Re-set

20-121
TROUBLESHOOTING

H13 - Power failure while travelling in both forward and

backward directions
Tests for the lower circuits
H For test details, see «TESTING AND ADJUSTING»
Cause Remedy

YES Repair or
Joint defective
substitute

YES
Brake valve group
defective Overhaul
1 4
Check whether Check that lea-
the fault disap- YES
pears when the kages from the
3 motor are nor-
swivel joint is
excluded mal
Check that the
intervention
YES point of the self- Overhaul or
Motor defective
regulating NO substitute
2 group of the
motor is normal
Check that the
setting of the Intervention point: Self-regulator unset Re-set or
NO motor safety 200 bar NO or failed overhaul
valves is normal

Pressure: 350w5 bar

Re-set or
Valves unset or failed substitute
NO

H14 - The engine is running but the machine will not travel

Cause Remedy

YES Substitute the

EV11 defective bobina od
2 coil or EV 11

Check that vol-

YES tage is reaching
the coil of the
EV 11

1
Electrical system Restore
Check that the NO interrupted continuity
work equipment
and the swing
are functioning
normally

See H10-H11
NO

20-122
TROUBLESHOOTING

H15 - The fast travel gears (1st and 2nd) cannot be selected

Cause Remedy

YES Substitute
EV12 defective the coil
2 or EV12

Check that the

YES stroke of the YES
See H11
travel spools is
normal 3

1 Stroke: 8w0.5 mm Check that ser-

vocontrol pres-
Check that the NO sure is reaching
servocontrol the spools
pressure is nor-
mal
Circuit obstructed Check
NO
Pressure: 35 3.5 bar

NO
Reducing gear Re-set

H16 - The 2nd travel gear cannot be selected

Cause Remedy

YES The selection pistons

of the defective Repair or
transmission substitute
2
YES Check that EV3 YES Substitute the
is executing the EV3 defective coil or EV3
exchange
3
Check that vol-
tage is reaching
NO the coil
1
Check that ser-
vocontrol pres- Electrical system Restore
sure is reaching NO interrupted continuity
EV3

Pressure: 35 3.5 bar YES

Joint defective Repair or
4 substitute
Check that ser-
vocontrol pres-
sure still arrives
NO when it by-
passes the swi-
vel joint

Servocontrol supply Check or

NO unit defective re-set

20-123
TROUBLESHOOTING

H17 - Front axle steering defective or lacking

YES

2
Check whether
YES there are lea- YES
kages in the
swivel joint
3
Check that EV9
NO is functioning

NO

1 In just one
Check that the steering di-
maximum pres- rection
sure of the
steering circuit
is normal in both YES
directions when
the steering
wheel is forced 5
as far as it will Check whether
go. YES
there is a load-
Pressure: 140 5 bar sensing signal
4
Check that
Completely pump P4 is nor-
lacking mal NO

NO

NO

In both steer-
ing directions

20-124
TROUBLESHOOTING

Cause Remedy

Swivel joint Repair

defective or substitute

Steering cylinder Repair

defective or substitute

EV9 defective Substitute

Shock-resistant Substitute
steering unit valve

Steering unit defective Repair or

Substitute

Priority valve Repair or

detective Substitute

Pump defective Repair or

Substitute

Steering unit Re-set or

safety valve Substitute
unset or failed

20-125
TROUBLESHOOTING

H18 - Rear axle steering lacking

Cause Remedy

YES
Cylinder defective
2
Check that
YES there is pres-
sure in the two
cylinder supply
branches
1
EV10 defective Substitute
Check that NO
EV10 is execut-
ing the ex-
change YES Substitute
EV10 defective the coil or
EV10
3
Check that vol-
tage is reaching
NO the coil of EV10

Electrical system Restore

NO interrupted continuity

H19 - The steering wheel vibrates when turned as far as it will go

Cause Remedy

Steering unit
check valve Substitute
defective

20-126
TROUBLESHOOTING

H20 - The steering wheel moves jerkily

Cause Remedy

YES Repair or
Steering unit defective
substitute
2
YES Check the Load-
Sensing signal

Nozzle for the

1 LS signal Clean or
NO on the steering unit substitute
Check that clogged
pump P4 is
pressurising
YES Repair or
Pump defective
substitute
3
Check that the
safety valve of
NO pump P4 has
been set

Re-set or
substitute
NO the valve

H21 - Total lack of braking power

Cause Remedy

YES Brake pump Repair or

defective substitute
1
Check that the
upper frame
swing is func-
tioning correctly

Pump P3 Repair or
NO defective substitute

20-127
TROUBLESHOOTING

H22 - Braking power weak or partial

Cause Remedy

YES Swivel joint Repair

defective
3
Check whether
YES there are lea- YES
Pistons defective Substitute
kages in the
swivel joint 4
Check whether
there are losses
NO in the axle
braking pistons
2
YES Check that the Brake disks
brake pressure Substitute
is normal NO worn
1
Check that ac- Pressure: 70 1 bar
cumulator re- Brake pump unset Re-set
loading pres- NO
sure is normal

Max. pressure:
150w5 bar Brake pump unset Re-set
Initial loading NO
pressure: 120w5 bar

H23 - The front axle cannot be locked

Cause Remedy

YES Axle-locking Repair or

valve defective substitute
2
Check that the
YES axle-locking cir- YES Substitute the
cuit pressure at EV2 defective coil or
the outlet of EV2 EV2
is normal 3
1 Pressure: 35 3.5 bar Check that vol-
tage is reaching
Check that the NO EV2
servocontrol
pressure is nor-
mal Electrical system Restore
NO interrupted continuity
Pressure: 35 3.5 bar

Reducing valve unset Re-set

NO

20-128
TROUBLESHOOTING

H24 - The front axle cannot be unlocked

Cause Remedy

YES Leakage inside Repair or

the swivel joint substitute
2
Check whether
YES there is a drop YES Axle-locking Repair or
in pressure at valve defective substitute
the outlet of EV2
3
Check that EV2 YES Substitute the
is executing the EV2 defective coil or
NO exchange EV2
1
4
Check that the Check that vol-
servocontrol tage is reaching
pressure is NO the coil of EV2
normal

Pressure: 35 3.5 bar

Electrical system Restore
NO interrupted continuity

Reducing valve unset Re-set

NO

H25 - The axle-locking pistons will not remain in position (when

the axle is unlocked this creates a vacuum in the cylinders)
Cause Remedy

Filling check-valve Substitute

defective

20-129
TROUBLESHOOTING

20-130
GROUP 30
 DISASSEMBLY AND ASSEMBLY
HOW TO READ THE MANUAL. . . .. . . . .. . . . . .. . . . .. . . 3
PRECAUTIONS TO BE TAKEN
WHEN WORKING .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
SPECIAL TOOLS . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5
STARTER MOTOR
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . . 7
ALTERNATOR
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . . 8
NOZZLE HOLDER
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . . 9
AIR FILTER GROUP
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 10
MUFFLER
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12
ENGINE HOOD
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 13
FIXED HOOD
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15
SEAT
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 16
CABIN
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 17
COUNTERWEIGHT
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 18
RADIATOR
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 19
HYDRAULIC OIL COOLER
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 20
HEATING FAN
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 21
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
FUEL TANK
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 23
HYDRAULIC OIL TANK
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 24
ENGINE-PUMP GROUP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 27
PUMP GROUP
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 28
HYDRAULIC PUMP
Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 36
GEAR-PUMP
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 42
Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 43
Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
ENGINE-PUMP COUPLING JOINT
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 51
SWIVEL JOINT
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 52
SWING MOTOR
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 53
SWING MACHINERY
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 54
Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 55
Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 63
REVOLVING FRAME
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 74
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 75
SWING CIRCLE
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 76
TRANSMISSION - REVERSER, DIRECTION
INDICATOR AND HEADLIGHT DIPPER BEAM
CONTROL GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 77
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 78
R.H. PPC VALVE (BOOM - BUCKET)
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 79
L.H. PPC VALVE (ARM-SWING)
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 80
BLADE PPC VALVE
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 81
REMOVAL OF PPC VALVE
(For travel, boom swing, 2-piece boom)
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 82
BRAKE PUMP
Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 83
30-1
SERVOCONTROL SUPPLY GROUP
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . . 84
CONTROL VALVE
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . . 85
TRAVEL MOTOR
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 86
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 87
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 88
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 92
TRANSMISSION
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . . 99
STEERING UNIT
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 100
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 101
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 107
PRIORITY VALVE
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 117
Disassembly and assembly . .. . . . .. . . . . .. . . . .. . . 118
AXLE-LOCKING VALVE GROUP
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 119
CHECK VALVE
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 120
AXLE-LOCKING CYLINDER
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 121
COMPLETE FRONT AXLE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 122
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 124
COMPLETE REAR AXLE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 125
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 127
AXLES
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 128
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 137
BOOM CYLINDER
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 150
BOOM CYLINDER
(For 2-piece boom)
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 151
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 152
2-PIECE BOOM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 153
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 154
30-2
ARM CYLINDER
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 155
BUCKET CYLINDER
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 156
BOOM SWING CYLINDER
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 157
CYLINDERS FOR OUTRIGGERS/BLADE
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 158
WORK EQUIPMENT CYLINDERS
Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 159
Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 160
OVERLOAD SENSOR
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 164
WORK EQUIPMENT
(For the boom)
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 165
WORK EQUIPMENT
(2-piece boom version)
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 166
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 167
BUCKET
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 168
ARM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 169
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 171
2-PIECE BOOM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 172
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 173
BOOM
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 174
BOOM (2-piece boom version)
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 175
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 176
SWING BRACKET
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 177
BLADE AND OUTRIGGER
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 178
BLADE AND OUTRIGGER ARMS
Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 179
DISASSEMBLY AND ASSEMBLY HOW TO READ THE MANUAL

HOW TO READ THE MANUAL

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

:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions to be followed when carrying

out the operation.
1 - Remove XXXX (1):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving XXXX (1)
2 - ~ ~ ~ (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This sign means that information is given for
the installation procedure
3 - Remove &&&& (3):
........... ,: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recovery of oil or water, and the quantity to be re-
covered.

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

. To install, reverse removal procedure.
: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique to be used for installation.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving ~ ~ ~ (2).
. Addition of water or oil: . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point to remember when adding water or oil.

2. To the precautions to be taken during the removal or installation of the groups, must be added the specific
«PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.

3. List of special tools.

(1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational
procedures, see the list «SPECIAL TOOLS» supplied in this section.

4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill
tanks and containers
(1) In the operating procedures, you will find the symbols , , , . In the following order, these
represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES
OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.

30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS TO BE TAKEN WHEN WORKING

PRECAUTIONS TO BE TAKEN WHEN WORKING

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

1. Precautions for removal operations

. If not otherwise indicated, lower the work equipment until it rests on the ground.
. If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
. After having removed flanges and tubes, insert plugs to prevent impurities from entering.
. Before removing a cylinder, fully retract the piston and tie it with wire.
. Use a sufficiently large container to collect the oil.
. Before removing a part from the machine, check the alignment reference marks which show the correct in-
stallation position. If necessary add further marks to avoid incorrect installation.
. While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
. If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
. Check the number and height of the adjustments to a given clearance and store them in a safe place.
. When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
. When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
. Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or
dust from gaining entrance.
2. Precautions to be taken during installation
. Tighten nuts and screws with the specified tightening torques.
. Install the flexible hoses, taking care not to entangle or twist them.
. Bend the cotter pins and stops in such a way as to secure them.
. When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough
adhesive to cover the threading in a uniform manner.
. When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there
are no dents or dirt, then apply the liquid sealant in a uniform manner.
. Clean all the parts, remove dirt, rust, burrs, or dents.
. Apply a film of engine oil over all the moving parts.
. Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking.
. After having mounted the snap-rings, check that they are firmly positioned in their seatings.
. When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them,
then connect them firmly.
. If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoist-
ing hook.
. Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive
pull on one side only.
3. Precautions to be taken on completion of removal and installation operations.
. If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level.
Start the engine to circulate the liquid throughout the cooling system and then top up the level once more.
. When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the en-
gine to circulate the oil in the hydraulic circuits, and then top up to the indicated level.
. If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves,
are removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the
machine.
H For details, see «20. TESTING AND ADJUSTMENTS».
. After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.

30-4
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS

SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

Installation of swing 1 ATR200390 Coupling for brake 1 Ð

machinery for revolving frame release
A 2 ATR200400 Rear raising equipment 1 Ð
Removal/Installation
revolving frame 3 ATR200410 Rear raising equipment 1 Ð
Removal/Installation of B 1 ATR200420 Swing circle raising 1 Ð
swing circle equipment
Removal/Installation of D 1 ATR200440 Tool for raising control 1 Ð
control valve valve

1 ATR200470 Pliers for mounting 1 All cylinders

gaskets
ATR200480 é 50 calibrator 1
2 ATR200490 é 60 calibrator 1 To calibrate piston rod
gaskets
ATR200500 é 70 calibrator 1
ATR200510 é 90 plunger 1
3 ATR200520 é 100 plunger 1 To assemble piston
gaskets
ATR200530 é 120 plunger 1
ATR200540 é 90 calibrator ring 1
4 ATR200550 é 100 calibrator ring 1 To calibrate piston
gaskets
Disassembly/Assembly F ATR200560 é 120 calibrator ring 1
of work equipment cylinders
é 50 insertion bushing
ATR200570 for piston rod 1

5 ATR200580 é 60 insertion bushing 1 To mount flange

for piston rod and head

ATR200590 é 70 insertion bushing 1

for piston rod

6 ATR200600 Pliers for mounting 1 All cylinders

snap-ring

Socket wrench For arm cylinder

7 ATR800180 (6-point 75) 1 Removal-installation of
piston-retaining nut

8 ATR200610 Tool for disassembly and 1 All cylinders

assembly cylinders
Removal/Installation of
counterweight
Disassembly/Assembly of G 1 ATR800190 Dynamometric wrench 1 Max. 400 kgm (400 dNm)
arm cylinder nut with multiplier
Removal and installation
of wheels
1 ATR500900 Puller 1 To extract bushings
Disassembly/Assembly H 2 ATR500910 Plunger 1 Assembling bushings
of gear-pump
3 ATR500920 Centering apparatus 1 To mount driving
gear

1 ATR500860 Wrench 1 To remove and

mount lock-nut
Disassembly/Assembly of M 2 ATR500870 Plunger 1 To remove inside ring
swing machinery from pinion bearing

3 ATR500880 Plunger 1 To assemble inside

bearing ring

30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS

SPECIAL TOOLS

Nature of work Symbol Code Denominazione Q.ty Notes

4 ATR500590 Plunger 1 To mount outside

bearing ring
Disassembly/Assembly of M To test brake release
swing machinery 5 ATR200380 Circuit sectioning tool 1 seal
6 ATR800140 Pressure gauge 1 Full scale 400 bar
Removal and installation N 1 ATR200630 Tool to raise swivel joint 2 Ð
swivel joint
To determine the
1 ATR501070 Spacer 1 clearance of the central
Assembly of travel motor P pin

2 ATR501080 Special tool 1 To check clearance

of the central pin

1 ATR200640 Special wrench 1 To remove steering unit

from the machine
Guide
2 ATR501090 Plunger 1 To install spool seal
Assembly of steering unit Q
Push rod
3 ATR501100 Fork 1 To secure the drive shaft

4 ATR501110 Plunger 1 To assemble the

dust-guard
Removal of the wheels R 1 ATR200650 Cage 1 To remove wheels
Tightening lock nut of
1 ATR500940 Wrench 1 bevel pinion

2 ATR500950 Wrench 1 Tightening lock nut of

bevel pinion

3 ATR500960 Tool 1 Assembly bearing ring,

bearings, bevel pinion
4 ATR500970 Tool 1 Adjusting bevel pinion
5 ATR500980 Tool 1 Adjusting bevel pinion

6 ATR500990 Tool 1 Assembly roller-bearing

on bevel pinion

7 ATR501000 Tool 1 Mounting complete

pinion and seal ring
Disassembly and Assembly S
axles 8 ATR501010 Wrench 1 Adjusting bevel gear
Assembling tapered-
9 ATR501020 Bushing 1 roller bearing of the final
reduction unit
10 ATR501030 Pin 1 Assembly bevel gear pin

11 ATR501040 Pin 1 Assembly bearing ring,

steering joint

12 ATR501050 Tool 1 Mounting dust-guard

rings
A Guide 1
13 ATR501060 B Guide 1 Assembly steering
cylinder piston gaskets
C Pin 1

30-6
DISASSEMBLY AND ASSEMBLY STARTER MOTOR

REMOVAL OF STARTER MOTOR

Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the lower central grid (1) of the revolving

frame.
2 - Remove the selector valve (2) from the fixed hood to
free access to the starter motor. 1
3 - Disconnect the three screws (3) from the hatch (4) of
the fixed hood.
H Loosen but leave in position the screw (5) that al-
lows the hatch (4) to be turned.
D0400466
4 - Remove the top two nuts (6).
5 - Remove the bottom nut (7) through the space below
the revolving frame. 2
3
6 - Pull the starter motor (8) out a little way and discon-
nect the electric wiring (9) and the earth cable (10). 5
7 - Extract the starter motor (8).
3

4
INSTALLATION OF STARTER
MOTOR F0400089

. To install, reverse the removal procedure.

9
6
8

7 10

F0400090

30-7
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the hatch (1) in the engine casing (2).

2 1
2 - Disconnect the cable (3) and the plug (4).
3 - Loosen the bolts (5-6-7) sufficiently to allow the alter-
nator (8) to be rotated.
4 - Free the pulley from the fan-belt (9) and draw out the
alternator (8).

F0400091

INSTALLATION OF ALTERNATOR 5 6
8
. To install, reverse the removal procedure.

H Adjust the tension of the fan-belt. (For details, see 4

«20. TESTING AND ADJUSTMENTS - Tightening
the fan-belt).
7
3
9
F0400092

30-8
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER

1 - Remove the flow-back tubing (1).

1
2 - Unscrew the high-pressure fittings (2) from the nozzle
holder and from the injection pump. 2
H Do not bend the tubes and, if necessary remove
the clamps (3).

3
F0400093

3 - Remove the screws (4) that hold the collar (5) in place
and remove the nozzle holder (6) and copper washer 5
(7). Remove the dust-seal (8) and the spacer (9).
6

7
9

D0400393

INSTALLATION OF
NOZZLE HOLDER
. To install, reverse the removal procedure.
H Use new dust-seals (8), spacers (9) and copper
washers (7).

High-pressure fittings: 18 Nm

Collar screws: 12 Nm

H Use new seals for the flow-back tubing.

30-9
DISASSEMBLY AND ASSEMBLY AIR FILTER GROUP

REMOVAL OF AIR FILTER GROUP

Disconnect the lead from the negative (±) battery
terminal.

1 - Loosen the clamp (1) that attaches the sleeve (2) to 1

2 3
the engine induction manifold.
2 - Loosen the clamp (3) that attaches the sleeve (4) to
the induction pipe (5). 5

4
F0400094

3 - Remove the fuses (7) from the filter support (6).

F0400095

4 - Disconnect the connectors (8) from the clogged-filter

indicator. 8
5 - Remove the screws (9) that attach the filter support (6).

6 - Remove the filter group (10).

10

F0400096

INSTALLATION OF AIR FILTER

GROUP
. To install, reverse the removal procedure.

Filter support screws: Loctite 242

30-10
DISASSEMBLY AND ASSEMBLY MUFFLER

REMOVAL OF MUFFLER
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the air filter. (For details, see «REMOVAL OF

AIR FILTER GROUP»). 1
3
2 - Loosen the tail-pipe clamp (1).
3 - Remove the screws (2) and the tail-pipe (3).
2

F0400097

4 - Remove the top hatch (4) of the engine-hood (5).

5 4

F0400230

5 - Remove the two screws (6) of the suction tube (7) and
loosen the screw (8). 8 7 6

F0400098

6 - Raise the suction tube (7) and secure it in position,

supported by a provisionally mounted M10x50 screw 7
(9).
12
7 - Remove the pipe (10) that supplies fuel to the cold
start equipment.
8 - Remove the fuel-lift pump control-rod support (11)
and the lifting support (12) for raising the engine. 9
10

11
F0400099

30-11
DISASSEMBLY AND ASSEMBLY MUFFLER

9 - Remove the screws (13) of the muffler (14) and en-

gine bracket (15). 13

10 - Remove the three nuts (16) that attach the muffler to 16

15
the exhaust manifold (17).

17

14

F0400100

11 - Lift out the muffler (14).

14

F0400101

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

Engine bracket screws: Loctite 242

30-12
DISASSEMBLY AND ASSEMBLY ENGINE HOOD

REMOVAL OF ENGINE HOOD

Lower the work equipment until it is resting on the
2
ground and switch off the engine.

1 - Detach the gas cylinder (1) from the engine hood. 1

2 - While holding up the engine hood (2) remove the
screws (3) that attach the hood to the hinges (4).

H Mark the position of any shims.

Engine hood: 60 kg
1
F0400102

INSTALLATION OF ENGINE HOOD

3
. To install, reverse the removal procedure.

H Check the centering and adjustment of the clos-

ing hook (5).
H Position any shims.
4
Replace the cotter pins (6).

F0400103

6
5

F0400104

30-13
DISASSEMBLY AND ASSEMBLY FIXED HOOD

REMOVAL OF FIXED HOOD

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»). 1
2
Disconnect the lead from the negative (±) battery
terminal.

. Drain the hydraulic oil.

Quantity of oil: approx. 82 ,
F0400231

1 - Remove the cabin and the engine hood.

(For details, see «REMOVAL OF CABIN» and «RE-
MOVAL OF ENGINE HOOD»).
4 3
2 - Remove the clamp (1) and the tail-piece (2).
3 - Remove the alternator inspection hatch (3).
4 - Disconnect the selector valve (4) from the fixed hood.

F0400105

5 - Disconnect the by-pass valve (5) and the tube (6) of

the servocontrol feed unit (7) from the tank. Also re- 10 5
move the tank unions.
11
6 - Disconnect the servocontrol feed unit tubes (8) from
the pumps.
9
7 - Inside the engine compartment, disconnect all the hy- 6
draulic tubes and all electrical cables that pass
through the wall (9) of the fixed hood towards the front
equipment.
8 7
8 - Remove the sleeve (10) that connects the air filter to
the suction pipe attached to the fixed hood (11). F0400654

9 - Disconnect the support (12) of the vibration damper of

the radiator. 12

F0400107

30-14
DISASSEMBLY AND ASSEMBLY FIXED HOOD

10 - Remove the eight screws (13) that attach the hood to

the revolving frame.
H Mark the position of any shims.

13

F0400108

11 - Screw the hoisting eyebolts into the engine hood.

12 - Attach the hood (14) to the hoisting tackle and re-
move it. 14
Engine hood: 83 kg

F0400109

INSTALLATION OF FIXED HOOD

. To install, reverse the removal procedure.
1 - Fill the hydraulic oil tank up to its maximum level.

While filling, bleed air from the main pumps.

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

Hydraulic oil needed: approx. 82 ,

2 - Start the engine to circulate the oil and check that

there are no leakages.
3 - Switch off the engine, check the levels and, if neces-
sary, top up.

H Position any shims.

30-15
DISASSEMBLY AND ASSEMBLY SEAT

REMOVAL OF SEAT
Lower the work equipment until it is resting on the
ground, switch off the engine and remove the ignition
key. 1

1 - Raise the front window (1) completely.

2 - Remove the lower window (2) and place it in the sup-
ports provided at the back of the cabin.
3 - Remove the four screws (3) that secure the seat.
H Slide the seat forwards and backwards in order to
reach the screws.
4 - Remove the seat.
Seat: 32 kg 2

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

F0400438

F0400111

30-16
DISASSEMBLY AND ASSEMBLY CABIN

REMOVAL OF CABIN
Lower the work equipment until it is resting on the
ground and switch off the engine. 2

1 - Remove the seat. (For details, see «REMOVAL OF

SEAT»). 1
2 - Temporarily remove the windshield-washer tray (1)
from its support (2).
3 - Remove the (6+1) attachment screws (3). 4

4 - Disconnect the connector (4).

5 - Replace the windshield-washer tray (1) on its support F0400112

(2).
6 - Disconnect the heating hose (5) from the diffuser (6).
7 - Remove the upper protective caps and mount the
hoisting eyebolts (7).
8 - Attach the eyebolts (7) to the hoisting tackle and 3
move the cabin.
Cabin: 250 kg

INSTALLATION OF CABIN F0400113

. To install, reverse the removal procedure.

H Make sure that the short screw (8) is placed on the
LH side.

7 7

F0400114 F0400439

30-17
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

REMOVAL OF COUNTERWEIGHT
Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Remove the engine-hood.

(For details, see «REMOVAL OF ENGINE HOOD»).
1
2 - Remove the engine-hood hook support (1).
3 - Remove the protective caps and firmly tighten the
hoisting eyebolts (2).
4 - Attach the hoisting tackle and apply slight tension to
the cables. F0400116

5 - Using the tool G1, loosen the screws (3) and their
safety washers.
6 - Remove the counterweight (4).

2 2
INSTALLATION OF
COUNTERWEIGHT
. To install, reverse the removal procedure.
4
F0400117
Counterweight screws: Loctite 242
Counterweight screws: 981 Nm

H Carefully check that the vertical positioning mea-

surement «A» is 95w1 mm with respect to the re- A
volving frame. 4

F0400118

30-18
DISASSEMBLY AND ASSEMBLY RADIATOR

REMOVAL OF RADIATOR
Lower the work equipment until it is resting on the
ground and switch off the engine.

. Drain the engine coolant liquid.

Coolant liquid: 24 ,

1 - Remove the engine hood.

(For details, see «REMOVAL OF ENGINE HOOD»). 1
2 - Remove the lower left hatch (1) of the revolving
frame.
D0400402
3 - Remove the fan guard.
4 - Remove the conveyor (3) and push it towards the en-
gine.
4
5 - Disconnect the tubes (4-5) between radiator and en-
gine.
6 - Remove the container (6) together with the relative
tubing and support (7). 2
3
7 - Remove the elastic support (8).
8 - Remove the four screws (9) and the upper frame (10).
9 - Lift out the radiator (11) from above.
5
F0400119

INSTALLATION OF RADIATOR
8 10
. To install, reverse the removal procedure.
1 - Fill up the coolant liquid circuit.

Coolant liquid: approx. 24 ,

2 - Start the engine to circulate the coolant liquid and 9

check that there are no leakages.
3 - Switch off the engine, check the level of the liquid in
11
the container and, if necessary, top it up. 7 6
F0400232

30-19
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER

REMOVAL OF HYDRAULIC OIL COOLER

Lower the work equipment until it is resting on the
ground and switch off the engine. 2

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»). 3

1 - Remove the radiator. (For details, see «REMOVAL

OF RADIATOR»).
2 - Slowly unscrew the bottom tube (1) to drain the oil 1
contained in the oil cooler.
Oil cooler: approx. 9 , F0400120

3 - Disconnect the tubes (1) and (2) and plug them to pre-
vent entry of impurities.
4 - Raise the hydraulic oil cooler (3) and move it towards
the back of the machine.
5 - Lift out the hydraulic oil cooler (3).

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

H Add oil to the hydraulic tank up to max. level.

Hydraulic oil needed: approx. 9 ,

1 - Start the engine to fill up the oil cooler and check that
there are no leakages.
2 - Switch off the engine, check the oil level of the hy-
draulic oil tank and, if necessary, top it up.

30-20
DISASSEMBLY AND ASSEMBLY HEATING FAN

REMOVAL OF HEATING FAN

Lower the work equipment until it is resting on the
ground and switch off the engine.

Disconnect the lead from the negative (±) battery

terminal.
1
Drain the coolant liquid to a level below that of the
connecting tubes (1-2) between the engine and the
heating fan.

Quantity of cooling liquid: approx. 6 , 2

1 - Disconnect the tubes (1-2) from the engine and lower F0400121

their extremities to drain the radiator completely.

Quantity of cooling liquid: approx. 1.5 ,
3
2 - Remove the seat. (For details, see «REMOVAL OF
SEAT»).
4
3 - Remove the swing locking pin knob (3).
4 - Remove the glove-compartment (4) (6 screws).

F0400122

5 - Move the sliding plate (5) forwards as far as it will go.

6 - Remove the screws (6) of the seat support group (7). 5

11

F0400123

7 - Remove the lower diffuser (8), complete with the tube

attaching it to the fan group.

6
8

7
F0400124

30-21
DISASSEMBLY AND ASSEMBLY HEATING FAN

8 - Raise the seat support group (7) from the rear.

H Wedge the group securely in this position with an
approx. 50 mm thick block.
9 - Disconnect the air delivery hose (9) from the cabin dif-
fuser (10), and release it from its clamps.
10 - Remove the fan two screws (11) and draw the fan (12)
towards the back of the machine.
11 - Disconnect the connector (13). 50 mm

12 - Disconnect the delivery and return tubes (14). 7

F0400125
13 - Disconnect the air delivery hose (15).

10

F0400233

11
13

12
14

15
F0400126

INSTALLATION OF HEATING FAN

. To install, reverse the removal procedure.

1 - Make sure that the heating cock is fully open.

2 - Fill up with coolant liquid.

Quantity of coolant liquid: approx. 7.5 ,

3 - Start the engine to circulate the coolant liquid.

4 - Switch off the engine and top up the level.

30-22
DISASSEMBLY AND ASSEMBLY FUEL TANK

REMOVAL OF FUEL TANK

Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Remove the top engine hood and the lower RH hatch

of the revolving frame.
2 - Disconnect the clamps from both battery terminals.

First disconnect the negative (±) terminal

clamps.

3 - Remove the battery (1). 1

F0400127

4 - Remove the grommet (2) and draw out the cables

connecting the battery (3), the horn and the fuel level
indicator (4).
5 - Remove the cap of the fuel tank, open the tank drai-
nage cock (5), and drain the fuel.
4
Fuel: max. 140 ,
2
6 - Close the delivery cock (6) and disconnect the fuel
delivery and flow-back tubes (7-8). Plug them to pre- 3
vent entry of impurities.
7 - Remove the six screws.

Check the number of shims needed for each F0400128

screw.

8 - Attach the tank (9) to the hoisting tackle and lift it out. 5
Fuel tank: 105 kg
7
8
INSTALLATION OF FUEL TANK
. To install, reverse the removal procedure.
1 - Fill the fuel tank and check that it does not leak. 6

F0400129

H Before starting the engine, bleed air from the

lines.

9
H Position any shims.

F0400130

30-23
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL TANK

REMOVAL OF HYDRAULIC OIL TANK

Lower the work equipment until it is resting on the
ground and switch off the engine. 1
Release residual pressures from all circuits. (For de-
2
tails, see «20. TESTING AND ADJUSTMENTS»).
Disconnect the lead from the negative (±) battery
terminal.

. Drain the hydraulic oil.

Quantity of oil: approx. 82 ,

1 - Remove the fuel tank. (For details, see «REMOVAL

OF FUEL TANK»).
F0400655

2 - Disconnect the by-pass valve (1).

3 - Disconnect the return tube (2) of the servocontrol
feed unit from the tank.
4 - Disconnect the suction tubes (3-4) from the main
pumps (P1 and P2) and from the gear pump. 3
5 - Disconnect all the return tubes (5) from the tank.
6 - Remove the tank attachment screws.
Check the quantity of shims necessary for each
screw.
4
7 - Attach the tank (6), complete with pump suction tubes F0400298

(7-8), to the hoisting tackle and lift it out.

Tank oil: 76 kg

INSTALLATION OF HYDRAULIC 5
OIL TANK
. To install, reverse the removal procedure.

H Position any shims.

1 - Fill the oil tank up to max. level.
During the filling operation, bleed the air from
the pumps P1-P2. (For details, see «20. TEST-
F0400131

ING AND ADJUSTMENTS»).

Hydraulic oil required: approx. 82 ,

2 - Start the engine to circulate the oil and check that
6
there are no leakages.
3 - Bleed the air from the servocontrol circuit. (For de- 7
tails, see «20. TESTING AND ADJUSTMENTS»).
4 - Switch off the engine, check the level and, if neces-
sary, top it up.

8
F0400132

30-24
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP

REMOVAL OF ENGINE-PUMP GROUP

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

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

Disconnect the lead from the negative (±) battery

terminal.
2
. Drain the hydraulic oil.
Quantity of oil: approx. 82 ,
F0400133

. Drain the engine coolant liquid.

Quantity of coolant liquid: 24 ,

. Turn off the diesel-fuel supply cock. 1

1 - Remove the cabin.

(For details, see «REMOVAL OF CABIN»).
2 - Remove the engine-hood.
(For details, see «REMOVAL OF ENGINE-HOOD»).

F0400440

3 - Disconnect from the pumps the servocontrol feed unit

tubes (1), the suction tube flanges (2), the delivery
tubes (3), and the pump horse-power control (4), (3- 3
circuit valve and Mode system). 4 3

1 4
2

F0400135

4 - Remove the lower casings (5-6) of the RH engine

compartment (7) of the revolving frame.
5 - Remove the fixed hood.
(For details, see «REMOVAL OF FIXED HOOD»).

5 6
7

D0400399

30-25
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP

6 - Disconnect the radiator tubes (8-9) and the heating

system tubes (10-11).
7 - Remove the fan guard (12). 14

8 - Remove the fastening screws (13) of the conveyor 10

8
(14). Push the conveyor towards the engine in order 12
to disengage it from the radiator supports.

13 11
F0400136

9 - Disconnect the lead from the positive (+) battery

terminal (15). Remove the two hose-clamps (16) and
the earth cable (±) (17) of the frame.
10 - Remove the knob of the swing-locking pin (18) and 15
the glove compartment (19). ---

21
17 16 20
D0400392

11 - Disconnect the engine wiring connectors (20) from

the diode box. Remove the clamp (21). 18

19

F0400235

12 - Disconnect the earth cable (22) from the starting mo-

tor and free the cables from the clamps (23) that se-
cure them to the frame.

23
22

23

F0400236

30-26
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP

13 - Disconnect the accelerator control cable (24).

14 - Using the lifting support supplied, slowly raise the en-
gine-pump group (25).
24

15 - Remove the nuts (26) from the screws (27).

16 - Slowly raise the engine-pump group.

H When moving the group, accompany the electric
cables and take care not to damage them.
H Check that the engine and the pump have been
completely released from all connections.
F0400137

Engine group and pump: 570 kg

INSTALLATION OF ENGINE-PUMP 27
27
GROUP
. To install, reverse the removal procedure.
26
F0400138

H Before re-connecting the tubes, check that no

seals have been damaged.

Engine fastening screws: 157w9.8 Nm 25

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

While filling the tank, bleed air from pumps P1-

P2 (For details, see «20. TESTING AND AD-
JUSTMENTS»).

Hydraulic oil needed: approx. 82 ,

2 - Fill the cooling circuit up to its maximum level. F0400139

Coolant liquid needed: approx. 24 ,

3 - Start the engine to circulate oil and coolant liquid, and

check that there are no leakages.
4 - Switch off the engine, check the levels and, if neces-
sary, top them up.
5 - Bleed air from the servocontrol circuit. (For details,
see «20. TESTING AND ADJUSTMENTS»).

30-27
DISASSEMBLY AND ASSEMBLY PUMP GROUP

REMOVAL OF PUMP GROUP

Lower the work equipment until it is resting on the
ground and switch off the engine.
4
3 5
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»). 2
Disconnect the lead from the negative (±) battery
terminal.
7
. Drain the hydraulic oil.
Quantity of oil: approx. 82 ,
6
1
1 - Remove the engine hood. (For details, see «RE-
MOVAL OF ENGINE HOOD»).
F0400237

2 - Disconnect the suction (1) and delivery (2-3) hoses of

the main pump.
3 - Disconnect the tube (4) of the MODE SYSTEM device
and the 3-circuit valve (5) and the supply tubes (6-7-8)
of the servocontrol supply group.
4 - Disconnect the suction (9) and delivery (10-11) tubes
of the gear-pump.
5 - Remove the air filter together with its support. (For de-
tails, see «REMOVAL OF AIR FILTER»).
6 - Attach the group (12) to the hoisting tackle.
Pump group: 68 kg
7 - Take out the screws and remove the pump group.

INSTALLATION OF PUMP GROUP 11

8
9
. To install, reverse the removal procedure.

H Before connecting the tubes, check the seals for

damage.
10
Pump group screws: Loctite 242
Pump group screws: 68 Nm
1 - Fill the hydraulic oil tank to maximum level. F0400238
While filling tank, bleed air from pumps P1 and
P2 (For details, see «20. TESTING AND AD-
JUSTMENTS»).
Hydraulic oil needed: approx. 82 ,
2 - Start the engine to circulate the oil and check that
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.
4 - Bleed air from the servocontrol circuit. (For details, 12
see «20. TESTING AND ADJUSTMENTS»).a

F0400140

30-28
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

DISASSEMBLY OF HYDRAULIC PUMP

1 - Remove the Mode System group (1) complete with

the 3-circuit valve (2).
If the seating (3) of the push-rod is removed dur-
ing removal of the complete Mode System, the
displacement regulation group (4) must also be 3
dismantled.
4

2
1
D0400312

2 - Remove the pressure regulation group (5) and the

spring (6).
5
6

D0400313

3 - Take away the calibration group (7) and the screw (8).
H Before proceeding with the removal, take mea-
7 8
A
surements «A» and «B» very accurately. Write B
them down and keep them somewhere safe, be-
cause they will be needed during the installation 9
phase in order to preserve the original pump cali-
bration.
H Take care that the calibration spring (9) does not
fall inside the pump body.

D0400314

4 - Loosen the twelve screws (10).

10

D0400315

30-29
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

5 - Remove the complete control body (4).

H If necessary, use a soft-headed mallet.
4

D0400316

6 - Loosen the screw (11) and take away the complete

rocker-arm support (12).
12

11

D0400317

7 - Remove the control piston (13).

13

D0400318

8 - Loosen the screws (14) and take away the complete

lower cover.
H Do not change the position of the screw (15).

15
14 D0400319

30-30
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

9 - Remove the pilot system bushing (16).

16

D0400320

10 - Remove the positioning piston (17) and the cylinder

block connecting fork (18).
16 18

17

D0400321

11 - Remove the cylinder blocks (19) and the distribution

plates (20). 20 19
H Be careful with the Belleville washers (21) (four for
each cylinder block) and the spring guide collars
(22), (one for each cylinder block).

21 22

D0400322

12 - Remove the transmission crankcase (23), using le-

vers and a soft-headed mallet. 23
H Take care not to damage the machined surfaces.

D0400323

30-31
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

13 - Remove the gear of the auxiliary pump (24), complete

with its bearing.
24
H Take care not to damage the machined surfaces.

D0400324

14 - Use a puller to remove the bearing (25).

25

D0400325

15 - Use specially-shaped levers to remove the rotating

groups (26).
H Take care not to damage the machined surfaces. 26 26

D0400326

16 - Clamp the rotating group (26) in a vice.

H Use a soft-jawed vice to avoid damaging the gear- 26
teeth.

D0400327

30-32
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

17 - Remove the seven screws (27) that secure the retain-

ing plate (28).
28
To facilitate removal, heat the rotating group up
to 120±130ëC.
H Repeat this operation for the other rotating group. 27

D0400328

18 - Remove the snap ring (29) from the transmission

crankcase. 30
29

D0400329

19 - Use levers to remove the front cover (31).

H Protect the toothing of the drive shaft (30) with ad-
hesive tape to prevent damage. 31

D0400330

20 - Take the front cover (31) to pieces, removing the re-

taining ring (32) and the O-ring (33).
Remove the spacer (34). 34
33
31 32

D0400331

30-33
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

21 - Remove the snap ring (35).

35

D0400332

22 - Clamp the gear of the drive shaft (30) in a vice.

H Use a vice fitted with jaws to prevent damage to 30
the gear teeth.

D0400333

23 - Loosen the locknut (36).

36

D0400334

24 - With a soft-headed mallet, extract the drive shaft (30)

from the transmission crankcase (37).

37
30

D0400335

30-34
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

25 - Remove the bearing ring (38), the bearing and the

bearing ring (39).

38
39

D0400336

26 - Remove the snap ring (40) and the spacers (41).

40
41

D0400337

30-35
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

ASSEMBLY OF THE HYDRAULIC PUMP

1 - Remove the retaining washer and clean all the ma-

chined surfaces.

D0400338

2 - Assemble the drive shaft (30) with the bearings (38-

39), the spacer (41), the retaining ring (40) and the 39 40 41 38
locknut (36). 30
H Tighten the locknut to a measurement of 51 0.05
mm.
Ring nut: Loctite 242

51--00,05 36
D0400339

3 - Mount the pistons (42) complete with the ring, king-

bolt (43), retaining plate (28) and screws (27). 43
Screws: Loctite 242 42
Screws: 2.9 Nm

28
27
D0400340

4 - Assemble the spring-guide collars (22) and the spring

(21). 21
H Make sure that the springs are the right way up.

22
D0400341

30-36
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

5 - Insert the rotating group complete with pistons (26) in

the cylinder block (19).
26
H Support the cylinder block on a surface of some
soft material, to prevent damage to the sliding sur-
face.
H Repeat operations 3,4 and 5 for the second rotat-
ing group. 19

D0400342

6 - Heat the transmission crankcase (37) to 80ëC and in-

sert the pre-assembled drive shaft (44). 37 44
H Make sure that the retaining ring (40) fits into the
crankcase seating.

40

80°C

D0400343

7 - Insert the rotating groups (45 and 46).

H Make sure that the reference notches between
45 46 44
the rotating groups (45 and 46) and between the
rotating group (46) and the drive shaft (44), are 44
aligned.

45 46
D0400344

8 - Mount the bearing (25), the neutral gear (24) and the
bearing (47).
47
24

25

D0400345

30-37
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

9 - Mount the washer (48) and the crankcase of the rotat- 80°C
ing group (23). 23
H To facilitate the installation of the crankcase, heat
the bearing seating area (47) to a temperature of 48
roughly 80ëC.

D0400346

10 - Insert the cylinder connection fork (18) with the ma-

chined surface facing upwards. 18

D0400347

11 - Mount the positioning piston (17).

Lato aspirazione
Suction side Foro
Hole
H Make sure that the hole in the bottom of the posi-
tioning piston (17) is facing the right way.

Lato cilindri
Cylinder side View
VistaAA

17

A D0400348

12 - Mount the pilot system bushing (16).

16

D0400349

30-38
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

13 - Mount the pilot system piston (13).

13

D0400350

14 - Mount the complete rocker-arm support (12).

Centring pin (49) and seating (3):
Loctite 262 12
Screws: 10 Nm 49
3

D0400351

15 - Mount the spring (6) and the lower cover (14) com-
plete with the seal (50).
Screw: 25 Nm 6
50

14 D0400352

16 - Mount the pressure regulation group (5) complete

with seals.
Pressure regulation group screw: 69 Nm
5

D0400353

30-39
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

17 - Mount the distribution plate (20).

H Make sure that the distribution plates are correctly
20 20
mounted and that they slide freely.
H To hold the distribution plates in place, spread
some ASL800050 on the surface.

D0400354

18 - Mount the control body (4) with the washer (51) and
the screws (10). 4
Screws: 25 Nm

10 51

D0400355

19 - Mount the Mode System group (1) complete with the

3-circuit valve (2).
H To facilitate installation, immobilise the push-rod
with ASL 800050 grease injected into the seating.
Mode System group: 60 Nm

D0400356

20 - Mount the calibration group (7) and the screw (8).

H Regulate the group and the screw until the pre- 7 52 53 8
cise measurements «A» and «B» have been ob-
tained (measured during phase 3 of the disman-
tling operations). A B
Nut (52): 10 Nm
Nut (53): 22 Nm
Group attachment screws (7): 69 Nm

D0400357

30-40
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

21 - Mount the retaining ring (32) and the O-ring (33) in the
front cover (31). 33
31
If the shaft looks worn in the area of contact with
the retaining ring (32), insert a spacer (54) be- 32
tween the cover and the retaining ring to vary
the contact area.
54

D0400358

22 - Mount in the transmission crankcase (23):

- the snap ring (35);
- the spacer (34); 34 35
- the complete front cover (31); 23
- the snap ring (29).
Retaining ring and front cover: ASL800050 29
H Check carefully that the snap rings (34) and (15)
are correctly positioned. 31

D0400359

30-41
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

REMOVAL OF GEAR-PUMP
Lower the work equipment until it is resting on the
ground and switch off the engine.
3

Release residual pressures from all circuits. (For de-

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

Disconnect the lead from the negative (±) battery

terminal.
2
. Drain the hydraulic oil. 1

Quantity of oil: approx. 82 ,

1 - Disconnect the suction (1), delivery (2), and servocon-
F0400239

trol supply (3) tubes.

2 - Remove the screws (4) and lift out the pump (5) to-
gether with its O-ring seal.
5

INSTALLATION OF GEAR-PUMP F0400141

. To install, reverse the removal procedure.

H Before connecting the tubes, check the seals for

damage.

H Before mounting the sealing ring, make sure that

the seal is undamaged.
1 - Fill the hydraulic oil tank to maximum level.
While filling, bleed air from the main pumps (P1-
P2). (For details, see «20. TESTING AND AD-
JUSTMENTS»).

Hydraulic oil needed: approx. 82 ,

2 - Start the engine to circulate the oil and check that
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.
4 - If necessary, bleed air from the servocontrol circuit.
(For details, see «20. TESTING AND ADJUSTMENTS»).

30-42
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

DISASSEMBLY OF GEAR-PUMP

H We shall describe here the dismantling of a double

pump. In the case of a single pump, ignore the opera-
tions regarding the body of pump P4.
H If it becomes necessary to use a lever while disman- P4
tling the pump, take care not to damage the machined P3
surfaces.
P3

F0400441

1 - Clamp the pump (1) in a vice with the drive shaft fa-
cing downwards, and mark all the sections.
H Do not tighten the vice near or on machined sur-
faces.

F0400060

2 - Remove the nuts (2), the washers (3) and, if the pump
is double, also the stud-bolts (4).
H If a main valve has been installed, remove it first.

2 4

F0400061

3 - Remove the rear cover (5).

The centring bushings (6) may remain either in
the pump body (11) or in the cover (5): do not re-
move them! 5
H Take care not to damage the machined surfaces.

11
6

F0400062

30-43
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

4 - Remove the thrust bearing (7).

8
7

F0400063

5 - Remove the driven gear (8), the driving gear (9) and
the internal thrust bearing (10).
H Take care that the two gears do not receive any
blows which could dent them.
9
10

F0400064

6 - Remove the pump body (11) from the bushing sup-

port (12).
H Take care not to damage the machined surfaces. 11

12

F0400065

7 - Remove the bushing support (12).

The centring bushings (14) may remain either in
the bushing support (12) or in the pump body.
Do not remove them!
H Take care not to damage the machined surfaces.

12
14

F0400066

30-44
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

8 - Remove the connecting shaft (15), the thrust bearing

(16), the driven gear (17), the driving gear (18) and the 15
thrust bearing (19). 19
H Take care that the two gears do not receive any 18
blows which could dent them.
16

17

F0400067

9 - Remove the first pump body (20).

H Take care not to damage the machined surfaces.

20

F0400068

10 - Extract the bushings (22), using the tool H1.

H1

22

F0400069

11 - Remove the retaining ring (21).

21

19
D0400401

30-45
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

ASSEMBLY OF THE GEAR-PUMP

H If difficulties are encountered when installing the

pump body and the bushing support, use only soft-
headed mallets.

1 - Remove all dents or burrs from the machined sur-

faces, using a medium-grain pumice stone.

F0400070

2 - If bushings have been removed, smooth the holes

with emery paper.
H Before commencing installation operations, wash
the pieces carefully with solvent and dry with com-
pressed air.

F0400071

3 - Clamp the front cover (23) in a vice with the flange fa-
cing downwards.
H Check that the caps (24) are not damaged or loo-
sened. If they are damaged, fit new ones.

24

23

F0400072

30-46
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

4 - Screw the caps (24) down as tightly as possible.

Cap: Loctite 542
H Chamfer the caps both round the edge and at the
end of the screwdriver slot.
H Chamfer the holes with a 1" 1/2 steel ball.

F0400073

5 - Remove all dents or burrs from the machined sur-

faces, using a medium-grain pumice-stone. Smooth
the edges of the bushings with emery paper.
H Before starting installation, wash the piece thor-
oughly with solvent and dry it with compressed
air.

F0400076

6 - Insert the bushings (22).

H Insert the bushings (22) in the holes of the driving Slit
Taglio
gear with the slit facing upwards.
H Insert the bushings (22) in the holes of the driven
gear with the slit facing downwards.
22
H The bushings should be inserted in the holes in Holes of the
Foro ingranaggio
one single operation, using the tool H2 and a driving gear
conduttore Hole of the
Foro ingranaggio
driven
condottogear
press.

Slit
Taglio

F0400074

H2

22

F0400075

30-47
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

7 - Insert the centring bushings (14) with a soft-headed

mallet.
H Check that the holes are free of burrs and impuri-
ties.
14

F0400077

8 - Mount the retaining ring (21) in the front cover (23).

External retaining ring and internal cover:
ASL800070
21
H After installation, carefully remove all excess li-
quid sealant ASL800070.

F0400078

9 - Mount the O-rings (25) in the pump body (20) and

mount the pump body (20) on the front cover (23).
H Make sure that no damage is done to the O-ring in
contact with the front cover.
20
H Mount the pump body, positioning the largest
hole on the suction side.

25

F0400079

10 - Mount the seals (26) on the thrust bearings (16 and

8
19).
H Make sure that the concave side of the seal is
turned towards the thrust bearing.
26

19

F0400080

30-48
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

11 - Mount the first thrust bearing (19) and the driven gear
(17).
H Make sure that the seal of the thrust bearing is
turned towards the front cover.
19

F0400081

12 - Insert the driving gear (18), slightly greased, into the

tool H3, also previously greased, and slide it gently,
with alternating rotatory movements, into the retain- 18
ing ring, until the driving gear makes contact with
thrust bearing.
H3
H Lubricate the gears with oil.
17

F0400082

13 - Mount the thrust bearing (16) with the seal facing up-
wards.
16

F0400083

14 - Mount the bushing support (12).

H Make sure that the centring bushings (14) are
aligned with the holes. Drive them home in the
pump body using a soft-headed mallet.
H Make sure that no damage is done to the O-ring
(25) mounted on the pump body.
14
12

25
F0400084

30-49
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

15 - Mount the connecting shaft (15) and repeat opera-

tions 9 and 10 for the second pump body.
15

F0400085

16 - Mount the driven (8) and driving (9) gears.

H Make sure that both the gears are in contact with
the thrust bearing. 8

25

F0400086

17 - Repeat operations 3, 4 and 5 for the rear cover (5)

and then mount it.
H Make sure that the centring bushings (14) are 15
aligned with the holes. Drive them home in the
pump body using a soft-headed mallet.
H Make sure that no damage is done to the O-ring
(25) mounted on the pump body.
9 8

14

F0400087

18 - Mount the stud-bolts (27), the washers (28) and tight-

en the nuts (29).
H Tighten the nuts in criss-cross sequence and in
two phases.
Final nut torque: 190 Nm

27

28

29
F0400088

30-50
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP COUPLING JOINT

REMOVAL OF ENGINE-PUMP COUPLING JOINT

Lower the work equipment until it is resting on the
ground and switch off the engine.
3
Release residual pressures from all circuits. (For de- 1
tails, see «20. TESTING AND ADJUSTMENTS»).

Disconnect the lead from the negative (±) battery

terminal.

1 - Remove the pump group. (For details, see «RE- 2

MOVAL OF PUMP GROUP»). 4
F0400142

2 - Unscrew the retaining screw (1) of the coupling half

(2) on the pump side.
3 - Unscrew the screws (3) and remove the coupling half
(4) on the flywheel side.

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

H Before coupling the engine to the pump, check the

condition of the rubber loose-pieces and make sure
that they are firmly attached to the coupling half on
the pump side.

Coupling half screws on pump side: Loctite 242

Coupling half screws on pump side: 88 Nm

Coupling half screws on flywheel side:

Loctite 242
Coupling half screws on flywheel side: 34 Nm

30-51
DISASSEMBLY AND ASSEMBLY SWIVEL JOINT

REMOVAL OF SWIVEL JOINT

Lower the work equipment until it is resting on the
ground and switch off the engine. 1
2
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).

Disconnect the lead from the negative (±) battery

terminal.

1 - Remove the distributor hood. 1

F0400442

2 - Disconnect the tubes (1) on the lower side of the joint

(2) and plug them.
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling.
3 - Disconnect the tubes (3) on the top of the joint (2) and
plug them. 3
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling.
4 - Disconnect the supply and drainage tubes (4) from
the swing motor, in order to raise the joint.
H Plug the tubes and fittings of the swing motor to 4
prevent entry of impurities.
3
5 - Unscrew and remove the screws (5) of the swivel F0400443

joint.
6 - Screw the raising equipment N1 onto the two upper
fittings (6) and move the swivel joint (2).
Swivel joint: 97 kg
5

INSTALLATION OF THE SWIVEL

JOINT 2
. To install, reverse the removal procedure.
6
1 - Start the engine and bleed air from the circuits by fol-
lowing the procedure given below: 5
a - Move the outriggers and blade (if mounted) sev- F0400444

eral times to the end of their stroke.

b - Perform several steering actions on both axles
and in both directions.
c - Bleed air from the brake line (For details, see «20.
TESTING AND ADJUSTING»).
d - Drive forwards and backwards several times.
6
2 - Stop the engine and restore the level of hydraulic oil
in the tank. 6
N1

N1
2
F0400656

30-52
DISASSEMBLY AND ASSEMBLY SWING MOTOR

REMOVAL OF SWING MOTOR

Lower the work equipment until it is resting on the
6
ground and switch off the engine.
4
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
3 1
1 - Disconnect the supply (1), return (2), and drainage 2
tubes (3), and the safety valve pilot system tubes (4) 7
and plug them.
2 - Remove the screws (5) that attach the motor (6) to the 5
reduction unit (7). F0400240

3 - Remove the motor (6).

Motor: 11 kg

INSTALLATION OF
SWING MOTOR
. To install, reverse the removal procedure.

30-53
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

REMOVAL OF SWING MACHINERY

Lower the work equipment until it is resting on the
ground and switch off the engine. 1

Release residual pressures from all circuits. (For de- 5

tails, see «20. TESTING AND ADJUSTMENTS»). 2
3
1 - Remove the fixed hood.
2 - Disconnect the tubes for delivery (1), return (2), drai- 4
nage (3), and braking (4), and the safety valve pilot
system (5) from the swing group and plug them all.
7
3 - Disconnect from the control valve (6) all tubes that F0400445

might obstruct the raising of the reduction unit, and

plug them.
4 - Remove the screws (7) from the swing machinery (8).

5 - Attach the hoisting tackle and remove the swing ma-

8
chinery (8-9).
Swing machinery: 65 kg

7 6

F0400241

INSTALLATION OF
SWING MACHINERY
. To install, reverse the removal procedure. 8 9

In order to centre the screw holes:

a - Connect the tool A1 to the brake release fit-
ting and connect a 5±6 bar compressed air
supply.
b - Raise the front work equipment by a few cen-
timetres and turn the revolving frame manu- F0400148
ally until the swing machinery is in the cor-
rect position for attachment.
1 - Start the engine, turn the frame in both directions,
and move the equipment from which the tubes have
been detached. Check the seals. 8 9
2 - Switch off the engine and check the level of hydraulic
oil in the tank.

A1

F0400446

30-54
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

DISASSEMBLY OF SWING MACHINERY

H Before dismantling the swing machinery, mark the po- 40

sitions between the hydraulic motor (40) and the mo-
tor flange (39), between the brake unit (30) and the 39
toothed ring (12), and between the toothed ring (12)
and the gearbox housing (17).
30

12

17

D0400467

1 - Take out the screws (42) and detach the hydraulic

motor (40).

42

40

F0400309

2 - Detach the O-ring (41) from the motor (40).

40

41
F0400310

3 - Take out the fifteen screws (9) and the nut (31) on the
stud-bolt corresponding to the position of the oil level
check rod.
31

F0400311

30-55
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

4 - Detach the brake-flange group (30-39) from the gear-

box housing. 39

30
F0400312

5 - Detach the O-ring (10) from the brake unit (30).

10
30

F0400313

6 - Take out the screws (2) and remove the motor flange
(39) from the brake unit (30).

39

30

F0400314

7 - Detach the O-ring (3) from the motor flange seating

(39). 3

39

F0400315

30-56
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

8 - Using a press and a pad, press on the spring retainer

(1) and remove the snap-ring (38).

38

F0400316

9 - Remove the spring retainer (1).

1

F0400317

10 - Remove the springs (36) from the piston seatings

(37). 37

36

F0400318

11 - Turn the brake unit (30) upside down and remove the
snap-ring (29).

29

30

F0400319

30-57
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

12 - In one movement remove the stack of brake disks

(32-33) and the spring retainer (28).

28

32 33

F0400320

13 - Using a punch of some soft material and in one move-

ment, remove the spacer (8) and the piston (37) from 30
the brake unit.

37

F0400321

14 - Detach the O-ring (35) and the ring wear (34) from the
spacer (8).
35

34

F0400322

15 - Detach the O-rings (5-6) and the rings wear (4-7) from
the brake unit (30). 4 5
6

30

F0400323

30-58
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

16 - Extract the brake shaft (17) from the gearbox hous-

ing. 17

F0400324

17 - Remove the pinion (13) from the 1st sun gear.

13

F0400325

18 - Remove the 1st sun gear group (11).

11

F0400326

19 - Remove the pinion (15) of the 2nd sun gear.

15

F0400327

30-59
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

20 - Take out the ring gear (12).

12

F0400328

21 - Remove the 2nd sun gear group (14).

14

F0400329

22 - Remove the O-ring (16) from the gearbox housing

(17). 16

17

F0400330

23 - Lift the safety riveting of the lock-nut (18) that secures

the swing pinion (23).

23

18

F0400331

30-60
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

24 - Using the tool M1 remove the lock-nut (18).

M1

F0400332

25 - Lift off the spacer (19).

19

F0400333

26 - Using an extractor, lift the swing pinion out (23) of the

gearbox housing (17).

17 23
F0400334

27 - Remove the stud-bolt (26) from the gearbox housing

(17).

17

26

F0400335

30-61
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

28 - Using an extractor, remove the external bearing ring

(20) from the gearbox housing (17).

20

17
F0400336

29 - Turn the gearbox housing (17) upside down and re-

move the swing pinion sealing ring (21).

17
21

F0400337

30 - Using an internal extractor, remove the external bear-

ing ring (22) from the reduction unit.

22

F0400338

31 - Using the tool M2 and a press, remove the internal

bearing ring (22), the sealing ring (24) and the spacer
(25) from the swing pinion (23). M2

23

24

25
F0400339

30-62
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

ASSEMBLY OF SWING MACHINERY

1. IMPORTANT REMARKS
When installing the swing machinery, some fundamental
rules must be followed:
a - In the case of a damaged sun gear, the entire reduc-
tion unit must be substituted, not just the single sun
gear.
b - Always fit a new O-ring with the part to be replaced,
after thoroughly cleaning the installation seating and
after having spread a film of grease (ASL800050) over
the seatings and the seals to facilitate installation.

2. INSTALLATION
1 - Mount the spacer (25) on the swing pinion shaft (23).
H Check that the chamfered part rests on the pinion.

25

23

F0400340

2 - Mount the metal sealing ring (24).

24

F0400341

3 - Fill the metal sealing ring (24) with grease:

(ASL800050).

24

F0400342

30-63
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

4 - Apply a layer of grease over the inside bearing ring

(22).
Bearing: ASL800050

22

F0400343

5 - Using the tool M3 and a press, drive the inside bear-

ing ring (22) down over the spacer (25).
M3

22

F0400344

6 - Using the tool M4 and a press, drive the outside bear-

ing ring (22) down over the gearbox housing (17).

M4

17

F0400345

7 - Using the same method as above, mount the outside

ring of the other bearing (20) in the gearbox housing.

20

F0400346

30-64
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

8 - Mount the sealing ring (21) in the gearbox housing

(17).

21

17

F0400347

9 - Position the gearbox housing (17) over the swing pi-

nion (23).
17

23

F0400348

10 - Mount the inside bearing ring (20) on the swing pinion

(23).
20

23
F0400349

11 - Using the tool M3 and a press, assemble the pinion

(23) - gearbox housing (17) group.

17

M3
F0400350

30-65
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

12 - Mount the spacer (19) over the swing pinion shaft

(23).

19

23
F0400351

13 - Tighten the lock-nut (18).

H Use a new lock-nut.
Lock-nut: Loctite 242

18

F0400352

14 - Use the special wrench M1 and a dynamometric

wrench to tighten the lock-nut (18).
Lock-nut: 1000w50 Nm
H If new bearings (20-22), pinion (23), or gearbox 17
housing (17) have been fitted, check the rotating
torque of the pinion (23).
Pinion rotation: 50±60 Nm M1
H If the torque is higher, increase the thickness of
the spacer (19).
H If the torque is lower, reduce the thickness of the
spacer (19).
F0400353

15 - Block the position of the lock-nut (18) with 3 safety

caulkings, corresponding to the grooves in the pinion
shaft (23).

23

18

F0400354

30-66
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

16 - Lubricate the O-ring seating of the gearbox housing

(17) and mount the seal (16). 16
Seating: ASL800050.
17

F0400363

17 - Mount the stud-bolt (26) in the hole in the gearbox

housing (17) and tighten it.
Stud-bolt: 45w5 Nm

17

26

F0400364

18 - Install the 2nd sun gear groups (14).

14

F0400365

19 - Mount the toothed ring (12).

H Check the position against the marks made be- 12
fore dismantling.

F0400366

30-67
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

20 - Mount the pinion (15) of the 2nd sun gear.

15

F0400367

21 - Mount the 1st sun gear (11).

11

F0400355

22 - Mount the pinion (13) of the 1st sun gear.

13

F0400368

23 - Mount the brake shaft (17).

17

F0400369

30-68
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

24 - Mount the O-ring (35) and the anti-extrusion ring (34)

in the spacer (8).
O-ring: ASL800050 34

35

F0400370

25 - Mount the O-rings (5-6) and the anti-extrusion rings

(4-7) in the brake body (30). 5
O-ring: ASL800050

6
7

4 5
F0400356

26 - Mount the brake piston (37) in the spacer (8) and

mount this complete group in the brake body (30).
H Take care not to damage the O-ring seals (5-6). 37

30

F0400357

27 - Insert the springs (36) into the seatings of the brake

piston (37). 36

37

F0400371

30-69
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

28 - Mount the springs retainer (1).

1

F0400372

29 - Using a press and a plunger, press down on the

springs retainer (1) and mount the snap-ring (38) in
the seating of the brake body (30).

38

30

F0400373

30 - Mount a new stack of brake disks, starting with a

bronze disk (33) (external toothing) and continuing
with a steel disk (32) (internal toothing). 33
H Mount 6 bronze and 5 steel disks.

F0400358

31 - Mount the springs retainer (28).

28

F0400359

30-70
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

32 - Mount the snap-ring (29) in the housing body (30).

29

30

F0400374

33 - Mount the O-ring (3) in the seating of the motor flange

(39).
3
O-ring: ASL800050
39

F0400375

34 - Join the motor flange (39) to the brake body (30)

(8 screws).
Screws: 50w5 Nm
H Check the position against the marks made be-
fore dismantling.
39

30

F0400360

35 - Mount the O-ring (10) in the brake body (30).

10
30

F0400376

30-71
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

36 - Position the motor flange/brake housing group (39-

30) over the toothed ring (12).
H Position the group (39-30) so that the oil filling and 39
control level cap is aligned with the stud-bolt (26).

30

F0400377

37 - Mount the nut (31) and the fifteen screws (9).

Screws and nut: 85 Nm
31

12 9
F0400361

38 - Mount the O-ring (41) in the seating of the hydraulic

motor (40).

41 40

F0400378

39 - Check that the axial height between the surface of the

motor flange (39) and the brake shaft (17) is within tol-
39
erance limits.
H Axial height: 90.5w0.5 mm.
17

90,5 ± 0,5

D0400468

30-72
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

40 - Mount the hydraulic motor (40) over the gearbox and

40
fasten the screws (42).
H Check the position against the marks made be-
fore dismantling.
Screws: 86 Nm

42

F0400362

41 - Check the leaktightness of the seals of the brake-re-

lease group.
For this job, use the tool M5 and the 400 bar pressure
gauge, M6.
H Testing pressure: 150 bar
H Testing time: 3 min.
H Max. pressure drop: 0 bar.

100
200
300
M5
0 400

bar

M6

D0400469

30-73
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

REMOVAL OF REVOLVING FRAME

1 - Remove the upper work equipment (For details, see

«REMOVING UPPER WORK EQUIPMENT»).
2

2 - Remove the engine hood and the top hood-panel. 1

(For details, see «REMOVAL OF ENGINE HOOD»).
3 - Remove the cabin, leaving the seat in place. (For de-
tails, see «REMOVAL OF CABIN»).
4 - Remove the boom cylinder. (For details, see «RE-
MOVAL OF BOOM CYLINDER»).
5 - Disconnect all the lower tubes (2) from the swivel joint
2
(1) and plug them. Also plug the fittings left on the F0400447

joint.
6 - Remove the lower left-hand protective casing (3) of
the revolving frame (4) to gain access to the retaining
nuts of the LH area.
7 - Start the engine, swing the revolving frame (4) about
90ë to the left, until a screw (5) is accessible on the
under carriage (6) side.
8 - Remove the screw (5) and its nut.
4
9 - Leave the next screw in place and but remove the 3
other thirty three screws.
Leave two opposite screws in position for rea-
sons of safety. D0400400

10 - Use tools A2 and A3 to put a sling around the revol-

ving frame. Apply a slight tension to the chains.

11 - Loosen and remove the two screws left in position for 6

safety.
5 7
12 - Slowly raise the revolving frame (4).

H During the lifting operation, take great care not to

damage the swivel joint.
Complete revolving frame group:
approx.3500 Kg
F0400448

A2

A3

F0400151

30-74
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

INSTALLATION OF REVOLVING FRAME

. To install, reverse the removal procedure.

H Position the swing circle in order to install the re-
volving frame turned 90ë to the left.

Revolving frame attachment screws

(with nut): 314w9.8 Nm
(32w1 kgm)
Revolving frame attachment screws
(without nut): 314w9.8 Nm
(32w1 kgm) 8 8
Revolving frame attachment screws
(without nut): Loctite 242
F0400449

H Align the two positions corresponding to the cen-

tering pins (9), then assemble.
Sealant and swing circle platform gaskets:
ASL800050
Internal swing circle grease:
approx. 25 kg

H After having connected the tubes of the hydraulic

system, start the engine and bleed air by following
the procedure given below: 7
a - Move the outriggers and blade (if mounted)
several times. 8
b - Steer both axles several times as far as pos-
sible in both directions. If the steering action
is not continuous, bleed air from the Load F0400153

Sensing circuit. (See «BLEEDING AIR FROM

THE LOAD SENSING CIRCUIT»)
c - Bleed air from the brake lines (For details see
«20. TESTING AND ADJUSTING).
d - Travel forwards and backwards several times. 9
H Stop the engine and check the level of oil in the
tank.
A1
Installation Procedure
In order to swing the revolving frame for centering
the reference pins (8), the pinion-swing circle cou-
pling and for mounting the screws (5): 11 10

1 - Disconnect the delivery tubes (9) from the swing

motor (10). F0400450

2 - Disconnect the brake release tube (11) and apply

the tool A1.
3 - Connect the tool A1 to 5±6 bar compressed air
supply.
4 - Rotate the revolving frame by hand until it is in
the correct position.
5 - Insert the two screws (5) left in the swing circle 5 7
(7) and secure them.
6 - Insert all the other screws (5).
7 - After having secured all the screws that join the
swing circle to the revolving frame, reconnect
the delivery tubes (9) of the swing motor (10),
and the brake release tube (11).
8 - Detach the hoisting tackle. F0400644

30-75
DISASSEMBLY AND ASSEMBLY SWING CIRCLE

REMOVAL OF SWING CIRCLE

1 - Remove the upper revolving frame. (For details, see S

«REMOVAL OF UPPER REVOLVING FRAME»).
2 - Completely remove all contaminated grease.
3 - Remove the screws (1) that secure the swing circle
(2).
4 - Remove the swing circle (2) using the tool B1.

Swing circle: 130 kg. 1

2
F0400451

INSTALLATION OF
SWING CIRCLE
B1
H Before installing the swing circle, check the condition
of the central gasket (3). 3

. To install, reverse the removal procedure.

Before attaching the swing circle, check that the area

marked with an «S» is positioned on the right-hand
side of the chassis. F0400452

Attachment screws: Loctite 242

Attachment screws: 314w10 Nm
Lubricating grease: approx. 25 kg

30-76
 TRANSMISSION - REVERSER, DIRECTION INDICATOR
DISASSEMBLY AND ASSEMBLY AND HEADLIGHT DIPPER BEAM CONTROL GROUP

REMOVAL OF THE TRANSMISSION - REVERSER, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Lower the work equipment until it rests on the ground
and stop the engine. 1
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the central cap (1).

2 - Remove the reatining nut (2) and its washer; lift off
the steering wheel (3).

3 2
F0400453

3 - Remove the four screws (4) from the base of the pro-
tective sleeve (5).
5

4
F0400454

4 - Free the connectors (6-7) from their clamps and dis-

connect them.

F0400455

5 - Remove the two connecting screws (8) of the switch-

ing groups (10-11).

11
10
F0400456

30-77
 TRANSMISSION - REVERSER, DIRECTION INDICATOR
DISASSEMBLY AND ASSEMBLY AND HEADLIGHT DIPPER BEAM CONTROL GROUP

6 - Remove the RH half-clamp (12).

11

12

10

F0400457

7 - Remove the LH half-clamp (13).

13

16

F0400527

8 - Remove the switching group (10 and 11) complete

with wiring assemblies and protection (14), letting it 15
slide along the steering column (15). 10

11

14
INSTALLATION OF THE
TRANSMISSION - REVERSER,
DIRECTION INDICATOR AND
HEADLIGHT DIPPER BEAM F0400458

CONTROL GROUP
. To install, reverse the removal procedure.

Steering wheel fastening nut: 40w5 Nm

H Check that the reference pin (16) can be fully in-

serted into the steering column and that the LH
half-clamp (13) adheres perfectly.

H Lubricate the wiring assemblies and the steering

column (15) to facilitate the sliding movement.
Wiring assemblies and steering column: Vaseline

30-78
DISASSEMBLY AND ASSEMBLY R.H. PPC VALVE (BOOM - BUCKET)

REMOVAL OF R.H. PPC VALVE (BOOM - BUCKET)

Lower the work equipment until it is resting on the
ground and switch off the engine. 1

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
3
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the five retaining screws (1-2) of the RH 1

dashboard 2
H To remove the inside screw (2), lower the seat and F0400307

push it right back.

2 - Remove the dashboard (3).
3 - Disconnect the connector (4). 3
H If a connector (5) has been fitted for the rotating
and cutting shovel, disconnect that also.
4 - Disconnect the six tubes (6) from the PPC valve and 5
plug them to prevent entry of impurities.
H Mark the positions to avoid errors during assem-
bly.
5 - Lift the rubber protection (7) and remove the PPC 4
valve (8).
F0400306

INSTALLATION OF 8
R.H. PPC VALVE
6
. To install, reverse the removal procedure.

F0400171

H Check the positions carefully when reconnecting

the tubes

P - Pressure
T - Unload
1 - Boom descent 1
2 - Bucket opening
3 - Boom rising P T
4 - Bucket closing

If necessary, bleed air from the servocontrol circuit.

(For details, see «20. TESTING AND ADJUST- 2 4
MENTS»).
3
F0400172

30-79
DISASSEMBLY AND ASSEMBLY REMOVAL OF L.H. PPC VALVE (ARM-SWING)

REMOVAL OF L.H. PPC VALVE (ARM-SWING)

Lower the work equipment until it is resting on the
ground and switch off the engine.
2
Release residual pressures from all circuits. (For de- 3
tails, see «20. TESTING AND ADJUSTMENTS»).

Disconnect the lead from the negative (±) battery

terminal. 1

2
1 - Remove the seven LH - dashboard retaining screws
(1-2). 1
H To remove the inside screws (2), lower the seat F0400308

and move both platform and seat back as far as

they will go.
2 - Remove the dashboard (3).
3 - Disconnect the connector (4). 3

4 - Disconnect the six tubes (5) from the PPC valve and
plug them to prevent entry of impurities.
H Mark the positions to avoid errors during assem-
bly.
5 - Lift the rubber protection (6) and remove the PPC
valve (7).
4
F0400174

INSTALLATION OF
7
L.H. PPC VALVE
. To install, reverse the removal procedure.
5

F0400175

H Check the positions carefully when reconnecting

the tubes.

P - Pressure
T - Unload
1 - Arm opening 1
2 - RH swing
3 - Arm closing P T
4 - LH swing

If necessary, bleed air from the servocontrol circuit.

(For details, see «20. TESTING AND ADJUST-
2 4
MENTS»).
3
F0400172

30-80
DISASSEMBLY AND ASSEMBLY OUTRIGGER AND BLADE PPC VALVE

REMOVAL OF OUTRIGGER AND BLADE PPC VALVE

Lower the work equipment until it is resting on the
ground and switch off the engine. 1

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
3
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the cabin (For details, see «REMOVAL OF 1

CABIN»). 2
F0400307

2 - Remove the five screws (1-2) from the RH dashboard.

H To remove the inside screw, lower the seat and
move it back as far as it will go.
3
3 - Remove the dashboard (3).
4 - Draw out the cotter pin (4) that connects the PPC
valve rocker arm (5) to the fork (6).
5 - Disconnect the four tubes (7) and plug them to pre-
vent impurities from entering.
6 - Remove the screws, nuts and washers (8).
7 - Remove the PPC valve (9).

F0400638

INSTALLATION OF OUTRIGGER
AND BLADE PPC VALVE
9 8
. To install, reverse the removal procedure.

7 4

8 5
F0400176

30-81
DISASSEMBLY AND ASSEMBLY PPC VALVE

REMOVAL OF PPC VALVE

(For travel, boom swing, 2-piece boom)
Lower the work equipment until it is resting on the
ground and switch off the engine. 3 1
1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).

1 - Disconnect the tubes (1-2) (four tubes for the boom

and 2-piece boom swing and three tubes for travel); 2
and plug them to prevent impurities from entering.
H Mark the positions to avoid errors during assem-
bly. 2
F0400459

2 - Remove the supply and return fittings (3) (P and T).

3 - Remove the screws (4) that attach the PPC valve to

the platform (four for each PPC valve).
4 - Lift out the PPC valve concerned (5).
1 3

INSTALLATION OF PPC VALVE

. To install, reverse the removal procedure. 2

Couplings: 35 Nm. F0400460

5
5
4

F0400461

F0400462

30-82
DISASSEMBLY AND ASSEMBLY BRAKE PUMP

REMOVAL OF BRAKE PUMP

Lower the work equipment completely until it rests it
on the ground and stop the engine.
Release all residual pressures from all circuits, and
in particular from the brake line (See «20. TESTING
AND ADJUSTING»).
1 - Disconnect the six tubes from the brake pump and
plug them.

H Make an identifying mark on the tubes to avoid 1

mixing them up during installation.
2 - Disconnect the solenoid valve (2) connector. F0400463

3 - Disconnect the terminals of pressure switches (3) and

(4).
H Make an identifying mark on the cables to avoid
mixing them up during installation.
4 - Remove the fastening screws (5) of the brake pump,
which are located on the cabin platform.
5 - Remove the brake pump (6).

INSTALLATION OF THE 4
3
BRAKE PUMP
. To install, reverse the removal procedure. 2
F0400464

Start the engine and bleed air from the brake lines
(See «20. TESTING AND ADJUSTING»).
6
After re-connection, make sure that the protective
sleeves are positioned correctly and firmly.

5
F0400465

30-83
DISASSEMBLY AND ASSEMBLY SERVOCONTROL SUPPLY GROUP

REMOVAL OF THE SERVOCONTROL SUPPLY GROUP

Lower the work equipment until it rests on the ground
and stop the engine.

Release all residual pressures from all circuits (For

details see «20. TESTING AND ADJUSTING). 8
Disconnect the lead from the negative (±) battery
terminal.

1 - Disconnect the connectors (1-2) from the supply 6

group.
2 - Disconnect the tubes (3-4-5) from the pumps and plug
them. Also plug the pump couplings to prevent entry 4
of impurities. 2
5
3 - Disconnect the tube (6) from the tank and plug the
hole in the tank to prevent entry of air and conse-
quent leakage of oil. Also plug the tube.
4 - Disconnect the supply tube (7) to the servocontrols.
5 - Loosen the screws (8) and lift out the entire group (9).

7
1

3
F0400466

INSTALLATION OF
SERVOCONTROL SUPPLY 9
GROUP 5
. To install, reverse the removal procedure. 4
1 - Start the engine to circulate the oil and check that 7
there are no leakages.
2 - Bleed air from the servocontrol circuits.
(For details, see «20. TESTING AND ADJUSTING») 6

3 F0400467

30-84
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

REMOVAL OF CONTROL VALVE

Lower the work equipment until it is resting on the
ground and switch off the engine. 3 D1

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»). 2

1 - Disconnect from the control valve all three delivery

tubes (1), all eighteen service tubes (2), all twenty ser-
vocontrol tubes (3), and the exhaust pipe (4). Plug all
the tubes and fittings.
H Mark the tubes to avoid errors when reconnect- 3
ing. F0400468

2 - Attach the hoisting equipment D1 to the control valve.

3 - Hook up the tackle and apply a slight tension. 1 1
4 - Remove the three screws (5) and lift out the control
valve.
Control valve: 60 kg

4
INSTALLATION OF
CONTROL VALVE 5
5
. To install, reverse the removal procedure. F0400528

1 - Start the engine to circulate the oil and check that

there are no leakages.
2 - Bleed air from the circuits. (For details, see «20.
TESTING AND ADJUSTMENTS»).
3 - Switch off the engine and check the level in the oil
tank.

30-85
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

REMOVAL OF TRAVEL MOTOR

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits. (For
details, see «20. TESTING AND ADJUSTING»). 2
1 - Remove the steps leading to the cabin (1) and the
transmission crankcase.

1
F0400469

2 - Disconnect the front drive shaft (3) from the transmis-

sion (4).

4
F0400470

3 - Disconnect the supply tubes (5), the motor drainage

tubes (6) and the drainage tube (7) of the anti-sway 7
axle-locking group from the travel motor. Plug the 5
tubes and the motor to prevent entry of impurities.

9
4 - Remove the drainage tube coupling (8) and plug the
hole in the motor.
8 6
5 - Loosen the four screws (9) that hold the motor in
place.
6 - Place a hydraulic jack underneath the motor to sup-
port it. F0400471

7 - Remove the screws (9).

8 - With the help of levers and a soft-headed mallet,
move the motor and slide the shaft off the transmis-
sion coupling.
H Take great care not to damage the coupling sur-
faces.

30-86
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

INSTALLATION OF THE TRAVEL MOTOR

. To install, reverse the removal procedure.

H Before connecting the drainage tube (7) of the

anti-sway axle-locking group, fill the motor casing
with hydraulic oil.

H Carefully check the O-ring seal between motor

and transmission. If there are any doubts as to
its condition, change it.
Sealant: ASL800050
F0400657

1 - Start the motor and travel both forwards and back-

wards at low speed to bleed the system and to check
the leaktightness of the tubing.
2 - Stop the motor and check the level of oil in the tank.
If the travel motor is to be dismantled for any form of
inspection or overhaul, before using the machine
again check:

1 - The setting of the automatic displacement control

system.
2 - The speed of the travel propeller shaft.
H For test and adjustment procedures, see «20.
TESTING AND ADJUSTING».

30-87
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DISASSEMBLY OF TRAVEL MOTOR

1 - Loosen the screws (1) and remove the brake valve

group (2). 1
2

D0400481

2 - Loosen the eight screws (3) and remove the auto-

matic displacement control system group (4).
3

D0400483

3 - Lift off the control valve plate (5).

5

D0400520

4 - Remove the cylinder block (6) complete with the

spring washer (7) and the four cup springs (8).
6

D0400482

30-88
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

5 - Remove the snap ring (9) and the cover (10) complete 14
with the sealing washer (11), the O-ring (12) and the 12
spacer (13). 10
H Protect the toothing of the control shaft (14) to
9
avoid damage.

13
11
D0400509

6 - Remove the snap-ring (15).

15

D0400511

7 - With the aid of a puller, lift out the complete rotatory

group (16).

16

D0400510

8 - Clamp the rotatory group in a vice and loosen the

screws (17) that hold the retaining plate (18).
H Use a soft-jawed vice.
H The screws are secured with Loctite. If necessary,
heat the screws to about 120ëC in order to re- 17
move them.

18
D0400512

30-89
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

9 - Loosen the screws (19) that fasten the control block

22 21
(20) and remove in sequence the spring (21), the
bushing (20), the spring (23), the spring-guide pin 24 23
(24), the snap-ring (25), the control bushing (26) the
O-ring (27) and the control piston (28) complete with 26 25
the snap ring.
27 28

20
19
D0400485

10 - Loosen the screws (29) and lift off the complete cover
(30). 29
30
Loosen the plug (31) and remove the throttle (32).
32
31

D0400488

11 - Loosen the locking screw (33) and the position trun-

nion (34).
H To facilitate removal, heat the pin (34) and the 34
screw (33) to about 120ëC.

33
D0400487

12 -Extract the position trunnion (35) complete with its cup

springs (36).
35
36

D0400486

30-90
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

13 - Remove the anti-extrusion rings (37) and the washer

(38) from the casing (4).
H The cup springs (36-38) and the anti-extrusion 4
rings (37) should be changed each time the travel 38 36
motor is dismantled.

37

D0400535

30-91
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

ASSEMBLY OF THE TRAVEL MOTOR

1 - Mount the washer (38) and the anti-extrusion rings

(37) onto the positioning piston (35), taking care that
4
the washer (38) faces in the right direction.
Insert the piston (35) into the body (4) and push it
home.
Extract the piston (35) and check that the sealing
group is in contact with the body.
Sealant: ASL800050

35 37
37 38
D0400514

2 - Mount the sealing cup springs (38) from opposite

ends of the positioning piston (35). 36
H Make sure that the gaps in the rings (36) are posi- 35
tioned at 180ëC with respect to each other.
36
Sealant: ASL800050

D0400516

3 - Mount the position trunnion (34) and the locking

screws (33).
Locking screw: Loctite 601 34

33

D0400515

4 - Mount the throttle (32) and the plug (31) complete

with the O-ring (41) in the cover (30). 30
Throttle: 8 Nm
32
Mount the cover group (30) complete with O-ring (42) 31
onto the body (4) and secure it with the screws (29). 42

4
41

D0400518

30-92
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

5 - Mount the control piston (28) in the control bushing

(26). 25
Insert the control bushing (26), the control piston (28) 26
and the snap ring (25) into the control block (20).
Mount the O-ring (27). 28
27
20

D0400484

6 - Mount the spring (21), the bushing (22), the spring

(23), the spring-guide pin (24) and the control block
21
(20), into the body (4). Tighten the screws (19).
22

23

24

20 4
19 D0400490

7 - Prepare the tool P1, assembly the parts with the code
indicated.

452237 452237

452249
D0400491

8 - Insert the tool P1 into the motor casing (43) and hold
it in position with the three stops provided (44). P1

44

43

D0400493

30-93
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

9 - Prepare tool P2, assembly the specific parts for the

motor in the positions indicated.
452010
083105

Best
Posizioni
position
utili per P2
for
452271
452271
083020
452271
452021
452014 D0400499
D0400496

10 - Insert the spring washer (7) into the cylinder block (6).
7

D0400536

11 - Mount the cylinder block (6) complete with spring

washer (7) and central pin (40) into the motor housing
(43).
6

40

D0400501

12 - Mount the control lens (5) and use the centering pin
(452021) of tool P2 to centre it. 452021
H Remove the gasket (44) and the centering pins
(45).
45

44
D0400507

30-94
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

13 - Assemble tool P2 and fasten it to the motor housing

(43). Check the comparator and return it to zero when
the knob has been turned as far as it will go in a coun- P2
terclockwise direction.

43

D0400494

14 - Give the knob four full turns in a clockwise direction

and use a feeler gauge to verify that the comparator
is following a value of 2 mm and that the needle
has returned to zero.
H This is the zero for starting the test.

D0400548

15 - Turn the knob as far as it will go in a clockwise direc-

tion and check that the clearance value of the central
pin (40) corresponds to the value indicated by the
comparator. P2
H Pin clearance: 0.2w0.05 mm
H If the clearance of the central pin does not come
within the tolerances, substitute the spring
washer (7).
43

D0400494

16 - Remove the tools P1 e P2, the cylinder group (6)

complete with centering pin (40) and the spring
washer (7).

30-95
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

17 - Assemble the pistons (39), the central pin (40), the re- 39
taining plate (18) and the screws (17). 40
Screws: Loctite 262
Screws: 6 Nm
H After tightening the screws (17), remove any ex- 18
cess Loctite.

17
D0400492

18 - Insert the spring washer (7) and the cup springs (8)
into the cylinder group (6). 8
H Check that the cup springs (8) are facing the right
way. 6

7
D0400555

19 - Insert the pistons (39) and the central pin (40) into the
cylinder block (6).
6
H Support the completed block on a surface made
of some soft material.
39

40

D0400504

20 - Heat the motor housing (43) to 80ëC and insert the

complete rotary group (16).
16 80°C 43

D0400503

30-96
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

21 - Mount the reference pins (45) and the gasket (44).

45

44

D0400505

22 - Mount the snap ring (15) that holds the rotatory group
(16) in place.
Mount the distributor plate (5) in the guides of the 16 5
automatic governor group (4).
4
H To facilitate assembly, grease the distributor plate
(5) with ASL800050 grease. 15

D0400508

23 - When the motor housing (43) has cooled down to

room temperature, attach a puller and firmly push
the rotating body (16) onto the snap ring (15).
H Tractive force: max. 20000 N (1950 Kg).

16
43

D0400510

24 - Attach a dynamometric wrench to the shaft of the ro-

tatory group and verify the torque needed for rotation.
H Max. permissible torque: 12.5 Nm

Max.

D0400533

30-97
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

25 - Assemble the cover (10) with the sealing washer (11)

and the O-ring (12). 12
Mount the spacer (13), the complete cover (10) and 10
the snap ring (9) onto the motor housing. 9
Sealant: ASL800050

13
11
D0400523

26 - Assemble the automatic governor group (4) and se-

cure it with the screws (3).
3

D0400483

27 - Mount the O-rings (45) and (46) and the brake valve
group (2). Secure the entire group with the screws (1).
45 2 1

46
D0400524

30-98
DISASSEMBLY AND ASSEMBLY TRANSMISSION

REMOVAL OF THE TRANSMISSION

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTING»).
1 - Remove the travel motor (See «REMOVAL OF TRA-
VEL MOTOR»).
2 - Disconnect the rear drive shaft (2) from the transmis-
sion (1). 2

1
F0400658

3 - Disconnect the movement sensor (3).

1
3
F0400529

4 - Disconnect the gear-change tubes (4-5) and plug

them.
H Make some identifying marks on the tubes, to
avoid mixing up the position when reconnecting. 4
5 - Place a supporting jack underneath the transmission
(1). 5
6 - Loosen the retaining screws (6) of the supports and
lift out the complete group. 1
H Take great care not to damage the sensor (3).

D0400532
INSTALLATION OF THE
TRANSMISSION
. To install, reverse the removal procedure.

H Position the protective sleeve with the cable outlet

pointing towards the ground to prevent accumula-
tions of water or condensates.
6
H Fill the transmission with lubricating oil.
Transmission oil: 1.9 <
3
1 - Start the engine to circulate the oil and, with the ma-
chine stationary, put it into gear several times to
bleed air from the circuit. F0400530

30-99
DISASSEMBLY AND ASSEMBLY STEERING UNIT

REMOVAL OF THE STEERING UNIT

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTING»).
1 - Remove the LH guard (1) of the revolving frame.

D0400402

2 - Disconnect the tubes (3) from the steering unit (2).

H Make some identifying marks on the tubes before
disconnecting them, to avoid mixing up the posi- 4
tions when reconnecting.

2
F0400472

3 - Using the special wrench Q1, remove the screws that

fasten the steering unit group (2) to the steering col-
umn (4). 5
H In order to remove the front screws, attach the
special wrench Q1 to the steering unit (2) and
move it with a normal wrench inserted in the lou-
ver provided between the cabin (5) and the revol-
ving frame (6).
2

6
D0400495

INSTALLATION OF THE
STEERING UNIT
. To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing
circuit (See «20. TESTING AND ADJUSTING»).

F0400473

30-100
DISASSEMBLY AND ASSEMBLY STEERING UNIT

DISASSEMBLY THE STEERING UNIT

Disassembly the body of the steering unit
1 - Loosen and remove the screws (1-3) that hold the 3
cover (2) in place (six screws plus one special screw). 1

F0400533

2 - Remove the cover (2) by sliding it sideways.

F0400534

3 - Raise the rotating gear (4) complete with the O-rings

(34). Also remove the spacer (5).
4

5
34

F0400535

4 - Remove the drive shaft (6).

F0400536

30-101
DISASSEMBLY AND ASSEMBLY STEERING UNIT

5 - Remove the control lens (7).

F0400537

6 - Remove the threaded bush (8) of the safety valve.

F0400538

7 - Remove the O-ring (9).

F0400539

8 - Lift out the ball (10) of the check valve, and the pins
(11) and balls (12) of the anticavitation valves.

11

10

12

F0400540

30-102
DISASSEMBLY AND ASSEMBLY STEERING UNIT

9 - While watching through the central hole of the spool,

position the spool-bushing connecting pin horizon-
tally. 13
Push the entire group (13) and the entire bearing until
they can be extracted from the body of the steering
unit (14).

14

F0400541

10 - Remove the outside ring (15), the inside ring (16), and
the roller bearing (17) from the spool. Also remove the
ring (33).
H The inside ring (16) sometimes gets left in the
body of the steering unit. Make sure that it has 33
been removed.
16

15 17

F0400542

11 - Lift out the cross pin (18), the bushing (19) and the
spool (20).
H Use the special cover-fastening screw (3) for total 19
extraction.
3

18

20

F0400543

12 - Slowly slide the spool (20) out of the bushing (19).

20

19

F0400544

30-103
DISASSEMBLY AND ASSEMBLY STEERING UNIT

13 - Push the neutral position springs (21) and extract

them from the spool (20).
21

20

F0400545

14 - Remove the dust-guard washer (22) and the compo-

site leaktight seal (23) (O-ring + washer).
23
22

F0400546

15 - Remove the caps (24) from the safety valves.

24

F0400547

16 - Remove the cup springs (25).

25

F0400548

30-104
DISASSEMBLY AND ASSEMBLY STEERING UNIT

17 - Remove the adjustment screws (26) (6 mm screw

wrench).

26

F0400549

18 - Extract the springs (27) and the two balls (28).

H The valve seatings are fixed in the body of the
steering unit and cannot be removed.

27

F0400550

19 - Check that the dismantled pieces resemble those in-

dicated in the figure. 26
25
27

28 24

27 25
26
F0400551

Removal of the safety valve

20 - Remove the cap (29) and its gasket (30) (8 mm screw
wrench).

29

30

F0400552

30-105
DISASSEMBLY AND ASSEMBLY STEERING UNIT

Disassembly the safety valve

21 - Remove the safety valve (31) and its washer (32).
22 - Make sure that the steering unit is completely dis- 31 32
mantled.

NOTE
Cleaning
H Clean all the components with an aliphatic solvent
(white spirits or similar).

Inspections and substitutions

F0400553
H Change all the cup springs and seals.
H Inspect all the pieces and change those in a doubtful
state of wear.

30-106
DISASSEMBLY AND ASSEMBLY STEERING UNIT

ASSEMBLY THE STEERING UNIT

H Before assembly, lubricate all the components

with hydraulic oil.
1 - There is only one possible and correct way to assem-
a
ble of the spool (20) and bushing (19).
Assemble with the three holes (a) of the bushing (19) 20
opposite the slots (b) in the spool (20). 19
Check that the holes in the bushing are at least par-
tially visible through the slots (b) in the spool.
b

F0400554

2 - Insert the two flat springs (21a) in the seating and

centre them with respect to the diameter of the spool
(20). Insert the four curved springs (21b) between the
two flat springs (21a) , arranged in pairs, and push
them completely home.

21a
20
21b

F0400555

3 - Align the springs (21).

21

F0400556

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

H Make sure that the position between bushing and
spool is as described in phase 1 of the assembly 20
instructions.

21 19

F0400557

30-107
DISASSEMBLY AND ASSEMBLY STEERING UNIT

5 - Push the springs (21) and the spool (20) down to-
gether until the springs are engaged in the seating
of the bushing (19).
21

20

19

F0400558

6 - Align the springs (21) with each other and centre

them with respect to the diameter of the bushing (19).
21

19

F0400559

7 - Install the ring (33) in the seating of the bushing (19).

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

19

33

F0400560

8 - Insert the cross pin (18).

18

F0400561

30-108
DISASSEMBLY AND ASSEMBLY STEERING UNIT

9 - Assemble the thrust bearing according to the se-

quence indicated at point 10.

16

17

15

F0400562

10 - Sequence for assembly the bearing.

15 - Outside ring 16
16 - Inside ring
17 - Needle bearing 17
19 - Bushing
15
20 - Spool

20

19
D0400464

11 - Place the body of the steering unit (14) with the hole
horizontal.
Insert the guide of tool Q2 into the hole of the spool/
bushing group. 14

Q2

F0400563

12 - Lubricate the seal ring (23a) and the O-ring (23b) and
mount them on the push-rod of tool Q2.

23a Q2
23b

F0400564

30-109
DISASSEMBLY AND ASSEMBLY STEERING UNIT

13 - Mount the tool Q2 and insert it in the guide already

inserted in the hole of the steering unit.

23
Q2

F0400565

14 - Push the gasket (23) into the seating of the body of

the steering unit (14), assisting the movement with
slight rotatory movements.

14

F0400566

15 - Extract the guide from the body of the steering unit

(14) using the tool Q2, and leaving in position the
push-rod carrying the gaskets.

14

F0400567

16 - Insert the bushing/spool group (13) into the hole of

the steering unit (14).
Assist the insertion with slight rotatory movements.
H Insert the group while keeping the cross pin hori-
zontal. 13

14

F0400568

30-110
DISASSEMBLY AND ASSEMBLY STEERING UNIT

17 - Push the group (13) as far as it will go in order to push

out the push rod that was left in position during phase
15.
14

13

F0400569

18 - Rotate the body of the steering unit (14) until the cen-
tral hole is vertical.
Insert the ball (10) of the safety valve into the hole in-
dicated by the arrow.
10

14

F0400570

19 - Screw the valve threaded bush (8) into the hole in the
safety valve.
H The upper part of the threaded bush should be
lower than the surface of the body of the steering
unit (14). 8

14

F0400571

Assembly of the anticavitation valve

20 - Insert the balls (12) into the two holes indicated by the
arrows.
12

F0400572

30-111
DISASSEMBLY AND ASSEMBLY STEERING UNIT

21 - Insert the pins (11) into the same holes.

11

F0400573

22 - Lubricate the O-ring (9) and mount it in the seating.

Mineral oil: viscosity approx. 500 cSt at 20ëC
9

F0400574

23 - Position the control lens (7) so that the holes corre-

spond to those in the body of the steering unit (14).

14

F0400575

24 - Insert the drive shaft (6) in the hole and engage the
cross pin; check that the pin engagement is parallel
to the connection flange between the steering unit
and the steering column. 6

F0400576

30-112
DISASSEMBLY AND ASSEMBLY STEERING UNIT

25 - Place the drive shaft in a vertical position and hold it

steady with the tool Q3.

Q3

F0400577

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

two seatings of the ring bevel gear of the gear rim (4).
Mount the gear rim (4) on the drive shaft (6).
Mineral oil: viscosity approx. 500 cSt at 20ëC 4 34

F0400578

Positioning the motor

27 - Install the motor (4a) on the drive shaft (6) in such a
way that the bottom of a motor tooth corresponds to
the tooth base on the drive shaft.
Then rotate the external ring bevel gear (4b) in order 6
to align the attachment holes.

4a

F0400579

28 - Install the spacer (5).

4b

F0400580

30-113
DISASSEMBLY AND ASSEMBLY STEERING UNIT

29 - Mount the cover (2).

F0400581

30 - Insert the special screw (3) complete with washer in

the hole indicated in the figure.

F0400582

31 - Insert the six screws (1) complete with their cup

springs.
Tighten the screws (1) crosswise with a torque of
30w6 Nm.

F0400583

32 - Position the dust-guard seal (22) in the body of the

steering unit (14).
22

14

F0400584

30-114
DISASSEMBLY AND ASSEMBLY STEERING UNIT

33 - Press the dust-guard seal (22) into the body of the

steering unit, using the tool Q4 and a plastic hammer.
Q4

22

F0400585

34 - Close the holes of the hydraulic couplings with plastic

caps to prevent the entry of impurities.
H Push the caps on by hand, without using the ham-
mer.

F0400586

Assembly of the main valve

35 - Mount the seal (32) on the main valve (31) and screw
the cartridge into the body of the steering unit (14)
using a 12 mm screw wrench.
31
Cartridge: 50w1 Nm
14

32

F0400587

36 - Screw the cap (29) complete with washer (30), using

an 8 mm. Screw wrench.
Cap: 50w1 Nm

29

30

F0400588

30-115
DISASSEMBLY AND ASSEMBLY STEERING UNIT

Assembly of the safety valve

37 - Insert the balls (28) of the safety valves into the holes 28
indicated by the arrows.

F0400589

38 - Insert the springs (27) of the safety valves into the

holes.
27

F0400590

39 - Screw the pressure adjustment screws (26) into the

holes.
26

F0400591

40 - Mount the sealing cup springs (25) on the caps (24)

and screw the entire group into the two holes of the
safety valves. 24
Use a 6 mm screw wrench.
Caps: 30 Nm
25

F0400592

30-116
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

REMOVAL OF THE PRIORITY VALVE

Lower the work equipment until it is resting on the
ground and stop the engine. 2
1
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTING»).
5
1 - Disconnect the tubes (2-3-4) and the coupling (5)
complete with adapter from the priority valve (1).
3
2 - Take off the nut (6) and the washer (7), and at the
same time remove the valve (1), the screw (8) the
washer (9) and the spacer (10).
4
F0400639

IINSTALLATION OF THE
PRIORITY VALVE
10 1
. To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing 6 9
circuit (See «20. TESTING AND ADJUSTING»). 7 8

D0400534

30-117
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

DISASSEMBLY THE PRIORITY VALVE

1 - Unscrew the cap (1) (PP port) and take it off together
with its aluminium washer.
2 - Loosen the cap (2) (LS port).
2
3 - Lift off the cap (2) complete with the aluminium
washer and the spring (3).
4 - Using a nylon plunger, extract the spool (4).
3

ASSEMBLY OF THE
PRIORITY VALVE
H Before assembly:
1 - Wash the pieces thoroughly in kerosene or similar
product.
2 - Make sure that the spool throttle is clean.
3 - Lubricate the pieces before assembly.
4 - Change the aluminium washers.
1 - Insert the spool (4) using the nylon plunger to keep it
centred. 4
1
2 - Screw the cap (1) complete with its aluminium
washer, into the PP port.
3 - Screw the cap (2), complete with its aluminium D0400522
washer and the spring (3) into the LS port.
4 - Tighten caps (2) and (1) firmly, and in that sequence.
Caps (1) and (2): 50w10 Nm

30-118
DISASSEMBLY AND ASSEMBLY AXLE-LOCKING VALVE GROUP

REMOVAL OF THE AXLE-LOCKING VALVE GROUP

Lower the work equipment until it is resting on the
ground and stop the engine.
1
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTING»). 2
1 - Disconnect the iron tubes (2) and the flexible hose (3)
from the valve, leaving the couplings in position. Plug 2
all the tubes to prevent entry of impurities.

3 6
F0400474

2 - Disconnect the rigid tube (5) from the union (4).

3 - Remove the clamps that attach the rigid tubes to the
under carriage.
4 - Remove the two screws that attach the valve support
(6) and remove the entire group.
5 - Take the group to pieces (locking valve, check valve
4
support). 5

INSTALLATION OF F0400475

AXLE-LOCKING VALVE
. To install, reverse removal procedure.

7
H Make sure that the check valve (7) is facing the
right way, with the symbol stamped on the car-
tridge.
1 - Start the engine and lock and unlock the axle several
times to restore the circuits and check the leaktight-
ness.

F0400640

30-119
DISASSEMBLY AND ASSEMBLY CHECK VALVE

REMOVAL OF THE CHECK VALVE

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTING»).
1 - Disconnect the rigid tube (3) from the axle-locking
valve (1) and the check valve (2). 1
2 - Remove the valve (2).
3
2

INSTALLATION OF THE F0400641

CHECK VALVE
. To install, reverse the removal procedure.

H Make sure that the check valve (2) is facing the

right way, with the symbol stamped on the car-
tridge.
1 - Start the engine and lock and unlock the axle several
times to restore the circuits and check the leaktight-
ness.

30-120
DISASSEMBLY AND ASSEMBLY AXLE-LOCKING CYLINDER

REMOVAL OF THE AXLE-LOCKING CYLINDER

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTING»). 2
1
1 - Turn the ignition key to the position «I» and act on the
axle-unlocking button. Return the key to the position
3
«O» (OFF) and remove it.
2 - Disconnect the tube (2) from the cylinder (1) and plug
it.
3 - Loosen the screws (3).
F0400476

4 - Put a supporting sling round the cylinder (1) and re-

move the screws (3).

INSTALLATION OF THE
AXLE-LOCKING CYLINDER
. To install, reverse the removal procedure.
1 - Start the engine and lock and unlock the axle several
times to restore the circuits and check the leaktight-
ness.

30-121
DISASSEMBLY AND ASSEMBLY COMPLETE FRONT AXLE

REMOVAL OF THE COMPLETE FRONT AXLE

1 - Remove the cabin access steps (1) from both sides of

the machine.

1
F0400477

2 - Disconnect the drive shaft (3) from the axle (2).

2 3
F0400478

3 - Start the engine and raise the front of the machine by

pushing down vertically with the boom, until the
wheels are about 20 cm above the ground.

20 cm

D0400550

4 - Place a trestle (A) underneath the machine and some

blocks (B), roughly 15 cm high, at points correspond-
ing to the chassis.
4
5 - Lower the machine slowly onto the blocks (B), making
sure that the travel motor and the drainage couplings
(4) are not resting on the trestle (A), and that the
wheels remain raised above the ground.
Lower the lower work equipment until it rests on the B
ground and stop the engine.
Completely release all residual pressures from all
circuits, and in particular from the brake line. (For A
details, see « 20. TESTING AND ADJUSTING»).
F0400479

30-122
DISASSEMBLY AND ASSEMBLY COMPLETE FRONT AXLE

6 - Mount the tool R1 on the wheel group (5) and apply a

slight tension to the hoisting cables. Using the dyna-
mometric wrench G1, take off the nuts and remove
the entire wheel group.
Wheel group: 160 kg

5
R1
F0400523

7 - Disconnect the tubes (6) from the steering cylinder

and plug both the tubes and the cylinder.
9 7
8 - Disconnect the brake-group tubes (7) and plug both 8
the tubes and the axle couplings.
9 - Remove the guard (8) and disconnect the steering
sensor cable (9).
H Protect both the sensor and the connector with vi-
nyl bags and insulating tape.

6
F0400480

10 - Take away the cotter pin (10), the nut (11), the pin (12)
and its washer (13).
10

12
11

13
F0400481

11 - Place a lifting platform (C) and some blocks (D) be-

neath the axle. Raise this until the blocks are being
forced up against the arms of the axle (14).
H The lifting platform should be capable of an excur-
sion of about 15 cm in descent.

14 D

C
F0400482

30-123
DISASSEMBLY AND ASSEMBLY COMPLETE FRONT AXLE

12 - Remove the screws (15) and take away the pin (12)
and the cup springs between the axle and the chas-
sis.
15
13 - Lower the lifting platform (C) until the axle is free of
the chassis.
14 - Extract the axle (2).
12

F0400483

INSTALLATION OF THE 16 10
FRONT AXLE
. To install, reverse the removal procedure.

Wheel lock nuts: 550w20 Nm 11

15
(56w2 kgm)
H Insert the cup springs (16) between chassis and 13
axle. 12
1 - Start the engine to circulate the oil, recharge the ac-
cumulators of the brake line, and check the leaktight- 14
ness. D0400506

2 - Execute several complete steering manoeuvres with

the front axle.
3 - Bleed air from the front brake line.
(See «20. TESTING AND ADJUSTING»).
4 - Stop the engine and check the level of the oil in the
tank.

30-124
DISASSEMBLY AND ASSEMBLY COMPLETE REAR AXLE

REMOVAL OF THE COMPLETE REAR AXLE

1 - Remove the cabin access steps (1) from both sides of

the machine.

1
F0400477

2 - Disconnect the drive shaft (3) from the axle (2).

3 2

F0400485

3 - Start the engine and raise the front of the machine by

pushing down vertically with the boom, until the
wheels are about 20 cm above the ground.

20 cm

D0400551

4 - Place a trestle (A) underneath the machine and some

blocks (B), roughly 15 cm high, at points correspond-
ing to the chassis.
5 - Lower the machine slowly onto the blocks, making
sure that the wheels remain raised above the ground.

Lower the lower work equipment until it rests on the B

ground and stop the engine.
Release all residual pressures from all circuits (For
details, see « 20. TESTING AND ADJUSTING»). A

F0400486

30-125
DISASSEMBLY AND ASSEMBLY COMPLETE REAR AXLE

6 - Mount the tool R1 on the wheel group (4) and apply a

slight tension to the hoisting cables. 4
Using the dynamometric wrench G1, take off the nuts
and remove the entire wheel group.

R1

F0400487

7 - Disconnect the sensor (8).

H Protect both the sensor (8) and the connector (9)
with vinyl bags and insulating tape.
8

F0400488

8 - Disconnect the steering cylinder tubes (5) and plug

both the tubes and the cylinder. 5
5
9 - Disconnect the brake group tubes (6) and plug both
the tubes and the axle couplings.
10 - Remove the parking brake tube (7) and plug both the
tube and the brake group.
6 7

F0400521

11 - Place a lifting platform (C) and some blocks (D) be-

neath the axle (2); raise it until the blocks are forced
up against the central housing.
2
H To prevent the axle from rotating and slipping,
place a block (E) on the forks, in such a way that E
it rests beneath the drive shaft coupling flange.

C
D
F0400489

30-126
DISASSEMBLY AND ASSEMBLY COMPLETE REAR AXLE

12 - Loosen and take away the nuts (10), and plates (11)
and the fastening screws (12).
13 - Lower the lifting platform and extract the complete 12
axle (2).

11

10 F0400659

INSTALLATION OF THE
REAR AXLE
. To install, reverse the removal procedure.

Wheel lock nuts: 550w20 Nm

(56w2 kgm)
1 - Start the engine to circulate the oil, recharge the ac-
cumulators of the brake line, and check the leaktight-
ness.
2 - Execute several complete steering manoeuvres.
3 - Bleed air from the rear brake line.
(See «20. TESTING AND ADJUSTING»).
4 - Stop the engine and check the level of the oil in the
tank.

30-127
DISASSEMBLY AND ASSEMBLY AXLES

DISASSEMBLY THE AXLES

1. Final reducing unit
1 - Loosen the screws (1) and remove the support of the 1 2
planetary gears (2).

F0400593

2 - Take away the snap ring (3).

Using a press, remove the planetary carrier pins (4). 5
Remove the planetary gears (5) complete with their
roller bearings and cup springs.

4
3

F0400594

3 - Remove the pinion (6) complete with spacer, and

loosen the four screws (7).
6 7

F0400595

4 - Use a puller to remove the toothed ring bevel gear (8)

and the wheel hub (9). 8 9
H Use the slightly loosened retaining screws of the
toothed ring bevel gear and a plate as a support-
ing surface for the puller.

F0400596

30-128
DISASSEMBLY AND ASSEMBLY AXLES

5 - Use a puller to extract the bearing (10) and the spacer

(11). Take out the O-ring (12).
12 11 10

11 10 9 8
5

6 F0400597 D0400545

3
2

7
1
D0400543

2. Joint
1 - Remove the cotter pin (13) and the nut (14).
Use a puller to remove the ball and socket joint (15).

15
14 13

F0400598

2 - Loosen the six screws and remove the upper pin (16).
Repeat this operation for the lower pin.
Remove the outside rings (17) of the roller bearings. 16 17
H To facilitate the extraction of the pin (16), screw
two screws into the threaded holes.
H Check (with an inside ring micrometer), that the
seatings of the outside rings have not been dis-
torted.

F0400599

30-129
DISASSEMBLY AND ASSEMBLY AXLES

3. Drive shaft
H If the drive shaft removal operation involves the front
axle, block the brakes in order to hold the position of
the brake disks. This condition must be maintained
until the drive shaft is re-assembled.
H If the drive shaft removal operation involves the rear
axle, no further steps need to be taken because the
brake disks are blocked by the parking brake.
1 - Dismantle the joint (See «2. Joint»).

2 - Loosen the nut (18) and the screw (19).

18 19

F0400614

3 - Use levers to remove the drive shaft (20).

20

F0400615

30-130
DISASSEMBLY AND ASSEMBLY AXLES

4. Brakes
1 - Disconnect the ball joints of the steering.
(See «2. Joint»).
Loosen the fourteen nuts (21) on each side and re-
move the complete arms (22).

21 21

22 22
F0400616

2 - Remove the push disk (23) and the brake disks (24).
H If there is no need to change the disks, remove 23 24
the entire stack without altering their positions.

F0400617

3 - Introduce compressed air and extract the pistons (26)

from the intermediate cover (25).

26
26

25

F0400618

4 - Remove the snap ring (27), the cup springs (28), the
27 28 29 31 30
spring (29), the anti-extrusion ring (30) and the O-ring
(31).

D0400502

30-131
DISASSEMBLY AND ASSEMBLY AXLES

5. Differential group

45

46
43
42 43 39
42 38
34 44
41

37
36
42 34
39

42
43
38
40
35

1 - Remove the parking brake cylinder (for the rear axle

only).
Remove the complete arms. (See «4. Brakes»).
Remove the stud bolts (32) (two horizontal bolts op- 32
posed for each side).

F0400610

2 - Take off the intermediate covers (25).

Remove the complete differential group (33).
H Take care not to damage the sealed areas of the 33
O-rings.

25

F0400611

30-132
DISASSEMBLY AND ASSEMBLY AXLES

3 - Extract the bearings (34) and take out the eight 35 36

screws (35).
34
Remove the cover (36) complete with the planetary
gear (37) and the shim.
37

F0400612

4 - Fully insert the three centering pins (38) into the sup-
porting pins (39-40). Draw out the supporting pins (39-
40), the cross journal (41), the planetary gears (42),
the shims (43) and the second planetary gear (44), 45
complete with its shim. 38
40
Loosen the screws (45) and lift out the bevel ring gear
(46). 39
46

F0400613

6. Bevel pinion 49 50 51 55
54
1 - Remove the differential.
(See «5. Differential group»)
Loosen the nut (47), take out the O-ring (48), the
flange (49) complete with the guard (50), and the seal
ring (51).

47
48 52 D0400525

2 - Use tools S1 and S2 to loosen the lock nut (52) and

extract the bevel pinion (53) complete with the roller
bearing (54) and spacer (55). S1

Remove the roller bearing (54) from the bevel pinion

(53).
53
H If it proves difficult to extract the bevel pinion, use
a soft-headed mallet.
54
S2

F0400671

30-133
DISASSEMBLY AND ASSEMBLY AXLES

3 - Take out the central body of the roller bearing (56), 57

the outside ring of the bearing (54) and the shims
54
(57).

56 D0400497

4 - Remove the snap ring (58) and the cap (59).

59

58
D0400498

7. Steering cylinder
1 - Disconnect the tie-rods of the steering mechanism
(15) from the joints (see «2. Joint») and from the piston
15 60
rods of the steering cylinder (60).
Remove the four screws (61).

61

F0400604

2 - Extract the complete cylinder (60) from the axle body.

60

F0400605

30-134
DISASSEMBLY AND ASSEMBLY AXLES

3 - Remove the snap ring (62).

62

F0400636

4 - Push the head-piece (63) inside the cylinder (64) and

remove the snap ring (65). 65 64
5 - Slide the piston (66) complete with head-piece (63) off
the cylinder (64).
6 - Remove all the cup springs and guide rings from the
cylinder (64), from the piston (66), and from the head-
piece (63).

66 63
D0400541

8. Removal of the negative brake cylinder

71 70
1 - Introduce oil into the cylinder at a pressure of 20±22 72
bar. 67
2 - Disconnect the cylinder from the levers (67), remov- 72
ing in sequence the lock nut (68), the nut (69), the
screw (70) and finally the dowel (71) of the cylinder
fulcrum. 67
H Check the positions of the shims (72). 69
H When the operation is completed, release all 72
72 68
pressure from the cylinder.
D0400538

30-135
30-136
DISASSEMBLY AND ASSEMBLY AXLES

ASSEMBLY OF THE AXLES

1. Bevel pinion
1 - Use the tool S3, assemble the outside rings of the
S3
roller bearings (54-56) without shims in the central
body.

F0400665

2 - Return tool S4 to zero on a surface plane.

S4

F0400667

3 - Using tool S5, assemble the roller bearings (54-56).

S5
«A»
54
56
D0400521

4 - Insert tool S4 into the central housing and take mea-

surement «A».
H Measurement «A» corresponds to the shim (57)
that should be inserted beneath the outside ring
of the roller bearing (54).
57

F0400666

30-137
DISASSEMBLY AND ASSEMBLY AXLES

5 - Extract the outside ring of the bearing (54), insert the

shim (57), then use tool S3 to replace the ring. C
Mount the bearings (54-56) and the spacer (55) on
tool S5 and take measurement «C». S5 56

54
F0400668 D0400517

6 - Use tool S5 to insert the roller bearings without the

spacer (55) and take measurement «B». B
54
H The measurement «B-C + X» corresponds to the 56
shim that should be inserted between the spacer
(55) and the roller bearing (56).
H X=0.10±0.12 mm

F0400669 D0400519

7 - Use tool S6 and a press to assemble the roller bear-

ing (54) on the bevel pinion.
Insert the spacer (55) and the shim (73) on the bevel
pinion. 73
53 55

S6
54

F0400670

8 - Use tool S7 to mount the complete bevel pinion (53)

and the roller bearing (56).
S7 S1
Use tools S1 and S2, to tighten the lock nut.
Use tool S7 to mount the seal ring (51).
Lock nut: Loctite 242
Lock nut: 900±1000 Nm

S2

F0400672

30-138
DISASSEMBLY AND ASSEMBLY AXLES

9 - Verify that the rotation torque of the bevel pinion falls

within the range of permissible values.
H Pinion rotation torque: 120±170 Ncm

F0400664

10 - Mount the flange (49), the O-ring (48), and tighten the
nut (47). 49 51
Nut: Loctite 242
Nut: 260±280 Nm
H Make sure that the sealant (1) is not damaged dur-
ing assembly of the flange.

47 48
D0400526

2. Differential
1 - Insert the shim and the planetary gear (44). 42 41
Insert the four shims (43), the four planetary gears
(42) and the cross journal (41). 38 40
31mm
Insert the dowels (39-40) and the pins (38).
H Check that the holes in the dowels are aligned
with the holes in the pins. 39
H Insert the pins to a depth of 31 mm.

F0400619

2 - Insert the clearance adjustment and the planetary

gear (37) in the cover (36) and mount it on the differ- 35
ential body.
Then tighten the eight screws (35).
Screws: Loctite 270
Screws: 120±123 Nm
36

F0400620

30-139
DISASSEMBLY AND ASSEMBLY AXLES

3 - Insert the ring bevel gear (46) and tighten the sixteen
screws (45).
Screws: Loctite 270 45
Screws: 73±76 Nm
H Should it become necessary to dismantle the ring
bevel gear, change all the fastening screws (45)
for re-assembly.
Mount the roller bearings (34). 46

F0400660

3. Adjustment of the bevel gear

1 - Mount the intermediate cover (25) of the side oppo-
site the ring bevel gear and tighten the stud bolts 25
(32) (two stud bolts, horizontal and opposite).
Use a rod to insert the complete differential group.
Mount the intermediate cover (25) on the ring bevel
gear side and tighten the stud bolts (32) (two horizon-
tal and opposite).
Remove the safety plates from the intermediate cov- S8
ers and take out the lock nuts using tool S8.
H Take care not to damage the sealing areas of the
O-ring. F0400673

H Clean the lock nuts very thoroughly.

2 - Tighten the lock nuts and check the clearance be-
tween the bevel pinion and the ring bevel gear.
Once the prescribed clearance has been obtained,
tighten the lock nut on the side opposite to the ring
bevel gear, until the rotation torque of the bevel pi-
nion has been increased by 35±45 Ncm.
Chamfer the safety plates. 32
Lock nuts: Loctite 222
H Clearance between pinion and ring bevel gear:
0.15±0.18 mm
H If the clearance measured is found to be LESS
than the prescribed value, LOOSEN the lock nut F0400674
on the RING BEVEL GEAR SIDE and tighten
the lock nut on the side opposite the ring bevel
gear to the same value.
H If the clearance measured is found to be MORE
than the prescribed value, LOOSEN the lock nut
on the SIDE OPPOSITE TO THE RING BEVEL
GEAR and tighten the lock nut on the ring bevel
gear side to the same value.
H Take care not to pre-load the differential roller
bearings.

S8
F0400675

30-140
DISASSEMBLY AND ASSEMBLY AXLES

4. Final reducing unit

74
1 - Use the tool S9 to mount the O-ring (12), the spacer
(11), and the bearing (10) on the articulation case S9
(74).
10
12 11

F0400600

2 - Mount the wheel hub (9).

H Check the state of the sealant.
9
H Check that the bearing (10) has a slight axial
clearance and that the rotation force of the empty
hub is 2±3 kg.
H Axial clearance of the bearing: 0±0.05 mm.

F0400601

3 - Take the measurements «A» and «B» to calculate the

thickness of the shim (75) to be inserted between the
toothed ring bevel gear (8) and the articulation case
(74).
H Shim (75) measurement: A±B
A B

F0400602

4 - Mount the shim (75), the toothed ring bevel gear (8)
and the screws (7). 75
Screws: Loctite 270 8
76
Screws: 250 Nm
H Verify that the tangential force applied to one of
the stud bolts (76) does not exceed 4±5 kg.
H A variation of 0.02 mm in the shim (75) causes the
tangential force to vary by about 1 kg.

7
F0400603

30-141
DISASSEMBLY AND ASSEMBLY AXLES

5 - Insert the spacer and the pinion (6).

H Lubricate the contact surface between the spacer
and the pinion.
Spacer: Tecnolube Seal 101
6

F0400661

6 - Insert the planet wheels (5) and the shims from the
planet carrier's central hole and use tool S10 to insert
the roller bearings (77) and the spacer (78).

S10
77

78

F0400621

7 - Insert the bevel gear pin (4) and, using a press, com-
plete the assembly.
Repeat operations 6. and 7. for the other planetary
gears.
H Take care that the shim is perfectly aligned with 4
the hole of the bevel gear pin (4).

F0400622

8 - Insert the snap ring (3).

H Check carefully that the snap ring is correctly in- 5
serted. 3
Chamfer the parts of the planetary carrier that do not
come into contact with the snap ring.

F0400637

30-142
DISASSEMBLY AND ASSEMBLY AXLES

9 - Mount the complete planetary carrier (2) and tighten

the four screws (1). 1 2
Screws: 86±89 Nm

F0400593

5. Drive shaft
1 - Mount the drive shaft (20).

20

F0400623

2 - Screw the dowel bolt (19) home and tighten the nut
(18). 18 19
Nut: 86±89 Nm

F0400614

6. Joint
1 - Use tool S11 to mount the outside rings of the bear-
ings (79).
S11
79

F0400624

30-143
DISASSEMBLY AND ASSEMBLY AXLES

2 - Put a sling round the complete final reduction unit

and place it in position.
H Before proceeding with the positioning operation,
use tool S12 to mount the two rings (80) in the S12
holes of the joint.
H While positioning the unit, make sure that the
rings (80) are not distorted.

80 80
F0400625

3 - Mount the gaskets (81) and the lower dowel complete

with the bearing (79) and tighten the six screws. 82
81
Viti: Loctite 270
Viti: 120±123 Nm
Mount the upper dowel (82) complete with bearing
(79) and tighten the screws (83) slightly. 79
H Tighten the four screws (83) until a rotation torque
of 1.5±1.7 kg is obtained.

F0400626

4 - Measure the shim to be inserted with a feeler gauge.

Insert the shims and tighten the six screws (83). 83
Screws: Loctite 270 83
Screws: 120±123 Nm

F0400633

5 - Mount the ball joint (15), tighten the nut (14) and in-
sert the cotter pin (13).
15
Nut: 260±290 Nm

14 13

F0400634

30-144
DISASSEMBLY AND ASSEMBLY AXLES

7. Brakes
27 28 29 31 30
1 - Insert the O-ring (31), the anti-extrusion ring (30), the
spring (29), the cup spring (28), and the snap ring
(27).
H Make sure that the washer (31) and the anti-extru-
sion ring (30) are correctly assembled.
H Make sure that the springs are correctly as-
sembled.

D0400502

2 - Insert the four pistons (26) of the intermediate cover

(25).

25

F0400635

3 - Insert the brake disks (24) and the push disk (23) into
their seating. 23 24
H Make sure that the lubrication holes are all
aligned.
H Make sure that the disks are mounted in the right
order.

F0400617

4 - Insert the O-ring and the complete arm (22) in their

positions and tighten the fourteen nuts (21).
H Take care not to damage the O-ring.
Nut: Loctite 242
Nut: 190±193 Nm

21 21

22 22
F0400632

30-145
DISASSEMBLY AND ASSEMBLY AXLES

5 - Use the tool H1 to verify the sealing of the piston gas-

kets (26).
H Time for the test: 10 minutes
H The pressure should not drop.

8. Steering cylinder

63

66

87 86 85
85 86 87
64
90 66

92 92

63 88 89 91 64

1 - Mount the gaskets (85), the anti-extrusion rings (86)

and the gasket seal (87) in the cylinder (64) and in
the head-piece (63).
Mount the O-ring (89) and the anti-extrusion ring (88)
on the head-piece (63).
H Verify the correct assembly position for the seals
of the anti-extrusion rings and the O-ring.

30-146
DISASSEMBLY AND ASSEMBLY AXLES

2 - Use tool S13B to mount the O-ring (90) and the seal
ring (91) on the piston (66).
b B b S13 B b S13
H To facilitate assembly, heat the O-ring (90) and
the seal ring (91) to 60±80 ëC. 90 91

66
66
F0400606

3 - Mount the guide rings (92).

Mount tool S13A and wait about 15 minutes be- 92 B b S13
fore proceeding with the next operation.
H Mount tool S13A from the bevel side.

F0400607

4 - Insert tool S13C on the piston from the same side as

the bevel of tool S13A.
B b S13
Then push the piston (66) complete with tools 66 64
S13A and S13C into the cylinder (64), until tool
S13A is completely free.
H Grease the contact areas between tool S13C and
the piston (66).

F0400608

5 - Remove tool S13C and insert it on the opposite side

of the piston (66).
Then assemble the head-piece (63) complete with 63
cup springs.
H Grease the contact areas between tool S13C and
the head-piece (63).
B b S13
66

F0400609

30-147
DISASSEMBLY AND ASSEMBLY AXLES

6 - Mount the two snap rings (65) and (62).

65 62

F0400627

7 - Push the complete steering cylinder (60) into the cen-

tral housing and seal the contact area between cylin-
der (60) and the central housing with a liquid sealant. 60
Then tighten the four screws (61).
H Take care not to damage the O-ring mounted in 61
the steering cylinder tube.
Screws: 135±138 Nm

F0400662

8 - Fasten the tie-rods of the steering (15) to the piston

rods of the cylinder (60) and chamfer them at the
joints (See «6. Joint»).
Tie-rods: Loctite 242 15 60
Tie-rods: 240±270 Nm

F0400663

9. Toe-in adjustment
1 - Position the piston rod of the steering cylinder (60) at
half-stroke and check the position with a gauge.

60

F0400630

30-148
DISASSEMBLY AND ASSEMBLY AXLES

2 - Verify that measurement «A» is equal on both sides.

Check the parallelism of both front and rear wheel
hubs. // 0,5 cm

A A

500 mm
D0400546

3 - If the parallelism of the hubs is outside permissible

limits, loosen the clamp (93) and loosen or tighten
the RH and LH tie-rods to the same extent.
93

93

F0400676

10. Steering angle adjustment

1 - Adjust the adjustment screw (a) to a measurement of
50 mm and after having completed a steering action
from one side, screw down the end-of-stroke screw
(b) on the opposite side. Repeat this operation with
the other adjustment screw (b).

b a A a
50

D0400547 d C

11. Assembly of parking brake cylinder

1 - Introduce a pressure of 20±30 bar in the cylinder and
proceed with re-assembly by following the removal
operation in the reverse order.
Adjust the end-of-stroke screws (See «20. TESTING
AND ADJUSTING» - Adjustment of parking brake).

30-149
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

REMOVAL OF BOOM CYLINDER

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 2
the ground

1 - Put a sling around the cylinder (1).

2 - Switch off the engine, release pressure in the cylinder
by moving the RH PPC valve lever several times.
3
3 - Remove the screw (2) and draw out the pin (3).
4
4 - Start the engine to retract the piston (4). 1
5 - Lower the cylinder (1) until it rests on a stand «A». F0400184

H To hold the piston rod in its fully retracted position

tie it with wire.
6 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
1
7 - Disconnect the tubes (5-6) and plug them. Also plug
the holes in the safety valve to avoid entry of impuri-
ties.
8 - Remove the screw (7) and take out the valve (8).
9 - Remove the screw (9) and draw out the pin. A
F0400185
10 - Lift out the cylinder (1).

INSTALLATION OF BOOM
CYLINDER
9
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder rod) until a
clearance of 1±2 mm is obtained.

10
When aligning the positions between hole and
pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the F0400186

alignment.

Inside bushings : ASL800050 7 8

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 0.5±1 mm is obtained.

. Start the engine and bleed air from the cylinder. (For 5
details, see «20. TESTING AND ADJUSTMENTS»).
6
H After bleeding the air, check the oil level in the
tank.
F0400187

30-150
 BOOM CYLINDER
DISASSEMBLY AND ASSEMBLY (For 2-piece boom)

REMOVAL OF BOOM CYLINDER

(For 2-piece boom)
1 - Fully extend the front work equipment, raise the
boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A

F0400491

3 - Put a sling round the RH cylinder (1) of the 2-piece

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment to a given clearance (4).

4
4
2

5
5 3
F0400492

4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6

H To secure the piston rod in this position, tie it with

wire and switch off the engine.
1
6 - Disconnect the tubes (6) from the RH cylinder (1) and
plug them.
7 - Slide out the pin (7) until the cylinder (1) is free and 7
remove it. F0400493

8 - Put the boom cylinder (8) in a sling.

9 - Slide the pin (7) out until the boom cylinder piston rod
(8) is disconnected.
H To hold the piston rod it its fully retracted position,
tie it with wire and switch off the engine.
8
10 - Start the engine and retract the piston.
11 - Lower the cylinder (8) and rest it on a stand (B). 7

B
F0400494

30-151
 BOOM CYLINDER
DISASSEMBLY AND ASSEMBLY (For 2-piece boom)

12 - Disconnect the tubes (9) and (10) and plug them. Also 11
plug hole in the safety valve (11) to prevent impurities
from entering.
10
13 - Remove the screws (12) and take out the safety valve
(11).

12

9
F0400490

14 - Remove the screws (13) and take out the pin (14).

15 - Remove the cylinder.

8 13

14

INSTALLATION OF THE BOOM

F0400495

CYLINDER (For 2-piece boom)

. To install, reverse the removal procedure.

Self-locking nut: 118 Nm.

Inside bushings: ASL800050.

When aligning the positions between hole and

pin, run the engine at minimum idling.
Do not insert fingers in the holes to check the
alignment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 0.5±1 mm is obtained.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5±1 mm is obtained.
. Start the engine and bleed the air from the cylinders
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the level of the oil
tank.

30-152
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM CYLINDER

REMOVAL OF 2-PIECE BOOM CYLINDER

1 - Fully extend the front work equipment, raise the

boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.90 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A

F0400491

3 - Put a sling round the RH cylinder (1) of the 2-piece

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment (4) to a given clearance.

4
4
2

5
5 3
F0400492

4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6
H To hold the rod in its fully retracted position, tie it
with wire and switch off the engine.
6 - Disconnect the tubes (6) from the RH cylinder (1) and 1
plug them.
7 - Slide out the pin (7) to free the cylinder (1) and re-
move it. 7
F0400493

8 - Put the boom cylinder in a sling.

9 - Slide the pin (7) out to disconnect the boom cylinder
piston rod (8).
10 - Start the engine and retract the piston.
H To hold the rod in its fully retracted position, tie it 8
with wire and switch off the engine.
11 - Lower the cylinder (8) and rest it on a stand (B). 7

B
F0400494

30-153
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM CYLINDER

12 - Repeat the procedure from points 3-7 to remove the

LH cylinder (9) of the 2-piece boom.
6

7
9

F0400499

INSTALLATION OF 2-PIECE
BOOM CYLINDER
. To install, reverse the removal procedure.

Self-locking nut: 118 Nm.

Inside bushings: ASL800050.

When aligning the positions between hole and pin,

run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides) until a clearance of 0.5±1
mm is obtained for each cylinder.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5±1 mm is obtained.
. Start the engine and bleed the air from the cylinders
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the level of the oil
tank.

30-154
DISASSEMBLY AND ASSEMBLY ARM CYLINDER

REMOVAL OF ARM CYLINDER

Open the front work equipment completely, then
raise it and place a supporting stand between the
boom and the 2-piece boom. Manoeuvre the bucket
until its teeth are resting on the ground, together with
the arm.

1 - Put a sling around the cylinder (1).

2 - Switch off the engine, release pressure in the cylinder
by moving the LH PPC valve lever several times.
3 - Remove the screw (2) and draw out the pin (3).

F0400500

4 - Start the engine to retract the piston (4).

H To hold the piston in its fully retracted position, tie
the rod with wire.
5
5 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
1
AND ADJUSTMENTS»).
6 - Disconnect the tubes (5) and plug them. 4
3
If a safety valve has been installed, disconnect
the tubes (6-7) from the valve.

7 - Remove the screw (8) and draw out the pin (9).
2
F0400501

8 - Lift out the cylinder (1).

INSTALLATION OF
ARM CYLINDER
. To install, reverse the removal procedure.

H IInsert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a 6
clearance of 1±2 mm is obtained.
7
When aligning the positions between hole and
pin, let the engine run at minimum idling. F0400247

Do not insert fingers into the hole to check the

alignment.

Inside bushings: ASL800050

9 8
1
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the cylinder) until a clear-
ance of 0.5±1 mm is obtained.
. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.
F0400189

30-155
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

REMOVAL OF BUCKET CYLINDER

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 4
the ground

1 - Switch off the engine and release pressure in the cy-

2
linder by moving the RH PPC valve lever several
times.
2 - Remove the ring nut (2) and draw out the pin (3).

3 - Switch off the engine and retract the piston rod (4).
H To hold the piston rod in its fully retracted posi- 3
tion, tie it with wire. F0400642

4 - Switch off the engine and release any residual hy-

draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
6
5 - Disconnect the hoses (5) and plug them. Also plug
7
the holes of the rigid tubes to avoid entry of impuri-
ties. 1

6 - Put a sling around the cylinder (1).

7 - Remove the screw (6) and draw out the pin (7).

8 - Lift out the cylinder (1).

5
F0400155

INSTALLATION OF BUCKET
5
CYLINDER
. To install, reverse the removal procedure.
6
7
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the piston rod) until a
clearance of 1±2 mm is obtained.

When aligning the positions between hole and

pin, do not insert fingers into the hole to check
the alignment. F0400190

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5±1 mm is obtained.

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.

30-156
DISASSEMBLY AND ASSEMBLY BOOM SWING CYLINDER

REMOVAL OF BOOM SWING CYLINDER

1 - Swing the boom to the right to extend the cylinder

fully.
2 - Swing the revolving frame 45ë and rest the work
equipment on the ground.
3 - Switch off the engine and move the PPC valve sev-
eral times to release all residual pressures.
2
4 - Remove the RH front guard (1) from the revolving 1
frame (2).
5 - Disconnect the tubes (3) from the cylinder and plug
them. Also plug the flanges (4) of the cylinder (5). D0400405

6 - Disconnect the lubricator tube (6).

7 - Place a block beneath the cylinder head to prevent
the edge of the frame making dents in the piston
rod. Also place a support beneath the cylinder.
8 - Remove the screw (7), draw out the pin (8) and detach
the piston rod from its support (9).
9 - Remove the screws (10) and draw out the stop (11) 4 4
and the pin (12). 3 5
10 - Slide the cylinder out partially from the front and, as
soon as possible, put it in a sling and lift it off.
H During this operation take great care not to dent F0400502
the piston rod.

INSTALLATION OF BOOM SWING 12 10

CYLINDER
. To install, reverse the removal procedure.
6
11
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the piston) until a clear-
ance of 1±2 mm is obtained.

When aligning the positions between hole and

pin, let the engine run at minimum idling. F0400193

Do not insert fingers into the hole to check the

alignment.

Inside bushings: ASL800050

7
8
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the cylinder) until a clear-
ance of 0.5±1 mm is obtained.

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
9
H After bleeding the air, check the oil level in the
tank. F0400194

30-157
DISASSEMBLY AND ASSEMBLY CYLINDERS FOR OUTRIGGERS/BLADE

REMOVAL OF CYLINDERS FOR OUTRIGGERS/BLADE

1 - Bring the arm into a vertical position and rest the back
of the bucket on the ground.
2 - Rest the blade and/or the outriggers on the ground.
3 - Stop the engine and release all residual pressures
from the blade and/or outriggers.
4 - Take away the screw (1), remove the dowel (2), and
disengage the piston rod from the blade or from the
outrigger.

5 - Start the engine and retract the piston rod (3).

H Secure the totally retracted position by binding
both sides of the piston rod with wire.

6 - Stop the engine and release all residual pressures. 10

7 - Disconnect the tubes (4) and (5) and plug them. Also
plug the safety valve (6) couplings. 9
8 - Put a sling around the cylinder (7).
H Take care not to distort the valve tube (8).
3
9 - Take out the screw (9) and remove the dowel (10). 2

1
10 - Take out the cylinder complete with valve.
F0400522

INSTALLATION OF THE 5
CYLINDERS FOR
OUTRIGGERS/BLADE 8
. To install, reverse the removal procedure. 4

H Insert the shims on both sides of the piston rod.

6

When aligning the positions between hole and

pin, let the engine run at low idling.
Do not insert fingers into the holes to check on F0400524

alignment.

Internal bushings: ASL800050

7
H Insert the shims on both sides of the piston rod.
. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTING»).
H After bleeding the air, check the level of oil in the
tank.

F0400525

30-158
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

DISASSEMBLY OF WORK EQUIPMENT CYLINDERS

1 - Place the cylinder on the tool F8 and partially extract

the piston. 3
2 - Loosen the retaining screws of the flange (1) that se- F8 5
cures the head (2) and take it away. Move the flange
(1) towards the piston rod.
3 - Push the head (2) into the cylinder (3) and remove the
snap ring (4).
H Take great care not to damage the inside of the
cylinder.
4 - Slide the piston rod (5) out of the cylinder (3), com-
plete with the flange (1), the snap ring (4), the head
F0400196

(2) and the piston (6).

5 - Remove the screws (7) and remove the two half-
flanges (8). 1 2
5 6
8

7
4
F0400197

For the arm cylinder only:

1 - Heat the safety valve (9) and the end nut (10)
to a temperature of 140±150 ëC
2 - Loosen and remove the safety screw (9).
10
9
3 - Loosen and remove the nut (10).
H Use the key F7 and the dynamometric key
G1.
H Before continuing with the dismantling op-
erations, allow the piston rod to cool down.

F0400198

6 - Take the group to pieces.

For the arm cylinder, first take away the thirteen
brake pin (12) retaining balls (11).

7 - Remove the seals from the piston rod, the piston, the
12
head and the flange.

11
F0400199

30-159
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

ASSEMBLY OF THE WORK EQUIPMENT CYLINDERS

H Take care not to damage the seals or the sliding sur-

faces.
H Prepare each individual component before final as-
3
2
sembly.
1 2

1. Assembly of the head-retaining flange.

1
1 - Mount the scraper (1) in the external seating of the
flange (2), making sure that it is positioned correctly.
Drive home the scraper using the press.
2 - Mount the O-ring seal (3). D0400398 F0400200

H Use grease to hold the washer in place.

Sealant: ASL800050

6 5
7 1
2. Head assembly
1 - Mount the internal central retaining ring, positioning 4 2
first the O-ring (1) and then the sealing ring (2).
H Make sure that the lowering of the retaining ring is
turned towards the inside of the cylinder.
3 4
2 - Use the tool F1, mount the lip seal (3).
H Check that the lips are facing towards the inside D0400395

of the cylinder.
3 - Mount the guide rings (4).
6 5 1 6 5 6
4 - Mount the O-rings (5) and relative anti-extrusion rings 7
(6) on the outside of the head (7).
H Check the position of the anti-extrusion rings (6).

4
3 2 4 D0400394

1 2 F1

7 2

F0400201 F0400202

30-160
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

5 - Gauge the diameter of the internal seals, mounting

the group underneath the press and using the speci-
fic gauging knuckle pin F2 for the diameter of the pis-
ton rod.

F2

F0400203

3. Piston assembly
1 - Using the tool F3, mount the piston seal. Mount in the
correct sequence the rubber ring (1), the external seal
(2), and the rings wear (3).
2 - Mount the guide rings (4).
1 2 F3
3 - For the arm piston only: Mount the O-ring (5) and
the rings wear (6) for the sealing between piston rod
and piston.

F0400204

4 3 2 3 4

6 5 6
D0400397

4 - Gauge the diameter of the seal (2) of the piston (7),

mounting the group under the press and using the
specific gauging ring F4 for the piston diameter.
7

F4

F0400205

30-161
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

4. Piston rod group assembly

1 - Mount on the end of the piston rod (1) the bushing F5
of the correct diameter. 2
1 4
2 - Slide the head-retaining flange (2), the snap ring (3)
and the head (4) onto the piston rod.
H Check carefully the positioning of the head-retain-
ing flange.
3 - Remove the bushing F5 from the end of the piston.
F5 3
F0400228

4 - Mount the O-ring (5) and the rings wear (6) in the end-
seating, for the sealing between the piston ring and 5
piston.
H For the arm piston ring, the seal is housed in the
piston itself. 7 8
6
5 - Mount in the correct sequence the brake bushing (7)
(for the boom and arm cylinders only) and the piston
(8).

F0400229

6 - For the arm piston only: mount the brake pin (9) and
slide the thirteen retaining balls (11) into the hole (10).
7 - Mount the half-flanges (12) that hold the piston (8) in 8 12
place, and secure them with the screws (1). 10
Flange retaining screws: 5w0.5 kgm

13
11 9
F0400248

For the arm piston only:

1 - Mount the nut (14) that holds the piston (8) in
place, and tighten with the socket wrench F7 8
14
and the dynamometric tool with multiplier G1.
Piston retaining nut: Loctite 262
15
Piston retaining nut: 300w20 kgm
(294w19.5 dNm)
2 - Mount the safety screw (15).
Safety screws: Loctite 262
Safety screws: 10w1 kgm (98w9.8 Nm)
F0400249

30-162
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

5. Cylinder assembly
1 - Place the cylinder (1) and the piston rod group (2) on 1 3
the equipment F8 and align their axes. 4
2
2 - Lubricate the external seals and insert the piston (3)
in the cylinder (1).
Piston sealants: Grease ASL800050
H Before inserting the piston, check that the seals
are not damaged and that they fit perfectly in their
seatings.
3 - Lubricate the external seals of the head (4) and insert 5
it completely into the cylinder (1). F8 F0400250

Head sealants: Grease ASL800050

H Before inserting the head, check that the seals
are not damaged and that they fit perfectly in their
seatings.
4 - Using the tool F6, position the snap ring (5) that holds
8
the head (4) in the cylinder seating. 6
H Check that the snap ring is completely inserted in
the seating.
5 - Position the flange (6) that holds the head in place,
and secure it with the screws (7). F6
H Before positioning the flange, check that the O-
ring flange seal (8) is in its seating.
Flange blocking screws: 5w0.5 kgm
F0400211

(49w5 Nm)

7
F0400226

30-163
DISASSEMBLY AND ASSEMBLY OVERLOAD SENSOR

REMOVAL OF OVERLOAD SENSOR

Lower the work equipment until it is resting on the
ground and switch off the engine.
6
1 - Disconnect the plug (1) of the pressure switch (2). 8
2 - Unscrew the screw (3) and remove the core hitch
clamp (4).
1 4
3 - Disconnect the tube (5) from the pressure switch (2) 3
and plug it. Also plug the hole in the pressure switch.
4 - Bring the activating lever (6) into its stop position and
secure it with a screw (7) (M6x12). F0400212

5 - Take out the screws (8) and draw out the group.

5
2
INSTALLATION OF OVERLOAD
SENSOR 6

. To install, reverse the removal procedure. 7

H When removing the screw (7), accompany the le-
ver in order to let the roller come down gently onto 9
the cam (9).

F0400213

30-164
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

REMOVAL OF WORK EQUIPMENT

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 2
the ground
1 - Put a sling around the cylinder (1) of the boom. 7
2 - Switch off the engine, release pressure in the cylinder
by moving the PPC valve lever several times.
3 - Remove the screw (2) and draw out the pin (3). 3
6
4 - Start the engine to retract the piston (4). 4
H To hold the piston in its fully retracted position, tie 1
it with wire.
F0400251

5 - Lower the cylinder (1) until it comes to rest on blocks

(A).
6 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
7 - Remove the overload sensor (For details, see «RE-
MOVAL OF OVERLOAD SENSOR»). 1
8 - Disconnect the hoses (5) and plug them. Also plug
the rigid tubes.
9 - Put the equipment in a sling and apply slight tension
to the cables.
10 - Remove the screw (6) and the pin (7). Lift off the work
equipment (8). A

Work equipment: 980 kg F0400185

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

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston) until a clear- 5 5
ance of 1±2 mm is obtained.

When aligning the positions between holes and

pin, let the engine run at minimum idling. F0400214

Do not insert fingers into the hole to check the

alignment.

Inside bushings: ASL800050.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the arm) until a clearance
of 0.5±1 mm is obtained.
. Start the engine to circulate the oil, and bleed air from
the cylinder.
H After bleeding the air, switch off the engine and
check oil level in the tank.
8
F0400503

30-165
 WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY (2-piece boom version)

REMOVAL OF WORK EQUIPMENT (2-piece boom version)

Fully extend the arm and the 2-piece boom and com-
pletely curl up the bucket. Position a stand (A)
(height 1.90 m.) between the boom and the 2-piece
boom, and rest the back of the bucket on the ground.
Stabilise the machine by resting the blade and/or the
stabilisers on the ground.
Completely eliminate residual pressures from all the A
circuits. (For details, see «20. TESTING AND AD-
JUSTMENTS»).

F0400653

1 - Disconnect the boom cylinder (1) from the 2-piece

boom and rest it on a stand (B).
H In order to disconnect the boom cylinder, it is ne-
cessary to remove the RH cylinder of the 2-piece
boom. (See «REMOVAL OF 2-PIECE BOOM CY- 2
LINDERS up to point 11). 1
A
After having disconnected the boom cylinder, re-
assemble the RH cylinder of the 2-piece boom
with the pin (2) and fasten it with its own screws.

B
F0400504

2 - Disconnect the eight hoses (3) that control the front

work equipment cylinders, and plug them. Also plug
the union fittings of the hoses (4).
3
3 - Remove the overload sensor (See «REMOVAL OF
OVERLOAD SENSOR»).

F0400505

4 - Put the boom (5) in a sling and apply slight tension to

the cables.
H Pass the cables through the rigid tubes to avoid 5
distortion.
7
5 - Remove the screws (6) and take out the pin (7).

6 - Raise the boom (5) until it is disengaged from the swi- 6

vel support (8) and take away the stand (A).

A 8
F0400506

30-166
 WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY (2-piece boom version)

7 - Swing the group to the side of the machine and rest

the boom on a stand (C).
5

D0400479

INSTALLATION OF THE
WORK EQUIPMENT
(2-piece boom version)
. To install, reverse the removal procedure.

H Insert the shims (distributed on both sides of the

top of the cylinder) until a clearance of 1±2 mm
is obtained.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.

Inside bushings: ASL800050

H Insert the shims (distributed on both sides of the

top of the piston rod) until a clearance of 1±2
mm is obtained.

. Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
H After bleeding the air, switch off engine and check
oil level in the tank.

30-167
DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL OF BUCKET
Lower the bucket to the ground, resting with its back
on a flat surface. 7
4
1 - Take out the safety pin (1) and the connecting pin (2)
between bucket (3) and tie-rod (4).
6
2
5
2 - Take out the safety pin (5) and the pin (6) that con-
nects the bucket to the arm (7).
1 3

INSTALLATION OF BUCKET F0400216

. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance be-

tween bucket (3) and tie-rod (4).

When lining up the hole and the pin, let the en-
gine turn at low idling speed.
Do not insert fingers into the holes to check
alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (on

both sides) between the bucket (3) and the arm
(7), until a play of 0.5±1 mm is obtained.

30-168
DISASSEMBLY AND ASSEMBLY ARM

REMOVAL OF ARM

1 - Remove the bucket (For details, see «REMOVAL OF

BUCKET»).
2 - Remove the bucket cylinder. (For details, see «RE- 1
MOVAL OF BUCKET CYLINDER»).
3 - If the machine is designed for the application of op-
tional front equipment, disconnect the boom (or the 2-
piece boom), the tubes (1) and remove the supports (2).

2
F0400507

4 - Loosen the ring nut (3) and pin (4) and remove the
thrust lever (5).
3

4
F0400146

5 - Raise the boom and bring the arm (6) into a vertical
position and then lower it to the ground.
6

D0400542

6 - Switch off the engine and release residual pressures.

10 7
7 - Put the arm cylinder (7) in a sling, remove the screw 9
(8) and take out the pin (9).
8 - Start the engine and fully retract the piston (10).

H To hold the piston rod in its fully retracted posi-

tion, tie it with wire.
8

F0400508

30-169
DISASSEMBLY AND ASSEMBLY ARM

9 - Rest the cylinder (7) on a block (A).

10 - Switch off the engine. 7

A
F0400509

11 - Connect the arm (6) to the hoisting tackle and apply

slight tension to the cable.
12 - Remove the cotter-pin (11) and the nut (12).

12
11

F0400510

13 - Take out the screw (13) and pull out the pin (14).
14 - Lift off the arm (6). 6
Arm: 156 kg.

14

13
F0400511

15 - Start the engine and, for reasons of safety, lower the

boom or 2-piece boom until it rests on the ground.

F0400512

30-170
DISASSEMBLY AND ASSEMBLY ARM

INSTALLATION OF ARM

. To install, reverse the removal procedure.

Inside bushings: ASL800050

H Insert shim

When aligning the positions between holes and

pin, do not insert fingers into the hole to check
the alignment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston) until a clear-
ance of 1±2 mm is obtained.
When aligning the positions between holes and
pin, let the engine run at minimum idling.
Do not insert fingers into the holes to check the
alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis-
tributed on both sides) until a clearance of 0.5±1
mm is obtained.
When aligning the positions between hole and
pin, do not insert fingers into the holes to check
the alignment.

30-171
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM

REMOVAL OF 2-PIECE BOOM

1 - Remove the bucket, the bucket cylinder, the arm cy-

linder and the arm. For details see:
. REMOVAL OF BUCKET
1
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
2 - Start the engine and bring the 2-piece boom (1) into a
vertical position. Lower it until it rests on the ground
and switch off the engine.
F0400496

3 - Put a sling round the RH cylinder (2) of the 2-piece

boom and remove the nut (3), the screw (4) and the 2 2
shim (5).
4 - Slide out the pin (6) that connects the RH cylinder (2)
to the 2-piece boom (1) until the piston rod is comple- 5
tely disconnected. 5
3

6 4
F0400531

5 - Start the engine and completely retract the piston rod

of the RH cylinder.
H To hold the piston rod in a fully retracted position,
tie it with wire and switch off the engine.
6 - Lower the cylinder until it is in a vertical position, leav-
ing the boom tied up.
7 - Repeat these operations from point 3 to point 6 in or-
der to disconnect the LH cylinder (7).

F0400532

8 - Hook the 2-piece boom to the hoisting tackle.

9 - Remove the screws and take out the pin (8).

10 - Take off the 2-piece boom. 8

2-piece boom: 195 kg

7
F0400513

30-172
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM

INSTALLATION OF 2-PIECE BOOM

. To install, reverse the removal procedure.

Self-locking nut: 118 Nm.

Inside bushings: ASL800050.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.

. Insert the shims (distributed on both sides of the

boom) until a clearance of 0.5±1 mm is obtained.
. Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
H After bleeding the air, switch off the engine and
check the oil level in the tank.

30-173
DISASSEMBLY AND ASSEMBLY BOOM

REMOVAL OF BOOM

1 - Remove the arm (For details, see «REMOVAL OF 2

ARM»).
2 - Remove the arm cylinder. (For details, see «RE-
MOVAL OF ARM CYLINDER»).
3 - Start the engine and lower the boom to the ground.
4 - Switch off the engine and move the PPC valve sev-
eral times to release pressures in the cylinder. 3
5 - Put the boom cylinder in a sling (1).
6 - Take out the screw (2) and pull out the pin (3). 4

1
7 - Start the engine and fully retract the piston (4). F0400184

H To hold the piston rod in its fully retracted posi-

tion, tie it with wire.
8 - Switch off the engine and release all pressures. (For 9
details, see «20. TESTING AND ADJUSTMENTS»).
9 - Lower the piston until it is resting on blocks (A).
10 - Remove the overload sensor. (For details, see «RE- 1
MOVAL OF OVERLOAD SENSOR»).
8
11 - Put the boom (5) in a sling, using the attachment hole
in the arm cylinder. Apply slight tension to the cable.
12 - Disconnect the front equipment hoses (6) and plug
them. Also plug the rigid tubes (7).
13 - Take out the screw (8) and pull out the pin (9). A
14 - Lift off the boom (5).
F0400300

Boom: 358 kg

INSTALLATION OF BOOM 5
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 1±2 mm is obtained.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment. F0400734

Inside bushings: ASL800050

7 7

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the boom) until a clear-
ance of 0.5±1 mm is obtained.
. Start the engine to circulate the oil and bleed air from
the cylinders.
6 6
H After bleeding the air, switch off the engine and
check the oil level in the tank.

F0400301

30-174
 BOOM
DISASSEMBLY AND ASSEMBLY (2-piece boom version)

REMOVAL OF BOOM (2-piece boom version)

1 - Remove the bucket, the bucket cylinder, the arm cy-

linder, the arm, and the 2-piece boom. For details
see:
. REMOVAL OF BUCKET
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
. REMOVAL OF 2-PIECE BOOM

2 - Replace the fulcrum pin (1) of the 2-piece boom and

secure it with the proper screws.
2 1
3 - Manoeuvre the boom (2) until the fulcrum pin is rest-
ing on a stand (A), 1.60 m high.
A
4 - Switch off the engine and release any residual pres-
sures in the boom cylinder.
5 - Remove the 2-piece boom cylinders (3) and let the
3
boom cylinder (4) rest on a stand. (For details, see
«REMOVAL OF 2-PIECE BOOM CYLINDER»).
4
F0400514

6 - Remove the overload sensor. (For details, see «RE-

MOVAL OF OVERLOAD SENSOR»).
7
7 - Disconnect the six connecting hoses of the front work 6
5
equipment cylinders (5) and the two tubes (6) of the
optional equipment.
H Plug the hoses and rigid tubes to prevent entry of im-
purities.

F0400515

8 - Take out the four screws (7) and lift away the com-
plete rack of tubes. 7

F0400516

30-175
 BOOM
DISASSEMBLY AND ASSEMBLY (2-piece boom version)

9 - Screw four M10 UNI 2947 eyebolts (8) as far as they

will go into the holes of the rack of tubes.
8 10
10 - Attach the hoisting tackle to the eyebolts and apply
slight tension to the cables.
11 - Take out the screws (9) and remove the pin (10).
12 - Lift away the entire boom (2).
Boom: 272 kg.
2
9
F0400517

INSTALLATION OF BOOM
(2-piece boom version)
. To install, reverse the removal procedure.

Inside bushings: ASL800050

Do not insert fingers in the holes in order to

check the alignment.

H Insert shims on both sides of the boom, until a

clearance of 0.5±1 mm is obtained.
. Start the engine to let the oil circulate and bleed air
from the cylinders.
H After bleeding the air, switch off the engine and
check the level in the oil tank.

30-176
DISASSEMBLY AND ASSEMBLY SWING BRACKET

REMOVAL OF SWING BRACKET

Extend the work equipment fully and rest it on the
ground.
1 - Remove the front work equipment. (For details see
«REMOVAL OF WORK EQUIPMENT»).
2 - Remove the boom cylinder (For details, see «RE-
1
MOVAL OF BOOM CYLINDER»).
3 - Remove the swing bomm cylinder from the swing
bracket (1). For details, see «REMOVAL OF BOOM
SWING CYLINDER».
4 - Attach the swing bracket to the hoisting tackle (1) and
apply slight tension to the cable. F0400221

5 - Place a jack (3) beneath the lower pin (2).

6 - Take out the retaining screws and pull out the pin (2).

7 - Take out the retaining screws and, with the help of a

lever, pull out the upper pin (4).
8 - Lift out the swing bracket (1). 2
Swing bracket: 36 kg
3

INSTALLATION OF SWING
BRACKET
F0400222

. To install, reverse the removal procedure.

Lower pin: ASL800050

Upper pin: ASL800050

H Insert the adjustments to a given clearance (dis- 4

tributed on both sides of the piston rod) until a
clearance of 1v2 mm is obtained.

When aligning the positions between holes and pin,

let the engine run at minimum idling.
Do not insert fingers into the hole to check the align- F0400223
ment.

H Insert the adjustments to a given clearance be-

tween the chassis and the support.
1
Unit: mm

Pos. Code No. Thick- Quantity

ness
1 390617004 5 1
3
2 390617003 1 2
3 390617004 5 1 2

Supporting surfaces and adjustments to a given

clearance: ASL800050 D0400396

30-177
DISASSEMBLY AND ASSEMBLY BLADE AND OUTRIGGERS

REMOVAL OF THE BLADE AND OUTRIGGERS

1 - Raise the blade (1) or the outriggers (2) and place 1

blocks (A) under the arms (3); Lower the equipment
until the arms rest lightly on the blocks.

A
F0400518

2 - Attach the blade (1) or the outriggers (2) to the lifting

equipment and apply slight tension to the cables.
3
3 - Take out the screws and remove the pins (4).

4 - Remove the blade (1) or the outriggers (2).

4

2
F0400519

INSTALLATION OF THE
BLADE AND OUTRIGGERS
. To install, reverse the removal procedure.

Internal bushings: ASL800050

Do not insert fingers into the holes to check on

alignment.

H Insert the shims on both sides of the arm, in order

to obtain a clearance of 0.5±1 mm.

30-178
DISASSEMBLY AND ASSEMBLY BLADE AND OUTRIGGER ARMSI

REMOVAL OF BLADE AND OUTRIGGER ARMS

1 - Remove the blade or the outriggers.

(For details, see «REMOVAL OF BLADE AND OUT-
RIGGERS»).
2 - Take out the screw (1) and remove the dowel (2).

3 - Start the engine and retract the piston (3). Stop the 2
3
engine.

1
F0400526

4 - Attach the arm (4) to the hoisting equipment and ap-

ply slight tension to the cables.
5
5 - Take out the screw (5) and remove the dowel (6).
6
6 - Remove the arm (4).

F0400520

INSTALLATION OF THE BLADE

AND OUTRIGGERS ARMS
. To install, reverse the removal procedure.

Internal bushings: ASL800050

Do not insert fingers into the holes to check on

alignment.

H Insert the shims on both sides of the arm, in order

to obtain a clearance of 0.5±1 mm.

30-179
GROUP 40
 MAINTENANCE STANDARD

P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40- 3 Swing motor relief valve . . . .. . . . .. . . . . .. . . . . .. . . . . 40-17

Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40- 4 Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-18
Front and rear axles differential - Travel motor brake valves . .. . . . .. . . . . .. . . . . .. . . . . 40-19
brake disks . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40- 5 Servocontrol feed unit . . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-20
Planetary - articulation. . .. . . . .. . . . . .. . . . .. . . . . 40- 6 Axle locking valve . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-21
Axles . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40- 7 L.H. and R.H. PPC valves. .. . . . .. . . . . .. . . . . .. . . . . 40-22
Steering cylinder . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40- 8 Travel PPC valve .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-23
Parking brake and cylinder. . .. . . . . .. . . . .. . . . . 40- 9 2nd boom and boom swing PPC valve . . . . .. . . . . 40-24
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40-10 Outrigger and blade PPC valves. . . . . .. . . . . .. . . . . 40-25
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40-11 Outrigger and blade safety valves . . . .. . . . . .. . . . . 40-26
Check valve and oil cooler safety by-pass. . 40-12 Axle locking cylinder . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-27
Pump drive . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40-13 Cylinders . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-28
Summation horsepower control - Work equipment (1 - piece boom) . . . .. . . . . .. . . . . 40-30
Mode-system . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40-14 Work equipment (2 - piece boom) . . . .. . . . . .. . . . . 40-32
Auxiliary pump . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40-15
Control valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . 40-16

40-1
P.T.O.

A
50 Nm

50 Nm

35 Nm
50 Nm

80 Nm

Section A - A D0400072

40-3
TRANSMISSION

45 450 Nm

15 v 18 Nm
with Loctite 242

86 489 Nm

Loctite 242

49 451 Nm

Loctite 242 350 v 400 Nm

with Loctite 242

350 v 400 Nm
with Loctite 242
2

49 451 Nm

D0400154
Loctite 573

Unit: mm

Në Check item Criteria Remedy

1 End play of output drive gear 0.0540.01 Adjust

2 End play of bearing 0.140.2 Adjust

40-4
FRONT AND REAR AXLES DIFFERENTIAL - BRAKE DISKS
(Also valid for L.H. crown)

190 v 193 Nm
with Loctite 242

190 v 193 Nm 73 v 76 Nm
with Loctite 242 with Loctite 270 120 v 123 Nm
with Loctite 270

Loctite 222
40 v 45 Nm
with Loctite 270

5
5 2

3 900 v 1000 Nm
with Loctite 270

1 260 v 280 Nm
with Loctite 242 D0400073

Unit: mm

Në Check item Criteria Remedy

1 Pinion rotation torque 1204170 Nm

2 Pinion - crown rotation torque 1554215 Nm

Standard clearance Clearance limit

3 Backlash of crown wheel and pinion
0.1540.18 0.2 Adjust

4 Bearing axial clearance 0.05 0.0840.1

Standard thickness Min. thickness

5 Disk thickness Replace
4.9 4.5

40-5
PLANETARY - ARTICULATION

120 v 123 Nm
86 4 90 Nm with Loctite 270 1

Loctite 270

Section A - A

250 v 253 Nm
with Loctite 270
145 4 148 Nm 86 4 89 Nm

A A
260 4 290 Nm
Section B - B

B B D0400074

Unit: mm

Në Check item Criteria Remedy

1 Axial bearings clearance 040.05 Adjust

Planetary wheel hub tangential force

2 (without bearing preload) 20430 N

Planetary wheel hub tangential force

3 (with bearing preload) 40450 N

4 Articulation rotation torque 15417 Nm

40-6
AXLES

A Front of machine
A
28°

28°
Front axle

145 4 148 Nm

50

Detail A
28°

28°
A
Rear axle A

= =
500

76,3 1370 76,3

// 0,5

1790

40-7
STEERING CYLINDER

2
240 v 270 Nm 240 v 270 Nm
with Loctite 242 with Loctite 242
1 1

D0400076

ASL800070

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
size clearance limit
1 Clearance between shaft and bushing Shaft Hole Replace

45 ÐÐ ÐÐ ÐÐ ÐÐ

± 0.060 0 0.060 ±
2 Clearance between bushing and pin 60 + 0.074 0.08
+ 0.106 0.180

40-8
PARKING BRAKE AND CYLINDER

73 4 76 Nm 73 v 76 Nm
10 v 11 Nm with Loctite 242
with Loctite 573

1
2 10 kg Loctite 270

3
A
Detail A

25 4 28 Nm 25 4 28 Nm
D0400077

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Replace
Installed Installed Installed if
1 Brake locking spring Free length Free length
length load load damage or
deformed
ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ

2 Clearance with 10 kg force 1.75 3.0 Set

3 Clearance with brakes locked 040.2 0.4 Set

40-9
SWING CIRCLE

314 6 10 Nm

314 6 10 Nm

1 Section A - A 2

D0400078

Unit: mm

Në Check item Criteria Remedy

Standard clearance Clearance limit

1 Axial bearing clearance
0.3 v 1.2 3 Replace
Backlash between pinion and swing
2 circle teeth 0.06 v 0.76 2.0

40-10
SWING MACHINERY

85 Nm

50 Nm

85 Nm

120 Nm

1 950 4 1050 Nm

D0400079

Unit: mm

Në Check item Criteria Remedy

Standard value Limit value

1 Preload bearing
6634765 kg
6634765 kg
(650047500 N)

40-11
CHECK VALVE AND OIL COOLER SAFETY BY-PASS

A
D0400080

Section A - A

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

By-pass valve spring Installed Installed Installed Replace

1 Free length Free length
length load load if
damage or
38 25 15w1 35 13 deformed

2 Check valve spring 38 25 7w0.5 35 5

40-12
PUMP DRIVE

A 20 Nm

3
Section A - A

A D0400081

Unit: mm

Në Check item Criteria Remedy

Standard clearance Clearance limit

Backlash between inlet gear and Replace
1 auxliary pump gear
ÐÐ ÐÐ

Backlash between inlet gear and

2 No. 1 pump gear ÐÐ ÐÐ Replace

Backlash between No. 1 pump gear Replace

3 and No. 2 pump gear ÐÐ ÐÐ

40-13
SUMMATION HORSEPOWER CONTROL - MODE-SYSTEM

40 Nm

A
22 Nm

10 Nm

20 Nm

2 2
20 Nm
3

Section A - A
4
60 Nm
40 Nm
40 Nm

D0400082

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Calibration spring Installed Installed Installed Replace

1 Free length Free length
length load load

42 33 366 N 41.1 339 N

2 Check valve spring 8 5 15.6 N 7.5 13.9 N Replace

3 Piston return spring 103.5 80 200 N 101 186 N Replace

4 Mode-system spring 23 18 151 N 22.1 138.3 Replace

40-14
AUXILIARY PUMP

P3 3 P4 190 Nm

1 1
2 D0400083

Unit: mm

Në Check item Criteria Remedy

Standard clearance Clearance limit

1 Clearance between side plate and gear
ÐÐ ÐÐ Replace

2 Clearance between shaft and bushing ÐÐ ÐÐ

3 Clearance between gears and casing ÐÐ ÐÐ Replace

Pump Delivery Standard Repair limit

speed pressure delivery delivery
rpm bar (,/min.) (,/min.)
4 Delivery Check
Pump P3 ÐÐ ÐÐ ÐÐ ÐÐ

Pump P4 ÐÐ ÐÐ ÐÐ ÐÐ

40-15
CONTROL VALVE

90 Nm 90 Nm
90 Nm

35 Nm
9 Nm 90 Nm 90 Nm
100 Nm
200 Nm 200 Nm 100 Nm

30 Nm 30 Nm 37 Nm
160 Nm 200 Nm 30 Nm
35 Nm 90 Nm
9 Nm 90 Nm

90 Nm 90 Nm
87 Nm 9 Nm
100 Nm
90 Nm 140 Nm 90 Nm

37 Nm D0400084

140 Nm

40-16
SWING MOTOR RELIEF VALVE

10 6 1 Nm

10 6 1 Nm

40 6 4 Nm

90 6 10 Nm
1

D0400085

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Brake locking spring Installed Installed Installed Replace

1 Free length Free length
length load load

ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ

2 Anticavitation valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

40-17
TRAVEL MOTOR

69 Nm 30 Nm

10 Nm
D0400086

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Valve guide retain spring Installed Installed Installed Replace

1 Free length Free length
length load load

ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ

2 Measure piston spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

40-18
TRAVEL MOTOR BRAKE VALVES

2 200 Nm
1 100 Nm

20 Nm
20 Nm

600 Nm

200 Nm
650 Nm

5
10 Nm
4

D0400087

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Pilot valve spring Installed Installed Installed Replace

1 Free length Free length
length load load

ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ

2 Main valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

3 Piston return spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

4 Single-acting valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

5 Check valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

40-19
SERVOCONTROL FEED UNIT

100 6 10 Nm 2 17,5 6 1,75 Nm

17,5 6 1,75 Nm

1
3
100 6 10 Nm
150 6 15 Nm

12 6 1,2 Nm 12 6 1,2 Nm

D0400088

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Relief valve spring Installed Installed Installed Replace

1 Free length Free length
length load load

ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ

2 Check valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

3 Reducing valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

40-20
AXLE LOCKING VALVE

D0400089

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Installed Installed Installed

1 Piston return unlocking spring Free length Free length Replace
length load load

ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ

40-21
L.H. AND R.H. PPC VALVES

A 1

T
A
P

2
4

1-2-3
4-5

D0400090
Section A - A

Në Item Pilot system

1 Metering spring 1

2 Metering spring 3

3 Metering spring 2-4

4 Centering spring 1-3

5 Centering spring 2-4

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Metering spring Installed Installed Installed Replace

1 Free length Free length
length load load

31.4 29.4 15.44 N ÐÐ 14.28 N

2 Metering spring 31.1 29.3 18.72 N ÐÐ 17.30 N Replace

3 Metering spring 30.5 29.0 15.9 N ÐÐ 14.75 N Replace

4 Centering spring 43.6 32.65 39.42 N ÐÐ 36.65 N Replace

5 Centering spring 43.6 32.65 23.1 N ÐÐ 21.50 N Replace

40-22
TRAVEL PPC VALVE

1,8 Nm

1 2

D0400091

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Metering spring Installed Installed Installed Replace

1 Free length Free length
length load load

ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ

2 Centering spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace

40-23
2nd BOOM AND BOOM SWING PPC VALVE

5 Nm
con ASL800030
A
8 Nm

1
1
2 30 Nm
2 con ASL800030

A Section A - A
D0400092

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Metering spring
Installed Installed Installed
Free length Free length
length load load
1 Replace
nd
2 Boom 30.4 29 14.84 N ÐÐ 13.76 N

Boom swing 30.4 29.0 14.84 N ÐÐ 13.80

2nd Boom 46.8 53.3 178.25 N ÐÐ 165.25 N

2 Centering spring Replace
Boom swing 44.8 35.2 56.25 N ÐÐ 52.32 N

40-24
OUTRIGGER AND BLADE PPC VALVES

2 2

1 1

D0400093

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Metering spring Installed Installed Installed Replace

1 Free length Free length
length load load

25.0 23.5 15.15 N ÐÐ 14.04 N

2 Centering spring 23.7 20.0 15.17 N ÐÐ 14.05 N Replace

40-25
OUTRIGGER AND BLADE SAFETY VALVE

83 Nm

33 Nm

D0400094

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Installed Installed Installed

1 Check valve spring Free length Free length Replace
length load load

16.5 11.12 2.464 kg 13.5 1.1 kg

40-26
AXLE LOCKING CYLINDER

180 Nm

60 Nm

D0400095

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
size clearance limit
Clearance between piston rod and Shaft Hole
1 Replace
cylinder
+ 0.050 + 0.100 0.030 ±
80 ÐÐ
+ 0.020 + 0.080 0.080

40-27
CYLINDERS

BUCKET
2 - PIECE BOOM
BOOM SWING
OUTRIGGER AND BLADE
3

2 50 Nm 1 50 Nm D0400096

BOOM

2 50 Nm 1 50 Nm D0400097

ARM

2 50 Nm 1 50 Nm D0400098

40-28
 Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Shaft Hole

± 0.030 0 0.030
Bucket 60 + 0.166 0.326
± 0.060 0.226

2 - piece ± 0.05 0 0.025

boom 50 + 0.166 0.316
± 0.025 0.216
Clearance between
1 piston rod and ± 0.030 0 0.030
bushing Boom swing 60 + 0.166 0.326
± 0.060 0.226

Outrigger and ± 0.030 0 0.030

blade 60 + 0.166 0.326
± 0.060 0.226

± 0.030 0 0.030
Boom 70 + 0.166 0.326
± 0.060 0.226

± 0.030 0 0.030
Arm 60 + 0.166 0.326
± 0.060 0.226

± 0.05 + 0.119 + 0.13

Bucket 50 1.0
± 0.089 + 0.08 + 0.208

2 - piece ± 0.05 + 0.119 + 0.13

boom 50 1.0
± 0.089 + 0.08 + 0.208

± 0.05 + 0.119 + 0.13

Boom swing 50 1.0
± 0.089 + 0.08 + 0.208
Clearance between
2 cylinder head
bushing and pin Outrigger and ± 0.05 + 0.119 + 0.13
blade 50 1.0
± 0.089 + 0.08 + 0.208

± 0.06 + 0.146 + 0.16

Boom 60 1.0
± 0.106 + 0.1 + 0.252

± 0.05 + 0.119 + 0.13

Arm 50 1.0
± 0.089 + 0.08 + 0.208

± 0.05 + 0.119 + 0.13

Bucket 50 1.0
± 0.089 + 0.08 + 0.208

2 - piece ± 0.06 + 0.146 + 0.16

boom 60 1.0
± 0.106 + 0.1 + 0.252

± 0.05 + 0.119 + 0.13

Boom swing 50 1.0
Clearance between ± 0.089 + 0.08 + 0.208
3 cylinder bottom
bushing and pin Outrigger and ± 0.05 + 0.119 + 0.13
blade 50 1.0
± 0.089 + 0.08 + 0.208

± 0.06 + 0.146 + 0.16

Boom 60 1.0
± 0.106 + 0.1 + 0.252

± 0.05 + 0.119 + 0.13

Arm 50 1.0
± 0.089 + 0.08 + 0.208

40-29
WORK EQUIPMENT
(1 - piece boom)

G
E

B
A

7 6 4 5 3

Section A - A Section B - B Section C - C

2 8

Section D - D Section E - E Section F - F

D0400100

40-30
9

Section G - G
D0400101

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Tolerance
Clearance between swing size clearance max.
bracket-to-revolving Shaft Hole
1
frame mounting and pin bushing
± 0.072 + 0.145 0.116 ±
100 0.8
± 0.0126 + 0.044 0.271

Clearance between boom-to-swing ± 0.060 + 0.047 0.107 ±

2 bracket mounting pin and bushing 60 0.8
± 0.106 + 0.127 0.233

Clearance between boom-to-arm ± 0.060 + 0.047 0.107 ±

3 mounting pin and bushing 60 0.8
± 0.106 + 0.127 0.233

Clearance between bucket

cylinder-to-link mounting pin ± 0.050 + 0.095 0.066 ±
4 50 1
and link bushingi ± 0.089 + 0.016 0.184
Replace

Clearance between arm-to-link ± 0.050 + 0.095 0.066 ±

5 mounting pin and bushing 50 1
± 0.089 + 0.016 0.184

Clearance between bucket-to-arm ± 0.050 + 0.095 0.066 ±

6 mounting pin and bushing 50 1
± 0.089 + 0.016 0.184

Clearance between bucket-to-link ± 0.050 + 0.095 0.066 ±

7 mounting pin and bushing 50 1
± 0.089 + 0.016 0.184

Clearance between bushing and ± 0.050 + 0.095 0.066 ±

8 connecting pin of outrigger 50 1
± 0.089 + 0.016 0.184

Clearance between bushing and ± 0.050 + 0.095 0.066 ±

9 bracket pin 50 1
± 0.089 + 0.016 0.184

40-31
WORK EQUIPMENT
(2 - piece boom)

H
F

B
A

7 6 4 5 3

Section A - A Section B - B Section C - C

8 2

Section D - D Section E - E Section F - F

D0400102

40-32
 9 10

Section G - G Section H - H
D0400103

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between swing size clearance limit
bracket-to-revolving Shaft Hole
1
frame mounting and pin bushing
± 0.072 + 0.145 0.116 ±
100 0.8
± 0.126 + 0.044 0.271

Clearance between boom-to-swing ± 0.060 + 0.047 0.107 ±

2 bracket mounting pin and bushing 60 0.8
± 0.106 + 0.127 0.233

Clearance between boom-to-arm ± 0.060 + 0.047 0.107 ±

3 mounting pin and bushing 60 0.8
± 0.106 + 0.127 0.233

Clearance between bucket

cylinder-to-link mounting pin ± 0.050 + 0.095 0.066 ±
4 50 1
and link bushing ± 0.089 + 0.016 0.184

Clearance between arm-to-link ± 0.050 + 0.095 0.066 ± Replace

5 mounting pin and bushing 50 1
± 0.089 + 0.016 0.184

Clearance between bucket-to-arm ± 0.050 + 0.095 0.066 ±

6 mounting pin and bushing 50 1
± 0.089 + 0.016 0.184

Clearance between bucket-to-link ± 0.050 + 0.095 0.066 ±

7 mounting pin and bushing 50 1
± 0.089 + 0.016 0.184

Clearance between bushing and ± 0.060 + 0.047 0.107 ±

8 connecting pin of 2nd boom 60 0.8
± 0.106 + 0.127 0.233

Clearance between bushing and ± 0.050 + 0.095 0.066 ±

9 connecting pin of outrigger 50 1
± 0.089 + 0.016 0.184

Clearance between bushing and ± 0.050 + 0.095 0.066 ±

10 connecting pin of bracket 50 1
± 0.089 + 0.016 0.184

40-33
© 2000 FKI FAI KOMATSU INDUSTRIES S.p.A.
All Rights Reserved
Printed in Europe