WEBM000802 pw110r-1 PDF

WEBM000802
CONTENTS
Page
10 STRUCTURE AND FUNCTION........................................................................................ 10-1
20 TESTING AND ADJUSTING ............................................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY .................................................................................. 30-1
40 MAINTENANCE STANDARD........................................................................................... 40-1
PW110R-1 00-1
PAGE INTENTIONALLY
LEFT BLANK
REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to table be-
low.
❍ Page to be newly Add
● Page to be replaced Replace
( ) Page to be delete Discard
Pages having no marks are those previously revised or

made additions.
LIST OF REVISED PAGES
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 10-17 10-58 10-99 10-140

00-2 10-18 10-59 10-100 10-141
00-2-1 10-19 10-60 10-101 10-142
00-2-2 10-20 10-61 10-102 10-143
00-3 10-21 10-62 10-103
00-4 10-22 10-63 10-104 20-1
00-5 10-23 10-64 10-105 20-2
00-6 10-24 10-65 10-106 20-3
00-7 10-25 10-66 10-107 20-4
00-8 10-26 10-67 10-108 20-5
00-9 10-27 10-68 10-109 20-6
00-10 10-28 10-69 10-110 20-7
00-11 10-29 10-70 10-111 20-8
00-12 10-30 10-71 10-112 20-9
00-13 10-31 10-72 10-113 20-10
00-14 10-32 10-73 10-114 20-11
00-15 10-33 10-74 10-115 20-12
00-16 10-34 10-75 10-116 20-13
00-17 10-35 10-76 10-117 20-14
00-18 10-36 10-77 10-118 20-15
00-19 10-37 10-78 10-119 20-16
00-20 10-38 10-79 10-120 20-17
00-21 10-39 10-80 10-121 20-18
00-22 10-40 10-81 10-122 20-19
10-41 10-82 10-123 20-20
10-1 10-42 10-83 10-124 20-21
10-2 10-43 10-84 10-125 20-22
10-3 10-44 10-85 10-126 20-23
10-4 10-45 10-86 10-127 20-24
10-5 10-46 10-87 10-128 20-25
10-6 10-47 10-88 10-129 20-26
10-7 10-48 10-89 10-130 20-27
10-8 10-49 10-90 10-131 20-28
10-9 10-50 10-91 10-132 20-29
10-10 10-51 10-92 10-133 20-30
10-11 10-52 10-93 10-134 20-31
10-12 10-53 10-94 10-135 20-32
10-13 10-54 10-95 10-136 20-33
10-14 10-55 10-96 10-137 20-34
10-15 10-56 10-97 10-138 20-35
10-16 10-57 10-98 10-139 20-36
PW110R-1 00-2-1
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
20-37 30-25 30-89 30-153 30-217

20-38 30-26 30-90 30-154 30-218
20-39 30-27 30-91 30-155 30-219
20-40 30-28 30-92 30-156 30-220
20-41 30-29 30-93 30-157 30-221
20-42 30-30 30-94 30-158 30-222
20-43 30-31 30-95 30-159 30-223
20-44 30-32 30-96 30-160 30-224
20-45 30-33 30-97 30-161 30-225
20-46 30-34 30-98 30-162 30-226
20-47 30-35 30-99 30-163 30-227
20-48 30-36 30-100 30-164 30-228
20-49 30-37 30-101 30-165
20-50 30-38 30-102 30-166 40-1
20-51 30-39 30-103 30-167 40-2
20-52 30-40 30-104 30-168 40-3
20-53 30-41 30-105 30-169 40-4
20-54 30-42 30-106 30-170 40-5
20-55 30-43 30-107 30-171 40-6
20-56 30-44 30-108 30-172 40-7
20-57 30-45 30-109 30-173 40-8
20-58 30-46 30-110 30-174 40-9
20-59 30-47 30-111 30-175 40-10
20-60 30-48 30-112 30-176 40-11
20-61 30-49 30-113 30-177 40-12
20-62 30-50 30-114 30-178 40-13
20-63 30-51 30-115 30-179 40-14
20-64 30-52 30-116 30-180 40-15
20-65 30-53 30-117 30-181 40-16
20-66 30-54 30-118 30-182 40-17
20-67 30-55 30-119 30-183 40-18
20-68 30-56 30-120 30-184 40-19
20-69 30-57 30-121 30-185 40-20
20-70 30-58 30-122 30-186 40-21
20-71 30-59 30-123 30-187 40-22
20-72 30-60 30-124 30-188 40-23
20-73 30-61 30-125 30-189 40-24
20-74 30-62 30-126 30-190 40-25
20-75 30-63 30-127 30-191 40-26
30-64 30-128 30-192 40-27
30-1 30-65 30-129 30-193 40-28
30-2 30-66 30-130 30-194 40-29
30-3 30-67 30-131 30-195 40-30
30-4 30-68 30-132 30-196 40-31
30-5 30-69 30-133 30-197 40-32
30-6 30-70 30-134 30-198 40-33
30-7 30-71 30-135 30-199 40-34
30-8 30-72 30-136 30-200 40-35
30-9 30-73 30-137 30-201 40-36
30-10 30-74 30-138 30-202 40-37
30-11 30-75 30-139 30-203 40-38
30-12 30-76 30-140 30-204 40-39
30-13 30-77 30-141 30-205 40-40
30-14 30-78 30-142 30-206 40-41
30-15 30-79 30-143 30-207 40-42
30-16 30-80 30-144 30-208 40-43
30-17 30-81 30-145 30-209 40-44
30-18 30-82 30-146 30-210 40-45
30-19 30-83 30-147 30-211
30-20 30-84 30-148 30-212
30-21 30-85 30-149 30-213
30-22 30-86 30-150 30-214
30-23 30-87 30-151 30-215
30-24 30-88 30-152 30-216
00-2-2 PW110R-1
SAFETY
IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu Utility and describe in this manual are both ef-
fective and safe methods of operation. Some of these operations require the use of tools specially designed
by Komatsu Utility for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be carefully followed. If any danger arises or may
possibly arise, first consider safety, and take necessary steps to face.
SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the wheels to
fully BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not
on the machine. possible, use blocks to prevent the work equipment
2. When carrying out any operation, always wear safe- from falling down. In addition, be sure to lock all the
ty shoes and helmet. Do not wear loose work control levers and hang warning sign on them.
clothes, or clothes with buttons missing. 9. When disassembling or assembling, support the
• Always wear safety glasses when hitting parts machine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding 10. Remove all mud and oil from the steps or other plac-
parts with a grinder, etc. es used to get on and off the machine. Always use
3. If welding repairs are needed, always have a the handrails, ladders or steps when getting on or off
trained, experienced welder carry out the work. the machine.
When carrying out welding work, always wear weld- Never jump on or off the machine.
ing gloves, apron, glasses, cap and other clothes If it is impossible to use the handrails, ladders or
suited for welding work. steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure
before starting. Always inform your fellow workers 11. When removing the oil filler cap, drain plug or hy-
before starting any step of the operation. Before draulic pressure measuring plugs, loosen them
starting work, hang UNDER REPAIR signs on the slowly to prevent the oil from spurting out.
controls in the operator’s compartment. Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit, first
5. Keep all tools in good condition and learn the correct
remove the pressure completely from the circuit.
way to use them.
12. The water and oil in the circuits are not hot when the
6. Decide a place in the repair workshop to keep tools
engine in stopped, so be careful not to get burned.
and removed parts. Always keep the tools and parts
Wait for the oil water to cool before carrying out any
in their correct places. Always keep the work area
work on the cooling water circuits.
clean and make sure that there is no dirt or oil on the
floor. 13. Before starting work, remove the leads from the bat-
Smoke only in the areas provided for smoking. Nev- tery. Always remove the lead from the negative ( – )
er smoke while working. terminal first.
PW110R-1 00-3
SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places. 20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent that they are not twisted. Damaged tubes are dan-
the component from hitting any other part. gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or tubes for high pressure circuits. Also, check that
crane. connecting parts are correctly tightened.
15. When removing covers which are under internal 21. When assembling or installing parts, always use
pressure or under pressure from a spring, always specified tightening torques.
leave two bolts in position on opposite sides. Slowly When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to rotate at high speed, be particulary careful to check
remove. that they are correctly installed.
16. When removing components, be careful not to 22. When aligning two holes, never insert your fingers
break or damage the wiring. or hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill- measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline
when washing electrical parts.
00-4 PW110R-1
FOREWORD
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service work-
shop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
STRUCTURE AND FUNCTION

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

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

This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any no-
tice.
Contact your Komatsu Utility distributor for the latest information.
PW110R-1 00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

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

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

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

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

(➀➁➂....)
When a manual is revised, an edition mark is recorded
on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
00-6 PW110R-1
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Hooks have maximum strength at the middle por-
tion.
Heavy parts (25 kg or more) must be lifted
with a hoist etc. In the Disassembly and Assem-
bly section, every part weighing 25 kg or more is
clearly indicated with the symbol
1. If a part cannot be smoothly removed from the ma-

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

sixth or one-seventh of the breaking strength of the
rope used.
2) Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the
rope to slip off the hook during hoisting, and a se-
rious accident can result.
PW110R-1 00-7
STANDARD TIGHTENING TORQUE

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

Thread Pitch of (mm)
diameter of bolts bolts
(mm) (mm) kgm Nm kgm Nm
6 1 10 8 0.96±0.1 9.5±1 1.3±0.15 13.5±1.5
8 1.25 13 6 2.3±0.2 23±2 3.2±0.3 32.2±3.5
10 1.5 17 8 4.6±0.5 45±4.9 6.5±0.6 63±6.5
12 1.75 19 10 7.8±0.8 77±8 11±1 108±11
14 2 22 12 12.5±1 122±13 17.5±2 172±18
16 2 24 14 19.5±2 191±21 27±3 268±29
18 2.5 27 14 27±3 262±28 37±4 366±36
20 2.5 30 17 38±4 372±40 53±6 524±57
22 2.5 32 17 52±6 511±57 73±8 719±80
24 3 36 19 66±7 644±70 92±10 905±98
27 3 41 19 96±10 945±100 135±15 1329±140
30 3.5 46 22 131±14 1287±140 184±20 1810±190
33 3.5 50 24 177±20 1740±200 250±27 2455±270
36 4 55 27 230±25 2250±250 320±35 3150±350
39 4 60 ---- 295±33 2900±330 410±45 4050±450
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
★ Nm (newton meter): 1 Nm = 0.102 kgm
00-8 PW110R-1
2. TIGHTENING TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter Width across flats TIGHTENING TORQUE

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

of nut part of nut part
(mm) (mm) kgm Nm
9/16” - 18 17 2.3–2.5 23–25
11/16” - 16 22 3.4–3.9 33–38
13/16” - 16 24 5.2–5.8 51–57
1” - 14 30 8.2–9.2 80–90
1.3/16 - 12 36 12.2–13.3 120–130
1.7/16 - 12 41 15.3–17.3 150–170
1.11/16 - 12 50 18.4–20.4 180–200
2” - 12 57 20.4–24.4 200–240
PW110R-1 00-9
COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
Nomenclature Code Applications
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking
keys and bearings.
Alternative product to 242; oil tolerant and so can used on lightly lubricated sur-
Loctite 243
faces without prior use of activator.
Adhesives Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.
Used by itself on mounting flat surface

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

Loctite 518
(Clearance between surfaces within 0.5 mm
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
00-10 PW110R-1
ELECTRIC WIRE CODE
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0,30 1.48 3.35 14
2.5 35 0,30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0,40 50.11 14 160
70 – – – 13.6 192
CLASSIFICATION BY COLOUR AND CODE

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

The coloration of two-colour wires is indicated by the composition of the symbol listed.
Example: G–V = Yellow-Green with longitudinal colouring
G/V = Yellow-Green with transversal colouring
PW110R-1 00-11
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model PW110R-1
From serial number 2260010001-
Engine assembly 350
Radiator - exchanger 37
Hydraulic tank (without hydraulic oil) 67
Fuel tank (without fuel) 47
Counterweight 1450
Swing circle 124
Revolving frame 1370
Swing machinery assembly 87
Main pump + gear pump 97
Cabin 220
Seat 32
Seat support 14,5
Platform 51
Control valve 65
Track frame assembly 1380
Front axle 380
Rear axle + transmission 436
Travel motor 49
Wheel 9.00 - 20 94
Swivel joint 54
Axle locking cylinder 32x2
Swing bracket 230
Engine hood 36
Front hood 27
Boom 405
1st boom 314
2nd boom 278
Arm (L=1850) 178
Arm (L=2000) 200
Arm (L=2300) 223
Blade 217
Outrigger 100x2
Bracket 42x2
Equipment plate 179
Equipment assy. (with 2-piece boom) (bucket L=900 - arm L= 2000) 1300
Equipment assy. (with 2-piece boom) (bucket L=900 - arm L= 1850) 1650
00-12 PW110R-1
TABLE OF OIL AND COOLANT QUANTITIES

AMBIENT TEMPERATURE CAPACITY ()
KIND OF
RESERVOIR – 30 –20 –10 0 10 20 30 40 50°C
FLUID Specified Refill
SAE 10W
SAE 30
OIL
Crankcase sump SAE 40 12.5 12.5
• API CD
SAE 15W-30
SAE 5W-30
SAE 10W
OIL
Hydraulic circuit 180 84
• API CD
SAE 5W-30
Hydraulic circuit
with biodegradable 180 84
oil
Front axle
9.0 9.0
• Differential
• Final reduction gear
0.8 0.8
(each.) OIL
68/F-100
Rear axle: • UTTO FLUID
9.0 9.0
• Differential
• Final reduction gear

0.8 0.8
(each.)
OIL
Transmission SAE 85W-90 1.6 1.6
• API GL5
OIL
Swing machinery SAE 85W-90 4 4
• API GL5
✽
Fuel tank FUEL 150 –
ASTM D975 N.2
Engine coolant PERMANENT

18 –
system LIQUID
✽ ASTM D975 N.
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: Military Specification
CCMC: Common Market Constructors Committe
PW110R-1 00-13
First filling quantity:

total quantity of oil, including the oil for the components and pipes.
Oil change quantity:
quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations.
NOTE:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds 0.5% change
the engine oil according to the following table:
Sulphur content Engine oil change interval
from 0.5 to 1.0% 1/2 of regular interval
over 1.0% 1/4 of regular interval
(2) When starting the engine at temperatures below 0 °C, use engine oil SAE 10W, 20W-20 and 10W-30, even if during
the day the temperature increases by 10 °C.
(3) Use engine oil with CD classification; if oil with CD classification is used, reduce the engine oil change interval by a
half.
(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic
circuit of equipment and for reductions.
00-14 PW110R-1
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The conversion table in this section is provided to enable simple conversion of figures.
For details of the method of using the conversion table, see the example given below.
EXAMPLE
• Method of using the conversion table to convert from millimeters to inches.
1. Convert 55 mm into inches.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
2. Convert 550 mm into inches
1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
2 - Carry out the same procedure as above to convert 55 mm to 2.165 in.

3 - The original value (550 mm) was divided by 10, so multiply 2.165Bin. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.
From millimeters to inches

1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 C

1.772 1.811 1.850 1.890 1.929
A
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
PW110R-1 00-15
CONVERSION TABLE
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-16 PW110R-1
CONVERSION TABLE
From liter to U.S. Gall.

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

1 = 0.21997 U.K. Gall.
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
PW110R-1 00-17
CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.633
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-18 PW110R-1
CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
0 0 0.102 0.204 0.306 0.408 0.510 0.612 0.714 0.816 0.918
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
PW110R-1 00-19
CONVERSION TABLE
From kgm to lb.ft.

1 kgm = 7.233 lb.ft.
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 PW110R-1
CONVERSION TABLE
From bar to psi (lb/in2)

1 bar = 14.503 psi
0 1 2 3 4 5 6 7 8 9
0 0 14.5 29.0 43.5 58.0 72.5 87.0 101.5 116.0 130.5
10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6
20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6
30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6
40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6
50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7
60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7
70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7
80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8
90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8
100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8
110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8
120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8
130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9
140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9
150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0
160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0
170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0
180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1
190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1
200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1
210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1
220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2
230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2
240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2
PW110R-1 00-21
CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 144.8 27.2 81 117.8

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-22 PW110R-1
STRUCTURE AND FUNCTION
P.T.O. ........................................................................ 2 Axle locking cylinder.................................................94

Power train ................................................................ 3 Servocontrol feed unit ..............................................96
Front axle................................................................... 4 Accumulator ...........................................................101
Transmission ............................................................. 8 Shuttle valve...........................................................102
Rear axle ................................................................. 10 PPC valves.............................................................104
Steering system....................................................... 15 Brake pump ............................................................114
Steering unit ............................................................ 19 Boom and arm safety valve....................................115
Swing circle ............................................................. 20 Blade or outriggers safety valve .............................116
Swing machinery ..................................................... 21 Overload sensor switch ..........................................117
Hydraulic diagram standard..................................... 23 Solenoid valves ......................................................118
Hydraulic circuit (work equipment) .......................... 25 Air-conditioning unit................................................124
Hydraulic pump........................................................ 26 Electrical diagram (1/8) ..........................................127
Priority valve ............................................................ 52 Electrical diagram (2/8) ..........................................129
Control valve............................................................ 54 Electrical diagram (3/8) ..........................................131
Swing motor............................................................. 82 Electrical diagram (4/8) ..........................................133
Swivel joint............................................................... 88 Electrical diagram (5/8) ..........................................135
Travel motor ............................................................ 89 Electrical diagram (6/8) ..........................................137
Displacement automatic control high pressure Electrical diagram (7/8) ..........................................139
related...................................................................... 90 Electrical diagram (8/8) ..........................................141
Travel motor brake valves ....................................... 91 Control unit fuses - relais (1/2) ...............................143
Cylinders.................................................................. 92 Control unit fuses - relais (2/2) ...............................145
PW110R-1 10-1
STRUCTURE AND FUNCTION P.T.O.
P.T.O.
1 2 3
6 5 4 RKP05340
1. Damper
2. Disc
3. Flywheel
4. Dowel
5. Hub
6. Pump
10-2 PW110R-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
Transmission Differential Planetary Axle Total
High speed 1.31 29.71
3.78 6.00 22.68
Low speed 4.53 102.74
Front of machine 10
Z=34
8
Z=70
Z=14
Z=27
Z=9
7 2
5
3
4
Z=51
Z=39
Z=86
Z=19
6
Z=70
Z=14
Z=27
Z=9 Z=34
9
11
RKP05681
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
PW110R-1 10-3
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
DIFFERENTIAL
1 2 3 4 5
8 7 6
11 12
9 10
16 15 14 13
RKP05390
1. Ring nut 11. Pinion (Z=9)

2. Differential housing 12. Plug
3. Pin 13. Bearing
4. Ring bevel gear (Z=34) 14. Spacer
5. Bearing 15. Ring nut
6. Bevel gear 16. Flange
7. Differential gear SPECIFICATIONS
8. Drive shaft Amount of oil: 9
9. Nut Reduction ratio: 9:34
10. Bearing
10-4 PW110R-1
BRAKES
A
1 2 3 a
A
Section A - A
4 5 6 7
RKP05381
1. Pin a. From swivel joint (7a Port)

2. Pressure disk
3. Screw
4. Disk
5. Brake disk
6. Bushing
7. Screw
8. Spring
PW110R-1 10-5
FINAL REDUCTION
4 5 6 7 8 9 10
11
1 2 3
12
13
14
16 15
23 22 21 20 19 18 17
RKP05370
1. Bearing 15. Bevel gear (Z=70)

2. Dowel 16. Ring gear carrier
3. Cardan shaft (Z=14) 17. Screw
4. Bushing 18. Seal
5. Pin 19. Seal
6. Seal 20. Bushing
7. Wheel hub 21. Housing
8. Bearing 22. Seal
9. Nut 23. Bush
10. Stud bolt
SPECIFICATIONS
11. Support Amount of oil: 0.8
12. Bevel gear (Z=27) Reduction ratio: 1:6
13. Bushing
14. Plug
10-6 PW110R-1
STEERING CYLINDER
A A
a 2 b
Section B - B
3 4 Section A - A
RKP05321
1. Steering cylinder
2. Sensor
3. Nut
4. Pin cotter
a. Port b - From swivel joint (1a Port)
b. Port a - From ST4 solenoid valve group (T Port)
PW110R-1 10-7
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
B
B
1 2 A 3
5
6
4
7
a b 10 9 8
Section B - B RKP05302
a. e Port - From swivel joint (14a Port) 9. Ball

b. f Port - From swivel joint (5a Port) 10. Spring
1. Filler and level oil plug SPECIFICATIONS

2. Oil drain plug Amount of oil: 1.6
3. Flange Reduction ratio:
4. Neutral manual control • Low speed: 1:4.53
5. Speed selector piston • High speed: 1:1.31
6. Selecting fork
7. Safety switch
8. Selector shaft
10-8 PW110R-1
STRUCTURE AND FUNCTION TRANSMISSION
1 2 3 4
5
6
19
18
17
16 15
9
14
13 12 11 10
RKP05271
SectionA - A
1. Flange 11. Protection

2. Breather 12. High speed drive gear (Z=51)
3. High speed drive gear (Z=39) 13. Oil drain plug
4. Front housing 14. Cover
5. Low speed drive gear (Z=19) 15. Bearing
6. Bearing 16. Flange
7. Low speed driven gear (Z=86) 17. Output shaft
8. Roller bearing 18. Nut
9. Protection 19. Bearing
10. Rear housing
PW110R-1 10-9
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
DIFFERENTIAL
1 2 3 4 5
8 7 6
11 12
9 10
16 15 14 13
RKP05290
1. Ring nut 12. Cover

2. Differential gear 13. Bearing
3. Pin 14. Spacer
4. Ring bevel gear (Z=34) 15. Seal ring
5. Bearing 16. Ring nut
6. Bevel gear SPECIFICATIONS
7. Differential gear Amount of oil: 9
8. Drive shaft Reduction ratio: 9:34
9. Bearing
10. Bearing
11. Pinion (Z=9)
10-10 PW110R-1
FINAL REDUCTION
4 5 6 7 8 9 10
11
1 2 3
12
13
14
16 15
23 22 21 20 19 18 17
RKP05370
1. Bearing 15. Ring gear (Z=70)

2. Dowel 16. Ring gear carrier
3. Cardan shaft (Z=14) 17. Screw
4. Bushing 18. Seal
5. Joint 19. Seal
6. Seal 20. Bushing
7. Wheel hub 21. Housing
8. Bearing 22. Seal
9. Nut 23. Bushing
10. Stud bolt SPECIFICATIONS
11. Support Amount of oil: 0.8
12. Bevel gear (Z=27) Reduction ratio: 1:6
13. Bushing
14. Plug
PW110R-1 10-11
STEERING CYLINDER
A A
a 2 b
2
3 4 Section A - A Section B - B
RKP05331
1. Steering cylinder
2. Sensor
3. Nut
4. Pin cotter
a. d Port - From ST4 solenoid valve (B port)
b. c Port - From ST4 solenoid valve (A port)
10-12 PW110R-1
BRAKES AND PARKING BRAKE CYLINDER
1 2 3
Section A - A
7 6 5
9 10 11
8 5
a b
13 12
RKP05251
1. Pin 9. Nut
2 Nut 10. Screw
3. Dowel 11. Bushing
4. Brake bleeding screw 12. Spring
5. Brake lever 13. Brake disk
6. Push-rod a. From swivel joint (8a Port)
7. Pressure disk b. From swivel joint (4a Port)
8. Fulcrum lever
PW110R-1 10-13
17 18 19 20
14 15 16
8
2 3
23 22 21
RKP05440
14. Tie-rod DESCRIPTION

15. Return lever The parking brake is of the “negative” type, e.i. it provides
16. Piston full mechanical braking in the absence of pressure in the
circuits that make the machine safe to drive.
17. Guide ring
18. Spring OPERATION
19. Gasket When the engine is started up the pump (P1) connected to
20. Cylinder fulcrum pin the servocontrol circuit pressurizes the system to which
21. Cylinder the solenoid valve Y11 is connected when the machine is
idle.
22. Filter
When push-button is pushed Y11 is energized and allows
23. Fulcrum lever oil to flow into chamber b of the cylinder (21); when the
pressure exceeds the loading on the spring (18), it is com-
pressed and the piston (16) moves, thus lengthening side
B-C of the parallelogram A-B-C-D formed by the swing
centers of the levers (8) and (23), the cylinder fulcrum B
(21) and the fulcrum C of the lever (8) connected to the pis-
ton (16).
The swing of levers (8) and (23), coupled directly to lever
(5), cancels out the action on the push rods (6) joined to the
push disks (7).
The limit of the swing are governed by adjustable screws
(3) that act directly on levers (8) and (23).
When the engine stops, Y11 is de-energized, and releases
pressure in the circuit. As pressure drops the spring (18)
commences the thrusting action that rotates the levers (8)
and (23). The force of the spring is transferred to the push
rods of the push disks (7) which act on the brake disks (13)
on the rear axle.
10-14 PW110R-1
STRUCTURE AND FUNCTION STEERING SYSTEM
STEERING SYSTEM
4 1
3
10
9 T P
a d
5
D
A 2 (P2)
11 6 12
B C
b 7 Y2 Y14 c
R L
P B
T A
Y1 Y13
RKP10413
1. Engine DESCRIPTION
2. Pump (P2) • The steering system is completely hydraulic. The oil
3. Tank required, supplied by the pump (2) driven by the motor
4 Priority valve (1), is sent to the priority valve (4) which functions by
Load Sensing, and sends the necessary quantity of oil
5. Steering unit
to the steering system (5), even when other oleody-
6. Steering wheel namic components supplied by the same circuit are in
7. Swivel joint operation. The oil passes from this group (5) into the
8. ST4 Solenoid valve group: swivel joint (7) and from there into the steering cylin-
– Y1: Rear steering cut out ders (9) and (10).
– Y2: Front/rear steering The solenoid valve group (8) can switch the oil flow to
provide three types of steering:
– Y13: Phase coincidence steering
1 - 2 wheels steering
– Y14: Crab steering
Steering condition in which the rear axle is ex-
9. Front axle steering cylinder cluded.
10. Rear axle steering cylinder 2 - 2 wheels steering and 2 wheels countersteer-
11. Front axle cylinder piston ing. Steering condition in which rear steering is
12. Rear axle cylinder piston activated and the direction of the rear wheels is
contrary to that of the front wheels.
3 - 4 wheels steering in the same direction. Steer-
ing condition in which rear axle steering is acti-
vated and the direction of the rear wheels agrees
with that of the front wheels.
• The hydraulic power supplied by the pump (2) is trans-
ferred to cylinders (9) and (10) and transformed into
mechanical steering power.
PW110R-1 10-15
OPERATION
1 - Steering with front wheels, only
b 12 a 10 b 10 12 a
B A B A
e R T e R T
h h
5 3 5 3
g g
L P L P
4 4
f f
7 7
6 2 6 2
(P2) (P2)
Y1 Y2 Y1 Y2
Y13 Y14 Y13 Y14
RKP10421 RKP04391
STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (6) clockwise causes rotation Turning the steering wheel (6) anti-clockwise causes ro-
of the steering metering group (5) and prepares the control tation of the steering metering group (5) and prepares the
valve (port R) to send oil through line e to solenoid valve control valve (port L) to send oil through lines f and h di-
group and thence through line g, into chamber a of the cyl- rectly into chamber b of the cylinder (10); the pressurized
inder (10); the pressurized oil moves the piston (12) which oil moves the piston (12) which then steers the wheels.
then steers the wheels. The oil in chamber a of cylinder (10) is impelled into line g
The oil in chamber b of cylinder (10) is impelled into line h to solenoid valve group and thence into line e which is cou-
and thence into line f which is coupled to the control valve pled to the control valve of the steering group (5) (port R);
of the steering group (5) (port L); from the control valve the from the control valve the oil passes out of Port T and
oil passes out of Port T and drains into the tank (3). drains into the tank (3).
10-16 PW110R-1
2 - Steering with 2 wheels steering and 2 wheels countersteering
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
(P2) (P2)
Y1 Y2 Y1 Y2
Y13 Y14 Y13 Y14

m m
n n
C D C D
c 13 11 c
d 11 13 d
RKP04411 RKP04421

valve (port R) to send oil (through line e) to solenoid valve control valve (port L) to send oil through line f and h directly
group and thence through line m into chamber d of cylinder to chamber b of cylinder (10).
(11). The pressurized oil moves the piston (12) of cylinder (10)
The pressurized oil moves the piston (13) of the cylinder which in turn steers the wheels while simultaneously im-
(11) that steers the wheels and at the same time impels the pelling the oil in chamber a (at the same pressure as cham-
oil in chamber c (at the same pressure as chamber d), ber b, through lines g - n into chamber c of cylinder (11).
through lines n and g into chamber a of cylinder (10). The oil in chamber d of cylinder (11) is impelled through
The oil in chamber b of cylinder (10) is impelled through lines m and e to the control valve of the steering group (port
lines h and f to the control valve of the steering group (5) R) from which it passes (port T) to drain into the tank (3).
(port L), from which it passes (port T) to drain into the tank
(3).
PW110R-1 10-17
3 - Steering with 4 wheels steering in the same direction
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
(P2) (P2)
Y1 Y2 Y1 Y2
Y13 Y14 Y13 Y14

m m
n n
C D C D
c c
11 13 d 13 11 d
RKP04431 RKP04451

valve (port R) to send oil (through line e) to solenoid valve control valve (port L) to send oil through lines f and h into
group and thence through line m into chamber d of cylinder chamber b of cylinder (10).
(11). The pressurized oil moves the piston (12) of cylinder (10)
The pressurized oil moves the piston (13) of the cylinder which in turn steers the wheels while simultaneously im-
(11) that steers the wheels while simultaneously impelling pelling the oil in chamber a (at the same pressure as cham-
the oil in chamber c (at the same pressure as chamber d) ber b) through lines g and n into chamber c of cylinder (11).
through lines n and g into chamber a of the cylinder (10). The oil in chamber d of cylinder (11) is impelled through
The oil in chamber b of cylinder (10) is sent through lines h lines m and e to the control valve of the steering group (5)
and f to the control valve of the steering group (5) (port L) (port R) from which it passes (port T) to drain into the tank
from which the oil passes (port T) to drain into the tank (3). (3).
10-18 PW110R-1
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT
a e b
LS
L R
T P
c d RKP03740
a. L Port - To swivel joint (1A Port) SPECIFICATIONS

b. R Port - To swivel joint (9A Port) Steering unit type: OSPC200LS
c. T Port - To tank Rated discharge: 20
d. P Port - From priority valve (CF Port)
OPERATION
e. LS Port - From priority valve (LS Port)
• The steering unit consists of a control valve and a ro-
tating oil dispenser and functions hydrostatically.
• When the steering wheel is moved, the control valve
sends oil from pump P2 (through the rotating oil dis-
penser) to one or other of the chambers of the steering
cylinder. The rotating oil dispenser ensures 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 dispens-
er functions automatically like a hand-pump to ensure
emergency steering.
PW110R-1 10-19
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
4 5
1
Section C - C
2 Section A - A
3
6
Section B - B
D
7
A
D
C
6
Section D - D
C
B
B
8
Section E - E
A E
RKP12261
1. Swing circle outer race 7. Nut

2. Ball bearing 8. Grease nipple (No. 2)
3. Swing circle inner race
SPECIFICATIONS
4. Pin
Reduction ratio: 81/11=7.37
5. Screw
6. Screw
10-20 PW110R-1
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
6
8
5
9
4
10
3
11
2
12
RKP12270
1. Swing pinion (Z=11) 7. Dipstick

2. Housing 8. No. 1 planetary gear
3. No. 2 planetary carrier 9. No. 2 planetary gear
4. No. 2 sun gear (Z=18i) 10. Ring gear (Z=78)
5. No. 1 planetary carrier 11. Bearing
6. No. 1 sun gear (Z=12) 12. Bearing
PW110R-1 10-21
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC DIAGRAM STANDARD
HYDRAULIC DIAGRAM STANDARD
Boom swing 2-Piece boom

PPC valve PPC valve
L.H. PPC valve T P P T

R.H. PPC valve T P
T Y19 Y20 OP2 Solenoid
Travel valve group
PPC valve
P T
B A
T
P
Rear axle
ST2 Solenoid
A P4 P2 P1 P3 P2 P1 P1 P2
valve group P
P3 P1 P2 P4 Y18 T P Y17
PPC
Valves ST3
Y7 A
ø 0.6 ø 0.6 Solenoid B A
valve group B d c
ø 0.7 ø 0.7 C f
Parking brake A
Y11 A1 e
ST4 Solenoid
T valve group Swing motor
P
M3
Y2 Y1
ø 0.6
TS PDB PA1 ø 0.7 PA7 PA8 PA9 PA10

PA2 PA3 PA4 PA5 PA6 P T
ST1 Solenoid
valve group B A
T
2-Piece boom
Boom swing
350 bar
L.H. travel
equipment
Additional
Y3 Y4 Y13
Bucket
Boom
Travel
High
Arm
Y14
A2 speed
294 bar
A3 Low
speed P1
Y10
Axle
A
324 bar
A1 locking B
R.H. swing
31.4 bar
P T
Front axle
196 bar
196 bar
a b
PLS
Axle locking
216 bar
ø 0.6
cylinder
TC TB TSW PB1 B1 A1 P2 PB2 B2 A2 PB3 B3 A3 PB4 B4 A4 PB5 B5 A5 PB6 B6 A6 PB7 B7 A7 PB8 B8 A8 PB9 B9 A9 PB10 B10 A10
B B
ø 0.7
ø 0.6
R.H. swing
L.H. swing
Oil cooler
Forwards
Reverse
Lower
Close
Close
Raise
Close
Open
Open
Open
2-Piece boom cylinder
Boom swing cylinder
R.H. side
L.H. side
(Ø100xØ60-900)
Bucket cylinder
(Ø110xØ70-770)
Boom cylinder
5 12 10 8 6 4 2
Swivel jonit
(Ø90xØ60-800)
13 11 9 7 14 3 1
Arm cylinder
(Ø100xØ60-650)
(Ø90xØ60-650)
70 艎
Delivery
filter 25␮
Pre - load: 12 bar
Filtro: 50␮
Hydraulic M3 MB S MA
tanck Filter: 10␮
Suction
226 / 186 bar
filter 90␮
Pre - load: 70 bar

PLS PEN PD3 P2
T
Swing
PEPC
39 bar ∅0.5
ø 0.9
ø 0.3min motor F R2 R1
PC
Q max
ø 0.9
T'1
B T1 P R
EPC
Q min
PR
PA
Ø1
P
ø 0.9
P1 T'2
170 bar
240 bar
B
32 bar
49 bar
1 bar T2
P CF
T L
PA3 PB PD PS PD2 T
EF LS
Brake pump N
PGA
PGS
M2 Priority Steering unit

valve LS
RKP12451
PW110R-1 10-23
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (WORK EQUIPMENT)
HYDRAULIC CIRCUIT (WORK EQUIPMENT)
REAR OUTRIGGER AND

FRONT BLADE VERSION 4 OUTRIGGER VERSION
LEFT RIGHT LEFT RIGHT

T P T P T P T P
P1 P2 P1 P2
P2 P1 P2 P1
P1 P2 P2 P1 P1 P2 P2 P1
REAR BLADE VERSION REAR OUTRIGGER VERSION

LEFT RIGHT
T P T P
T P
PA2 P B2 P A7 P B7 PA2 PB2 PA7 PB7
P2 P1 P2
P1 P2 P1
P1 P2 P2 P1
P1 P2
A2 A7 A2 B2 A7 B7 PA2 PB2
B2 B7
PA2 PB2 PA7 PB7
FRONT BLADE FRONT OUTRIGGER
Left Right Left Right
10 2 6 10 2 6
A2 B2
A2 B2 A7 B7
C2 C1 C2 C1 C2 C1 C2 C1
10 2 6
V2 V1 V2 V1 V2 V1 V2 V1 10 2 6
V2 V1 V2 V1
C2 C3 C2 C3
P1 P1 V2 V1 V2 V1
C2 C1 C2 C1
P2 P2
Y12 Y12
C2 C1 C2 C1
C4 C1 C4 C1
V2 V1 V2 V1 V2 V1 V2 V1 Left Right
REAR BLADE
Left Right
C2 C1 C2 C1 C2 C1 C2 C1
REAR OUTRIGGER
Left Right Left Right
REAR OUTRIGGER REAR OUTRIGGER
RKP07190
PW110R-1 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
1 2 3
c 4 b
d e f
l 6
View Y h g 5
RKP03411
a. PGS Port - From hydraulic tank 1. LS valve

b. PEPC Port - From servocontrol feed unit (PR Port) 2. PC valve
c. PS Port - From hydraulic tank 3. Fixed throttle valve
d. PA Port - To servocontrol feed unit (P1 Port) 4. Mode System solenoid valve
e. PB Port - From control valve (P1 Port) 5. Main pump
f. PD Port - To hydraulic tank 6. Gear pump
g. PA3 Port - From gear pump (PGA Port)
h. PLS Port - From control valve (PLS Port) SPECIFICATIONS
l. PGA Port - From control valve (P2 Port) Main pump theorical displacement: 90 cc/rev.
Gear pump theorical displacement: 37.5 cc/rev
10-26 PW110R-1
1. MAIN PUMP HPV95
a b
A A
B B
View X
X Y
View Y
View Z RKP03401
a. PD1 Port - To hydraulic tank

b. PA Port - To servocontrol feed unit
(P1 Port)
c. PS Port - From hydraulic tank
PW110R-1 10-27
1 2 3 4 5 6 7 8 9
10 12 11
Section A - A Section C - C
D
C
C
D Section D - D
1. Shaft 7. Cylinder block

2. Cradle 8. Valve plate
3. Case 9. Cover
4. Swash plate 10. Spring
5. Shoe 11. Servo piston
6. Piston 12. Lever
10-28 PW110R-1
FUNZIONE
• The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil
is discharged according to the load.
• It is possible to change the delivery amount by changing the swash plate angle.
1 2 3 4 5 A 6 7 8 9
B a 10
Section A - A RKP03121
STRUCTURE • The piston (6) carries out relative motion in the axial
• The cylinder block (7) is supported to the shaft (1) by direction inside each cylinder chamber of the cylinder
the spline a, and the shaft (1) is supported by the front block (7).
and rear bearings. • The cylinder block (7) seals the pressure oil to the
• Tip of the piston (6) is a concave ball, and shoe (5) is valve plate (8), and carries out relative rotation.
caulked to it to form one unit. The piston (6) and the This surface is so designed that the oil pressure bal-
shoe (5) form a spherical bearing. ance is maintained at a suitable level.
• The rocker cam (4) has a flat surface A, and the shoe And oil inside each cylinder of the cylinder block (7) is
(5) is always pressed against this surface while sliding sucked in and discharged through the valve plate (8).
in a circular movement.
The rocker cam (4) brings high pressure oil at the cy-
lindrical surface B with the cradle (2), which is se-
cured to the case, and forms a static pressure bearing
when it slides.
PW110R-1 10-29
OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the shaft 1 4 5 A 7
(1), and the shoe (5) slides on the flat surface A.
At this time, the rocker cam (4) moves along the cy-
lindrical surface B, so the angle "α" between the
center line X of the rocker cam (4) and the inclination
of the cylinder block (7) in the axial direction chang-
es.This angle "α" is called the swash plate angle.
X
B RKP03560
2 - When the center line X of the rocker cam (4) main-

tains the swash plate angle "α" in relation to the axial
direction of the cylinder block (7), the flat surface A 1 4 5 A 6 F
acts as a cam for the shoe (5).
By this, the piston (6) slides on the inside of the cyl-
inder block (7), creates a difference between ca-
pacities E and F, then suction and discharge of oil
for the amount of the difference (F–E) will be carried
out.
In other words, oil is discharged as the capacity of
the chamber E decreases when the cylinder block X
(7) rotates.In the mean time, the capacity of the
chamber F increases, and the oil is sucked at this 7 E RKP03570
process. (The figure shows the state of the pump

when suction of the chamber F and discharge of the
chamber E have completed).
3 - When the center line X of the rocker cam (4) be-

comes in line with the axial direction of the cylinder
block (7) (swash plate angle “α"=0), the difference
between capacities of E and F inside the cylinder 4 F
block (7) becomes 0, so the pump does not carry out
any suction or discharge action of oil.
(In actual fact, the swash plate angle never be-
comes 0).
X
4 - In other words, discharge amount of the pump is di-
rectly proportional to the swash plate angle "α".
7 E RKP03580
10-30 PW110R-1
2. Control of Discharge Amount

• As the swash plate angle "α" becomes larger, dif- 2 4
ference between the capacities E and F becomes
larger, so the discharge amount Q increases.
The swash plate angle "α" is changed by the servo
piston (11).
• The servo piston (11) moves in a linear reciprocat-
ing motion ( ) under the signal pressure of TVC
and LS valve.
This linear motion is transmitted with the lever (12)
to the rocker cam (4), which is supported by the cy-
lindrical surface of the cradle (2), and the rocker cam
slides in the semi-circular reciprocating direction
( ).
• The upper and lower pressure receiving area of the
servo piston (11) are different from each other, and
to the pressure chamber of the smaller piston side
(right), discharge pressure (self pressure) PP of the RKP03550
main pump is always introduced.

To the pressure chamber of the larger piston side
(left), output pressure PEN of the LS valve is intro-
11 12
duced.
Movement of the servo piston (11) is controlled by
the relationship between pressures PP and PEN
and the proportion of the pressure receiving areas
PEN
of the smaller and larger pistons (11).
PP
RKP03610
PW110R-1 10-31
LS VALVE
1 2 3 4 5 6 7 8
f
a
b c d e
RKP03420
a. PLS Port - Control valve LS pressure inlet port 1. Union

b. PA Port - Pump delivery pressure inlet port 2. Nut
c. PLP Port - LS valve signal pressure outlet port 3. Sleeve
d. PPL Port - PC valve signal pressure inlet port 4. Spring
e. Pa Port - Drain pressure outlet port 5. Seat
f. PA Port - Pump delivery pressure inlet port 6. Spool
7. Piston
8. Sleeve
PC VALVE
1 2 3 4 5 6 7 8 9 10 11
a b c d e
RKP03430
a. Pa Port - Drain pressure outlet port 1. Piston

b. PPL Port - PC valve signal pressure outlet port 2. Spring
c. PA Port - Pump delivery pressure inlet port 3. Seat
d. PA3 Port - Swing sensing pressure port 4. Spring
a. PM Port - PC mode select pressure inlet port 5. Seat
6. Spool
7. Piston
8. Sleeve
9. Nut
10. Union
11. Nut
10-32 PW110R-1
FIXED THROTTLE VALVE
1 b c 2
RKP03380
a. Pa Port - Drain pressure outlet port 1. Plug

b. Pout Port - Control pressure outlet port 2. Plug
c. Pin Port - LS valve signal pressure inlet port
PW110R-1 10-33
LS VALVE
FUNCTION
Q ( / min)
• The LS valve detects the load and controls the dis-
charge amount.
Pump discharge amount Q

This valve controls main pump discharge amount Q
according to differential pressure ∆PLS (the differ-
ential between main pump pressure PP and control
valve outlet port pressure PLS).
Main pump pressure PP and PLS coming from the
control valve output, enter this valve.
The relationship between discharge amount Q and
differential pressure ∆PLS, changes as shown in 22(2.5) bar (kg/cm2)
the diagram on the right. Differential pressure ∆PLS
RKP03451
PC VALVE (Power Control)

FUNCTION
• The PC valve carries out an approximate equal
horse-power control so that the hydraulic horse- Mode system P with
swing pump in operation
power sucked by the pump does not exceed the en-
gine horse-power by limiting the discharge amount x=0.4A Mode system E
Pump amount discharge Q
Q to a specified about in relation with the discharge

pressure PP, even if the LS valve tries to increase x=0 Mode system P
the pump discharge amount Q when the discharge
pressure PP becomes high and opening area of the
control valve is large.
• In other words, when a load becomes large during
operation and the pump discharge pressure PP ris-
es, the PC valve reduces the pump discharge
amount Q, and when the pump discharge pressure Pump discharge pressure PP
PP lowers, it increases the pump discharge amount RKP03443
Q.
• Relationship between the pump discharge pressure
PP and the pump discharge amount Q is as shown
in the chart.
Normally, it is set to the pump suction torque of the
standard mode, but when a signal from the PC-EPC
mode switching solenoid valve is inputted, the pump
suction horsepower lowers by approximately 20%
as shown by the light-load mode curve.
• Since the swing pump is mounted directly on the
main pump, when the swing pump is in operation,
suction torque of the main pump is reduced by the
amount sucked by the swing pump so that the sum
of the main pump suction torque and the swing
pump suction torque becomes the total suction
torque (100%).
10-34 PW110R-1
PAGE INTENTIONALLY
LEFT BLANK
LS VALVE
OPERATION
1. When the control valve is at "NEUTRAL" position
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
Gear pump
D
Main
pump C
Fixed throttle H 6 B 4
valve
A A
K J
Large
diameter end 11 Small diameter end
Direction of
RKP03461
min. discharge
10-36 PW110R-1
• The LS valve is a three-way selector valve, with

pressure PLS (LS pressure) from the inlet port of the
control valve brought to spring chamber B, and
main pump discharge pressure PPLS brought to
port H of sleeve.
The size of the force produced by this LS pressure
PLS+force Z of spring (4) and the main pump pres-
sure (self-pressure) PPLS determines the position
of spool (6).
• Before the engine is started, servo piston (11) is
pushed to the left (large diameter end). 11
(The spring chamber B is open to the drain circuit
through the spool of the control valve).
• Therefore, the spool (6) is pushed to the right side
( ), a path is formed between the Ports C and D,
and then the pump pressure PP is led to the cham-
ber K at the large diameter side of the servo piston Section A - A RKP03851
(11).
• Though the pump pressure PP is always introduced
to the chamber J of the small diameter side of the
servo piston (11), because the force to the large di-
ameter side is larger due to the difference of the ar-
eas at two ends of the servo piston (11), the servo
piston (11) is moved to the minimum swash plate
angle side ( ).
PW110R-1 10-37
2. When the opening of the control valve is large (lever stroke large)
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
Gear pump E
Main
D
pump
C
B
Fixed throttle 6 4
valve
K J
Large
Direction of
RKP03491
min. discharge
10-38 PW110R-1
• When the control lever is moved to full-stroke, in oth-

er words, as the opening area of the control valve
becomes large, the difference of the pump pressure
PPLS and the LS pressure PLS (LS differential
pressure ∆PLS) becomes smaller.
• LS pressure PLS introduced to the spring chamber
B of the LS valve becomes more or less the same as
the pump pressure PPLS and the spool (6) is
pushed to the left side ( ) by the combined force
of the LS pressure and the spring (4), closing the
Port C and forming a path between the Ports D and
E.
• Therefore, the pressure oil functioning to the cham-
ber K at the large diameter side of the servo piston
(11) flows to the Port D from the Port E, and then to
the PC valve.
• At this time, since the Port E of the PC valve is open
to the drain inside the pump case through the inside
of the piston, pressure in the chamber K of the large
diameter side of the servo piston (11) also becomes
to the drain pressure.
• By this, the servo piston (11) is moved to the max.
swash plate angle side ( ) by the pump pressure
PP functioning to the chamber J at the small diam-
eter side.
PW110R-1 10-39
3. When pump delivery reduces
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
Gear pump
D
Main
pump C
Fixed throttle 6 4
valve
K J
Large
Direction of
min. discharge RKP03501
10-40 PW110R-1
• The following explains the situation if servo piston

(11) moves to the left (the discharge amount be-
comes smaller). When LS differential pressure
∆PLS becomes larger (for example, when the area
of opening of the control valve becomes smaller and
pump pressure PPLS rises), the force produced by
pump pressure PPLS pushes spool (6) to the
( ).
• When spool (6) moves, main pump pressure PP
flows from port C to port D, and it enters the large di-
ameter end of the piston (11) from port K.
• Main pump pressure PP also enters port J at the
smaller diameter end of the piston, but because of
the difference in area between the large diameter
end and the small diameter end of servo piston (11),
servo piston (11) is pushed to the ( ). As a result,
the swash plate moves in the direction to make an-
gle smaller.
PW110R-1 10-41
4. When the pump flow is proper the demand of the control valve
To the actuator
PLS
Control valve
PPLS
PT
Servocontrol
PC valve feed unit
PP
E
Gear pump
D
Main
pump C
H 6 4
Fixed throttle
valve
PEN
A1 A2
Large
K J
RKP03481
10-42 PW110R-1
• Let us take the pressure receiving area at the large

diameter side of the servo piston (11) as A1, pres-
sure receiving area at the small diameter side as A2,
pressure functioning to the large diameter side as
PEN, and the pressure to the small diameter side as
PP.
• When the pump flow rate reaches the flow demand
of the control valve, the pump pressure PPLS func-
tioning to the Port H of the LS valve balances with
the combined force of the LS pressure PLS func-
tioning to the spring chamber B and the spring (4),
and the piston (6) stops at the intermediate position.
(It will stop at a position where the openings of the
throttle from port D to port E and from port C to port D
of spool (6) are approximately the same).
• At this time, because the relationship of the pres-
sure receiving areas on the servo piston (11) is
A2 : A1=1 : 1.75, the pressure functioning to two
ends of the servo piston (11) becomes
PP : PEN=1.75 : 1; so the forces to the two ends of
the servo piston (11) becomes 1:1, and the servo
piston (11) stops at the position, balancing the flow
demand of the control valve and the pump dis-
charge.
• Spring force is so adjusted that the piston (6)
is balanced when
PPLS – PLS=∆PLS= 22 bar.
PW110R-1 10-43
PC VALVE (Power Control)

FUNCTION
1. When load on the actuator becomes small (pump discharge pressure lowers)
To the actuator
PLS
Control valve
PPLS
Servocontrol
feed unit
PP Swing
blade
PG
PT
Main pump
pressure Gear pump
C
Gear pump
pressure
4 6 Main pump
LS valve
Fixed
throttle
valve
2 3
Large
Small diameter end diameter end
Direction of Direction of
max discharge min. discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03471
10-44 PW110R-1
a) Action of PC-EPC solenoid

• The command current from resistor flows to PC-
EPC solenoid (1).
This command current acts on the PC-EPC valve
and outputs the signal pressure.
When this signal pressure is received, the force
pushing piston (2) is changed.
• On the opposite side to this force pushing piston (2)
is the spring set pressure of springs (4) and (6) and
pump pressure PP pushing spool (3). Spool (3)
stops at a position where the combined force push-
ing spool (3) is balanced, and the pressure (pres-
sure of port C) output from the CP valve.
PW110R-1 10-45
b) Function of the spring
To the actuator
PLS
Control valve
PPLS
Servocontrol
feed unit
PP Swing
blade
PG
B C
B
PT
Gear
C pump
A
D
Main pump
When port B and C

are connected
4 5 6 7 E
LS valve
8
G
9 Fixed
throttle
valve
2 3
J
Large
Direction of
max discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03511
10-46 PW110R-1
• Port C of the PC valve is connected to port E of the

LS valve (see (1) LS valve). Self-pressure PP en-
ters port B, the small diameter end of servo piston
(9), and port A.
• The spring load of springs (4) and (6) in the PC valve
is determined by the swash plate position.
• When servo piston (9) moves, piston (7), which is
connected to slider (8), also moves to the right or
left.
• If piston (7) moves to the left, spring (6) is com-
pressed, and if it moves further to the left, spring (6)
contacts seat (5) and is fixed in position.
From this point, only spring (4) is actuated. In other
words, the spring load is changed by piston (7) ex-
tending or compressing springs (4) and (6).
• If the command current input to PC-EPC valve so-
lenoid (1) changes further, the force pushing piston
(2),changes. The spring load of springs (4) and (6)
also changes according to the value of the PC-EPC
valve solenoid command current.
• When pump pressure PP is small, spool (3) is on the
left. At this point, port C and D are connected, and
the pressure entering the LS valve becomes drain
pressure PT. If port E and G of the LS valve are con-
nected (see (1) LS valve), the pressure entering the
large diameter end of the piston from port J be-
comes drain pressure PT, and servo piston (9)
moves to the right. In this way, the pump discharge
amount moves in the direction of increase.
• As servo piston (9) moves further, piston (7) is
moved to the right by slider (8). Spring (4) and (6) ex-
pand and the spring force becomes weaker.
When the spring force becomes weaker, spool (3)
moves to the right, so the connection between port
C and port D is cut, and the pump discharge pres-
sure ports B and C are connected. As a result, the
pressure at port C rises, and the pressure at the
large diameter end of the piston also rises, so the
movement of piston (9) to the right is topped.
In other words, the stop position for piston (9)
(=pump discharge amount) is decided at the point
where the force of springs (4) and (6) and the push-
ing force from the PC-EPC valve solenoid and the
pushing force created by pressure PC acting on
spool (3) are in balance.
PW110R-1 10-47
2. When load on the actuator is large (pump discharge pressure is high)
To the actuator
PLS
Control valve
PPLS
Servocontrol
feed unit
PP Swing
blade
PG
B PT
Gear
A C pump
D Main pump
2 3 4 6 7 E
LS valve
9 G
Fixed
throttle
valve
Large
Direction of
min. discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03521
10-48 PW110R-1
• When the load is large and pump discharge pres-

sure PP is high, the force pushing spool (3) to the left
becomes larger and spool (3) moves to the position
shown in the diagram above.
When this happens, as shown in the diagram
above, part of the pressurized oil from port X passes
through the LS valve, flows out from port C to port D,
and the pressurized oil flowing from port C to the LS
valve becomes approximately 3/5 of main pump
pressure PP.
• When port E and port G of the LS valve are con-
nected (see (1) LS valve), the pressure from port J
enters the large diameter end of servo piston (9),
and servo piston (9) stops.
• If main pump pressure PP increases further and
spool (3) moves further to the right, main pump pres-
sure PP flows to port B and port C and acts to make
the discharge amount the minimum. When piston
(9) moves to the left, piston (7) is moved to the left.
For this reason, springs (4) an(6) are compressed
and push back spool (3).
When spool (3) moves to the left, the opening of port
C and port D becomes larger. As a result, the pres-
sure at port C (=J) drops, and piston (9) stops mov-

ing to the left. The position in which piston (9) stops
when this happens is further to the left than the po-
sition when pump pressure PP is low.
• The relation of pump pressure PP and the position
of servo piston (9) forms a bent line because of the
double-spring effect of springs (6) and (4).
The relationship between pump pressure PP and
pump discharge amount Q is shown in the figure on
the right. Pump discharge pressure PP RKP04131
• If command current X sent to solenoid (1) increases
further, the relationship between pump pressure PP
and pump discharge amount Q is proportional to the
pushing force of the PC-EPC valve of output pres- 2 (x:Large)
sure. In other words, if the pushing force of output
pressure is added to the force pushing to the left be- 1 (x:SMall)

cause of the pump pressure applied to the piston
(2), the relationship between PP and Q moves from
1 to 2 in accordance with the increase.
Pump discharge pressure PP RKP04121
PW110R-1 10-49
3. When the swing is operated
To the actuator
PLS
Control valve
PPLS
Servocontrol
feed unit
Swing
PP blade
PG
B C
B PT
Gear
A C pump
D Main pump
When port B and C

are connected
LS valve
9 Fixed
throttle
valve
2 3
J
Large
Direction of
min. discharge
mode-system
PC-EPC selector
valve
Resistor
1 RKP03541
10-50 PW110R-1
• When the swing is not being used, in other words

when no load is applied o the swing pump, the pump
suction torque is same as the standard mode or the
light-load mode.
• Once the swing is activated, thus, a load is applied
on the swing pump, the signal pressure PG is putted
t the port A and the piston (9) is pushed to the left
( ) side according to the volume of the signal
pressure.
• By this action, the springs (4) and (6) are contracted
and, because the spring load increases, the pump
suction torque lowers according to the volume of
load on the swing pump.
PW110R-1 10-51
STRUCTURE AND FUNCTION PRIORITY VALVE
PRIORITY VALVE
P
b
PP LS
EF CF
d c
RKP03680
a. P Port - From P2 pump (PGA Port) OPERATION

b. LS Port - To steering unit (LS Port) • The oil from the pump is distributed through the pri-
c. CF Port - To steering unit (P Port) ority valve to the steering unit (Port CF) and to the oth-
d. EF Port - To by-pass valve (C Port) er hydraulic components (Port EF).
• Distribution is determined by the position of the pri-
SPECIFICATIONS
ority valve slider in function of:
Type: OLS/40
a - the Load Sensing signal coming from the steering
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 delivery to
the steering unit always corresponds to the actual re-
quirements.
10-52 PW110R-1
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
A
C B
D A
aa
AA AA
Pt Ps
Pr O O
v N Pq
N x
Pp Po
t u
M M
Pn Pm
r s
L L
Pl Pk
p q
B K K
Pj n Pi
J J o
Ph Pg
l m
H H
Pf j Pe
G G
k
Pd h Pc
F F i
P Pb Pa
f g
E E xx
d e
BB BB
c
C D A
Pu
a b P B
View A
y
w
View B
RKP03162
10-54 PW110R-1
a. TC Port - To exchanger
b. TSW Port - To swing motor (S Port)
c. TB Port - To hydraulic tank
d. A1 Port - To swing motor (MA Port)
e. B1 Port - To swing motor (MB Port)
f. A2 Port - See hydraulic circuit
g. B2 Port - See hydraulic circuit
h. A3 Port - To swivel joint (13A Port)
i. B3 Port - To swivel joint (12A Port)
j. A4 Port - To boom cylinder (bottom side)
k. B4 Port - To boom cylinder (head side)
l. A5 Port - To arm cylinder (head side)
m. B5 Port - To arm cylinder (bottom side)
n. A6 Port - To bucket cylinder (head side)
o. B6 Port - To bucket cylinder (bottom side)
p. A7 Port - See hydraulic circuit
q. B7 Port - See hydraulic circuit
r. A8 Port - To boom swing cylinder (head side)
s. B8 Port - To boom swing cylinder (bottom side)
t. A9 Port - To 2-piece boom cylinder (head side)
u. B9 Port - To 2-piece boom cylinder (bottom side)
v. A10 Port - To attachment (L.H. side)
x. B10 Port - To attachment (R.H. side)
y. P2 Port - From priority valve (EF Port)
w. P1 Port - From servocontrol unit (P2 Port) and to pump (PB Port)
aa. PLS Port - To hydraulic pump (PLS Port)
xx. TS Port - To hydraulic tank
Pa. PA1 Port - From L.H. PPC valve (P2 Port)
Pb. PB1 Port - From L.H. PPC valve (P4 Port)
Pc. PA2 Port - See hydraulic circuit
Pd. PB2 Port - See hydraulic circuit
Pe. PA3 Port - From ST3 solenoid valve group (A Port)
Pf. PB3 Port - From ST3 solenoid valve group (B Port)
Pg. PA4 Port - From R.H. PPC valve (P4 Port)
Ph. PB4 Port - From R.H. PPC valve (P2 Port)
Pi. PA5 Port - From L.H. PPC valve (P3 Port)
Pj. PB5 Port - From L.H. PPC valve (P1 Port)
Pk. PA6 Port - From R.H. PPC valve (P3 Port)
Pl. PB6 Port - From R.H. PPC valve (P1 Port)
Pm. PA7 Port - See hydraulic circuit
Pn. PB7 Port - See hydraulic circuit
Po. PA8 Port - From boom swing PPC valve (P1 Port)
Pp. PB8 Port - From boom swing PPC valve (P2 Port)
Pq. PA9 Port - From 2-piece boom PPC valve (P2 Port)
Pr. PB9 Port - From 2-piece boom PPC valve (P1 Port)
Ps. PA10 Port - From OP2 solenoid valve group (B Port)
Pt. PB10 Port - From OP2 solenoid valve group (A Port)
Pu. PDB Port - From PA4 Port
PW110R-1 10-55
17
15 16
13 14
11 12
9 10
7 8
5 6
3 4
1 2
18
1. Travel suction valve (A3 port) 10 - R.H. outrigger suction valve (B7 Port)
2. Travel suction valve (B3 port) 11. Boom swing suction valve (Head side) (A8 port)
3. Boom suction valve (Bottom side) (A4 port) 12. Boom swing suction valve (Bottom side) (B8 port)
4. Boom suction valve (Head side) (B4 port) 13. 2-piece boom suction valve (A9 Port)
5. Arm suction valve (Head side) (A5 port) 14. 2-piece boom suction valve (B9 Port)
6. Arm suction valve (Bottom side) (B5 port) 15. Attachment safety valve (L.H. side) (A10 port)
7. Bucket suction valve (Head side) (A6 port) 16. Attachment safety valve (R.H. side) (B10 port)
8. Bucket suction valve (Bottom side) (B6 port) 17. Safety valve
9 - R.H. outrigger suction valve (A7 Port) 18. Lift check valve
10-56 PW110R-1
11
10
Section B - B
RKP03181
1. Main relief valve (P1 Port) 7. Spool (bucket)

2. Spool (swing) 8. Spool (R.H. outrigger)
3. Spool (blade or outriggers) 9. Spool (boom swing)
4. Spool (travel) 10. Spool (2-piece boom)
5. Spool (boom) 11. Spool (attachment)
6. Spool (arm)
PW110R-1 10-57
18
8 16
7 15
6 14
5 13
4 12
3 11
2 10
1 9
17
19
Section C - C
RKP03191
Flow compensation valve: Reducing pressure compensation valve:

1. Travel 9. Travel
2. Boom 10. Boom
3. Arm 11. Arm
4. Bucket 12. Bucket
5. R.H. outrigger 13. R.H. outrigger
6. Boom swing 14. Boom swing
7. 2-piece boom 15. 2-piece boom
8. Attachment 16. Attachment
17. Main relief valve (P2 Port)
18. Plug
19. Spool (boom raise at joining pump discharge)
10-58 PW110R-1
Section D - D RKP03201
1. Swing check valve 6. Outrigger check valve

2. Blade check valve 7. Boom swing check valve
3. Boom check valve 8. 2-piece boom check valve
4. Arm check valve 9. Attachment check valve
5. Bucket check valve
PW110R-1 10-59
STRUCTURE AND FUNCTION SWING VALVE
Section BB - BB RKP02822
5 3
4 Section E - E RKP02812

2. Lift check valve
SWING VALVE
3. Spool (swing)
4. Spool (boom raise at joining pump discharge)
5. Check valve (swing)
10-60 PW110R-1
STRUCTURE AND FUNCTION BLADE VALVE
3
Section AA - AA
RKP02842
6
Section F - F RKP02832
1. Pump pressure detection plug

2. Pressure relief plug
3. LS bypass plug
4. Safety relief valve
BLADE VALVE
5. Spool (blade)
PW110R-1 10-61
TRAVEL VALVE
STRUCTURE AND FUNCTION BOOM VALVE
1 2
5 4
Section G - G RKP02852
6 7
10 9
Section H - H
RKP02862
TRAVEL VALVE BOOM VALVE

1. Suction valve (A3 Port) 6. Suction valve (Head side)
2. Suction valve (B3 Port) 7. Suction valve (Bottom side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve
10-62 PW110R-1
ARM VALVE
STRUCTURE AND FUNCTION BUCKET VALVE
1 2
RKP02872
5 4
Section J - J
6 7
RKP02882
10 9
Section K - K
ARM VALVE BUCKET VALVE

1. Suction valve (Head side) 6. Suction valve (Head side)
2. Suction valve (Bottom side) 7. Suction valve (Bottom side)
3. Spool 8. Spool
PW110R-1 10-63
OUTRIGGER VALVE
STRUCTURE AND FUNCTION BOOM SWING VALVE
1 2
5 4
Section L-L RKP03211
6 7
10 9
RKP03221
Section M-M
OUTRIGGER VALVE BOOM SWING VALVE

1. Suction valve (A7 Port) 6. Suction valve (Head side)
2. Suction valve (B7 Port) 7. Suction valve (bottom side)
3. Spool 8. Spool
10-64 PW110R-1
2-PIECE BOOM VALVE
STRUCTURE AND FUNCTION ATTACHMENT VALVE
1 2
5 4
RKP03231
Section N-N
6 7
10 9
RKP03241
Section O-O
11
RKP03251
Section P-P
2-PIECE BOOM VALVE ATTACHMENT VALVE
1. Suction valve (A9 Port) 6. Safety valve (R.H. side)
2. Suction valve (B9 Port) 7. Safety valve (L.H. side)
3. Spool 8. Spool
11. Unload valve
PW110R-1 10-65
PAGE INTENTIONALLY
LEFT BLANK
FUNCTION PRINCIPLE
1. Control of pump swash plate angle
•The pump swash plate angle (pump discharge amount) is so controlled that the LS differential pressure ∆PLS, which
is the difference between the pump discharge pressure PP and the LS pressure PLS at the outlet Port of the control
valve (actuator load pressure), is maintained at a constant level.
(LS differential pressure ∆PLS=Pump discharge pressure PP -- LS pressure PLS).
• If the LS differential pressure ∆PLS becomes lower than the setting pressure of the LS valve, the pump swash plate
angle becomes larger, and if it becomes higher, the pump swash plate angle becomes smaller.
★ For the details of this action, refer to the descriptions of "HYDRAULIC PUMP".
Actuator
Max.
Swash plate angle Q

Control valve
Min.
PLS
Pump passage
LS passage
0 LS differential
pressure ∆PLS Set differential
Main pump pressure of LS valve
PP
RKP02931
Min. Max.
Servo piston
∆PLS
LS valve
Differential
pressure high Differential
pressure
low
PC valve
Pump pressure Pump pressure

high low
RKP02921
PW110R-1 10-67
2. Pressure compensation control

• Valves (pressure compensation valves) are installed at the inlet Port side of the spools of the control valves to bal-
ance the loads.
When the actuators are complex-operated, the pressure differences ∆P at the upstream (inlet) and downstream
(outlet) are made equal by these valves.
In this way, the flow from the pump are distributed in proportion to the opening areas S1 and S2 of each valve.
Load
Load
W W
Actuator Actuator
∆P ∆P
S1 S2
Pressure Pressure
compensation compensation
valve valve
LS valve RKP02941
10-68 PW110R-1
3. Operation for each function and valve
Hydraulic circuit diagram and names of valves
PLS
324 bar
1. Unload valve: LS pressure+31.4 bar
5 Ls ø0.5 2. Main relief valve (P1 Port) 294 bar
9 3. Pressure compensation valve
A10
B10
4. Suction valve
Attachment 5. Safety valve: 324 bar
PA10 Pb10
9 6. Main relief valve (P2 Port): 216 bar
3 4 7. Lift check valve
A9 8. Cooler bypass valve:
B9 2-piece boom
PA9 PB9 Cracking pressure 8.1 bar
4
9. Safety valve (attachment): 196 bar
3 4
A8
B8
PA8 Pb8
Boom swing
4
3 4
A7
PA7
B7
R.H. outrigger
Pb7
4
3 4
A6
B6
PA6
PB6
Bucket
4
3 4
A5
B5
PA5 Arm
PB5
4
3 4
A4
B4
PA4
Boom
PB4
4
3 4
A3
B3 Travel
PA3 PB3
4
3
A2
B2
Pb2
Blade and/or
PA2
outrigger
P2
216 bar 6
A1
B1 Swing
PA1 Pb1
PDB
TSW
2 294 bar 1 31.4 bar 8 TSW

7 TB
TC
P1
RKP03261
PW110R-1 10-69
1. Unload valve
FUNCTION
1. When the control valve is at NEUTRAL, pump discharge amount Q for the minimum swash plate angle is released
to the tank circuit.
At this time, the pump discharge pressure PP is set at 31.4 bar by the spring (2) inside the valve.
(LS pressure PLS = 0 bar)
PP PLS
T
1 2 3
RKP02960
OPERATION
When the control valve is at NEUTRAL
•To two end surfaces of the spool (1), the pump discharge pressure PP is acting on the left and the LS pressure PLS is
acting on the right side.
• Since no LS pressure PLS is generated when the control valve is at NEUTRAL, only the pump discharge pressure
PP is acting, and PP is set only by the load of the spring (2)
• As the pump discharge pressure PP rises and reaches the spring load of the spring (2) (31.4 bar), the spool (1) is
shifted to the right ( ) side and the pump circuit PP becomes open to the tank circuit T through the drill holes in the
sleeve (3).
• In this way, the pump discharge pressure PP is set to 31.4 bar.
10-70 PW110R-1
2. When the flow demand from the actuator is within the discharge amount for the pump minimum swash angle plate
during fine control of the control valve, the pump discharge pressure PP is set to the LS pressure PLS +31.4 bar.
Since the unload valve opens when the differential pressure between the pump discharge pressure PP and the LS
pressure PLS reaches the spring load of the spring (2) (31.4 bar), the LS differential pressure ∆PLS at this time be-
comes 31.4 bar.
PP PLS
T
1 2
RKP02970
OPERATION
Fine control of the control valve
• When the control valve is fine-controlled, the LS pressure PLS is generated and acts on the right end of the spool (1).
At this time, since the LS pressure PLS is small because the opening area of the spool of the control valve is small,
there is big difference from the pump discharge pressure PP.
• When the differential pressure between the pump discharge pressure PP and LS pressure PLS reaches the spring
load of the spring (2) (31.4 bar), the spool (1) moves to the right ( ) side and a path is formed between the pump
circuit PP and the tank circuit T.
• Thus, the pump discharge pressure PP is set to the combined pressure of the spring force (31.4 bar) and the LS
pressure PLS, and the LS differential pressure ∆PLS becomes 31.4 bar.
PW110R-1 10-71
3. When the flow demand from the actuator becomes greater than the pump flow for the minimum swash plate angle
during operation of the control valve, the flow to the tank circuit T is cut off, and all the pump discharge Q flows into
the actuator circuit.
PP PLS
T
1 2
RKP02980
OPERATION
When the control valve is operated

• When the control valve is operated to a bigger stroke, the LS pressure PLS is generated and acts on the right end
surface of the spool (1).
At this time, since the opening area of the spool of the control valve is large, the difference between the LS pressure
PLS and the pump discharge pressure PP is small.
• For this reason, because the differential pressure between the pump discharge pressure PP and the LS pressure
PLS noes not reach the spring load of the spring (2) (31.4 bar), the spool (1) is pushed to the left ( ) side by the
spring (2).
• As the result, the path between the pump circuit PP and the tank circuit T is shut off, and whole pump discharge Q
flows to the actuator circuit.
10-72 PW110R-1
2. Introduction of LS pressure
Function
• The LS pressure denotes the actuator load pressure at the outlet Port of the control valve.
• Actually, in the control valves, the pump pressure PP is reduced to the same pressure of the actuator circuit pressure
A by the pressure reducing valve (3) in the pressure compensation valve before introducing into the LS circuit PLS.
Furthermore, the orifice C is provided in the middle of the circuit from the pump circuit PP to the pressure reducing
valve (3) for damper function.
• In the travel valves, the actuator circuit pressure A is directly introduced into the LS circuit PLS.
A
b
1
a d
PP SA PA 3 PLS1 SLS
2
C 4 PLS
RKP02990
OPERATION
Control valves (boom, arm, bucket, boom swing, attachment)
• When the spool (1) is operated, the pump pressure PP starts to flow to the actuator circuit A from the flow control
valve (2) and the spool notch a through the bridge path b.
• At the same time, the pressure reducing valve (3) moves to the right ( ) side, so the pump pressure PP introduced
from the orifice c is depressurized by the pressure loss at the notch d and introduced to the LS circuit PLS, and then,
further introduced to the spring chamber PLS1.
• At this time, the LS circuit PLS is open to the tank circuit T through the LS bypass plug (4) (refer to the description of
the LS bypass plug).
• Areas of the both ends of the pressure reducing valve (3) are same (SA=SLS), and on the SA side, the actuator cir-
cuit pressure PA (=A) is acting, and on the opposite SLS side, the reduced pump pressure PP is acting.
• Therefore the pressure reducing valve (3) balances at the point where the actuator circuit pressure PA and the
spring chamber pressure PLS1 are balanced, and the pump pressure PP reduced by the notch d is introduced to the
LS circuit PLS as the actuator circuit pressure A.
PW110R-1 10-73
A
b
1
a d
PP 2 PA 3
e PLS
RKP03000
Travel valves
• When the spool (1) is operated, the pump pressure PP starts to flow to the actuator circuit A from the flow control
valve (2) and the spool notch a through the bridge path b.
• At the same time, the pressure reducing valve (3) is moved to the right ( ) side by the actuator circuit PA, and paths
are made between the notches c and d to the travel path circuit e and the LS circuit PLS respectively.
• By this, the actuator circuit pressure PA (=A) is introduced to the LS circuit PLS from the notch c through the notch d.
★ In the travel circuits, unlike the work equipment circuits, the actuator circuit pressure PA is directly introduced to the
LS circuit PLS.
10-74 PW110R-1
LS bypass plug
DESCRIPTION
1 - The LS bypass plug releases the residual pressure of the LS pressure PLS.
2 - This makes the pressure-rising speed of the LS pressure PLS more gentle, and with this discarded throttled flow, it
creases a pressure loss in the throttled amount of the spool or shuttle valve and increases the stability to lowering the
effective LS differential pressure.
1 T
PLS
RKP03010
OPERATION
• The pressurized oil in the LS circuit PLS flows from the clearance filter a, which is formed by the clearance between
the LS bypass plug (1) and the body, to the tank circuit T through the orifice b.
PW110R-1 10-75
Pressure compensation valve
FUNCTION
1. During complex operation, if the load pressure at one side becomes lower than that of the other actuator and the oil
flow is about to increase, pressure compensation is carried out.
(In this case, the other actuator (right side) of the complex operation has higher load pressure than that of this side
(left side).
W W
A A
PA
PPA
a a
T
PLS1
PPA PA
2 1
PP
PLS PP
RKP03020
OPERATION
• During complex operation, when the load pressure of the other actuator side (right side) becomes higher, the flow
in the actuator circuit A at this (left) side tends to increase.
• In this case, the LS pressure PLS at the other actuator acts on the spring chamber PLS1, and pushes the pressure
reducing valve (1) and the flow control valve (2) to the left ( ).
• The flow control valve (2) throttles the opening area between the pump circuit PP and the upstream side of the spool
PPA, and generates a pressure loss in between PP and PPA.
• The flow control valve and the pressure reducing valve (1) are balanced at the point where the differential pressure
between PA and PLS, which act on the both end surfaces of the pressure reducing valve (1), becomes equal to the
pressure loss in between PP and PPA before and after the flow control valve (2).
• By this operation, the differential pressures between the upstream pressure PPA and the down stream pressure PA
of both spools in the complex operation are made same, and the pump flow is distributed in proportion to the opening
areas of notches a of each spool.
10-76 PW110R-1
Area ratio of pressure compensation valve

FUNCTION
• The pressure compensation valve determines the compensation characteristics by carrying out fine adjustment of
the area ratio (S1/S2) between the area S1 of the flow control valve (2) side and the area S2 of the pressure reducing
valve (1) side to match the characteristics of each actuator.
S1= Area of the flow control valve (2) – Area of the piston (3)
S2= Area of the pressure reducing valve (1) – Area of the piston (3)
S1 PPB PP 2 1 PA 3 S2
PLS
RKP03030
Area ratio (S1/S2) and compensation characteristics

• When the ratio is 1.00 :
[Pump pressure PP - Upstream pressure of the spool notch PPB]ⱌ[LS circuit pressure PLS - Actuator circuit pres-
sure PA (=A)]
Thus, the flow is distributed in proportion of opening areas of the spool.
• When the ratio is larger than 1.00 : PP – PPB>PLS – PA (=A)
Thus, the flow is divided less than the proportion of opening areas of the spool.
• When the ratio is smaller than 1.00 : PP – PPB<PLS – PA
Thus, the flow is divided more than the proportion of opening areas of the spool.
PW110R-1 10-77
Travel LS bypass circuit
FUNCTION
• When the travel and another actuator are operated at the same time, by increasing the LS throttle amount in the LS
circuit PLS which is discarded, and relaxing the pressure compensation precision in the travel circuit, drop in the
travel speed is minimized.
• The bypass circuit is closed when the travel or another actuator is operated individually.
A1 1 A2 PA
PLS
PLS1
a
4
PB c
2
RKP03060
OPERATION
Normal operation
• When the boom spool (1) is operated, the pressure in the LS circuit PLS becomes same as the boom circuit pressure
A1.
• At the same time, the LS circuit pressure PLS is also introduced to the spring chamber PLS1 of the pressure re-
ducing valve (2) in the travel valve.
• Since the travel spool is not operated, the travel actuator circuit is closed, and the check valve (4) in the reducing
valve (2) is also closed.
• Thus, during individual operation of the boom, the travel LS bypass circuit is closed.
10-78 PW110R-1
A1 1 A2 PA
PLS
PLS1
a
4
PB 2 c
RKP03070
When the travel and another actuator are operated together

• When the boom spool (1) is operated, the pressure in the LS circuit PLS becomes same as the boom circuit pressure
A1.
• Since the pressure in the boom RAISE actuator circuit is normally higher than that of the travel actuator (A1>A2), the
pressure in the spring chamber PLS1 in the reducing valve (2) at the travel side is higher than the travel circuit pres-
sure (PA).
• Therefore, the pressure reducing valve (2) moves to the left ( ) ide, and the LS pressure in the spring chamber
PLS1 from the orifice a pushes and opens the check valve (4), and flows to the travel circuit PA through the path b
and the path c.
• Thus, the LS circuit pressure PLS, which has been the same as the boom circuit pressure A1, flows to the travel cir-
cuit A2 and lowers.
PW110R-1 10-79
Boom and arm regeneration circuit
FUNCTION (Explanation by boom)

1. When the boom is being lowered, if the bottom pressure A of the cylinder (1) is higher than the head pressure B, and
there is hydraulic drift, this sends the return flow at the bottom end to the head end to increase the cylinder speed by
that amount.
1
B
A
4
2
T
3
a
PP PLS
RKP03080
OPERATION
• When there is hydraulic drift when lowering the boom, the pressure A at the bottom end of the boom cylinder (1) be-
comes higher than the pressure B at the head end.
• At this time, a part of the return flow at the bottom end passes the regeneration passage a of the boom spool (2),
pushes the check valve (3) open, and flows to the head end.
• As the result, the boom lowering speed is increased.
10-80 PW110R-1
2. When lowering the boom, if the head pressure B of the cylinder (1) is greater than the bottom pressure A, and the op-
eration is in the load process, the check valve (3) closes to shut off the circuit between the head and the bottom sides.
B
A
4
2
T 3
a
PLS
PP
RKP03090
OPERATION
• During a load process such as lowering the boom, etc., the pressure B at the head side of the boom cylinder (1) be-
comes higher than the pressure A at the bottom side.
• At this time, the check valve (3) is closed by the pressure B at the head side and the spring (4), and the passage be-
tween the head circuit and the bottom circuit is shut off.
PW110R-1 10-81
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
a C A
B B
Z
e
C
View Z
RKP11921
a. S Port - From control valve (TSW Port) SPECIFICATIONS

b. T Port - To hydraulic tank Type: LMF30AB
c. B Port - From shutthe valve Motor capacity: 31 cc/rev.
d. MB Port - From control valve (B1) Rated speed: 2065 rpm
e. MA Port - From control valve (A1) Safety valve set pressure: 225 bar
Suction valve cracking pressure: max. 0.3 bar
Brake releasing pressure: 5.5± 0.7 bar
10-82 PW110R-1
3 4 5 12 13 14 15 16 2
7 1
Section A - A Section B - B
10
11
RKP11931
Section C - C
1. Output shaft 9. Safety valve

2. Housing 10. Check valve
3. Shoe 11. Spring
4. Piston 12. Spring
5. Cylinder block 13. Brake piston
6. Valve plate 14. Ring
7. Spring 15. Disc
8. Swash plate 16. Plate
PW110R-1 10-83
SAFETY VALVE WITH SUCTION

FUNCTION
• When swing operation is stopped, outlet circuit of
the motor is closed by the control valve. However, 1
the motor will run for a while by inertial force, so
pressure at the outlet side of the motor will abnor-
mally rise, which may cause damage to the motor.
• To avoid such danger, the safety valve releases the S
CA CB
abnormally high pressure oil from the outlet side of
the motor to the Port S, as well as performing swing
brake function.
• The suction valve supplies oil of equivalent amount
to the oil released by the safety valve from the Port S
to the inlet side of the motor to avoid cavitation.
OPERATION
1. When swing starts

• When the swing control lever is operated to SWING
LEFT, pressure oil from the pump will be sent to the
Port MB through the control valve.
• By this, pressure in the Port MB rises, which gen-
erates starting force to the motor, and the motor MA MB
starts to swing.
• Oil coming out of the outlet Port returns to the tank Control valve
from the Port MA though the control valve.
RKP11941
2. When swing stops

• When the swing control lever is returned to the NEU- 1
TRAL position, pressure oil from the control valve is
not sent to the Port MB.
• At the Port MA, pressure rises, which generates ro-
tational resistance to the motor, which then acts as S
braking force to the motor. CA CB
• When the pressure at the Port MA reaches the set
pressure of the safety valve (1), the valve (1) opens
to release the pressure oil in the Port MA to the Port
S.
• At the Port MB, since the motor runs without being
supplied with pressure oil, negative pressure will be
generated.
When this negative pressure lowers to the set pres-
sure of the suction valve (2), the suction valve (2)
opens and oil is sent from the Port S to avoid cav-
itation..
MA MB
Control valve
RKP11951
10-84 PW110R-1
OPERATION OF THE MODULATING RELIEF VALVE

FUNCTION
• The relief valve for the swing motor has the prop- Modulating relief valve
erties to suppress the rapid increase of the relief P Normal relief valve
pressure as per shown in the figure right, and serves
P2
to reduce the shock at the time of start and stop of
swing.
P1
P0
t
T
RKP11970
OPERATION
When the circuit pressure is P0 1 2 a 3 4 5
• The relief valve does not operate.
When the circuit pressure has rapidly increased

• When the circuit pressure increases to P1, the valve P
(3) starts to open bacause the oil pressure acts on
the difference in area between D1 and D3 (D1>D3),
thus pressing the spring (4). D2 D1 D3
On this occasion, the seat (1) tries to follow the valve
(3) because the pressure acts on the difference in S
area between D1 and D2 (D1<D2).
However, the route that the oil in the chamber a
compressed by the movement of the seat (1) can
flow to the S port has been throttled by the ball (2),
P1
so that the movement of the seat (1) is slower than P2
that of the valve (3).
Therefore, during the time T until the seat (1) makes
contact with the sleeve (5), the relief pressure grad-
ually increases from P1 to P2
S
P2
S RKP11960
PW110R-1 10-85
OPERATION OF SWING BRAKE
1. PPC valve (swing) at HOLD SWING

• When the PPC valve (swing) is at HOLD, the PPC
output pressure P is 0 bar
• For this reason, brake piston (1) is pushed up by PPC
brake spring (2), and disc (3) and plate (4) are VALVE
pushed together to apply the brake.
L.H. R.H.
4
3
P
1
2 RKP11980
2. PPC valve (swing) actuated

SWING
• When the PPC valve is actuated, PPC output pres-
sure P enters port B and flows to brake chamber a.
• The pressurized oil entering chamber a overcomes
PPC
brake spring (2) and pushed braked piston (1) VALVE
down. As a result, disc (3) and plate (4) separate
and the brake is released.
L.H. R.H.
4
3
B
a
2 1 RKP11990
10-86 PW110R-1
ACTUATION OF HYDRAULIC TIMER VALVE

FUNCTION
• The hydraulic timer acts to delay the start of the SWING
swing brake effect in order to ensure smooth decel-
eration and to prevent damage to the parts of the
motor if the swing brake is applied suddenly when
PPC
stopping the swing motor. VALVE
• When the PPC valve (swing) is actuated, PPC out-
put pressure P goes to chamber a and the swing
brake is released.
In this condition, if the PPC valve is returned to L.H. R.H.
HOLD, the supply of pressure oil to port B stops and
the pressure in chamber a drops.
As a result, the oil in chamber a is pushed out by
brake spring (2).
• There is a check valve in the PPC valve circuit at the
P
port B side, so the oil flow is stopped and it flows out
to passage c.
However, the passage of the flow is throttled by or-
ifice (5) in the hydraulic timer valve, so the oil inside B
chamber a flows out only slowly, and this delays the a
actuation of the swing brake by the determined
amount. c
2 5 RKP12000
PW110R-1 10-87
STRUCTURE AND FUNCTION SWIVEL JOINT
SWIVEL JOINT
Front of machine
1 Inlet axis
3A-7A-11A
2
4a 7a
3 8a
13a
4 1a
11a
14A
6a
3a
13A
5
Inlet axis Inlet axis
4A-8A-12A 1A-5A-9A-13A
11A 2a
14a
12A 10A
12a 9a
6 9A 5a 10a
8A 7A
Inlet axis
6A 2A-6A-10A-14A
5A View Z
4A 3A RKP03781
2A 1. 14 slip ring collector

1A 2. Collector support
7 3. Screw
10
4. Screw
5 9 5. Anti-friction ring
6. Seal
8 7. O-Ring seal
8. Body
Z 9. Guard ring
10. Rotor
1A. From steering unit (L Port) 1a. To front axle (b Port)

2A. See hydraulic circuit 2a. See hydraulic circuit
3A. To hydraulic tank 3a. From travel valve (T Port)
4A. From ST1 solenoid valve group (A1 Port) 4a. To locking axle cylinders (B Port)
5A. From ST1 solenoid valve group (A3 Port) 5a. To transmission (e Port)
7A. From brake pump (T1 Port) 7a. To front axle brake
8A. From brake pump (T2 Port) 8a. To rear axle brake
9A. From steering unit (R Port) 9a. From ST4 solenoid valve group (P Port)
11A. From ST2 solenoid valve group (A1 Port) 11a. To brake
12A. From control valve (B3 Port) 12a. To travel motor (A Port)
13A. From control valve (A3 Port) 13a. To travel motor (B Port)
14A. From ST1 solenoid valve group (A2 Port) 14a. To transmission (f Port)
10-88 PW110R-1
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
5
c 1
2 4 a b 4
3
View X
RKP04461
1. Motor SPECIFICATIONS
2. Brake valve Min. displacement: 35.5 cc/rev
3. Displacement automatic control Max. displacement: 80 cc/rev
4. Relief/anti-cavitation valve Check valve rated pressure: 350 bar
5. Gear power change solenoid valve (Y15)
a. A Port - To swivel joint (12a Port)

b. B Port - To swivel joint (13a Port)
c. T Port - To swivel joint (3a Port)
PW110R-1 10-89
DISPLACEMENT AUTOMATIC CONTROL HIGH
STRUCTURE AND FUNCTION PRESSURE RELATED
DISPLACEMENT AUTOMATIC CONTROL HIGH PRESSURE RELATED

3
b
cc
1 1 6
Xc
5
4
4
a
7
5
Detail X
RKP04471
FUNCTION
• This device automatically varies the displacement in • The pressure moves the positioning piston (2) which,
function of the working pressure. because it is connected mechanically to the engine
A displacement increase leads to a reduction in the cylinder, causes this to move and increase the dis-
engine shaft rpm and an increase in the torque. placement.
The movement of the positioning piston (2) continues
OPERATION until equilibrium has been reached between the de-
• The pressurized oil coming from the control valve ar- livery pressure acting on the smaller surface of the
rives through the brake valve (1) on the smaller sur- piston and the pressure acting on the larger surface.
face of the positioning piston (2), thus pushing it Once equilibrium has been reached the spring (6) re-
towards the minimum displacement limit stop. turns the measuring piston (5) to its neutral posi-
The smaller surface is connected hydraulically to the tion.“Maximum displacement is determined by the
pilot system bushing (4), which contains a measuring mechanical limit stop (7).
piston with two different surfaces. The available pres- • When delivery line pressure diminishes there is no
sure therefore acts in a differential manner and, with longer equilibrium between the forces acting on the
the spring (6), causes the piston (5) to perform the positioning piston; the measuring piston moves, and
function of governing the pressure flows. opens passage c to release the existing pressure in
• When delivery line pressure increases the measure- chamber b.
ment piston (5) moves, compresses the spring (6), Under this new pressure the positioning piston (2)
and allows oil to pass through line a into chamber b of gradually returns to the minimum displacement posi-
the larger surface of the positioning piston (2). tion. The movement stops when a new equilibrium is
reached between the forces acting on the measure-
ment piston (5) and the positioning piston (2).
10-90 PW110R-1
STRUCTURE AND FUNCTION TRAVEL MOTOR BRAKE VALVES
TRAVEL MOTOR BRAKE VALVES
8 9 10 11 f 11 10 9 2
5
5
3
6
4
7 c
b a RKP04550
FUNCTION motor to return to the tank through the valve opening

• The brake valves control loading in order to prevent (7).
the cavitation phenomenon which occurs when the ro- • When the pressure in line a drops due to loading
tation speed of the hydraulic motor exceeds the speed changes or due to the movement of the controls, there
determined by pump delivery through the control is an immediate reduction of pressure in the spring
valve. housing e; pressure from the spring (4) and residual
• The brake valves are not a substitute for the ma- pressure from the drainage lines cause the piston (3)
chine duty brakes. to return, leading to a reduction in the amount of oil
draining through the throttle (6), and thus provoking
OPERATION an automatic braking action.
• Pressurized oil from the control valve enters line a • Valves (2) and (8) protect the engine against both
causing valve (1) to open, and acts through the pilot pressure peaks and the cavitation phenomenon.
system channel c the ring chamber d and valve (2) to
• When the pressure in line f exceeds the calibration
feed the piston motor.
value of the spring (9), the pilot valve (10) opens to
The pilot system oil acts on the surface of piston (3)
eliminate pressure inside the main valves (11). The
and causes it to move to compress the spring (4) while
pressure in line d acts on the outside of the main
the throttles (5) control the passages to obtain slow
valves (11) which causes them to open and allow
and regular piston movement.
communication between their lines of delivery a and
The piston movement (3) releases a progressive
drainage b.
throttling action (6) and allows the oil drained out of the
PW110R-1 10-91
STRUCTURE AND FUNCTION CYLINDERS
CYLINDERS
BOOM
2 3 4 5 6 7 8 9 10
1 17 16 15 14 13 12 11
RKP04340
ARM
2 3 4 5 6 7 8 9 19 11
1
17 16 15 14 13 12 20
RKP04310
BUCKET, BOOM SWING, BLADE AND OUTRIGGERS

(★ (The figure shows the blade cylinder)
2 3 4 5 6 8 9 10 11
1
17 16 15 14 12 13
RKP05700
10-92 PW110R-1
STRUCTURE AND FUNCTION CYLINDERS
2-PIECE BOOM
2 3 4 5 6 8 9 18 11
1
17 16 15 14 13 12 RKP04330
1. Head side bushing 8. Washer 15. Head-piece

2. Guard ring 9. Wear ring 16. Washer
3. Washer 10. Half flange (No. 2) 17. Coupling flange
4. Washer 11. Bottom side bushing89 18. Nut
5. Wear ring 12. Piston 19. Bottom cushion
6. Piston rod 13. Washer 20. Ball (No. 12)
7. Head cushion plunger 14. Cylinder
Blade or
Cylinder Boom 2-piece boom Arm Bucket Boom swing
outriggers
Piston rod diameter 70 50 60 60 60 60
Cylinder inside 120 90 100 90 100 120

diameter
Piston stroke 770 580 898 800 650 185
Max. cylinder length 1990 1510 2230 1970 1650 710
Min. cylinder length 1220 930 1332 1170 1000 525
Piston nut width – 60 70 – – –

across flat
PW110R-1 10-93
STRUCTURE AND FUNCTION AXLE LOCKING CYLINDER
AXLE LOCKING CYLINDER
B
2
3 4 5 6
RKP03771
a. B Port - From swivel joint (4a Port)
1. Cylinder
2. Piston
3. Cover
4. Plunger
5. Valve seat
6. Screw
7. Oil seal
8. Gasket
10-94 PW110R-1
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION SERVOCONTROL FEED UNIT
SERVOCONTROL FEED UNIT
a d
B
A A
c
RKP03961
a. P2 Port - To control valve (P1 Port)

b. PR Port - To ST1 solenoid valve group (P Port)
c. T Port - To hydraulic tank
d. PC Port - To brake pump (P Port)
10-96 PW110R-1
11 6 5 4
Detail Z
1
8 7 Z
Section A - A
10 9
1. Hydraulic pump
2. Valve
3. Spring
4. Screw
5. Poppet
6. Spring (reducing valve pilot)
7. Spring (reducing valve)
8. Spool (reducing valve)
9. Spring (safety valve)
10. Ball
11. Filter
PW110R-1 10-97
OPERATION
PC
1. When engine is stopped
P1 P2
• Poppet (5) is pushed against the seat by spring (6),
and the passage from Port PR T is closed.
• Valve (8) is pushed to the left by spring (7), and the
passage from Port P1 PR is open.
• Valve (2) is pushed to the left by spring (3), so the
passage between Port P1 P2 is closed.
(See Fig. 1)
T
PR
Hydraulic diagram
RKP03861
Control valve
P2
PC 2 3
P1
PR
8 7 5 6
PC valve PPC valve
LS valve
RKP03871
Fig. 1
10-98 PW110R-1
2. At neutral
Control valve
3. When load pressure P2 is low (when moving
P2
down under own weight boom LOWER or arm
IN) PC d 2 3
Note: When load pressure P2 is lower than output pres-
sure PR of the self-reducing pressure valve.
• Valve (2) receives force in the direction to close the
P1
passage from Port P1 P2 from spring (3) and
pressure PR (when the engine is stopped, the pres-
sure is 0 bar).
However, when hydraulic oil flows in from Port P1, T
the pressure is balanced so that pressure P1 ⱶ
force of spring (7) + (area Ød x pressure PR), and
the opening from Port P1 P2 is adjusted so that
pressure P1 is kept at a certain value above pres-
sure PR. PR
• When pressure PR goes above the set pressure,
8 a 7 5
poppet (5) opens, and the hydraulic oil flows in the
following circuit: Port PR hole a inside spool (8)
opening of poppet (5) tank Port T.
As a result, a pressure difference is created on both M
sides of hole a inside spool (8), so spool (8) moves in
the direction to close the opening from Port PC valve PPC valve
P1 PR.
LS valve
Pressure P1 is reduced to a certain pressure (set
RKP03881
pressure) by the amount of opening at this point, Fig. 2
and is supplied as pressure PR. (See Fig. 2)
4. When load pressure P2 is high

Control valve
• If load pressure P2 increases and the pump dis-
charge amount also increases because of digging P2
operations, pressure P1 also increases (pressure PC d 2 3
P1> force of spring (7) + (area Ød x pressure PR), so
valve (2) moves to the right to the end of the stroke.
As a result, the amount of opening from Port
P1 P2 increases and the resistance in the pas- P1
sage is reduced, so the loss of engine horsepower is
reduced.
• If pressure PR goes above the set pressure, poppet T
(5) opens and the hydraulic oil flows in the following
circuit: Port PR hole a inside spool (8) a
opening of poppet (5) tank Port T.
As a result, a pressure difference is created on both
sides of hole a is inside spool (8), so spool (8) moves
in the direction to close the opening from Port
PR
P1 PR. 8 a 7 5
Pressure P1 is reduced to a certain pressure (set
pressure) by the amount of opening at this point,
and is supplied as pressure PR (See Fig. 3).
M
PC valve PPC valve
LS valve
RKP03891
Fig. 3
PW110R-1 10-99
5. When there is abnormal high pressure

• When pressure PR of the self-reducing pressure
valve becomes abnormally high, ball (10) pushes
against the force of spring (9), separates from the M
seat, and allows hydraulic oil to flow from output Port
PR T, so pressure PR goes down.
PPC valve
This action protects the equipment at the destina-
tion for the hydraulic pressure supply (PPC valve,
PR P1 T
electromagnetic valve, etc.) from abnormally high
pressure. (See Fig. 4)
10 9
Fig. 4 RKP03901
10-100 PW110R-1
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
RKP03910
TECHNICAL DATA FUNCTION

Servocontrol feed group: • A rubber bag (1) containing nitrogen gas is used in the
Nominal volume: 0.35 accumulator. Its function is to maintain oil pressure in
Pre-set pressure: 12 +0 1 bar the circuit to which the accumulator is connected.
Working pressure: 35–45 bar OPERATION
• When the engine is running, the chamber A of the rub-
Gruppo alimentazione servocomandi
ber bag (1) (containing nitrogen) is compressed by the
Nominal volume: 0.70 pressurized oil from line B.
Pre-set pressure: 70 bar If the oil pressure in line B falls below the maximum
Working pressure: 65–150 bar calibration pressure (even after intensive use), the
rubber bag (1) will expand due to the pressure of the
nitrogen inside it.
PW110R-1 10-101
STRUCTURE AND FUNCTION SHUTTLE VALVE
SHUTTLE VALVE
2 3 1 2
A
c a
A
b RKP12181
Section A - A
1. Body valve a. A Port - From L.H. PPC valve (P4 Port)

2. Seat valve b. B Port - To swing motor (B Port)
3. Ball c. C Port - From L.H. PPC valve (P2 Port)
10-102 PW110R-1
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION PPC VALVES
PPC VALVES
ATTACHMENT
a e
f
d b
A A
c
View A RKP12621
L.H. PPC VALVE R.H. PPC VALVE

a. P1 Port - To control valve (PB5 Port) a. P4 Port - To control valve (PA4 Port)
(Close arm) (Raise boom)
b. P4 Port - To control valve (PB1 Port) b. P3 Port - To control valve (PA6 Port)
(R.H. swing) (Open bucket)
c. P3 Port - To control valve (PA5 Port) c. P2 Port - To control valve (PB4 Port)
(Open arm) (Lower boom)
d. P2 Port - To control valve (PA1 Port) d. P1 Port - To control valve (PB6 Port)
(L.H. swing) (Close bucket)
e. T Port - To hydraulic tank e. T Port - To hydraulic tank
f. P Port - From ST2 solenoid valve group f. P Port - From ST2 solenoid valve group
(A Port) (A Port)
10-104 PW110R-1
7
3
2 1
1. Spool 5. Joint
2. Metering spring 6. Cover
3. Centering spring 7. Retainer
4. Plunger 8. Body
PW110R-1 10-105
FUNCTION
1. At neutral
Ports A and B of the control valve and Ports P1 and
P2 of the PPC valve are connected to drain chamber
D through fine control hole f in spool (1). (Fig. 1)
f T
2. During fine control

(NEUTRAL fine control) 1
When piston (4) starts to be pushed by disc (5), re-
tainer (7) is pushed; spool (1) is also pushed by me-
P3 (P1) P P4 (P2)
tering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same time,
it is connected to pump pressure chamber PP, so pi-
lot pressure oil from the control pump passes A Control valve
B
through fine control hole f and goes from Port P1 to
Port A.
When the pressure at Port P1 becomes higher, RKP12841
Fig. 1
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at Port P1. When
this happens, spool (1) moves up or down so that
the force of metering spring (2) is balanced with the
pressure at Port P1. The relationship in the position
of spool (1) and body (8) (fine control hole f is at a 5
point midway between drain hole D and pump pres- 4
sure chamber PP) does not change until retainer (7)
contacts spool (1).
Therefore, metering spring (2) is compressed pro-
portionally to the amount of movement of the disc 7 D
(5), so the pressure at Port P1 also rises in propor-
tion to the travel of the disc (5). In this way, the con-
2
T
trol valve spool moves to a position where the
pressure in chamber A (the same as pressure at 1
Port P1) and the force of the control valve spool re-
f
turn spring are balanced. (Fig. 2)
PP
P1 P P2
A Control valve
B
Fig. 2
RKP12851
10-106 PW110R-1

(when the lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and
the pressure at Port P1. 5
When this happens, fine control hole f is connected
4
to drain chamber D and the pressure oil at Port P1 is
released.
If the pressure at Port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con- 7 D
trol hole f is shut off from drain chamber D. At almost
the same time, it is connected to pump pressure 2
T
chamber PP, and the pump pressure is supplied un-
til the pressure at Port P1 recovers to a pressure that 1
corresponds to the lever position.
f
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f' in f'
PP
the valve on the side that is not working. The oil P1 P P2
passes through Port P2 and enters chamber B to fill
the chamber with oil. (Fig. 3)
4. At full stroke A Control valve

B
When disc (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut Fig. 3
RKP12861
off from drain chamber D, and is connected with

pump pressure chamber PP. Therefore, the pilot
pressure from the control pump passes through fine
control hole f and flows to chamber A from Port P1,
and pushes the control valve spool.
The oil returning from chamber B passes from Port
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4). 5
4
7 D
2
T
1
f
PP
P1 P P2
A Control valve
B
RKP12871
Fig. 4
PW110R-1 10-107
BLADE OR OUTRIGGERS PPC VALVE
A
Z
c d
View Z RKP12241
a. T Port - To hydraulic tank d. P2 Port - For blade or L.H. outrigger:

b. P Port - From ST2 solenoid valve group (A Port) to control valve (PB7 Port)
c. P1 Port - For L.H. outrigger: For R.H. outrigger:
to control valve (PA7 Port) to control valve (PA2 Port)
For R.H. outrigger or blade: For blade:
to control valve (PB2 port) to control valve (PB2 Port)
For blade:
to control valve (PA2 Port)
10-108 PW110R-1
6
3
2 7
1
8
Section A - A
RKP12641
1. Spool
2. Metering spring
3. Centering spring
4. Plunger
5. Lever
6. Cover
7. Retainer
8. Body
PW110R-1 10-109
FUNCTION
1. At neutral
Ports A and B of the control valve and Ports P1 and
P2 of the PPC valve are connected to drain chamber
D through fine control hole f in spool (1). (Fig. 1).
D
T
P
f
1
P1 P2
A Control valve B
(NEUTRAL fine control) RKP12911
Fig. 1
When piston (4) starts to be pushed by lever (5), re-
tainer (7) is pushed; spool (1) is also pushed by me-
tering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same time,
it is connected to pump pressure chamber PP, so pi- 5
lot pressure oil from the control pump passes
through fine control hole f and goes from Port P1 to
Port A. 4
When the pressure at Port P1 becomes higher,
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP. 7
At almost the same time, it is connected to drain
chamber D to release the pressure at Port P1. When
this happens, spool (1) moves up or down so that
2 T
the force of metering spring (2) is balanced with the
pressure at Port P1. The relationship in the position D
of spool (1) and body (8) (fine control hole f is at a P
point midway between drain hole D and pump pres- f
sure chamber PP) does not change until retainer (7)
contacts spool (1). 1
Therefore, metering spring (2) is compressed pro-
P1 P2
portionally to the amount of movement of the control
PP
lever, so the pressure at Port P1 also rises in pro-
portion to the travel of the control lever. In this way,
the control valve spool moves to a position where
the pressure in chamber A (the same as pressure at A B
Control valve
Port P1) and the force of the control valve spool re-
turn spring are balanced. (Fig. 2). Fig. 2 RKP12901
10-110 PW110R-1

(when the lever is returned)
When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and 5
the pressure at Port P1.
When this happens, fine control hole f is connected
to drain chamber D and the pressure oil at Port P1 is 4
released.
If the pressure at Port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con- 7
trol hole f is shut off from drain chamber D.
At almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
2 T
supplied until the pressure at Port P1 recovers to a
pressure that corresponds to the lever position. D
When the spool of the control valve returns, oil in P
drain chamber D flows in from fine control hole f' in f
the valve on the side that is not working. f'
The oil passes through Port P2 and enters chamber 1
B to fill the chamber with oil. (Fig. 3)
P1 P2
PP
4. At full stroke A B
Control valve
When lever (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut
RKP12891
off from drain chamber D, and is connected with Fig. 3
pump pressure chamber PP.
Therefore, the pilot pressure from the control pump
passes through fine control hole f and flows to
chamber A from Port P1, and pushes the control
valve spool. 5
The oil returning from chamber B passes from Port
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4) 4
2 T
D
P
f
f'
1
P1 P2
PP
A Control valve B
RKP12881
Fig. 4
PW110R-1 10-111
BOOM SWING, 2-PIECE BOOM PPC VALVES
T
P
P1 P2
RKP03920
d c
RKP12250
a. T Port - To hydraulic tank

b. P Port - From ST2 solenoid group valve (A Port)
c. P1 Port - For boom swing:
to control valve (PA8 Port) (L.H. swing) For 2-piece boom:
to control valve (PB9 Port) (bottom side)
d. P2 Port - For boom swing: to control valve (PB8 Port) (R.H. swing)
For 2-piece boom: to control valve (PA9 Port) (head side)
10-112 PW110R-1
TRAVEL PPC VALVE
25
°
1
4
6 2 3
1
2
b
a 5
3
View Z RKP03691
1. Pedal
2. Pedal adjustment
3. Adjustable stop
4. Control unit
5. Support
6. Rubber jacket
a. P Port - From servocontrol feed unit (PR Port)

b. T Port - To tank
c. A Port - To ST3 solenoid valve group (P Port)
PW110R-1 10-113
STRUCTURE AND FUNCTION BRAKE PUMP
BRAKE PUMP
1
2
c d
b
4
e g f a
i h
View A
RKP11561
1. Parking brake pedal SPECIFICATIONS

2. Lever Brake pressure: 50±5 bar
3. Pump Unitary displacement: 70 cc
4. Brake pressure adjusting screw Recharge pressure: 90±10 bar
Max. pressure accelerator: 120±10 bar
a. P Port - From servocontrol feed unit (PC Port)
b. N Port - To hydraulic tank
c. T1 Port - Brake light pressure switch port
d. F Port - Accumulator pressure switch port
e. B Port - To pump (PLS Port)
f. R2 Port - To A1 accumulator
g. R1 Port - To A2 accumulator
h. T1 Port - To swivel joint (7A Port)
i. T2 Port - To swivel joint (8A Port)
10-114 PW110R-1
STRUCTURE AND FUNCTION BOOM AND ARM SAFETY VALVE
BOOM AND ARM SAFETY VALVE
a b
c d
1 2
3
4
5
e
RKP04170
1. Screw SPECIFICATIONS
2. Valve Pilot ratio: 22 : 1
3. Rod
20
4. Nut
Differential pressure ⌬p (bar)
5. Nut 16
2

C
➔
12 V2
V2
➔
b. P Port - For boom: C2
8
From control valve (PB4 Port)
For arm 4
From control valve (PB5 Port)
c. V2 Port - For boom: 0
0 25 50 75 100 125 150
From control valve (A4 Port) Amount Q ( / min)
For arm:
RKP04161
From control valve (A5 Port)
d. C2 Port - For boom: To the cylinder (Bottom side)
For arm: To the cylinder (Head side)
e. M Port - For boom: To the overload sensor switch
PW110R-1 10-115
STRUCTURE AND FUNCTION BLADE OR OUTRIGGERS SAFETY VALVE
BLADE OR OUTRIGGERS SAFETY VALVE
a b
A A
Section A - A
c d
RKP03761
a. V2 Port - See hydraulic diagram SPECIFICATIONS

b. V1 Port - Vedere schema idraulico Start opening: 8 bar
c. C2 Port - To blade or outriggers cylinder (bottom side)
16
d. C1 Port - To blade or outriggers cylinder (Head side) 14

12
10
8 C2
V2
6 V2
4 C2
2
0
0 6 12 18 24 30
Amount Q ( / min)
RKP04541
10-116 PW110R-1
STRUCTURE AND FUNCTION OVERLOAD SENSOR SWITCH
OVERLOAD SENSOR SWITCH
3 4 5
3
1
2
RKP11580
a. From boom safety valve (M Port) TECHNICAL DATA

Setting valve: 140 bar
1. Connector
2. Pressure sensor switch FUNCTION
3. Adjusting screw The overload sensor switch is connected through the
boom safety valve to boom cylinder (bottom side).
4. Protection
When the pressure rises over the setting valve, the sensor
5. Connection plate close the electrical circuit and the actives the horn.
PW110R-1 10-117
STRUCTURE AND FUNCTION SOLENOID VALVES
SOLENOID VALVES
SOLENOID VALVE GROUP ST1 (Y3 - Y4 - Y10)
1
3
b c
d e
RKP12300
a. T Port - To hydraulic tank 1. Y4 High speed

b. P Port - From servocontrol feed unit (PR Port) 2. Y3 Low speed
c. A3 Port - To swivel joint (14A Port) 3. Y10 Locking axle
d. A2 Port - To swivel joint (5A Port)
e. A1 Port - To swivel joint (11A Port)
10-118 PW110R-1
SOLENOID VALVE GROUP ST2 (Y7 - Y11)
1 2
c d RKP11550

b. P Port - From servocontrol feed unit (PR Port)
b. A Port - To servocontrol feed unit
c. A1 Port - To swivel joint (4A Port)
1. Y7 - Servocontrol
2. Y11 - Parking brake
PW110R-1 10-119
SOLENOID VALVE GROUP ST3 (Y17 - Y18)
1 a b 2
d c
RKP04570
1. Y17 Reverse
2. Y18 Forward Measured at V=41 mm2/s e t=50°C 1 2
10
a. Port P - From travel PPC valve (A Port)
8
b. Port B - To control valve (PB3 Port)
c. Port T - To hydraulic tank 6
d. Port A - To control valve (PA3 Port) 4
0
0 20 40 60 80
Amount Q ( / min)
RKP04491
10-120 PW110R-1
SOLENOID VALVE GROUP ST4 (Y1 - Y2 - Y13 - Y14)
2 3
a b
T A
P B
c 5 d
1 4
RKP03670
Measured at V=41 mm2/s e t=50°C Measured at V=41 mm2/s e t=50°C

5 3 6 9
10 10
8 8
6 6
4 4
2 2
0 0
0 20 40 60 80 0 20 40 60 80
Amount Q ( / min) Amount Q ( / min)
RKP04501 RKP04511
1. Y1 Rear steering cut out

2. Y2 Front/rear steering
3. Y13 Phase coincidence steering
4. Y14 Crab steering
5. Blocks connection
a. T Port - To front steering cylinder (a Port)

b. A Port - To rear steering cylinder (c Port)
c. P Port - From swivel joint (9a Port)
d. B Port - To rear steering cylinder (d Port)
PW110R-1 10-121
OUTRIGGERS SOLENOID VALVE (Y12)
c d
b e
10
4
C
P
2
a f
0
10 30 50 70 90
Amount Q ( / min)
RKP05460 RKP04521
a. P1 Port - From swivel joint (10a Port)

b. C1 Port - To L.H. rear outrigger safety valve (V1 Port)
c. C2 Port - With 4 outriggers:
To L.H. front outrigger safety valve (V1 Port)
For front blade and rear outrigger:
Not used
d. C3 Port - With 4 outriggers:
To R.H. front outrigger safety valve (V1 Port)
For front blade and rear outrigger:
To blade cylinder safety valve (V1 Port)
e. C4 Port - To R.H. rear outrigger safety valve (V1 Port)
f. P2 Port - From swivel joint (2a Port)
10-122 PW110R-1
SOLENOID VALVE GROUP OP2 (Y19 - Y20)
a b
1 2
d c
RKP03940
1. Y19 L.H. attachment control

2. R.H. attachment control

b. A Port - To control valve (PB10 Port)
c. P Port - From ST2 solenoid valve group (A Port)
d. B Port - To control valve (PA10 Port)
PW110R-1 10-123
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
AIR-CONDITIONING UNIT
2
Low pressure steam
Low pressure liquid/steam
High pressure steam

AIR AT AMBIENT TEMPERATURE
High pressure liquid
10
1a
3 1
8
5
4
7
9
INTERIOR OF CAB
RKP12650
1. Compressor TECHNICAL DATA

2. Condenser Operating pressure in circuit with engine at 2500 rpm
and ambient temperature at 25–30°C:
3. Drying-filter tank
Normal pressure: 15–17 bar
4. Safety pressure
Low pressure: 1.6–1.8 bar
5. Expansion valve
Safety pressures:
6. Evaporator High pressure: 20 bar
7. Thermostatic clutch control sensor Low pressure: 2.5 bar
8. Air-circulation fan in cab Coolant fluid: R134a
– 30
9. Air conveyor Quantity of coolant: 1100 + 50 g
10. Condenser ventilator
10-124 PW110R-1
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
HOW THE AIR-CONDITIONING UNIT FUNCTIONS

The compressor (1) is driven directly by the engine shaft On leaving the evaporator (6) the coolant is drawn once
by means of a belt, and made to rotat by a pulley fitted more into the compressor (1) and a new cycle commenc-
with an electromagnetically-engaged clutch (1a). es.
A thermostatic sensor (7) controls the engagement and The yielding of heat from the atmosphere in which the
disengagement of the clutch. It disengages the clutch evaporator is positioned leads to the condensation of the
when the evaporator reaches the lower temperature limit water suspended in the air, and hence to dehumidifica-
and engages the clutch when the evaporator reaches tion. The condensate is deposited on the evaporator fins
the upper temperature limit. where, if a temperature higher than 0°C is not main-
The coolant fluid (in gaseous phase) is drawn into the tained, it freezes and inhibits the functioning of the evap-
compressor where it is subjected to compression and an orator.
intense heating process. In these conditions the fluid is The task of keeping the temperature of the evaporator
then sent into the condenser (2) where, due to the heat above 0°C (and thus within the optimum limits for heat
extracted by ambient temperature air flowing over fins, it exchange) is entrusted to a thermostatic sensor (7).
reaches condensation temperature, and passes into a The condensate that forms on the evaporator fins (6)
high-pressure liquid state. also contains dust, pollens and particles suspended in
Subsequently the coolant passes into the drying-filter the air. Continual condensation therefore effectively pu-
group (3) which performs three functions: it filters out im- rifies the air, and the droplets of condensate are dis-
purities, absorbs any moisture present in the circuit and, charged to the exterior.
finally, also functions as a reserve tank. A fixed quantity of anti-freeze oil is also introduced into
The coolant in its liquid state is then transferred to the the circuit, with the function of lubricating all the mechan-
evaporator (6), first passing through an expansion valve ical parts of the unit. A percentage of this oil circulates
(5). The task of this valve is the constant metering of the constantly throughout the unit in nebulized form, lubri-
quantity of fluid in order to maintain optimum evapora- cating the compressor (pistons and bearings) and the
tion. expansion valve.
In the evaporator the coolant fluid is subjected to expan- A pressure switch (4) has been inserted in the electrical
sion, bringing it up to the critical evaporation point at a control circuit to protect the unit in the case of a lack of
temperature of approximately – 8°C. coolant fluid or if the quantity becomes insufficient due to
The flow of air generated by centrifugal fan (8) which leakages. This switch will inhibit the engagement of the
passes through the evaporator (6) at ambient tempera- electromagnetic clutch and hence the functioning of the
ture is considerably warmer than – 8°C. For this reason it air-conditioning unit.
yields heat to the coolant fluid, bringing it up to boiling
point and complete evaporation.
PW110R-1 10-125
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (1/8)
ELECTRICAL DIAGRAM (1/8)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
M-V1 X76 8 X492 C-B1
CONTROL PANEL 3.1
C-B1
X76 4
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
X81
G-N1
X82
X82
X82
X82
X82
2.16
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
6 5 4 3 2
X76 1 X493 H-L1
R1 ACC BR R2 C 3.1
B1
OFF ACC M-B1
G-N1
H-L1
X75
G-M1
R1 8 4.1
H-G1
B-G1
R-V1
H-N1
A-R1
A-V1
Z-B1
V-B1
V-Z1
G0.5
S0.5
A1
ST
G1
V1
N1
R-G1
4.1
X76
X76
B
X75
X75
X75
X76
X75
X76
X75
X75
X76
X75
X75
X75
X75
S19 B1
3.8
H-N1
4.1
5 11
4 16 9 6 11 3 10 13 13 1 12 14 3 H-R1
HA5 4.1
M-N1
2.1
G4
R6
L6
H-G1
2.19
Z-N1 X75
4.18
15
R-N1
A-V1
2.1
G1
A-R1
1 1 5 16 7 19 20 9 5 11 4 8 2 12 4
X47 X70 X7 X7 X4 X9 X9 X9 X3 X4 X3 X4 X11 X4 X4

3
3.15
S0.5
2.16
G0.5
2.16 +30 +15 F4B F2B +15
F1B 3A
7.5A 3A
B-R1
Z-N1
Z-B1
V-B1
1
3.9
1 2 1 8 5 2 9 3 2 7 2
3.4
X34 X15 X41a X46 X46 X34 X46 X46 X46 X46
K8
V-B1
30
l K4 86 87a 87 4.13 86 87a 87
X45
R6 KT2 85 30 85 30
B-N1
V1
G4
R6
+15
53M
53S
K1 K2 K3
15
31
86 87a 87 86 87a 87 86 87a 87
+30
X45
X36
X36
X36
X36
- 85 30 85 30 85 30
M6 1 2 4 3 F4C F3B F6A
5A 7.5A 15A
G1
B1.5
N1
B-R1
K01 K03 K02
FUG2 FUG4 FUG1 86 87 86 87 86 87
50A 80A 30A
B-R1
Z-N1
Z-B1
85 30 85 30 85 30
B1 X5 X5 X5 X5 X6 X6 X6 X8 X9 X8 X9 X8 X7
10 5 11 3 3 6 4 9 3 3 13 13 14
B1.5
A-N1
H2.5
B-N1
A-N1
4.6
2 X23
B1.5
R10
R10
1
G4
B-R1.5
R-N1.5
3.1
X22
- l
H-R1
R70
H-G1.5
H-G1.5
A-G1
A-N1.5
B-R1.5
X41
X41
X55
1 2 1
H-N1
X39 X39 X38
+
1
S26 K12 86 87
V-B1
G1 30 50 D+ R1 1 R4
B1.5
R1.5
X43 HA4
1
S21
V1
M1 M G2 30 G W Y18 Y17
R3
X44 X56
p 85 30
12Vcc 3
HA2 1
U
X55
S17 S20
2
31
Y0 p p X23 1
B-G1
X39 S27
t X43 M2 2
3 X44
M S25 X22
N1.5
N1.5
N1.5
N1.5
-
N70
N1
N1
N1
N1
N1
N1
N1
N1
31
2.1
M1 Starter motor Y0 Fuel shut off solenoid valve X34 Power 3 way connector 3 X22
RKP11780
COMPONENTS M2 Transfer pump Y17 Reverse speed solenoid valve X36 Pull solenoid timer 4 way connector
G1 Battery Y18 Forward speed solenoid valve X38 Heating start 1 way connector X76 Dashboard extension 17 way connector
R1 Heating start
G2 Generator X39 Fuel shut off 3 way connector X81 Control panel 16 way connector
R3 Water temperature sender CONNECTORS
HA2 Reverse buzzer X41 Generator 2 way connector X82 Control panel 8 way connector
R4 Fuel level sender X3 Right lateral dashboard line 18 way connector
HA4 Frame horn S16 Heater switch X4 Right lateral dashboard line 12 way connector X41a Frequence alternator 1 way connector FUSES
HA5 Buzzer S17 Air filter switch X5 Engine line 11 way connector X43 Water temperature sender 2 way connector F1B Gear valve fuse 7.5A
K1 Forward speed valve relay S19 Starting switch X6 Lights switch-gear shift line 13 way connector X44 Back-up alarm 2 way connector F2B Joystick -instrument power fuse 3A
K2 Reverse speed solenoid valve relay S20 Engine oil low pressure switch X7 Steering interface line 21 way connector X45 Diode 2 way connector F3B Safety start- fuel shut off fuse 7.5A
K3 Speed connection relay S21 Brakes less pressure switch X8 Loom line 21 way connector X46 Dashboard wiring 9 way connector F4B Right traffic light and instrument light fuse 3A
K4 Key safety start relay S25 Fuel tank full sensor X9 Lights switch-gear shift line 21 way connector X47 1 way connector M6 (+30) F4C Generator and pull timers fuse 5A
K8 Horn relay S26 Transfer pump start button X11 Lateral dashboard line 13 way connector X49 Diode 2 way connector F6A Horn-current intake-transfer pump fuse 15A
K12 Transfer pump relay S27 Transfer pump switch X15 Parking brakes lamp 1 way connector X55 Optional horn connector FUG1 Fuel shut off fuse 30A
KT2 Pull fuel solenoid timer V1 Start antirepetition relay 1A diode X22 Fuel level sender 3 way connector X70 1 way connector M5 (+15) FUG2 General fuse 50A
X56 Current intake 12V X23 Transfer pump 2 way connector X75 Dashboard extension 21 way connector FUG4 Preheating fuse 80A
PW110R-1 10-127
PAGE INTENTIONALLY
LEFT BLANK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
MANIPOLATORE DX
PULSANTIERA PRINCIPALE RIGHT JOYSTICK
MAIN SWITCHES PANEL
S10 S11
X79
X79
X79
X79
X79
X79
X79
X79
X79
X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X73 X72 X72 X72 X72 X72 X72 X72 X72 X72 X72 X72 X72
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
G-N1.5
A-G1.5
R-G1.5
G-R1.5
A-R1.5
C-V1.5
B-N1.5
Z-G1.5
G-R1
M-B1
M-N1
R-G1
B-R1
R-N1
S-N1
Z-N1
V-N1
G0.5
R0.5
C0.5
V-B1
H0.5
C-L1
L-R1
S0.5
L0.5
Z1
M1
L1
M-N1
1.20
R-N1
1.20
L-R1
4.20
X49 6 S18
G0.5
1.10
R-N1 S0.5 2 9 12 10
3.1 1.7
X76
X76
X76
X76
G-N1 B0.5
1.20 3.1
H-G1 H-G1
1.20 3.1
V1
R-N1.5
3.16
10 12 5 7 8 6 1 2 18 3 9 10 15 16 14 12 13 9 11 17 1
X4 X11 X4 X3 X3 X3 X3 X3 X3 X3 X4 X3 X3 X3 X3 X3 X3 X3 X3 X3 X15
C1
11 14
4.12 4.1 +15 1 10
10 13 0 1
4.12 4.1
9 12
4.12 4.1
5 9
+15
8
4.13 +15 +15 F3A S2
7.5A
C0.5
F7A K9 F2C F2A
86 87a 87
15A 7.5A 5A C1
3.1
85 30
1 10
0 1
OP
5 9
S3
N1
N1
X6 X6 X5 X6 X6 X6 X8 X8 X8 X8 X8 X8 X9 X8
H0.5
2 8 1 13 12 11 15 7 20 8 19 6 21 18
G1.5
R1
S1
S-G1
L/G1
M1
R-N1
L-B1
M-V1
Z-N1
M-N1
A-V1
R1
S14
R1
X51
B R1 R1
1
3.13
G-N1
1
X50
S-G1 MANIPOLATORE SX
X19 LEFT JOYSTICK
OPTIONAL
S13 S23 Y20 Y19 Y21 Y10 Y11 S15 Y7 S8 S9 S22

p p p
OPTIONAL
X50 X50
C A
X19
2
V1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
31 31
1.18 3.1
RKP11710
COMPONENTS S13 Brake light pressure switch Y19 Hammer or close grab solenoid valve X11 Lateral dashboard line 13 way connector FUSES
K9 Stop light relay S14 PPC enable micro switch Y20 Open grab solenoid valve X15 Parking brakes lamp 1 way connector F2A Servocontrol valve fuse 5A
S2 Parking brake button S15 Anti overturning pressure switch CONNECTORS X19 Optional pliers solenoid valve 2 way connector F2C Steering buttons relais fuse 7.5A
S3 Axle lock button S18 Joystick horn button X3 Right lateral dashboard line 18 way connector X49 7 way connector lights switch and dashoboard line F3A Steering buttons relais fuse 7.5A
S8 Hammer pedal button S22 Parking brakes pressure switch X50 3 way connector stop light sensor F7A Stop light and heater 15A
X4 Right lateral dashboard line 12 way connector
S9 Pliers button S23 Work brakes proximity (NPN NC) X72 Switches panel 12 way connector
X5 Engine line 11 way connector
S10 Joystick hammer button or close grab bucket Y7 Servocontrol solenoid valve X73 Switches panel 18 way connector
X6 Lights switch-gear shift line 13 way connector
S11 Joystick open grab button Y10 Axle lock solenoid valve X76 Dashboard extension 17 way connector
X8 Loom line 21 way connector
Y11 Parking brake solenoid valve X79 10 way connector push-buttons dashoard
X9 Lights switch-gear shift line 21 way connector
PW110R-1 10-129
PAGE INTENTIONALLY
LEFT BLANK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 10 G1
0 1 DEVIO LUCI
2 3 4
LIGHTS SWITCH 0 1 2
1 6 8 10
1 0
2 8 5 10
0 1 2 0 1
15/1 30/3 L/6
3
5 9
S1 1 2 3 4 5 6 7 8 9 10 11 12
3 2 9 4 6 3 1 7 49/4 30b/2 R/7
+ 1
X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 S4 S6 S16 S7
A-B1
H1
G-L1
R-N1
V1
X13a
L-N1
H-G1
A1
N1
R-G1.5
B-R1.5
H-G1
2.20 1
R-N1
2.3
B-R1.5
1.19
X15
2
X75
X75
X75
R-N1.5
X75
X75
X75
X75
C1
2.20 2.4
X75
X75
6 17 21 20 7 18 19
1 10 2 5
0 1
B1 X49 5
1.11
C-V1.5
A-G1.5
A-R1.5
S-G1
A-B1
A-N1
H-R1
G1.5
B1.5
V1.5
H1.5
L1.5
5 9
A1
R1
S5
B0.5 7 16 15 10 10 5 3 14 18 2 9 7 6 17 6 12 1 3 8 4 1
2.20 X9 X9 X9 X11 X11 X4 X9 X9 X9 X11 X11 X11 X9 X4 X9 X4 X11 X11 X11 X11
X76
H-L1
1.20
C-B1 2 +15 28
1.20 1.20 4.1
G-V1
H-L1
C-B1
F5A F5C
8 11 6 3A 10A
X9 X9 X9 +30
+15 +30 +15 K10
K5 86 87a 87 K6 86 87a 87
+15
F3C F5B F4A F7B F6C F6B +
7.5A 15A 15A 85 30 85 30 10A 10A 7.5A F7C

25 C R
4.12 10A
24
4.1
15 1
4.1 1.20 3
1.20
16
4.1
X8 X8 X8 X8 X8 X8 X8 X8 X6 X6 X9 X6 X5 X5 X5 X5 X14 X14 X14 X10 X10

10 4 1 2 12 17 14 16 5 7 1 10 6 8 9 7 2 1 3 1 4
G-R1
A-B1
R1
G1
R1
A1
S-N1
A-B1
G-R1
B1
G1
B1.5
R1
A1
M1.5
G-N1.5
B1.5
M1.5
C-V1.5
A-G1.5
A-R1.5
G1.5
H1.5
5 4 1 2 3 6 8 7
X37 X37 X37 X37 X37 X37 X37 X37
G1
A1
G-R1
1 3 2 4 1 6 4
A-B1
X64 X64 X64 X64 X63 X63 X63
1 2 1 2
X67
X25 X25 X26 X26 X57 X57 X60 X60 X65 X65 X65 X67 X67 X67 X65 H7
H2 H3 H4 H5
Y3 Y4
R
L
57
57
56a
56b
56a
56b
R
59c
59c
L
57
57
1 2 H1 H6 M H8
X16 X16
M3 M
31
31
31
31
AUTORADIO RIGHT LEFT LEFT B.
POWER SUPPLY X25 FRONT FRONT
X57 RIGHT B.
3 3
N1.5
N1.5
N1.5
N1.5
N1.5
R1
N1
N1
2.9
N1
N1
31 31
2.20 4.1
COMPONENTS K10 Flasher unit CONNECTORS X25 Right front light 3 way connector RKP11720
H1 Boom working light M3 Blower motor X4 Right lateral dashboard line 12 way connector X26 Right side and direction light terminals X76 Dashboard extension 17 way connector
H2 Front right light S1 Gear high-low speed button X5 Engine line 11 way connector X37 Rear line 8 way connector FUSES
H3 Front left light S4 Working light switch X6 Lights switch-gear shift line 13 way connector X49 7 way connector lights switch and dashoboard line F3C Radio and cabin power fuse 7.5A
H4 Rear left light S5 Shovel-stabilizer selection button X8 Loom line 21 way connector X57 Left front light 3 way connector F4A Main beam fuse 15A
H5 Rear right light S6 Hazard X9 Lights switch-gear shift line 21 way connector X60 Left side and direction light terminals F5A Left traffic light fuse 3A
H6 Number plate lamp S7 Rotating lamp switch X10 Colum switch line 5 way connector X61 Lights switch 12 way connector F5B Low beam fuse 15A
H7 Beacon lamp S16 Heater switch X11 Lateral dashboard line 13 way connector X63 Cabin 7 way connector F5C Lights switch power fuse 10A
H8 Cabin working light Y3 Slow speed valve X13a Air condition interface 1 way connector X64 Heater 4 way connector F6B Direction indicators power fuse 7.5A
K5 Main beam relay Y4 High speed solenoid valve X14 Colum switch-frame line 5 way connector X65 Left side and direction light terminals F6C Hazard power fuse 10A
K6 Low beam relay X15 Parking brakes lamp 1 way connector X67 Right side and direction light terminals F7B Working light fuse 10A
PW110R-1
X16 Radio 2 way connector X75 Dashboard extension 21 way connector F7C Cabin power(+15) and beacon fuse 10A 10-131
PAGE INTENTIONALLY
LEFT BLANK

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

GEAR SHIFT STEERING CONTROL UNIT
X62 X62 X62 X62 X62 X62 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68 X68
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B-G1
S-N1
B-G1
H-R1
H-N1
H-N1
1.20
G-R1
R-G1
C-N1
G-V1
B-G1
B-N1
M-B1
C-L1
R-N1
S-N1
B-R1
A-V1
R-V1
Z-B1
Z-N1
L-R1
L-R1
V/B1
S1.5
B1.5
S1
C1
N1
V1
H1
R1
H-R1
1.20
R-G1
1.20
M-B1
1.20
Z-N1
7 7 4 5 2 1 3 4 5 11 12 20 19 17 18 9 21 6 10 8 3 13 2 15 4 1 1 1.4
X9 X7 X9 X9 X1 X1 X1 X1 X1 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X33
2.11 12 F1A F1C 25

7.5A 3A 3.4 1
X46
13 L-R1
2.1
2.12 10
2.7
14
2.13 9 8
2.7 2.7
24
3.4 11
+15 +15 30
2.7 1.17
15
3.4
16
3.7
28 A-N1
3.20 1.20
X10 X10
2 3
R-N1
R-V1
V-B1
L-R1
R1
L-R1
H1
A1
S1
V1
9 8 13 10 12 11 6 2 3 5 7 1 4 14
1
X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30 X30
X48
GIUNTO
JOINT
B-R1
C1
X30a X30a X28 X30a X30a X30a X30a X30a X30a X30a X30a X30a X30a X28 X28 X28
9 8 1 10 12 11 6 2 R1 3 5 7 1 4 3 4 2
B1
C-B1
Z1
G-R1
V-B1
H1
S1
A/V1
S1
V1
L1
3 2 5
X29
X29
X29
X29
S12 C B A C B A
R-N1.5
X63 X63 X63
R-N1
R-V1
X32a
X32a
X32a
X31a
X31a
X31a
1 2 3 4
H9
M4
M1
M1
N1
N1
L1
L1
Y12 Y15 Y1 Y2 Y14 Y13 L-R1
1
M
1
SENSORE DI
MOVIMENTO SENSORE PONTE SENSORE PONTE -
MOVEMENT ANTERIORE POSTERIORE XW
SENSOR FRONT AXLE REAR AXLE Y6
2
SENSOR SENSOR
+
XW
N2.5
N1.5
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
31 31
3.20 /./
RKP11730
COMPONENTS Y12 Stabilizer solenoid valve X10 Colum switch line 5 way connector X46 Dashboard wiring 9 way connector
H9 Cabin lamp Y13 Round steering solenoid valve X28 Inferior cart line 4 way connector X49 Diode 2 way connector
M4 Washer wiper motor Y14 Crab steering solenoid valve X29 Optional 4 way connector X62 Gear shift 6 way connector
S12 Speed connection microswitch Y15 Gear power change solenoid valve X30 Joint 17 way connector X63 Cabin 7 way connector
V2 Power Mode valve 1A diode X30a Inferior cart line 12 way connector X68 Steering and gear unit 35 way connector
CONNECTORS
Y1 Front steering solenoid valve X31a Rear axle sensor 3 way connector XW EV Power Mode 2 way conn.
X1 Gear-steering interface line 5 way connector
Y2 Double steering solenoid valve X32a Front axle sensor 3 way connector FUSES
X7 Steering interface line 21 way connector
Y6 Working Mode solenoid valve X33 Engine line 7 way connector F1A Steering valves fuse 7.5A
PW110R-1 X9 Lights switch-gear shift line 21 way connector
X35 Power Mode resistor 2 way connector F1C Axle proximity power fuse 3A
10-133
PAGE INTENTIONALLY
LEFT BLANK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PANNELLO DI CONTROLLO CONTROL PANEL
POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO
COMUNE SPIE LENTA-VELOCE ILLUMINAZIONE NOTTURNA
L7-L8 X81/1 -- ISOLATA A-V1 +L X81/9 NIGHTLIGHT +LUCI G-M1
STRUMENTO IND. LIV. CARB. USCITA BUZZER
S3 X81/2 FUEL LEVEL GAUGE ohm G1 X81/10 BUZZER O/P NEGATIVO A-R1
S2 S3 STRUMENTO TEMPERATURA SPIA AVARIA FRENI (rosso)
H F S2 X81/3 COOLANT TEMP. GAUGE ohm H-N1 L5 X81/11 W/L BRAKE SYSTEM FAILURE (red) NEGATIVO V-Z1
SEGNALE DI START SPIA PRERISCALDO (giallo)
+50 X81/4 START SIGNAL +50 B-G1 L2 X81/12 W/L PREHEAT (yellow) POSITIVO R-V1
S1
SPIA BLOCCAGGIO PONTE (giallo)
X81/5 NC L12 X81/13 NEGATIVO S0.5
00000 00 h W/L AXLE BLOCKED (yellow)
MASSA SPIA FILTRO ARIA (rosso)
S1 GND X81/6 GROUND GND N1 L4 X81/14 W/L AIR FILTER (red) NEGATIVO V-B1
C E
L11 X81/7
SPIA PALA-STABILIZZATORI (giallo)
W/L SHOVEL-STABILIZER (yellow) NEGATIVO G0.5 L1 X81/15
SPIA GENERATORE (rosso)
NEGATIVO Z-B1
W/L CHARGE (red)
L1 L2 L3 L4 L5 L11 +15 X81/8
POSITIVO ALIMENTAZIONE (+12V)
+15 H-G1 L3 X81/16
SPIA PRESS. OLIO MOTORE (rosso)
NEGATIVO V1
POWER SUPPLY (+12V) W/L ENGINE OIL PRESS. (red)
F
POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO POS. PIN FUNZIONE CONNESSA COMANDO COLORE FILO
SPIA INDIC. DI DIREZIONE (verde)
X82/1 NC L9 X82/5 W/L DIRECTION INDICATOR (green) POSITIVO A1
L6 L7 L8 L9 L10 L12 SPIA MARCIA LENTA (giallo) SPIA LUCI ABBAGLIANTI (blu)
L8 X82/2 W/L FLOAT (yellow) ISOLATA C-B1 L10 X82/6 W/L HIGH BEAM (bleu) POSITIVO B1
SPIA FRENO A MANO (rosso)
L6 X82/3 W/L PARKING (red) NEGATIVO G-N1 X82/7 NC
SPIA MARCIA VELOCE (giallo)
L7 X82/4 W/L FAST GEAR (yellow) ISOLATA H-L1 X82/8 NC
S2 S3
INTERNAL ELECTRICAL SCHEME
TABELLA VALORI DI TARATURA STRUMENTO TABELLA VALORI DI TARATURA STRUMENTO
X81/11
X81/15
X81/12
X81/16
X81/13
X81/10
X81/14
X81/7
UNITA' CALIBRAZIONI UNITA' CALIBRAZIONI
∞C <55 80-95 105-110 >110 level 0 RISERVA 1/2 4/4

X81/8
da sconnesso 6,6K 100 3,3K100 <2,9 K100 da sconnesso 360 2 155 2 35 2 +
OUT BUZZER
ohm ohm
a >14,2K100 4,3K 100 2,9K 100 0 a >360 262 2 116 2 0
L1 L2 L3 L4 L5 L11 L12
n∞ barra 1 4 7 8 n∞ barra 0 1 4 8
TERMOMETRO LIVELLO
barra sempre barra barra lamp. tutte le barre barra riserva ACQUA CARBURANTE
Note accesa al +15 lampeggiante +suono buzzer Note spente lampeggiante
S2
S1
S1 CONTAORE
CONTAORE MECCANICO S3
CONNECTOR
CIFRE BIANCHE INDICANO LE ORE L6 L9 L10
CIFRE ROSSE INDICANO I CENTESIMI DI ORA

1 9 - L7 L8
LED VERDE INTERMITTENZA OGNI SECONDO X81/6
1 5
X81/3 X81/2
X81/1
X82/3
X82/2
X82/5
X82/6
X82/4
4 8 8 16 X81/9
RKP11740
PW110R-1 10-135
PAGE INTENTIONALLY
LEFT BLANK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
POS DESCRIZIONE FUNZIONE FUNCTION DESCRIPTION
1 MASSA GROUND PULSANTIERA PRINCIPALE MAIN SWITCHES PANEL

2 ALIMENTAZIONE SCHEDA/PULS. PANEL POWER SUPPLY
4 PULSANTE AVV. ACUSTICO HORN BUTTON
5 OUT PULS. FRENO PARCHEGGIO OUT BUTTON PARKING BRAKE
6 INTERR. STERZATURA TONDO ROUND STEERING SWITCH
7 INTERR. 2 RUOTE STERZANTI 2 WHEEL STEERING SWITCH
8 INTERR. STERZATURA GRANCHIO CRAB STEERING SWITCH

X73 9 OUT E/V BENNA GRAB VALVE OUT SIGNAL
10 OUT E/V MARTELLO HAMMER VALVE OUT SIGNAL
11 ALIMENTAZIONE RELE' RELAIS POWER SUPPLY
12 N.C. N.C.
13 N.C. N.C.
14 OPTIONAL OPTIONAL
15 RELE' PINZA PLIERS RELAY
16 OUT E/V BLOCCO ASSALE AXLE LOCK VALVE OUT SIGNAL
17 OUT E/V WORKING MODE WORKING MODE VALVE OUT SIGNAL
18 OUT E/V STABILIZZATORI / LAMA STABILIZER,BLADE VALVE OUT SIGNAL
1 ALLINEAMENTO POSTERIORE REAR ALIGNMENT
2 ALLINEAMENTO ANTERIORE FRONT ALIGNMENT
3 SEGNALE PRESS. ANTIRIBALTAMENTO ANTI OVERTURNING PRESSURE SWITCH SIGNAL
4 N.C. N.C.
5 N.C. N.C.
X72 6 PULSANTE PEDALE MARTELLO HAMMER PEDAL BUTTON
7 PULSANTE PINZA PLIERS BUTTON
8 PULS. MARTELLO O CHIUDI BENNA HAMMER OR CLOSE GRAB BUTTON
9 PULSANTE APRI BENNA OPEN GRAB BUTTON
10 N.C. N.C.
11 ALIMENTAZIONE RELE' RELAIS POWER SUPPLY
12 OUT E/V FRENO DI PARCHEGGIO PARKING BRAKE VALVE OUT SIGNAL
1 OUT SPIA FRENO DI PARCHEGGIO OUT PARKING BRAKE LAMP
2 N.C. N.C.
3 OUT SPIA BLOCCO ASSALE OUT AXLE LOCK LAMP
4 OUT SPIA PALA/STABILIZZATORI OUT BLADE STABILIZER LAMP

X79
5 +COMUNE PULSANTI E SPIE +COMMON SWITCH AND LAMP
6 PULSANTE FRENO DI PARCHEGGIO PARKING BRAKE BUTTON
7 N.C. N.C.
8 PULSANTE PALA /STABILIZZATORI BLADE/ STABILIZER BUTTON
9 PULSANTE BLOCCO ASSALE AXLE LOCK BUTTON
RKP11750
PW110R-1 10-137
PAGE INTENTIONALLY
LEFT BLANK

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

STEERING CONTROL UNIT CONNECTION
X68
1 + RELE' E/V STERZATURA STEERING RELAYS POWER SUPPLY
2 N.C. N.C.
3 E/V STERZATURA ANTERIORE 2 WHEEL STEERING SOLENOID VALVE
4 E/V STERZATURA DOPPIA DOUBLE STEERING SOLENOID VALVE
5 E/V STERZATURA GRANCHIO CRAB STEERING SOLENOID VALVE
6 E/V STERZATURA TONDO ROUND STEERING SOLENOID VALVE
7 + SCHEDA ELETTRONICA ELECTRONIC BOARD POWER SUPPLY
8 + DEVIO CAMBIO AVANTI / INDIETRO FORWARD/REVERSE SHIFT POWER
9 E/V CAMBIO CILINDRATA (I e II) E. POWER CHANGE VALVE (I and II)
10 E/V MARCIA VELOCE FAST SPEED SOLENOID VALVE
11 E/V MARCIA LENTA SLOW SPEED SOLENOID VALVE
12 + E/V CAMBIO GEAR SHIFT VALVE POWER
13 N.C. N.C.
14 N.C. N.C.
15 N.C. N.C.
16 N.C. N.C.
17 N.C. N.C.
18 INTERRUTTORE CAMBIO VEL. (I e II) SWICH SPEED CHANGE (I and II)
19 N.C. N.C.
20 MASSA CENTRALINA (GND) MAIN BOARD GROUND
21 N.C. N.C.
22 INGR. MARCIA AVANTI / INDIETRO INPUT FORWARD/REVERSE SPEED
23 N.C. N.C.
24 E/V POWER/ECONOMY POWER/ECONOMY VALVE
25 INGR. ALLINEAMENTO POSTERIORE INPUT REAR ALIGNMENT
26 INGR. ALLINEAMENTO ANTERIORE INPUT FRONT ALIGNMENT
27 N.C. N.C.
28 PULSANTE MARCIA LENTA/VELOCE SLOW/FAST SPEED SWITCH
29 PULSANTE STERZATURA GRANCHIO CRAB STEERING SWITCH
30 PULSANTE STERZATURA TONDO ROUND STEERING SWITCH
31 PULSANTE STERZATURA ANTERIORE 2 WHEEL STEERING SWITCH
32 INGR. FRENO DI PARCHEGGIO INPUT PARKING BRAKE
33 SENSORE CAMBIO IN MOVIMENTO GEAR MOVEMENT SENSOR
34 "W" FREQUENZA ALTERNATORE "W" GENERATOR FREQUENCY
35 OUT BUZZER OUT BUZZER
RKP11840
PW110R-1 10-139
PAGE INTENTIONALLY
LEFT BLANK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
DEVIO LUCI LIGHTS SWITCH DEVIO GUIDA GEAR SHIFT
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12
X62 X62 X62 X62 X62 X62
X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61 X61
15 SX DX MI MA I II
I 0
0 SX MI MA
DX II
+ +
56a 56b 30 57/58 L
X61 X62
POS DESCRIZIONE FUNZIONE FUNCTION DESCRIPTION POS DESCRIZIONE FUNZIONE FUNCTION DESCRIPTION
1 +15 DEVIO LUCI LIGHTS SWITCH POWER
1 + CAMBIO AVA./IND. GEAR FW/BW POWER S.
2 LUCI DI POSIZIONE SIDE LIGHT SIGNAL
2 + CAMBIO C. I e II GEAR I e II POWER S.
3 LUCI ABBAGLIANTI HIGH BEAM LIGHT SIGNAL
3 N.C. N.C.
4 N.C. N.C.
4 MARCIA AVANTI DEVIO FORWARD SPEED SIGNAL
5 LUCI ANABBAGLIANTI LOW BEAM LIGHT SIGNAL
5 OUT II VELOCITA' OUT II SPEED
6 AVVISATORE ACUSTICO HORN
6 MARCIA INDIETRO DEVIO REVERSE SPEED SIGNAL
7 MASSA CLAXON HORN GROUND
8 +30 LUCI POSIZIONE LIGHTS SWITCH POWER
9 DIREZIONE DX RIGHT INDICATOR SIGNAL
10 DIREZIONE SX LEFT INDICATOR SIGNAL
11 COMUNE DEVIO FRECCE INDICATORS SWITCH POWER
12 N.C. N.C.
RKP11760
PW110R-1 10-141
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION CONTROL UNIT FUSES - RELAIS (1/2)
CONTROL UNIT FUSES - RELAIS (1/2)
D1
+15V 4
X2 1 8 5 4 1 5 4 3 1 7 7
+30V
1A 1A
X1 X3 X4 3A X5 J3 X6
1 +BUZZER-
18 16 15 12 11 9 12 10 9 8 7 6 1 1 D2 D3
F1 F2 F3 F4 F6 F5 F7
A B C A B C A B C A B C A B C A B C A B C
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 7.5A
FUSE 15A
FUSE 15A
FUSE 10A
FUSE 15A
FUSE 15A
FUSE 10A
FUSE 15A
FUSE 10A
FUSE 10A
FUSE 3A
FUSE 3A
FUSE 5A
FUSE 3A
FUSE 3A
FUSE 5A
F1A
F1B
F1C
F2A
F2B
F2C
F3A
F3B
F3C
F4A
F4B
F4C
F5A
F5B
F5C
F6A
F6B
F6C
F7A
F7B
F7C
1 1 1 1 1 1 1
D6 D8 D10 D11 D12 D13 D15 D19 D16
1A K1 1A K2 1A K3 1A K4 1A K5 1A K6 1A K8 1A K9
3A
Z1
L1
L2
L3
L4
1A D9 3A D17
R1
1A D9
J6
J4 J5 6A D18
L5
L6
L4
6A D5
12 12 12 4 8
X7 X8 X9 X10 X11
1 1 1 1 1
RKP11800
RELAIS CONNECTORS FUSES F5A Left traffic light fuse 3A

K1 Forward speed valve relay X1 Gear-steering interface line 5 way connector F1A Steering valves fuse 7.5A F5B Low beam fuse 15A
K2 Reverse speed solenoid valve relay X3 Right lateral dashboard line 18 way connector F1B Gear valve fuse 7.5A F5C Lights switch power fuse 10A
K3 Speed connection relay X4 Right lateral dashboard line 12 way connector F1C Axle proximity power fuse 3A F6A Horn-current intake-transfer pump fuse 15A
K4 Key safety start relay X5 Engine line 11 way connector F2A Servocontrol valve fuse 5A F6B Direction indicators power fuse 7.5A
K5 Main beam relay X6 Lights switch-gear shift line 13 way connector F2B Joystick -instrument power fuse 3A F6C Hazard power fuse 10A
K6 Low beam relay X7 Steering interface line 21 way connector F2C Steering buttons relais fuse 7.5A F7A Stop light and heater 15A
K8 Horn relay X8 Loom line 21 way connector F3A Steering buttons relais fuse 7.5A F7B Working light fuse 10A
K9 Stop light relay X9 Lights switch-gear shift line 21 way connector F3B Safety start- fuel shut off fuse 7.5A F7C Cabin power(+15) and beacon fuse 10A
X10 Colum switch line 5 way connector F3C Radio and cabin power fuse 7.5A FUG1 Fuel shut off fuse 30A
X11 Lateral dashboard line 13 way connector F4A Main beam fuse 15A FUG2 General fuse 50A
F4B Right traffic light and instrument light fuse 3A FUG4 Preheating fuse 40A
F4C Generator and pull timers fuse 5A
PW110R-1 10-143
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION CONTROL UNIT FUSES - RELAIS (2/2)
CONTROL UNIT FUSES - RELAIS (2/2) +/devio/cambio

libero
9
7
8
5
7
6
+/devio/cambio
(libero)
puls./lenta/veloce ing/lenta/veloce puls.
10 4
ing/c/cilindrata II ing/c/cilindrata II
20 8
EV/2R/S spia/m/lenta crusc.
K4A
D10
D11
19 2 L1 1
EV/4R/S 11 spia/m/veloce crusc.
18 2 L2 1 K3B 5
EV/tondo 9 com/spie crusc.
K3A
17 2 L31 2 1 2 1 3 4 F5C 15
+15
EV/granchio +/devio/luci
14 2 L4 1 5 6 16
sw/marcia/ins 2 1
58/devio pos.
5 2 1 18
ing. marcia Ava./Ind. 56B/devio anabb.
X7 ing/freno/parcheg.
15 10 56A/devio abb. X9
4 2
1
out/buzzer +L/devio/freccie
K5A
K6A
D13
D12
2 1
ing.2R/S direz/sx
13 12
2 2
2 2
2 2
2 2
ing/tondo direz/dx
3 17
ing/granchio spia/hazard
K1A
K2A
D8
D6
11 F1A 14
+EV/sterz spia/abbagl.
16
+15
1 2 F1B 20
1
+EV/cambio m/avanti/devio
6 3 4 F1C 19
+proximity/scheda m/indietro/devio
12 5 6 13
EV/freno/rotaz alim/presa +30
1 3
press/rotaz avv/acustico
21 21
EV/c/cilindrata puls/pedale mart.
L5 1
R1
2 2 1 F5A
1/2W
1 2 10 58/ant/sx (posizione)
+30 +30
F5B 5
prox/all/post 1 K6B 7 56/B (anabbaglianti)
3 3 4 K5B 3 4 5
prox/all/ant 56/A (abbaglianti)
1 2
X1 2 3 4 11
L6
L7
EV/stabilizz/lama F4A ev/freno/di lavoro
5 5 8
EV/veloce +press./luci stop
EV/lenta 4 2 press./luci stop
4 press./avaria freni X6
1
1 1a/veloce/Risc
D9
D7
9 2a/veloce/Risc
2
K1B 5 3
3 4
EV/M/avanti
K2B 6
3 EV/M/indietro
4 12 EV/martello
5 13 EV/benna
8 EV/freno/parcheggio
4 EV/veloce
10 EV/lenta
14 21
prox/all. anteriore EV/freno/rotaz
16 7
prox/all. posteriore EV/blocco/ass
8 F2A 20
+15
sw.2R/S +sw/servocom
7 1 2 18
sw/tondo puls/pinza
6 19
sw/granchio press/antiribalt.
buzzer 5 1 +autoradio
12 11
sw/freno parcheggio press/rotaz
EV/stabilizz/lama
15 K8B 5 3 avv/acustico X8
2 3 4 16
sw/martello 1
58/ant/dx
1
X3 sw/benna 2 17 56/B
5404
10 12
D19
sw/blocco/assale 56/A
3 15
(sw/freno/lavoro) EV/pinza
sw/pinza 11 2 Faro/lavoro su braccio
press/antirib. 13 14 direzione/dx
9 F6A
+30
puls/pedale mart 13 +pompa/travaso
17 F3A 1 2 9
+rele pulsantiera livello carb.
1 2 16
+15
+rele pulsantiera 18 F2C op
5 6 F4B J4
4 F2B 15
+scheda/pulsantiera 3 4 3 4 J5 op
12
+strum
7
58/strum 10
4 +alternatore
sw/avv/acustico 11
K9A
9 +elettrostop
D16
rele/pinza 5
8 cons/avviam
press/avaria freni K4B 5 6
11 58/dx
livello carb 3 4 9
X4 (-) rele/stop
10
K9B 1
58/sx
2 luci/arresto
lamp/sw/risc
3
2 1
3 4 3 avv/retrom
X5
lamp/sw/fari/lavoro 2 1 5 4
6 GND
direx/sx 7
5 2 1 direz/dx
freno/parcheg.
P600
D18
1 8 direz/sx
direz/dx 2
J3 op
4
K8A
D15
f/lavoro su cabina
4007
4007
P600
F3B 1 girofaro
+15
2
5404 D1
2 1 4 3 +15/CAB X10
1
2
5404
1
1
+30/CAB
D17
5
X2-2
X2-1
2 1 op
D5
D2
D3
FLASCHER UNITS
1
J6
2
2
3
2
+15 +30
Z1
+30/sw/hazard 7 F6C 6 5
5 6
6 F6B F4C
+15/sw/hazard 3 4
4 1
1 F7C
(+sw/girofaro) 5 6
+sw/riscald 12 F7A
1 2
5
+sw/f/lavoro1 9 F7B
3 4
out/f/lavoro su brac. 5
10
X11 out/f/lavoro su cab.
13
(out/1/velocita/R)
11
(out/2/velocita/R)
out/girofaro 4
L/intermitt. 8
spia/frecce 2 F3C
+30
+intermittenza 3 5 6
RKP1810
PW110R-1 10-145
TESTING AND ADJUSTMENTS
Normal or standard technical data............................. 2 Checking and regulating the pressure

Special tools ............................................................ 15 of the steering system ..............................................41
Measuring the engine speed ................................... 17 Checking leakages in the steering cylinders ............42
Adjusting valve clearance........................................ 18 Checking the braking system ...................................43
Measuring compression pressure ........................... 19 Checking wear in the brake disks.............................48
Testing and adjusting fuel injection timing............... 20 Bleeding air from the brake lines..............................49
Testing and adjusting fan belt tension ..................... 22 Adjusting the parking brake......................................50
Checking and tightening the compressor fan-belt ... 23 Travel hydraulic equipment checking procedure......51
Adjusting the stroke of the accelerator lever ........... 24 Checking and adjusting the automatic
displacement control system of the travel motor ......52
Adjusting PPC valves clearance.............................. 25
Checking for leakages in the travel motor ................53
Adjusting the safety microswitch ............................. 26
Checking and adjusting the speed of
Measuring the swing circle axial clearance ............. 27
the travel propeller shaft...........................................54
Air bleeding from hydraulic circuits .......................... 28
Adjustment of the speed surveyor............................55
Releasing residual pressure from the circuits.......... 31
Adjusting boom and arm safety valves.....................56
Checking and regulating pressure in the hydraulic
Adjusting 2nd boom safety valves............................57
circuits ..................................................................... 32
Measuring and setting of pressure switch
Testing and setting of main valves .......................... 33
signal overload operation .........................................58
Adjusting PC valve .................................................. 35
Measurement of internal oil leakages
Measuring LS differential pressure in the swing motor ....................................................59
and adjusting LS valve ............................................ 36
Checking for leakages inside the swivel joint ...........60
Checking and adjusting pressures in
Analysis of the causes of hydraulic drifts .................63
the servocontrol feed unit ........................................ 38
Testing the air-conditioning unit ...............................73
Measuring pumps delivery and flow control
starting point pump P1............................................. 39 Emptying the air-conditioning unit ............................75
Checking that the priority valve is
functioning correctly................................................. 40
When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level ground.
Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine is un-
dergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed while the
liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
PW110R-1 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
NORMAL OR STANDARD TECHNICAL DATA

FOR ENGINE

Engine S4D106-1FB
Standard Permissible
Check item Test Conditions Unit
value value
High idling rpm 2200±50 2200±50
Engine speed Low idling rpm 1050±50 1050±50
Set speed rpm 2000 –
Sudden acceleration Bosch 0.9 Max. 1.5
Exhaust gas colour
At high idling speed index 0.5 Max. 1.0
Intake valve (20°C) mm 0.30±0.05 Max. 0.35
Valve clearance
Exhaust valve (20°C) mm 0.30±0.05 Max. 0.35
Compression
Oil temperature 69–72°C bar 34.3±1 27.5±1
pressure
(Engine speed) rpm 250 250
(SAE30 oil)
Blow-by
Water temperature in operating range -- --
pressure mm H2O
At high idling speed -- --
(SAE30 oil)
Max. idling (in cold state) bar Max. 5.9 Max. 5.9
Engine oil pressure High idling bar 3.92–4.90 –
At low idling bar Min. 1.0 –
Oil temperature Entire speed range °C 120 Max. 120
Fuel injection
B.T.D.C. degrees 11 1045–5512
timing
Deflection when pressed with finger
Fan-belt tension mm Max. 10 10–15
force of approx. 10 kg
20-2 PW110R-1
FOR MACHINE
★ All tests, if not otherwise specified, should be performed with WORKING MODE in posizion P.
Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Engine speed with – 50 – 50
pump P1 2050 + 100 2050 + 100
at max. pressure
Engine speed with • Oil temperature: 45–55 °C – 70 – 70
pumps P1 and P2 • Engine oil pressure: in correct range 2050 + 100 2050 + 100
at max. pressure
Engine
• Cooling water temp.: in correct range

Engine speed with • Swing lock pin inserted rpm
pumps P2 • Max. pressure P1: with boom 2150±50 2150–50
at max. pressure • Max. pressure P1-P2: with boom and swing
• Max. pressure P2: with arm and swing
Engine speed when pumps
P1-P2 are at max. pressure 2100±50 2100–50
and the WORKING MODE
selector is in pos. E
Boom a b a b
Arm
Spool travel control valve
Bucket
a b
Swing
Boom swing mm
45 6.5±0.3 6.5±0.3 45 6.5±0.3 6.5±0.3
Blade and outrigger
2nd boom
RKP08070
Travel
Attachment
Raise
Boom control lever Neutral 75±8 65–85
Lower
Extended
Arm control lever Neutral 75±8 65–85
Retracted
Open
Bucket control lever Neutral 75±8 65–85
Curled
Travel of levers and pedals
• At the and off Swing right

Swing control lever lever knob and Neutral 75±8 65–85
Swing left
at 90° of lever
Blade and outrigger • Reading at end Raise
of travel adding Neutral 100±10 85–115
control lever helf stroke Lower mm
• Engine
Fuel control lever stopped Min. Max. 120±15 100–140
• Equipment
on the ground Swing right
Boom swing pedal Neutral 14±4 8–20
Swing left
Open
2nd boom pedal Neutral 25±5 18–32
Closed
Travel control lever Neutral Max. 80±12 65–95
Brake pedal Zero Max. 30±3 25–35
PW110R-1 20-3
FOR MACHINE

cation value value
Raise boom 1±0.4 0.5–1.5
Operaring force for control of levers and pedals
Lower boom 1±0.4 0.5–1.5

Bucket curled-open 1±0.4 0.5–1.5
Arm open-close • Engine speed: low idling 1±0.4 0.5–1.5

• Oil temperature: 45–55 °C
Swing (R.H.-L.H.) • Instrument coupling at 70 mm from bottom lever 1±0.4 0.5–1.5
knob and perpendicular.
Read value 10 mm before end of stroke
Blade - outirgger kg 1.2±0.3 0.7–1.7
• For control pedal: Instrument coupling on outsi-
de edge.
Fuel control levers Read value 10 mm before end of stroke. 4±1 2.5–5.5
• For levers: Instrument coupling at centre of knob.
Boom swing pedal Read value 10 mm before end of stroke. 6.5±2.5 3.5–9.5
2nd boom pedal 2±0.5 1.2–2.8

Travel control lever 3±0.8 2–54
Brake pedal 0
50 -- 5 40–50--
• Engine speed: high idling 294 +0 20 294 +0 20

Main valve
P1 pump (Safety)
pressure

• Check one circuit at a time bar
• P1 pressure: boom control
P2 pump (Safety) • P2 pressure: blade control 216 +0 20 216 +0 20
Raise 294 +0 20 294 +0 20

Boom
Lower 294 +0 20 294 +0 20
Arm 294 +0 20 294 +0 20
Bucket 294 +0 20 294 +0 20
Swing 186/226 +0 10 186/226 +0 10
0
Blade 216 + 20 216 +0 20
R.H. outrigger bar 216 +0 20 216 +0 20
• Engine speed: high idling
L.H. outrigger • Oil temperature: 45–55 °C 216 +0 20 216 +0 20
• Check one circuit at a time
Hydraulic pressure
Boom swing 294 +0 20 294 +0 20

2nd boom 294 +0 20 294 +0 20
Travel 294 +0 20 294 +0 20
– 0.2
Servocontrols 32 + 1 Max. 33
• Engine speed: • Lever at NEUTRAL -- –

high idling
LS differential pressure • Travel speed: Hi bar
• Oil temperature: 14±2 12.2–16.2
45–55 °C • Wheels: raised

Steering 170 +0 10 170–180
• Engine speed: low idling
Braking bar 50±5 45–55
Recharge brake • Engine speed: low idling

90/120 ±10
accumulator • Press brake pedal until min and Max. pressures
20-4 PW110R-1
FOR MACHINE

cation value value
Work equipment at max. reach
– 0.3
Braking angle RKP06000
sec. 1+ 1 0,7–2
• Working Mode: P
• Make centring marks on the outer swing circle
rings. Rotate the upper turret 360° and stop.
Measure the difference between the marks after
stopping.
90° – –
Time taken to start swing sec.

RKP06000

• Oil temperature: 45–55 °C 180° 5.5±0.5 Max. 6.5
• Time taken also from starting position
to swing 90° and 180°

Swing
Time taken to swing RKP06000

sec. 35±3 30–40
• Working Mode: P
• Measure the time taken to make 5 full swings
• Check all the direction of swing
15°
Hydraulic drift of swing 135° RKP12690

degrees 0 –
• Load in the bucket 630 kg
• Engine stopped
• Oil temperature.: 45–55 °C
• Park the machine on a 15° slope and set the
boom at 135° 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.

Internal leakage
from swing motor
•
•
Oil temperature: 45–55 °C
Swing block: engaged
/min Max. 0.608 Max. 1.3
• Measure the leakage
PW110R-1 20-5
FOR MACHINE

cation value value
Measuring posture
2nd speed
+ 50 + 50
1150 – 100 1150 – 100
Travel motor swing RKP06020 rpm

speed (no-load) • Working Mode: P
4th speed
• Rest the front work equipment on the + 100 + 100
ground and push it down to raise the 3730 – 200 3730 – 200
machine
• Measure the speed of the propeller
shaft in 4th speed
Measuring posture
45°
2nd speed
8.9±1 8.9±1
2nd speed km/h

Traslazione
RKP06030
• Working Mode: P
4th speed

• Oil temperature: 45–55 °C 30.8±1 30.8±1
• On flat ground
• Travel for at least 20 metres and then
check on the time needed to cover 50
metres.
Hydraulic drift 15°

of travel motor mm 0 --
RKP06040
• Engine stopped
• Oil temperature.: 45–55 °C
• After 1 minute, mark the position; measure drift
for every 5 minutes and then check total drift in 15
minutes.
• Engine speed: 2000 rpm
• Oil temperature: 45–55°C
Leakage from
travel motor
• Working brakes: engaged /min – –
• 2nd fast gear engaged
• After 30 seconds start to measure for full minute
20-6 PW110R-1
FOR MACHINE

cation value value
Boom
Measuring posture A Max. 600 Max. 800
Total work equipment L=1850
(Standard boom) Boom
B Max. 600 Max. 800
(Downward movement L=2000
bucket teeth tips) A Boom
B C Max. 600 Max. 800
C
L=2300
Boom
RKP06051 A Max. 40 Max. 60
L=1850
Boom cylinder • In this position, measure extension or Boom
retraction of each cylinder, and any le- B Max. 40 Max. 60
(Retraction) L=2000
akages occurring when a load is ap-
plied to the tips of the bucket teeth. Boom
C Max. 40 Max. 60
• Horizontal levelled ground L=2300
• Bucket rated load: 630 kg
Boom
• Levers: neutral A Max. 40 Max. 60
• Engine: switched off L=1850
Arm cylinder • Oil temperature: 45–55 °C Boom
• Safety valve disengaged. B Max. 40 Max. 60
(Extension)
• Take measurements as soon as the L=2000
engine stops. Boom
C Max. 40 Max. 60
• Measure the variations every 5 minu-
L=2300
Hydraulic drift of working equipment
tes and check the total variation after

Bucket cylinder 15 mins. Max. 15 Max. 22
(Retraction)
Boom
A Max. 600 Max. 800
L=1850
Total work equipment Measuring posture
(2-piece boom) Boom
(Downward movement B mm Max. 600 Max. 800
L=2000
of tips of bucket teeth)
Boom
C Max. 600 Max. 800
L=2300
Boom
A A Max. 40 Max. 60
B L=1850
C
Boom cylinder Boom
B Max. 40 Max. 60
(Retraction) RKP06061 L=2000
Boom
C Max. 40 Max. 60
L=2300
Boom
A Max. 15 Max. 22
• In this position, measure extension or L=1850
retraction of each cylinder, and any le- Boom
2nd boom cylinders akages occurring when a load is ap- Max. 15 Max. 22
(Retraction) B
plied to the tips of the bucket teeth. L=2000
• Horizontal levelled ground Boom
• Bucket rated load: 580 kg C Max. 15 Max. 22
• Levers: neutral L=2300
• Engine: switched off Boom
A Max. 40 Max. 60
• Oil temperature: 45–55 °C L=1850
• Safety valve disengaged. Boom
Arm cylinder • Take measurements as soon as the Max. 40 Max. 60
(Extension) B
engine stops. L=2000
• Measure the variations every 5 minu- Boom
tes and check the total variation after C Max. 40 Max. 60
15 mins. L=2300
Bucket cylinder Max. 15 Max. 22
(Retraction)
PW110R-1 20-7
FOR MACHINE

cation value value
A
Boom
B A Max. 15 Max. 22
C L=1850
Boom swing Boom

B Max. 15 Max. 22
(Standard boom) L=2000
15° Boom
135° C Max. 15 Max. 22
L=2300
RKP12700
mm
• Bucket rated load: Boom
620 kg (with 1-piece boom) A Max. 15 Max. 22
580 kg (with 2-piece boom) L=1850
• Engine: switched off
Boom swing • Oil temperature: 45–55 °C Boom
• In the same position as above, park L=2000
B Max. 15 Max. 22
(2-piece boom)
the machine on a 15° slope and bring
the turret round to 135°. Measure the Boom
Hydraulic drift of working equipment
extension and retraction of the cylin- C Max. 15 Max. 22

der after 15 mins. L=2300
Outriggers RKP06081
mm Max. 10 Max. 15
• Engine: switched off
• Raise the outriggers and and measure the height
of the edge from the ground.
Measure the downward after 15 mins.
• Check one cylinder at a time
Blade
(measure the downward
movement of the edge of mm Max. 10 Max. 15
RKP06091
the blade) • Engine: switched off
• Raise the blade and measure the height of the
edge from the ground.
Measure the downward after 15 mins.
• Check one cylinder at a time
Boom Max. 3.3 Max. 13.0
2nd boom Max. 2.0 Max. 8.0

Internal cylinder leankage
(2 cylinders) (each cylinder) (each cylinder)

Arm • Oil temperature: 45–55 °C Max. 2.4 Max. 9.6
• Check leakages: on the cylinder on the side op-
cc/
Bucket posite to the one under pressure Max. 2.0 Max. 8.0
★ Check one cylinder at a time min
Boom swing ★ For the 2-piece boom check the two cylinders in- Max. 2.4 Max. 9.6
dividually but simultaneously.
Blade - Outriggers Max. 3.3 Max. 13.0
(each cylinder) (each cylinder)
Steering Max. 2.0

(each cylinder)
20-8 PW110R-1
FOR MACHINE

cation value value
(whitout braking)
Measuring posture
Raise
Boom – 0.1
3.0 +0.7 Max. 4.2
Bucket teeth on
the ground
RKP06100
Cylinders completely
Lower
extended 3.0±0.4 Max. 3.7
• Working Mode: P
• Oil temperature: 45 –55 °C
Measuring posture
Closed
2nd boom – 0.3
4.3 +0.7 Max. 5.5
retracted
RKP06110
Cylinder completely
Inout

• Working Mode: P
Work equipment

Speed
sec.
Measuring posture
Closed
Arm – 0.1
3.0 +0.7 Max. 4.2
Cylinder completely
retracted
RKP06120
Inout
• Whitout braking 0
extended 2.5 + 0.6 Max. 3.5
• Working Mode: P
Measuring posture
Curled
Bucket 3±0.3 Max. 3.0

Cylinder completely
retracted
RKP06130
Dump

• Working Mode: P
PW110R-1 20-9
FOR MACHINE

cation value value
Measuring posture
L.H.
Boom swing 5.5±0.6 Max. 6.2
Cylinder completely
retracted
RKP06140
R.H.
• Work equipment at max. reach
• Working Mode: P
Measuring posture
Raise
Attrezzature di lavoro
2.5 +0 1.4 Max. 4.5

Outriggers
Velocità
Resting on ground
sec.
RKP06150
Fully raised
Lower
– 0.2
2.6 + 0.7 Max. 3.6
• Working Mode: P
Measuring posture
Raise
Blade 2.5 +0 1.4 Max. 4.5
Blade on the ground
Blade raised to max. RKP06160

Lower
height – 0.2
2.6 + 0.7 Max. 3.6
• Working Mode: P
20-10 PW110R-1
FOR MACHINE

cation value value
Measuring posture
Boom (Standard) Max. 1 Max. 3
RKP06170
• Retract fully the cylinders of the arm and buc-
ket. Lower bucket to ground and measure time
taken for chassis to rise from ground.
Measuring posture
Work equipment
Time lags
Boom (2-piece boom) Max. 2 Max. 3

sec.
RKP06180
ket.
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

RKP06190

ket.
Extend the 2nd boom fully. Bring the boom into
a vertical position.
Close completely the 2nd boom and measure
the time taken increase the pressure.
PW110R-1 20-11
FOR MACHINE

cation value value
Measuring posture
A
B Boom
C A Max. 2 Max. 3
L=1850
Boom
Arm RKP06201
B Max. 2 Max. 3
L=2000
• Bring the boom into a horizontal po-
sition.
Retract the cylinder of the arm com- Boom
pletely and then extend it. C Max. 2 Max. 3
L=2300
Amount of time when arm stops for a
moment.
Measuring posture
Work equipment
Time lags
RKP06210 sec.
Bucket Max. 2 Max. 3

• Bring the boom into a horizontal position.
Retract the bucket cylinder completely, then ex-
tend it.
Measure the time that elapses between the buc-
ket stopping at dead centre and then starting to
move again.
Measuring posture
Outriggers RKP06220 Max. 1 Max. 1.5

• Raise the outriggers to their max. height and
then lower them. Measure the time it takes for
the front of the machine to be lifted off the
ground, starting from the time the outriggers
contacts the ground.
20-12 PW110R-1
FOR MACHINE

cation value value
Measuring posture
Work equipment
Time lags
Blade RKP06230 sec. Max. 1 Max. 1.5

• Raise the blade to its max. height, then lower
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.
PW110R-1 20-13
FOR MACHINE

cation value value
Working Mode P
Pumps delivery
with pressure at 140–183 Min. 140

• Engine: 2000±10 rpm 200±1 bar
Pumps
Gear pump and

piston pump
with pump under load
• Oil temperature:
/min
45–55 °C Working Mode E
with pressure at 116–150 Min. 116
100±1 bar
20-14 PW110R-1
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Measurement check points Symbol Code Name Q.ty Remarks
Commercially
Valve clearance A 1 Feeler gauge 1 –
available
1 Pressure gauge 1 Kit Yanmar

Compression pressure B –
2 Adapter 1 TOL-97190080
Commercially
1 Multi-scale tachometer 1 20 - 4000 rpm
available
Engine speed C
Commercially
2 Stroboscopic tachometer 1 6 - 30000 rpm
available
Commercially Digital temperature

Water and oil temperature D 1 1 – 50 - 1200°C
available gauge
823001279 Pressure gauge kit 1 –
1 – Pressure gauge 2 Scale 60 bar
E 3 – Pressure gauge 1 Scale 400 bar

Hydraulic pressure
Servocontrol kit
5 Digital differential 1 0–1000 bar
878000473 pressure gauge
F 1 Flowmeter 1 Delivery 0–300 /min
Commercially
Thickness of brake disks G 1 Feeler gauge 1 4.5/4.3 mm
available
Mount with O-Ring code

Hydraulic drift of boom H 1 21D-62-15530 Flange 1
21D-09-69870
Commercially
1 Maintenance station 1 For coolant R134a
available
Commercially Sampling every

Air conditioning unit L 2 Thermometer-hygrometer 1
available 15 seconds
Commercially
3 Leak detector 1 For coolant R134a
available
PW110R-1 20-15
PAGE INTENTIONALLY
LEFT BLANK
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 entan-
gled in rotating elements.
★ Do not start to measure engine speed until the following
conditions have been met:
• Engine cooling water temperature: 68–80°C C1
• Hydraulic system oil temperature: 45–55°C.
1 - Install and connect the tachometer C1.

★ If a stroboscopic tachometer C2 is used, make a
distinct mark on the motor pulley to facilitate the
reading.
RKPA5120
2 - Start the engine and check:

• Low idling without load (accelerator lever in «min-
imum» position).
• High idling without load (accelerator lever in «max-
imum» position).
★ Low idling: 1050±50 rpm
★ High idling: 2200±50 rpm
★ If the minimum and maximum engine speeds with-
out load do not fall within the correct range, check
the position stops of the accelerator lever and the
accelerator cable sheathing (See «ACCELERA-
TOR LEVER ADJUSTMENT») before performing RKPA5130
the stress tests.
• Engine rpm with the pumps working.
★ Max. speed with the P1 pump working:
– 50
2050 + 100 rpm
★ Max. speed with the P1 and P2 pumps working:
– 70
2050 + 100 rpm
★ If the efficiency is not within the permissible limits,
call the Authorised Repair Shop to come and give
the engine a diagnostic check.
PW110R-1 20-17
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

★ Adjust clearance between valves and rocker levers as
follows: 1
Unit: mm
At cold Intake valve Exhaust valve
engine 0.30 0.30
★ Ignition order: 1-3-4-2-1.....

★ Normal rotation sense: counterclockwise from flywheel
view.
• Adjusting procedure
RKPB1370
1 - Remove the cover valves (1).
2 - Rotate crankshaft in normal direction as long as cylinder

piston to be checked is at compression Top Dead Cent- 3
er (TDC).
2
★ In this position intake and exhaust valves are
closed.
3 - Loose lock nut (2) and unscrew tappet (3) of about 1
turn.
4
★ Check that valve insert (4) is laying flat on valve
YES NO
stem and that it is not worn askew.
1 - If valve inserts (4) are damaged, replaced
them with new ones. RKP10811
4
2 - Make sure that inserts feet and lay flat on valve
stem.
4 - Connect A1 feeler gauge between insert and rocker le- 3

ver to adjust; rotate the tappet (3) until touching A1 feel- 2
er gauge. Tight tappet (3) with lock nut (2).
A1
★ After tightening the lock nut, check the clearance
again.
5 - Adjust with same procedures second cylinder valve and
repeat same operation for the other cylinders, accord-
ing to the ignition order.
RKP10501
• Cover valves installation

1 7
1 - Check condition of cover valves (1), gasket (5), O-Rings
(6) and lock nuts (7); clean carefully contact surface on 6
cylinder head.
2 - Install valves cover (1), fit O-Rings (6) and lock nuts (7).
Cover lock nut: 25±3 Nm
5
RKP10511
20-18 PW110R-1
TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

When measuring the compression pressure be careful
not to get caught in cooling fan, in the alternator belt or in
1
other rotating parts.
★ Test condition: 2
• Engine: at operating temperature
• Hydraulic oil: 55–60°C.
• Battery: at full charge
• Valve clearance: adjusted (see «ADJUSTING
VALVE CLEARANCE»)
1 - Disconnect high pressure pipe (1).

RKPA5140
2 - Remove nozzle holder assembly (2) of cylinder to be

checked.
3 - Disconnect connector (3) of fuel cut-off solenoid valve.
4 - Crank engine with starting motor.
RKPB1380
5 - Install B2 adapter and connect B1 pressure gauge.

★ Check that seal is installed in the adapter and that it
is not damaged.
6 - Crank engine with starting motor and measure com-
B2
pression pressure.
★ Compression value:
Normal: 34.3±1 bar
Minimum permissible 27.5±1 bar at 250 rpm
★ Difference between cylinders: 2–3 bar B1
7 - After measuring, install the nozzle holder assembly (2),
connect high pressure pipe (1) feedback pipe and con-
RKPA5160
nector (3).
Nozzle holder collar bolts: 6.9–8.8 Nm
High pressure union: 19.6–24.5 Nm 40

Compression pressure
35
30
25
20
(bar)
200 250 300 350 400
Engine speed (rpm)
RKP10524
PW110R-1 20-19
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

★ Check fuel injection timing of N.1 cylinder by means of
N.1 delivery valve of injection pump.
Cylinder Nº1
★ Cylinders are numbered 1-2-3-4 starting from flywheel
side.
1 - Rotate crankshaft using engine pulley and put N. 1 cyl-
inder piston at top dead centre (TDC). 1
Flywheel
RKP11101
★ Top dead centre (TDC) is shown by notch (4) on

pulley (1) positioned on «zero» of the scale (5) and 4
by closing of both cylinder N. 1 valves.
★ If the notch (4) of pulley (1) is in «zero» position on
the scale (5) but cylinders N. 1 valves are not
closed, rotate the crankshaft of 1 turn.
5
★ After recognition of TDC, rotate the crankshaft in
counterclockwise direction (from pulley side view)
of about 20°.
1
RKPB3840
2 - Disconnect cylinder N.1 high pressure pipe (2) from in-

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

pulley side view, checking fuel level into the N. 1 delivery
of injection pump.
Nº1
RKPB3850
4 - Stop pulley (1) rotation as soon as fuel level starts to in-

crease. Level
N. 1 Union
RKP11111
20-20 PW110R-1
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING
5 - Check notch (4) position on crankshaft pulley (1) com-

pared with scale (5); reading value corresponds to an- 5
gle of fuel injection timing.
★ With new belt, deflection must be of 11°±1°
NOTE. Repeat checking more than once.
4
1
RKPB3860
6 - If injection timing is not on standard value, rotate injec-

tion pump (6) toward external or toward engine after 6
loosening pump nuts (7) (quantity 4) and pump lock nuts
(8) fixing the bracket (9) to injection pump.
7
• To RETARD injection, rotate the pump (6) toward
external.
• To ADVANCE injection, rotate the pump (6) toward
8
cylinders block.
Pump side
7 - Tight the pump lock nuts (7) at cylinder block and the nut
(8) fixing injection pump to bracket (9).
Carter side
9 Testing advance
Nuts: 34.2–44.1 Nm RKPB3871 injector
Bracket nut: 44.1–53.9 Nm
8 - Connect fuel delivery pipes (2) to pump.
Delivery pipe unions: 19.6–24.5 Nm
PW110R-1 20-21
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION

1. Tension check
1 - Push fan belt (1) at midway point between alternator (2)

and pulley operating water pump; check the deflection.
With a pressure of 98 N, deflection should be of 10–15 2
1
mm; if this value is not reached, tension fan belt.
★ With new belt, deflection must be of 7–9 mm.
RKPB1390
2. Fan belt tension

4
1 - Loosen mounting bolt (3) of the alternator (2) and
mounting bolt (4) of adjustment plate.
2 - Rotate the alternator (2) to give correct tension to fan

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

★ If belt has been replaced, check tension again after
about 20 operating hours.
3
Mounting bolt (3): 44.1–53.9 Nm
RKPB1400
Mounting bolt (4): 22.5–28.4 Nm
98 N
Water pump
pulley
10--15mm
Alternator
Crankshaft
pulley
RKP10533
20-22 PW110R-1
TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT
CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT

1. Checking tension
1 - Push fan belt (1) at midway point between compressor
(2) and pulley (3). Check the deflection. 7÷10 mm
With a pressure of 98 N, deflection should be of 7–10
mm; if this value is not reached, tension fan belt.
★ With new belt, deflection must be of 4–6 mm.
3
1 2
RKP12610
2. Fan belt tension

1 - Loosen bolts (4), (5) and (6) to leave free the compres- 5
sor (7) to rotate.
4
2 - Rotate the compressor (7) for tension the belt (8) and 7
lock the position with bolts (4), (5) and (6). 6
3 - Check fan belt (1) tension
★ If belt has been replaced, check tension again after
about 20 operating hours.
4
Bolt: 22.5–28.4 Nm 8
RKPB6181
PW110R-1 20-23
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR LEVER
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER

★ Test conditions:
• Engine: Switched off, but at working temperature.
• Low idling: within correct range.
• Hydraulic oil: 45–55°C
• Accelerator lever at the mid-point of its stroke.
1 2
1 - Use the stretcher (2) to eliminate clearance in the jacket
(1).
RKPA5240
2 - Raise the right-hand cover in order to reach the screws

(3) and (4).
3 - Unscrew the nuts (5) and (6) and tighten the screws (3)
and (4) in the support.
9
4 - Move the accelerator lever (9) slowly towards low idling 9
5 3 6 4
position. Stop this movement when the lever (7) on the
cover of the injection pump comes into contact with the
low idling adjustment screw (8).
5 - Adjust the screw (3) until it is 0.1 mm from the lever (9)
and lock it in this position with the nut (5).
RKPA5250
6 - Move the lever (9) towards the high idling position. Stop
this movement when the lever (7) on the cover of the in-
8 10
jection pump rests against the lead-sealed high idling
adjustment screw (10).
7 - Adjust the screw (4) to 0.1 mm from the lever (9) and
lock it in this position with the nut (6).
★ After adjustment, replace the right-hand cover and
check that the aperture does not impede the move-
ment of the lever (9) towards its extreme positions.
7
RKPA5260
20-24 PW110R-1
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE
ADJUSTING PPC VALVES CLEARANCE

The clearance of the PPC valve (hand and foot) levers is ad-
justed as follows.
Lower the working equipment to the ground and stop

the engine.
Turn the ignition key to the “I” position and move the
command levers in all directions in order to release all
pressure in the hydraulic circuits.
Return the ignition key to the “O” (OFF) position and re-
move it.
Push the lever of the safety device into the “LOCKED”
position.
Slowly loosen the oil-tank refuelling cap to eliminate re-
sidual pressure.
1 - Tighten the dowel (1) until eliminate clearance; tighten a

further quarter of a turn (90°).
★ While making this adjustment, take care not to ac-
tivate the plunger (2).
2 - Check that the pedal stroke is 25°. To adjust this stroke,
act on the end-of-stroke screw (3), after having loos-
ened the nut (4).
25
3 - Block the set position by tightening the nut (4) to the
°
specified torque.
Nut: 8±1 Nm
2
4
3
1
RKP11020
PW110R-1 20-25
TESTING AND ADJUSTMENTS ADJUSTING THE SAFETY MICROSWITCH
ADJUSTING THE SAFETY MICROSWITCH

• Engine: switched off but at working temperature.
• Hydraulic oil: 45–50°C. 2
1 - Unscrew the nut (1) that secures the microswitch (2).
2 - Tighten or unscrew the microswitch (2) to the extent in-

dicated.
★ Projection of microswitch: 16 +0 1 mm
3 - Secure it in position with the nut (1). 1
RKPA5270
2
1
16 0+1
RKP07480
20-26 PW110R-1
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 re-
volving frame with the revolving frame.
2 - Extend the boom, the arm and the bucket, in such a way
that they cover the maximum radius of action 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.
RKP09250
4 - Attach a comparator with a magnetic base (1) to the rear

surface of the under carriage (2), and rest the tracer on 3
the part machined to support the swing circle (3).
1
★ Place the tracer as close as possible to the swing
circle.
5 - Preload the comparator by about 3 mm and set this
measurement to zero.
2
RKPB0920
6 - Close the bucket, position the arm perpendicular to the

ground and rest the back of the bucket on the ground. Worked zone
7 - Force the boom down until the front of the machine ris-
es, in order to transfer the weight of the under carriage
onto the rear wheels.
8 - Check the movement of the comparator (1) in these

conditions. The value read corresponds to the value of
the swing circle axial clearance. 1
While the machine is raised, take care not to place
hands or feet beneath the wheels.
RKP09261
9 - Return the machine to phase 2 conditions and check

that the comparator returns to “zero”. If it does not, re-
peat the test, starting at phase 4.
150 ÷ 200 mm
RKP09270
PW110R-1 20-27
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS
AIR BLEEDING FROM HYDRAULIC CIRCUITS

Order for operations and procedure for bleeding air
Air bleeding procedure

Air bleeding item
1 2 3 4 5 6 7
Bleeding air Bleeding air Bleeding air Bleeding air
Bleeding air Start
Nature of work Start engine from from swing from travel from steering
from pump operations
cylinder motors motor unit LS circuit
• Replace hydraulic oil ❍ ❍ ❍ ❍ ❍ ❍
• Clean strainer ★1 ★1
• Replace return filter element ❍ ❍
• Replace, repair pump
❍ ❍ ❍ ❍
• Remove suction piping
• Replace, repair control valve ❍ ❍ ❍ ❍
• Replace cylinder
❍ ❍ ❍
• Remove cylinder piping
• Replace swing motor
❍ ❍
• Remove swing motor piping
• Replace travel motor, swivel
• Remove travel motor, ❍ ❍
swivel piping
• Replace steering unit or
priority valve
❍ ❍ ❍
• Remove steering unit or
priority valve piping
★1 Bleed the air from the swing motors or travel motors only when the oil inside the motor case has been drained.
1. Bleeding air from pump P1
★ When the hydraulic oil tank is drained, or when the main

pumps are removed for revision or replacement, air
must be bled from the intake circuit as follows:
1 - Loosen air bleed plug (1) from body pump (2).
2 - Fill the tank with oil up to the level of the hole in the
plug (1).
3 - Tighten plug (1).
Plug: 17.2±2.5 Nm 1
4 - Continue to fill the tank until the maximum level is
reached.
5- Starting the engine and run the engine at low idling 2

for 10 minutes.
(See «Bleeding air from hydraulic cylinders»).
RKPB2620
20-28 PW110R-1
2. Bleeding air from hydraulic cylinders

★ Once the hydraulic cylinders or the tubes connected to
them have been removed, the air must be bleed as fol-
lows:
1 - Start the engine and run at idling for approx. 5 min-
utes.
2 - Run the engine at low idling, then raise and lower

the boom 4-5 times in succession.
★ Operate the piston rod to approx. 100 mm be-
fore the end of its stroke.
3 - Increase engine speed to high idling and repeat the
operations described at point 2. Reduce engine
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.
3. Bleeding air from swing motor

1 - Connect hoses (1), drain hose (2) and brake swing
1
4
release hose (3). 3
2 - Fill the swing motor case with hydraulic oil from un-
5
ion (4). 2
3 - Connect hose (5).
4 - Start engine at low idling for approx. 10 minutes.
5 - Slowly swing in both direction few times.
2 1
RKPB6130
4. Bleeding air form the travel motor
1 - Connect motor feed pipes (1). 3 4

2 - Using the union (2) of the draining pipe, fill the cas-
ing with hydraulic oil (4) up to the bottom level of
hole.
3 - Connect the draining pipe (3).
4 - Start the engine and let it run for about 10 minutes in

2 1
order to heat the oil.
5 - Execute some slow travel actions in both ways.

RKPB2722
PW110R-1 20-29
5. Bleeding air from the Load Sensing circuit
★ 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 1
speed.
2 - Loosen the outgoing union (1) of the steering unit

(2). 2
3 - Start turning the steering wheel slowly, and con-
tinue until oil runs out of the union (1) without a trace RKPA7720
of air.
4 - Stop turning the steering wheel and tighten the un-

ion (1).
★ After the bleeding operation and before start-
ing to travel, execute a complete steering ac-
tion with both axles.
20-30 PW110R-1
TESTING AND ADJUSTMENTS RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS

1 - Rest the work equipment on the ground and stop the en-
gine.
2 - Put the ignition key at position “I” and move the control 0 1
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 remove

it. 0 1
4 - Put the lever of the safety device into the «LOCKED»
position.
5 - Slowly loosen the oil-tank filler-cap to release any re-
RKP10570
sidual pressure.
2. From the brake line accumulators

1 - Rest the work equipment on the ground and stop the en-
gine.
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).
PW110R-1 20-31
CHECKING AND REGULATING PRESSURE IN
TESTING AND ADJUSTMENTS THE HYDRAULIC CIRCUITS
CHECKING AND REGULATING PRESSURE IN

THE HYDRAULIC CIRCUITS
INTRODUCTION
• The control valve is divided into two normally independ-
3
ent sections, supplied by pumps P1 e P2 respectively.
• Each section is protected against overpressures by a
main (or primary) relief valve with a regolable cartridge.
• Each section is protected by safety valve with pre-set-
ting cartridge.
1 - Main relief valve (Section 1)
SECTION 1
2 - Main relief valve (Section 2)
3 - Safety valve
SECTION 2
P2
DIESEL P1 P2 2
TANK
P1
1
RKP10581
• The sections consist of the spools that govern:
Sezione Comando Utilizzi
Swing (Left-Right) A1 - B1
2
Blade (Down-Up) A2 - B2
9 9
Travel motor A3 - B3 10 10
Boom (Raise-Lower) A4 - B4 8 8
Arm (Open-Close)) A5 - B5 7 7
Bucket (Curl-Dump) A6 - B6 6 6
1 Blade and/or R.H. outrigger ✽ A7 - B7 5 5
(Lower - Raise) 4
4
Boom swing (Left-Right) A8 - B8
3 3
2-piece boom A9 - B9
2 2
★ Attachment (L.H. side - R.H. side) A10 - B10
1 1
✽ If expected
★ Optional PORTS A B RKP10591
20-32 PW110R-1
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES
TESTING AND SETTING OF MAIN VALVES

★ Check condition:
• Engine: at working temperature
• Engine idling MIN. and MAX.: within standard val-
ues
• WORKING MODE selector: position P
• Swing lock pin: applied.
Release the remain pressure from circuits.

(See «REMAIN PRESSURE REMOVAL FROM CIR-
CUITS»).
1. Main valve Section 1
Release the remain pressure from circuits. E3

(See «REMAIN PRESSURE REMOVAL FROM CIR- M1
CUITS»).
1 - Connect to pressure port M1 the gauge E3 (400
bar).
2 - Start the engine and bring the accelerator on high
idling speed position.
3 - Acting on one of upper attachments (boom, arm,
bucket) bring the piston rod at the end of its stroke
and check that the pressure value reading on RKPB2640
gauge is 294 +0 20 bar.

★ If the reading values on gauge are not the same as
shown, proceed to main valves setting.
2. Main valve Section 2 and swing motor safety valve
1 - Connect to pressure port M2 the gauge E3 (400

bar).
2 - Start the engine and bring the accelerator on high

idling speed position.
E3
3 - Raise the blade up to the end of stroke and check
that the gauge connected to port M2 shows a pres-
sure of 216 +0 20 bar. M2
4 - Put the blade or the outrigger on the ground and
make the upper structure swing on both directions;
check that the gauge connected to port M2 shows a
pressure value of 216 bar.
★ If the pressure values are lower than the value
shown, check the safety valves of swing motor. RKPB2650
PW110R-1 20-33
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES
3. Main valves setting

To make the valve setting, prepare the machine in the
same way as for pressure testing.
1st Section
1 - Loosen the locking nut (1).
2 - Adjust the pressure with screw (2).
2nd Section
• To INCREASE the pressure turn in CLOCKWISE
direction.
• To DECREASE the pressure turn in COUNTER-
CLOCKWISE direction.
3 - Lock the position with nut (1). RKPA5361
Locking nut: 49–59 Nm
RKP10600
20-34 PW110R-1
TESTING AND ADJUSTMENTS ADJUSTING PC VALVE
ADJUSTING PC VALVE
★ In case the engine speed lowers as a load becomes
larger, or in case the work equipment speed is slow
even though the engine speed, pump discharge pres- 1
sure and LS differential pressure are normal, adjust the
PC (1) valve according to the following procedure.
1 - Loosen the lock nut (2). For the cases of slow speed,
turn the sleeve (3) clockwise, and for the cases of low-
ering of engine speed, turn the sleeve counterclock-
wise.
★ Clockwise rotation of the sleeve «increases» the
suction torque of the pump, and counterclockwise
rotation «decreases» the absurption torque.
RKPB1490
★ Rotation range of the sleeve (3) shall be within 180°
for both clockwise and counterclockwise.
2- After adjustment finished, tighten the lock nut (2).
2
3
RKP10830
PW110R-1 20-35
MEASURING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE

AND ADJUSTING LS VALVE
1. Measuring ∆PLS differential pressure
i) Disconnect pipe (1) and connect a Tee on the union

(2); screw an adapter (3) on the Tee.
2
Connect pipe (1).
RKPA5370
3 E5
RKPB1500
ii) Connect the pressure gauge E5 to adapter (3) on

control valve and to adapter M1 (delivery pump
P1).
iii) Measure the ∆PLS differential pressure according

to the conditions shown in table 1. M1
Table 1
Work Fuel Differential
Operation
mode lever pressure
P Full Lever at NEUTRAL
Travel speed: Hi
p Full 14±2
Travel idling (lever full) RKPB1510
NOTE: Raised machine - Front axle locked.
20-36 PW110R-1
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE
2. Adjusting of the LS valve
If the values obtained during the measurement of the

differential pressure according to the foregoing condi-
tions are not in the standard value range, adjust the LS
valve (4) according to the following procedure. 4
1 - Loosen the lock nut (5) and turn the screw (6) to ad-
just.
• Turn the screw:
CLOCKWISE to increase the differential pressure;
COUNTERCLOCKWISE to decrease the differen-
tial pressure. RKPB4941
2 - After the adjustment finished, tighten the locknut

(5).
NOTE: Make sure to adjust the LS valve with measur- 5

ing the differential pressure.
6 RKP10820
PW110R-1 20-37
CHECKING AND ADJUSTING PRESSURES IN
TESTING AND ADJUSTMENTS THE SERVOCONTROL FEED UNIT
CHECKING AND ADJUSTING PRESSURES IN

THE SERVOCONTROL FEED UNIT
• Hydraulic oil: 45–55°C.
Release any residual pressures from the circuits (See

«RELEASING RESIDUAL PRESSURES FROM THE M3
CIRCUITS»).
1 - Connect the pressure gauge E1 to the adapter M3.
2 - Start the engine and move the accelerator into its max- E1
imum position.
3 - Put the lever of the safety device in its working position,

(UNLOCKED). RKPB5440
4 - Bring a servocontrol circuit up to pressure by operating

the work equipment (i.e. bucket).
5 - Check the working pressure on the pressure gauge E1

★ Working pressure: 32 --+ 12 bar
★ If the working pressure is lower that the permissible
value, check servocontrol feed unit valve.
RKP10630
20-38 PW110R-1
MEASURING PUMPS DELIVERY AND FLOW CONTROL
TESTING AND ADJUSTMENTS STARTING POINT PUMP P1
MEASURING PUMPS DELIVERY AND FLOW CONTROL

STARTING POINT PUMP P1
• Engine: at working temperature.
• WORKING MODE selector: position P.
• Work equipment on the ground and made safety.
• Swing lock pin inserted
1. Connecting the flowmeter

1 - Disconnect the delivery tube of the pump to be tested.
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 tube
disconnected in phase 1.
4 - Mount a rev. counter (C1 or C2) to measure that the de-
livery from the tested pump is within the tolerances al- To control valve
lowed for the rated engine rpm.
★ If an electronic pressure-transducer type rev. coun- 1
ter is installed on a diesel supply tube to the nozzle,
make sure that it is mounted at a distance from the
hose-clamps. From pump
★ When measuring deliveries with the pumps mount-
ed on the machine, it is difficult to use the acceler-
ator to count the precise number of revs needed for
this test. F1
Make delivery measurements with the engine run- RKP10641
ning at a speed close to the test speed and then

make a proportional calculation.
Example:
MEASUREMENT
Engine speed: 1950 rpm
Delivery: 108.80 /min
PROPORTIONAL DELIVERY AT 2000 rpm
108.80 x 2000 = 111.6 /min
-----------
1950
2. Measurement for pump P1

1 - Start the engine and bring it up to a speed of 2000±10
rpm with pump under load and WORKING MODE in P
position.
2 - Start the low speed travel and adjust the delivery pres-
sure with the flowmeter F1 knob (1) regulated at 200±1
bar.
3 - Check the flow with the value of «TECHNICAL DATA»
and making if necessary, the proportional calculating to
obtain the flow values referred to 2000±10 rpm neces- 1
sary to make the control.
If the measured values are lower than those per-
missible, it is necessary to overhaul or to replace
the pump.
4 - Turn the WORKING MODE selector on position E, re- F1
duce the pressure with flowmeter knob at 100±1 bar and
repeat the checks comparing the flow values with
«TECHNICAL DATA». RKPB1540
PW110R-1 20-39
CHECKING THAT THE PRIORITY VALVE IS
TESTING AND ADJUSTMENTS FUNCTIONING CORRECTLY
CHECKING THAT THE PRIORITY VALVE IS FUNCTIONING

CORRECTLY
• Working brakes: engaged.
E3
1. Checking the Load Sensing signal
1 - Connect pressure gauge E3 (400 bar) to the adapter
M2. M2
2 - Start the engine and put it into swing speed of 2000 rpm.
3 - Use the pressure gauge E3 to check the pressure value

when the steering wheel is not moving. RKPB5420
4 - Start to turn the wheel very slightly and see whether the
pressure increases.
5 - Complete the steering action and check that the pres-

sure increases up to the normal value (170 +0 10 bar)
when force is applied to the steering wheel. 1
★ If the pressure as measured by the pressure gauge
shows no variation when the steering wheel is
turned, or if excessive effort is required on the
steering wheel to execute the steering movement,
check that the priority valve (1) is functioning cor-
rectly.
RKPB5450
2. Checking that the priority valve is functioning

correctly 2 3
1 - Remove the priority valve (1).
(See «30. DISASSEMBLY AND ASSEMBLY»).
2 - Remove the cap (2) of the PP port and check (by push-
ing 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 ob-
structions. 1
4 - Re-assemble the priority valve (1). RKP09280
5 - Start the engine and bleed the Load Sensing circuit.

(See «BLEEDING AIR FROM THE LOAD SENSING
CIRCUIT»).
6 - Execute several steering operations and, if the difficulty

persists, overhaul or replace the steering unit.
20-40 PW110R-1
CHECKING AND REGULATING THE PRESSURE
TESTING AND ADJUSTMENTS OF THE STEERING SYSTEM
CHECKING AND REGULATING THE PRESSURE OF THE

STEERING SYSTEM
Test E3
1 - Connect pressure gauge E3 (400 bar) to the adapter
M2.
2 - Start the engine and put it into high idling and turn the M2
steering wheel as far as it will go.
3 - Apply extra force to the steering wheel in its fully turned

position. RKPB5420
★ Normal pressure: 170 +0 10 bar

4 - Repeat this check while steering in the other direction.
3
Adjustment
If the pressure is not within permissible limits, it can be ad- 5
justed from the safety valve (1) of the steering unit (2).
4
1 - Remove the cap (3).
2 - Using a 4 mm screw wrench, adjust the maximum pres-

sure through the screw (4). 1
• To INCREASE pressure turn in a CLOCKWISE di-
rection.
2
• To DECREASE pressure, turn in a COUNTER-
RKPB1360
3 - Stop the engine and replace the cap (3), making sure
that the washer (5) is properly seated.
Cap: 50±10 Nm
PW110R-1 20-41
TESTING AND ADJUSTMENTS CHECKING LEAKAGES IN THE STEERING CYLINDERS
CHECKING LEAKAGES IN THE STEERING CYLINDERS

• Hydraulic oil: 45–55°C 1
• Working brakes: engaged.
• Maximum steering pressure: within permissible
limits.
3
★ First check the front axle cylinder and then the rear axle
cylinder. 2
1 - Start the engine and execute a full steering movement
in one of the two directions.
RKPB2690
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 collect

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 leakages
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»).
★ 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 re-
lease air from the circuit.
10 - Use the same procedure to check the rear axle cylinder

after having selected one of the two types of steering.
20-42 PW110R-1
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM
CHECKING THE BRAKING SYSTEM

1. Checking accumulator recharging pressure

1 - Connect pressure gauge E3 (400 bar) to the adapter M5
of the accumulator line (1).
M5
2 - Start the engine and put it into low idling.
3 - Depress the brake pedal completely to fully recharge

E3
the accumulators. Check that the maximum accumula-
tor recharging pressure corresponds to the normal val- RKPB2700
ue (120±10 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 (90±10 bar).
Adjustment
If the pressures are not within normal values, proceed as fol-
lows:
Pressure at which to start recharging the

accumulators
2
This setting also causes variation in the maximum re-
charging pressure of the accumulators. It will therefore
also be necessary to perform the adjustment described
in the next paragraph.
3
1 - Loosen and remove the protective cap (2) and the
washer (3). RKPB5740
2 - Depress the brake pedal several times to reduce pres-

sure in the accumulators and then measure the pres-
sure at which the recharging operation will start.
3 - Loosen the nut (4) and adjust the initial recharging pres-
sure using the adjustment screw (5).
★ Initial recharging pressure: 90±10 bar.
• To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction. 5
• To DECREASE pressure, turn in a CLOCKWISE
direction.
4
4 - Secure the adjustment screw (5) with the nut (4).
RKPB5750
PW110R-1 20-43
Maximum accumulator recharging pressure

1 - Loosen the nut (6) and adjust the pressure by screwing
or unscrewing the screw (7).
★ Maximum pressure: 120±10 bar
6
direction.
2 - Secure the screw (7) with the nut (6).

7
3 - Re-assemble the washer (3) and the cap (2).
RKPB5751
2. Checking the braking pressure

1 - Connect the pressure gauge E2 (250 bar) to the adapter
of the brake line M6.
E2
2 - Start the engine and put it into low idling. M6
3 - Recharge the accumulators.
4 - Completely depress the brake pedal and check whether

or not the pressure is normal (50±5 bar).
RKPA7770
Adjustment of braking pressure

If the pressure is not within normal values, proceed as fol-
lows:
1 - Loosen the nut (8) locking adjusting screw (9).
2 - With the pedal fully depressed, adjust the braking pres-

sure using the adjusting screw (9).
★ Braking pressure: 50 +0 1 bar.
8
direction. RKPB5910
3 - Secure the position of the screw (9) with the nut.
Lock nut: 45±4 Nm
9 8
RKPB5760
20-44 PW110R-1
3. Check the leaktightness of the hydraulic braking

circuit
1 - Connect the pressure gauge E2 (250 bar) to the adapter
of the braking line M6.
E2
M6
3 - Execute several braking actions to empty the accumu-

lators and then recharge them completely.
4 - Stop the engine and return the ignition key to position “I”
in order to supply voltage to the electric circuits.
RKPA7770
5 - Use the working brake engagement button to execute 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 reading.
★ 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 details, see
«MEASUREMENT OF INTERNAL OIL LEAKAG-
ES IN THE SWIVEL JOINT»).
3 - The leaktightness of the brake groups (For details,

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 axles is iden-
tical.
11
1 - Release all residual pressure in the accumulators. A
2 - Disconnect the flexible hose (12), leading out of the 12
swivel joint (branch 7 for front axle, branch 8 for rear ax-
le), from the rigid front axle supply tube (11) (on the LH
side of the lower frame).
E2 13
3 - Insert tube “A” between the two tubes, connecting it in
such a way that the cut-off cock (13) is connected to the
flexible hose leading out of the swivel joint.
RKPA7801
PW110R-1 20-45
4 - Attach the pressure gauge E2 (250 bar) to the adapter

and open the cock (13).
6 - Push the working brake engagement button to recharge

the accumulators.
7 - Check that the braking pressure indicated by the pres-

sure gauge E2 is 50±5 bar.
8 - Close the cock (13) in order to maintain pressure in the

branch under examination, then stop the engine.
9 - Watch the pressure indicated by pressure gauge E2 for

2 minutes.
• If the pressure value goes down, it means that at
least one piston in one of the two brake groups un-
der examination is defective. Test the defective
group, following the procedure described in the
next paragraph.
• If the pressure value remains constant, the leak-
ages are occurring in the rear axle.
Identification of the defective brake group

1 - Insert tube “A”, complete with the pressure gauge E2,
into the supply line of the defective axle.
2 - Disconnect the supply tube (15) of one of the two brake

groups from the Tee (14). Seal the free side of the Tee
(14) securely. 11
A
3 - Following the same procedure indicated for identifica- 12
tion of the defective axle (from point 5 to point 8), pres-
surise the brake group that is still connected and close
the cock (13).
E2 13
4 - Watch the pressure indicated by the pressure gauge E2
for two minutes.
• If the pressure value goes down, it means that at
least one brake piston is defective. RKPA7801
• If the pressure value remains constant, the other

brake group is defective.
1- Further confirmation of the leakage of one or more

brake pistons can also be found through an in-
crease in the level of oil in the central body of the 15
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, 14
change all sealing rings between axle sections
and carry out a complete change of the lubrication
oil.
RKPB2710
20-46 PW110R-1
5. Checking the alarm pressure switch setting

for insufficient braking pressure
Before performing this test, first verify that there are no leak- 1
ages in the brake lines.
1 - Connect pressure gauge E3 (400 bar) to the adapter M5

of the accumulator line (1).
2 - Start the engine and put it into low idling. M5

3 - Execute several braking actions with the pedal until the
accumulators are completely recharged (120±10 bar). E3
4 - Stop the engine and return the ignition key to position “I”, RKPB2700
in order to supply voltage to the electrical circuits.
5 - Using the working brake engagement button, execute

several braking actions (count them) while keeping a
check on both the warning light that indicates insuffi-
cient braking pressure and the pressure gauge E3.
The warning light should come on when the following
conditions have been reached:
• residual pressure: 80 +0 2 bar
• minimal number of braking actions:15.
Adjustment
If the warning light comes on at values higher or lower than
80 +0 2 bar, adjust the intervention setting of the pressure
switch (16) that causes the warning lamp to light up.
The setting is obtained by turning the screw (17).
• Switching pressure: 80 +0 2 bar
• To INCREASE pressure turn in a CLOCKWISE direc-
tion. 16
• To DECREASE pressure, turn in a COUNTERCLOCK- 17
WISE direction.
RKPA7820
PW110R-1 20-47
TESTING AND ADJUSTMENTS CHECKING WEAR IN THE BRAKE DISKS
CHECKING WEAR IN THE BRAKE DISKS

2 - Execute several braking actions with the working
brakes, until the braking system accumulators are com-
pletely recharged.
3 - Stop the engine. 1
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».
★ Minimum thickness «S»: 4.5 mm
6 - Following the same procedure, check all the brake RKPB2890
groups.
1- If the thickness «S» of one of the two brake groups

of an axle is equal to or less than the minimum per-
missible thickness, change the disks on both
brake groups.
2- After changing the brake disks, bleed air from the
brake line. G1
(See «BLEEDING AIR FROM THE BRAKE
LINES»).
S
RKPB2900
20-48 PW110R-1
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE BRAKE LINES
BLEEDING AIR FROM THE BRAKE LINES

★ Bleed air from both axles.
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 but- 1
ton that engages the working brakes.
5 - Attach a transparent flexible hose (1) to the bleeding

RKPA7870
screws (2) in order to collect the oil.
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). 2

1
8 - Repeat the bleeding operation for the other brake
group.
★ If the level in the accumulators drops during the
bleeding operation, and the warning light for low
brake oil pressure comes on, interrupt the bleeding
operation and recharge the accumulators.
★ Once the bleeding operation is concluded, replace RKPA7880
the protective caps over the screws (2).
PW110R-1 20-49
TESTING AND ADJUSTMENTS ADJUSTING THE PARKING BRAKE
ADJUSTING THE PARKING BRAKE

★ Conditions for the adjustment:
• Engine at working temperature
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 - Adjust the clearance between the braking disks (For de- 5 4

tails see «ADJUSTING BRAKING DISKS CLEAR- RKPB2880
ANCE»).
3 - Press the button that releases the parking brake in order

to bring the circuit up to pressure.
4 - Loose nut (4) and (5) completely, disconnect the cylin-

der (1) from the levers (2-3).
2
★ Check the positions of the washer.
5 - Push the lever (2) towards the centre housing. Apply a 8÷10 N
force of approximately 1 kg until the inner part of the le-
ver rests on the brake disc.
7 6
RKPB2870
6 - Turn the adjusting screw (6) until it reaches the lever

(2).Tighten the lock nut (7) to block the adjusting screw
(6) in position.
Nut: 20–25 Nm
7 - Follow the same adjustment procedure for the other le-

ver (3).
8 - Tighten the nut (5) until the levers (2) and (3) rest
against the adjusting screws. 3
2
9 - Tighten the nut (5) against the bracket (8).
8 9 1 RKP11060
Nut: 50–60 Nm
10 - Stop the engine and check that when the parking brake
is on, the stem (9) juts out 4–5 mm from the head of cyl-
inder (1).
20-50 PW110R-1
TESTING AND ADJUSTMENTS TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE
TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE

★ Check conditions:
• Hydraulic oil: 45–55 °C
• Service brakes: on
This test id divided into two sections to facilitate identification
of the faulty member or part that is to be set.
1. Top portion of the equipment

Check that:
• Servocontrol pressure is normal (for details, see
«CHECKING AND ADJUSTING PRESSURES IN
THE SERVOCONTROL FEED UNIT»).
• That spools receive pressure from servocontrol.
• The distributor spool involved in travel executes the
whole travel (See «TECHNICAL DATA»).
• The valve in section 1 of the distributor is set. (For
details, see «TESTING AND SETTING OF MAIN
VALVES»).
• The pressure of differential unit ∆PLS of the LS is
normal (For details, see «MEASURING LS DIF-
FERENTIAL PRESSURE AND ADJUSTING LS
VALVE»).
• There is no internal blow-by in the swing joint (for
details, see «CHECKING FOR LEAKAGES IN-
SIDE THE SWIVEL JOINT»).
• The safety valves of the travel motor are set
(320±10 bar, bench controlled).
2. Bottom part of the equipment

Check:
• The operating point of the travel motor automatic
displacement change device.
For details, see «CHECKING AND ADJUSTING
THE AUTOMATIC DISPLACEMENT CONTROL
SYSTEM OF THE TRAVEL MOTOR»).
• Blow-by in the travel motor.
For details, see «CHECKING FOR LEAKAGES IN
THE TRAVEL MOTOR».
PW110R-1 20-51
CHECKING AND ADJUSTING THE AUTOMATIC
TESTING AND ADJUSTMENTS DISPLACEMENTCONTROL SYSTEM OF THE TRAVEL MOTOR
CHECKING AND ADJUSTING THE AUTOMATIC

DISPLACEMENT CONTROL SYSTEM OF THE TRAVEL MOTOR
E3
• Working brakes: engaged
M1
Test
1 - Connect the adapter M1 to the pressure gauge E3 (400
bar).
2 - Take off the cap and connect pressure gauge E4 (600

bar) to the automatic displacement control system (1).
3 - Select the 2nd fast forward gear. RKPB5410
4 - Bring the engine up to a speed of 2200 rpm.
5 - Press lightly on the travel pedal and watch whether the

pressure gauge E4 connected to the control system
starts to move when the pressure gauge E3 connected 1
to the adapter M1 indicates a pressure of 200 +0 10 bar.
E4
RKPA7900
Adjustment
1 - Take off the safety cap (2).
2 - Loosen the nut (3).

3 - Adjust the intervention point with the screw (4).
★ Intervention point: 200 +0 10 bar
2
CLOCKWISE direction
direction
4 - Secure the position of the screw (4) with the nut (3). RKPA7910
Lock nut: 10 Nm
5 - Replace the cap of the control system (1).
Cap: 30 Nm
4
6 - Replace the safety cap (2) to protect against unauthor-
ised tampering. 3
RKP09320
20-52 PW110R-1
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.
• Engine at working temperature 1 3
• Hydraulic oil: 45–55 °C
• Working brakes: engaged
• Selector in WORKING MODE: position P 2
1 - Disconnect the drainage tube (1) from the lower union
(2) of the motor (3) and plug it.
2 - Attach a provisional tube to collect the draining oil. RKPB2720
3 - Start the engine and bring it up to 2200 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 DA-
TA»).
7 - Stop the engine and re-assemble the hydraulic connec-

tions.
PW110R-1 20-53
CHECKING AND ADJUSTING THE SPEED OF
TESTING AND ADJUSTMENTS THE TRAVEL PROPELLER SHAFT
CHECKING AND ADJUSTING THE SPEED OF THE

TRAVEL PROPELLER SHAFT
• Machine: completely raised
• Front axle: blocked BLOCK
BLOCK
Test
★ 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 back
of the bucket resting on the ground. 10 cm
RKPB0821
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. 1
3 - Place safety blocks, height 10 cm, beneath the centre of
the axles to prevent the machine from dropping acci-
dentally.
After having lowered the axles gently onto the
blocks, check that the wheels are raised approxi- C2
mately 10 cm above the ground.
4 - Use blocks to stop the front axle from turning.
5 - Select the 2nd fast forward gear. RKPB2730
6 - Bring the engine up to high idling (2200±50 rpm) meas-

uring it with instrument 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
+ 100
Normal speed: 3730 – 200
Speed for TUV approval:
20 km/h 2550±100 2
25 km/h 3200±100
Adjustment
RKPB2130
1 - Take off the safety cap (2).
3 - Regulate the speed with the minimum displacement ad-
justment screw (4).
• To INCREASE the speed turn in a COUNTER-
• 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 unauthor-
ised tampering. 4 3
RKP10070
20-54 PW110R-1
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 transmission
(3) by hand until it rests on the toothed wheel (4).
★ Check the condition of the sealing washer (2) with
care.
2 - Unscrew the sensor (1) until a space of 0.5 +0 0.2 mm is
obtained between the sensor and the toothed wheel (4)
(0.5 - 0.6 turns). 5
3 - Secure the sensor with the nut (5). RKP09340
Lock nut: 22±2 Nm

4 - Connect the electric cabling and mount the protective
rubber sleeve (6). 6
Turn the protective sleeve (6) so that the cable
opening points towards the ground, in order to pre-
vent accumulations of water or condensates.
RKPB2740
PW110R-1 20-55
TESTING AND ADJUSTMENTS ADJUSTING BOOM AND ARM SAFETY VALVES
ADJUSTING BOOM AND ARM SAFETY VALVES

Boom
• WORKING MODE selector: position P V2
• Secondary valves: set to normal values.
(See «SETTING OF PRIMARY AND SECOND- 2
ARY VALVES»).
1
1 - Rest the work equipment on the ground, stop the engine
and release any residual pressures.
(See «RELEASING RESIDUAL PRESSURES FROM C2
THE CIRCUITS»).
RKPB1580
2 - Disconnect the pipe (1) from the coupling V2 and the

Arm
pipe (2) from coupling C2. 1
★ Disconnect the safety valve from the arm cylinder.
3 - Cap the pipe (2) to prevent entry of impurities.
C1
★ For the arm, cap the cylinder.
4 - Connect the tube (1) to the coupling C2.
★ For the arm, connect the flange V2 to the coupling
C2.
5 - Unscrew the nut (6) and remove the threaded rod (5) V2
and the nut (4).
RKPB1050
6 - Start the engine and bring it up to high idling speed.

5
7 - Bring the boom cylinder bottom side or the arm cylinder
6 10
head side slowly up to maximum pressure (270 bar),
checking that no oil leaks out of the valve. 4
3
8 - Maintaining pressure, adjust the valve with the screw 140 Nm
(3), until a slight leakage of oil (just a few drops every 7
minute) is seen coming from the flange V2.
• To INCREASE pressure, turn in a CLOCKWISE di-
rection. V2
• To DECREASE pressure, turn in an COUNTER-
★ Every turn of the screw (3) changes the pressure by
110 bar.
C2
9 - Block the screw (3) in position with the nut (4).
Lock nut (4): 70 Nm
10 - Screw the rod in (5) until it comes into contact with the T
retaining element (7) and then turn it back for 5-6 turns.
Secure it in position with the nut (6).
11 - Rest the equipment on the ground, stop the engine, and
P
release any residual pressures.
12 - Re-assemble the valve connections.
RKP07440
20-56 PW110R-1
TESTING AND ADJUSTMENTS ADJUSTING 2nd BOOM SAFETY VALVES
ADJUSTING 2nd BOOM SAFETY VALVES

• Engine: at working temperature 4
• WORKING MODE selector: position P
5
• Secondary valves: set to normal values. 2
(See «SETTING OF PRIMARY AND SECOND- 3
ARY VALVES»). 8
1 - Rest the work equipment on the ground, stop the engine
and release any residual pressures (See «RELEASING 1
RESIDUAL PRESSURES FROM THE CIRCUITS»).
★ Adjust the valves of one cylinder at a time. 7
RKPA5460
2 - Disconnect the pipes (1), (2), (3) and (4).
3 - Use hoses of equal section to connect up the pipes in

the following manner:
pipe (1) port (5). 10 9
pipe (2) port (6)
4 - Cap pipes (3) and (4) to prevent entry of any impurities.
5 - Remove the access caps (9) to the adjustment screws

(10) and (11).
6 - Start the engine and bring it up to high idling speed. 13
7
7 - Move the 2nd boom pedal to the end of its opening
stroke.
8 - Adjust the valve (12) until a slight leakage of oil can be

seen from the flange (8). 5
• To INCREASE pressure, turn in a CLOCKWISE di-
rection.
• To DECREASE pressure, turn in an COUNTER-
★ 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 valve

(13) until a slight leakage of oil is visible from the port (7).
6
11 - Stop the engine and release any residual pressures.
12 - Replace the caps (9) and re-assemble the hydraulic cir-

cuits.
8 12
Lock nut: 20 Nm
13 - Repeat the same regulation operations for the valves of

the other cylinder.
11 9
RKP07430
PW110R-1 20-57
MEASURING AND SETTING OF PRESSURE SWITCH
TESTING AND ADJUSTMENTS SIGNAL OVERLOAD OPERATION
MEASURING AND SETTING OF PRESSURE SWITCH

SIGNAL OVERLOAD OPERATION
E3
1 - Connect to pressure port M1 the gauge E3 (400 bar).

M1
2 - Start the engine and bring it at medium throttle.
3 - Apply the overload alarm.
4 - Raise boom until the lift end of stroke and increase lowly
the pressure; check the pressure value when appear
the overload signal.
★ Standard operating pressure: 140 bar RKPB1470
Setting
If the operating pressure in not within the standard limits,
make the pressure switch (1) setting as follows:
1 - Remove cover (2).
2 - Raise the boom checking on gauge E3 that hydraulic
cylinder approach the operating pressure.
3 - Loose the dowel (3) and turn the adjusting screw (4) un-
til to obtain the overload alarm signal. 1
• To INCREASE the operating pressure, turn the
screw in CLOCKWISE direction.
2
• To DECREASE the operating pressure, turn the
screw in COUNTERCLOCKWISE direction. RKPB6580
4 - Lock the position with dowel (3).

5 - Release the pressure and repeat several times the 4
measuring to check the setting stability.
RKPB5620
20-58 PW110R-1
MEASUREMENT OF INTERNAL OIL LEAKAGES
TESTING AND ADJUSTMENTS IN THE SWING MOTOR
MEASUREMENT OF INTERNAL OIL LEAKAGES

IN THE SWING MOTOR
2
• 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.
4 - Push the swing control lever as far as it will go. RKPB6131
5 - Hold it in this position for 30 seconds and then measure

the oil leakage for the next minute.
6 - Reduce motor speed to low idling, swing the revolving

frame 180° and repeat the measurement.
7 - Check that the average between the two measure-

ments falls within the normal range. (See «TECHNICAL
DATA»).
8 - Reassemble the hydraulic drainage circuit.
PW110R-1 20-59
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT

14 Slow gear insertion
13 Travel motor (Forward)
• WORKING MODE selector: position P. 12 Travel motor (Backward)
11 Axle locking
1. Functionality test
10 Blade-outrigger command (R.H. side)
1 - When one of the lower-level tools (blade, travel motors, 9 Blade-outrigger command (L.H. side)
speed increment, brakes) is found to be defective, one 8 Rear axle braking
of the causes of the failure may be the swivel joint. 7 Front axle braking
6 Blade-outrigger command (Rise)
2 - To confirm the defect it is sufficient to by-pass the joint
5 Fast gear insertion
by connecting (using an additional length of tubing) the
4 Parking brake
input and output hoses of the joint of the branch to be
3 Drainage (travel motor + EV OP2)
checked. 2 Front steering to the left
If the defect disappears, it is certainly due to the swivel 1 Front steering to the right
joint.
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 branch-
es subjected to working pressures. Tests on un-
stressed or unused branches are therefore
excluded.
The test method consists in pressurising the branch un-
der examination and measuring any leakage from ad-
jacent branches, as set out in the following table:
N° Branch to be tested (under pressure) Adjacent parts (Leakages) N°

External leakage (visible) --
14 Slow gear insertion
Travel motor (Forward) 13
Slow gear insertion 14
13 Travel motor (Forward)
Travel motor (Backward) 12
Travel motor (Forward) 13
12 Travel motor (Backward)
Axle locking 11
Travel motor (Backward) 12
11 Axle locking
Blade-outrigger command (Descent) (R.H. side) 10
Blade-outrigger command (Descent) Axle locking 11

10
(R.H. side) Blade-outrigger command (Descent) (L.H. side) 9
Blade-outrigger command (Descent) Blade-outrigger command (Descent) (R.H. side) 10

9
(L.H. side) Rear axle braking 8
Blade-outrigger command (Descent) (L.H. side) 9
8 Rear axle braking
Front axle braking 7
Rear axle braking 8
7 Front axle braking
Blade-outrigger command (Rise) 6
Front axle braking 7
6 Blade-outrigger command (Rise)
Fast gear insertion 5
20-60 PW110R-1
N° Branch to be tested (under pressure) Adjacent parts (Leakages) N°

Blade-outrigger command (Rise) 6
5 Fast gear insertion
Parking brake 4
Fast gear insertion 5
4 Parking brake
Drainage (travel motor and EV OP2) 3
Parking brake 4
3 Drainage (travel motor and EV OP2)
Front steering to the left 2
Drainage (travel motor and EV OP2) 3
2 Front steering to the left
Front steering to the right 1
Front steering to the left 2
1 Front steering to the right
External leakage (Visible) –
The numbers correspond to the numbers stamped on the input and output ports of the swivel joint.
3. Preparation for testing:

• travel motors 2 1
• travel brakes
• speed increment
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. RKP09350
Make sure that the detached tubes are securely
sealed, to prevent jets of high-pressure oil escap-
ing if circuits that are not undergoing tests should
accidentally become pressurised.
★ 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. 3
4. Preparation for testing the blade

1 - Relieve all residual hydraulic pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR-
CUITS»).
1
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.
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. 3

5 - Disconnect from the swivel joint the hoses (2) of the
branches adjacent to the branch to be tested, and cap
them tightly.
RKP07410
PW110R-1 20-61
Make sure that the detached hoses are securely

sealed, to prevent jets of high-pressure oil escap-
ing if the circuits that are not undergoing tests
should accidentally become pressurised.
★ The tubes of adjacent branches must be discon-
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.
5. Test
1 - Start the engine and bring it up to the test speed de-
scribed for each group or component.
2 - Pressurise the branch to be tested.
3 - After 30 seconds, watch for another minute if there are
any leakages.
★ If oil leaks out of one of the two provisional hoses, it
means that there is a leakage in the intermediate
gasket between the branch connected to the pro-
visional hose and the pressurised branch.
20-62 PW110R-1
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

★ If hydraulic drift occurs in the work equipment, a check
must be carried out to see if the cause is due to a cyl-
inder gasket or to the control valve.
★ Conditions for all checks:

• Removal and connection of tubes only after relief of
residual pressures. (See «RELEASING RESIDU-
AL PRESSURES FROM THE CIRCUITS»).
RKP09370
1. Boom test
1 - Position the machine with the arm vertical and the 3

bucket on the ground, resting on its back.
2 - Stop the engine and release any residual hydraulic

pressure.
4
3 - Disconnect the hose (1) that feeds the cylinder on
the head side.
★ Plug the hose to keep out impurity.
1
4 - Disconnect the hose (2) and plug it to keep out im- 2
purity. RKPB1041
5 - Remove safety valve (3) together with the pipe (4)

and plug the bottom side under port using flange
L1.
★ Plug the pipe to keep out impurity.
6 - Start the engine and extend the arm completely.
7 - Stop the engine and check the position of the boom

for 5 minutes.
• If the boom drops, the drift is due to the cylinder
gasket.
• If the boom does not drop, the drift is due to the
control valve.
2. Arm test
1 - Position the machine with the arm completely ex-

tended and the bucket teeth on the ground.

pressure.
RKP09380
PW110R-1 20-63
3 - Disconnect the hoses (1) and (2) from the pipes

and plug them to keep out impurity.
2
Standard 3
4 - Plug the hose (1) feeding the cylinder on the head
side and connect a provisional hose on the bottom
side to collect any leaking of oil.
Safety valve version
5 - Remove the safety valve (3) from the cylinder and
plug it to keep out impurity.
1
6 - Plug the head side cylinder port using flange L1.
RKPB1060
All version
7 - Start the engine and raise the boom.
8 - 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
★ This test should be carried out after having checked
that the drift is not due to the cylinder gaskets (See V2
«BOOM TEST» and «ARM TEST»), and after hav-
ing checked the valve settings (See «ADJUSTING
BOOM AND ARM SAFETY VALVES»). 2
1 - Depending upon which valve is to be checked, po-
1
sition the machine as for the «Boom test» or for the
«Arm test».
C2
2 - Disconnect the hose (1) that supplies the valve
(port V2). RKPB1580
3 - Disconnect:
For the boom, the head side pipe.
For the arm, the bottom side pipe.
4 - Start the engine and extend the arm completely for
1
the «Boom test», or raise the boom for the «Arm
test». V2
5 - Stop the engine and check for leakages from the
valve for 5 minutes.
• If there is any leakage, the valve is defective.
RKPB1051
20-64 PW110R-1
4. 2nd boom test

1 - Position the machine with the arm and the 2nd
boom completely extended. Rest the bucket teeth
on the ground.

pressures.
RKP09390
3 - Disconnect the two pipes (1) and (2) and cap them
to prevent entry of impurities. 2
★ If a safety valve has been installed, remove it.
4 - Cap the cylinder couplings on the bottom side and
attach provisional hoses on the head side to collect
any leaking oil.
RKPB1600

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 cyl-
inder gasket.
• If the 2nd boom does not close, the drift is due to 50 cm
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.
RKP09400
8 - From one cylinder remove the cap mounted on the
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.
PW110R-1 20-65
5. Testing the functionality of the 2nd boom safety

valves
★ This test should be performed after having ascer-
tained that the drift is not due to the cylinders. (See V2
«2nd BOOM TEST») and after having checked the
adjustment of the safety valves (See «ADJUSTING
2nd BOOM SAFETY VALVES»).
V1
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
pressures.
RKPA5530
3 - Disconnect the connecting tubes of the safety

valves (two pipes of ports V1 and V2 for each
valve).
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.
RKP09400
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.

pressure.
3 - Disconnect the pipes (1 and 2) of the bucket cylin-

der and cap them to prevent entry of impurities.
RKP09430
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.
1
RKPA5520
20-66 PW110R-1
6 - Stop the engine and check the position of the buck-

et 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
RKP09420
7. Boom swing test

1 - Position the machine with the boom, arm and buck-
et raised and with the revolving frame turned 135°
to the right.
pressure.
3 - Disconnect the pipes (1 and 2) of the boom swing
cylinder and cap them.
4 - Cap the hole in the boom swing cylinder on the bot- 15°
tom side and attach a provisional hose to the head
side to collect any oil leakages. 135°
5 - Start the engine and move the machine onto a 15° RKP12710
slope.
6 - Stop the engine and check the position of the boom
for 15 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
RKPA5490
8. Test for the outriggers

★ 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. RKP09450
PW110R-1 20-67
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 side to 3
collect any leakages. 3
6 - Start the engine, push down with the boom to raise
the machine and remove the supporting block from 4
beneath the outriggers.
4 1
7 - Lower the machine and stop the engine.

RKPA7960
8 - Check the position of the outriggers for 5 minutes.
• If the outriggers drops, the drift is due to the cyl-
inder (4).
• If the outriggers does not drop, the drift is due to
the safety valve (1).
★ To discover whether the drift is due to the swiv-
el joint, see «CHECKING FOR LEAKAGES IN-
SIDE THE SWIVEL JOINT - CIRCUITS FOR
OUTRIGGERS AND BLADE».
RKP09460
20-68 PW110R-1
9. Blade test
1 - Position the machine with the arm vertical and rest-

ing 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
pressure.
4 - Disconnect from both safety valves (1) union (2) RKP09470

and pipe (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 cyl- 2 2
inder (4) and attach a provisional tube on the base
side of the same cylinder to collect any leakages.
★ The second cylinder should be left completely
free.
3
6 - Start the engine, push down with the boom to raise
the machine in order to remove the block on which 3 1
the blade is resting. 4
7 - Lower the machine and stop the engine. 4
8 - Check the position of the blade for 5 minutes. RKPA7970
• 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).
★ To discover whether or not the drift is due to the
swivel joint, see «CHECKING FOR LEAKAG-
ES INSIDE THE SWIVEL JOINT - CIRCUITS
FOR OUTRIGGERS AND BLADE».
9 - To test the other cylinder repeat these operations,
starting from point 5.
RKP09480
PW110R-1 20-69
9. Swing motor test
1 - Position the machine with boom, arm and bucket

raised as in the figure, and with the revolving frame
turned 135°.

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

cap them to prevent entry of impurities. Attach 1
some provisional hoses to the motor to collect any 3
oil leakages.
4 - Disconnect brake swing hose (3) from motor.
5 - Connect unlocking brake cock “A” between motor

and hose (3).
Check that cock is open and near the hose (3).
2
RKPB6132
6 - Connect gauge E1 to the cock “A”.
7 - Start engine and start swing. E1

★ In this way the swing brake will be disengaged.
8 - With the swing brake circuit under pressure (30
bar) close the cock “A”.
A RKP12492
9 - Let the machine travel onto a 15° slope, and stop

the engine.
10 - Mark the position between revolving frame and
track frame on the swing circle. Check on any
swinging movement of the revolving frame for 15
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°
★ During this test, the pressure indicated on the 135°
pressure gauge E1 should not drop below the RKP12830
limit value of 18 bar.
20-70 PW110R-1
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 the cock “A” between the brake (1) and the
tube (2).
Attach the pressure gauge E1 (60 bar) to the adapt-
er of cock “A”. to keep a check on the parking brake
release pressure throughout the test. RKP09520
4 - With the cock “A” open, start the engine and en-
gage and release the parking brake several times.
2
5 - Raise the front work equipment and travel the ma- A
chine over a surface with a 15° slope. 1
★ The articulated axle should be facing towards
the lower part of the slope.
6 - Using the working brakes to hold the machine in po-
sition, close the cock “A”. in order to maintain pres-
sure (35 --0 3.5 bar) and thus to keep the parking
brake released.
Stop the engine.
E1
7 - After 5 minutes, mark the position of the machine. RKPA7981
8 - Check whether or not the machine has moved eve-

ry 5 minutes for a total of 15 minutes.
★ During this test the pressure indicated on the
pressure gauge E1 should not drop below a
minimum limit of 22 bar.
15°
RKP09530
PW110R-1 20-71
12. Test for the axle-locking valve

★ 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. 45° to bring the work

70 cm
equipment over the axle-locking cylinder (1-3) be-
ing tested.
4 - Stop the engine and check to see for 5 minutes,

whether the work equipment has dropped at all. RKP09540
★ If cylinder yields and there is no visible leakage,
drift comes from the check valve inside the cyl-
inder; check valve should be overhauled.
RKP09410
20-72 PW110R-1
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
TESTING THE AIR-CONDITIONING UNIT

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

1 - Connect the maintenance station L1 to the high pres-
sure valve (H.P.) and the low pressure valve (L.P.)
2 - Start the engine and bring it up to a speed of 1500 rpm.
3 - Switch on the A/C unit using the switch in the cab.
4 - Select an intermediate ventilation speed inside the cab.
5 - Use the thermometer/hygrometer L2 to check that the

temperature inside the cab is equal to or lower than the
ambient temperature.
★ If the temperature of the cab is higher than the am-
bient temperature, open the doors and widows and
wait until the cab temperature stabilizes at the out-
side value.
6 - Close the doors and windows and let the A/C unit op-
erate in these conditions for 5 - 10 minutes.
7 - Use the thermometer L2 to check the temperature of the

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

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

not fall within the values given in the table, it will be nec-
essary to thoroughly check the unit.
PW110R-1 20-73
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
2. Checking the unit

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

• Electromagnetic pulley that slips or does not engage correctly
L.P. high - H.P. normal or low • Expansion valve blocked in open position
• Compressor damaged
• Expansion valve blocked in closed position or obstructed
• Filter saturated with moisture
L.P. low - A.P. high or normal
• Obstruction in the L.P. line or in the H.P. line between the filter and the
evaporator L.P.
• Infiltration of hot air into the evaporator group, the pipes or the cab
L.P. normal - H.P. normal • Hot air circulating in the heating group
• Formation of ice on the evaporator
• Normal condition with very high ambient temperature (higher than 43°C)
• Excess coolant (30 - 35% more)
• Overheating of condenser
L.P. high - H.P. high
• Air present in the unit
• Obstruction in the H.P. line between the compressor and the condenser-
filter tube, behind the measurement point of the H.P.
• Normal condition with very low temperature (lower than 5°C)
• Lack of coolant (70 - 75% less) (probable leakages)
L.P. normal or low - H.P. low • Obstruction in the H.P. line between the compressor and the condenser-
filter tube, before the measurement point of the H.P.
• Compressor belt missing
L.P. roughly equal to H.P. • Electromagnetic pulley that slips or does not engage
20-74 PW110R-1
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT
EMPTYING THE AIR-CONDITIONING UNIT

1 - Connect the maintenance station L1 to the service
valves (1) and (2) and follow the specific maintenance 1 2
station instructions relative to the drainage of the unit.
2 - Disconnect the group to be substituted or reconditioned
immediately after switching off the maintenance station.
Plug the removed or disconnected connection
tubes tightly and with a minimum of delay.
3 - Carefully check the quantity of anti-freeze oil recovered
and contained in the disassembled parts, since the L1
same quantity must be replaced when the air-condi-
tioning unit is refilled.
RKPB6155
PW110R-1 20-75
REMOVAL AND INSTALLATION
HOW TO READ THE MANUAL................................. 3 HEATING FAN UNIT

PRECAUTIONS TO BE TAKEN WHEN Removal ...................................................................39
WORKING ................................................................ 4 Intallation ..................................................................40
SPECIAL TOOLS ...................................................... 5 AIR CONIDTIONING FAN UNIT
Removal ...................................................................41
STARTER MOTOR
Intallation ..................................................................43
Removal and installation ......................................... 15
RADIATOR
ALTERNATOR
Removal ...................................................................44
Intallation ..................................................................45
AIR-CONDITIONING UNIT COMPRESSOR
FUEL TANK
Removal .................................................................. 17
Removal ...................................................................46
Intallation ................................................................. 18
Intallation ..................................................................47
INJECTION PUMP
HYDRAULIC OIL TANK
Removal .................................................................. 19
Removal ...................................................................48
Intallation ................................................................. 22
Intallation ..................................................................49
INJECTION NOZZLE
ENGINE-PUMP GROUP
Removal ...................................................................50
THERMOSTAT Intallation ..................................................................52
PUMP GROUP
MUFFLER Removal and installation ..........................................53
ENGINE-PUMP COUPLING JOINT
TURBOCOMPRESSOR Removal and installation ..........................................54
GEAR-PUMP
CYLINDER HEAD Removal and installation ..........................................55
Removal .................................................................. 27
SWIVEL JOINT
Intallation ................................................................. 31
Removal and installation ..........................................56
SEAT
SWING MOTOR
CABIN
SWING MACHINERY
Removal .................................................................. 33
Intallation ................................................................. 34
Disassembly .............................................................59
ENGINE HOOD Assembly..................................................................65
CONTROL VALVE
CONDENSER UNIT Removal and installation ..........................................73
Removal .................................................................. 36
REVOLVING FRAME
Intallation ................................................................. 37
Removal ...................................................................74
FRONT HOOD Intallation ..................................................................75
COUNTERWEIGHT
PW110R-1 30-1
SWING CIRCLE BOOM CYLINDER (For 2-piece boom)
Removal and installation ......................................... 77 Removal .................................................................201
TRANSMISSION - REVERSER, DIRECTION Intallation................................................................202
INDICATOR AND HEADLIGHT DIPPER BEAM 2nd BOOM CYLINDERS
CONTROL GROUP Removal .................................................................203
Removal and installation ......................................... 78 Intallation................................................................204
R.H. PPC VALVE (BOOM-BUCKET) ARM CYLINDER
Removal .................................................................. 79 Removal and installation ........................................205
Intallation ................................................................. 80 BUCKET CYLINDER
L.H. PPC VALVE (ARM-SWING) Removal and installation ........................................206
Removal .................................................................. 81 BOOM SWING CYLINDER
Intallation ................................................................. 82 Removal and installation ........................................207
OUTRIGGER AND BLADE PPC VALVE CYLINDERS FOR OUTRIGGERS OR BLADE
Removal and installation ......................................... 83 Removal and installation ........................................208
BOOM SWING PPC VALVE WORK EQUIPMENT CYLINDERS
Removal and installation ......................................... 84 Disassembly ...........................................................209
TRAVEL AND 2nd BOOM PPC VALVE Assembly................................................................210
Removal and installation ......................................... 85 WORK EQUIPMENT (For 1-piece boom)
BRAKE PUMP Removal and installation ........................................214
Removal and installation ......................................... 86 WORK EQUIPMENT (For 2-piece boom)
STEERING UNIT Removal .................................................................215
Removal and installation ......................................... 87 Intallation................................................................216
Disassembly ............................................................ 88 BUCKET
Assembly ................................................................. 94 Removal and installation ........................................217
PRIORITY VALVE ARM
Removal and installation ....................................... 104 Removal .................................................................218
Disassembly .......................................................... 105 Intallation................................................................220
Assembly ............................................................... 105
2nd BOOM
TRAVEL MOTOR Removal .................................................................221
Removal ................................................................ 106 Intallation................................................................222
Intallation ............................................................... 107
BOOM (For 1-piece boom)
Disassembly .......................................................... 108
Removal and installation ........................................223
Assembly ............................................................... 111
BOOM (For 2-piece boom)
TRANSMISSION
Removal .................................................................224
Removal and installation ....................................... 116
Intallation................................................................225
Disassembly .......................................................... 117
Assembly ............................................................... 124 SWING SUPPORT
AXLE LOCKING CYLINDERS
Removal and installation ....................................... 131 BLADE AND OUTRIGGERS
FRONT AXLE
Removal ................................................................ 132 BLADE AND OUTRIGGER ARMS
Assembly ............................................................... 134 Removal and installation ........................................228
REAR AXLE
Removal ................................................................ 135
Assembly ............................................................... 137
AXLE
Disassembly .......................................................... 138
Assembly ............................................................... 164
BOOM CYLINDER (For 1-piece boom)
Removal and installation ....................................... 200
30-2 PW110R-1
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL
HOW TO READ THE MANUAL

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

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

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

(1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational pro-
cedures, see the list «SPECIAL TOOLS» supplied in this section.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks
and containers
(1) In the operating procedures, you will find the symbols , , , . In the following order, these rep-
resent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES OF
OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
PW110R-1 30-3
PRECAUTIONS TO BE TAKEN WHEN WORKING
REMOVAL AND INSTALLATION
PRECAUTIONS TO BE TAKEN WHEN WORKING

★ When dismantling or installing a part, always take the following general precautions.
1. Precautions for removal operations
• If not otherwise indicated, lower the work equipment until it rests on the ground.
• If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
• After having removed flanges and tubes, insert plugs to prevent impurities from entering.
• Before removing a cylinder, fully retract the piston and tie it with wire.
• Use a sufficiently large container to collect the oil.
• Before removing a part from the machine, check the alignment reference marks which show the correct in-
stallation position. If necessary add further marks to avoid incorrect installation.
• While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
• If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
• Check the number and height of the adjustments to a given clearance and store them in a safe place.
• When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
• When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
• Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or dust
from gaining entrance.
2. Precautions to be taken during installation
• Tighten nuts and screws with the specified tightening torques.
• Install the flexible hoses, taking care not to entangle or twist them.
• Bend the cotter pins and stops in such a way as to secure them.
• When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough ad-
hesive to cover the threading in a uniform manner.
• When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there are
no dents or dirt, then apply the liquid sealant in a uniform manner.
• Clean all the parts, remove dirt, rust, burrs, or dents.
• Apply a film of engine oil over all the moving parts.
• Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking.
• After having mounted the snap-rings, check that they are firmly positioned in their seatings.
• When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them, then
connect them firmly.
• If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoisting
hook.
• Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive pull
on one side only.
3. Precautions to be taken on completion of removal and installation operations.
• If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level. Start
the engine to circulate the liquid throughout the cooling system and then top up the level once more.
• When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the engine
to circulate the oil in the hydraulic circuits, and then top up to the indicated level.
• If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves, are
removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the machine.
★ For details, see «20. TESTING AND ADJUSTMENTS».
• After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.
30-4 PW110R-1
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Description Q.ty Notes
Removal/Installation of
counterweight Commercially Dynamometric wrench
A 1 1 Max. 700 kgm (700 dNm)
Disassembly/Assembly of available with multiplier
cylinder nut
1 Wrench Te remove and

1 mount lock-nut
To remove inside ring

2 Plunger 3 from pinion bearing
Disassembly/Assembly C
of swing machinery
3 Plunger To assemble inside
1 bearing ring
4 Plunger To mount outside

1 bearing ring
Commercially
Air conditioning unit D 1 Maintenance station 1 –
available
1 – Wrench 1 –
Removal/installation of
2 – Tool 1 differential planetary
wheel pins
3 – Bushing 1
Installation of differential
4 – Tool 1 planetary wheel pins
– Wrench 1
5 Flange locking
– Wrench 1
6 – Wrench 1 Flange ring nut locking
7 – Wrench 1 Pinion locking
8 – Block 1 –
9 – Spacer 1 –
Disassembly/Assembly axles M
– 1
Bearing inner ring
10 – 1 Installation pinion bearing
installation kit
– 1
Pinion dimension
11 – Tool 1 measuring
Bearing outer ring

12 – 1 Installation pinion bearing
installation kit
13 – Wrench 1 Pinion torque measuring
14 –0 Plunger 1
15 – Plunger 1
16 – Tool 1 Arm alignment
17 – Bush 1
PW110R-1 30-5
Punti di controllo Simbolo Codice Denominazione Q.tà Note
18 – Extension 1
19 – Plunger 1
20 – Plunger 1
21 – Plunger 1
22 – Plunger 1
Disassembly/Assembly axles M
23 – Plunger 1
24 – Plunger 1
Bearing inner ring Planetary bearing

25 – 1
installation kit installation
26 – Plunger 1
27 – Plunger 1
30-6 PW110R-1
60
C1 40
31
A
3.2
R2 20
Ø6.5 H7/m6
8
3/4”
R2
3.2
Ø76 ±0.01
Ø65
Ø90
Ø63
3.2
1x45°
N°4 SPINE A 90°

Nos 4 PINS AT 90°
1x45°
Ø4
Particolare «A»
1x45°
RKP13300
C2 125 C3 59
15 14
10
3.2
3.2
3.2
Ø78.5 ± 0.1
Ø84.5 ± 0.1
Ø74 ± 0.1
1 x45°
Ø35
Ø62
Ø76
Ø90
1x45°
R2 R2
R2
RKP13310
RKP13330
C4
14
6
Ø40
3.2
Ø124 ±0.01
3.2
Ø130 ±0.01
RKP133200
PW110R-1 30-7
Ø125
10x15°
Ø41
M1 Ø35.5 ---- 0.1
0.2
M2 Ø25
Ø20 + 00.2
0.8
1x45°
Ø5.5
R1
0.8
Ø15H7-n6
100
5
Ø14
2 x15°
36
8
31
26
0.8
20
24
17
20
238
0 0.8
R1 Ø25
Ø10 M26X1.5
Ø35
123
125
Ø5.5
33
36
18
22.5
0.8
33
6 9
10.5
Ø37H7-n6
1 x45°
Ø47
6
0.8
Ø106 ± 0.1 Ø20 + 00.2
R30
25
Ø25
Ø41 RKP13100
RKP13090
M3 24.5 ⫾ 0.0.1 M4 3x30° 2x30°

Ø28.5 ± 0.2
Ø19.9 +-- 0.1
Ø19.9 +-- 0.1

0
8.5
0
Ø30
0.8
Ø6
15° 10 46.45 ± 0.1 ± 0.5
10 19.6
56.6 29.6
Ø20 ++ 0.08
0.12
0.5x45°
Ø27 ---- 0.1
0.2
Ø23
Ø30
0.8
Ø19.9 +-- 0.1

0
RKP13110
1x30°
175
RKP13120
135 ±0.5
Ø185 ± 0.2
M5
97
73
Ø105 ± 0.2
120
61.5
80
61.5
85
126 12
Ø32 Ø105 ± 0.2
25
10
150 125
10
15
15
125
25
100
Ø34.5--+ 00.2
Ø45 Ø50 RKP13160
30-8 PW110R-1
Ø85
M6 Ø66 M7 Ø75
Ø55H7 Ø55 –– 0.08

0.12
0.8
0.8
5 x15
Tornito Ø
0.8
32,25
22
75
35
10
60
15
6
14
34
60
6 3/4"
Ø15H7-n6
20
40
20
15°
60
100
275 RKP13170
RKP13180
M8 99.5
M9 Ø30.2 ± 0.001
Ø17
5x45°
25
Ø88.8 ± 0.005
131
Ø42
20
RKP13200
RKP13190
M10
Ø19.55H7
A
21°
0.8
R5
R2
23
B 3x15°
Ø83
Ø40
Ø88
R2
0.8
0.8
Ø20 +-- 00.1
0.8
21°
Ø89 ---- 0.08

0.12
Ø55
Ø83
0.8
R2
23 40
0.8
R2 73
10 56 C B A
66
Ø16.5---- 0.2
0.1
M18x1.5
M18x1.5
473.5
C 433.5
0.8 0.8 0.8
Ø35
Ø40
15°
5 5x15°
-- 0.08
-- 0.12
11 30
Ø19.5
45
RKP13210
PW110R-1 30-9
M11 Ø110 Ø20

Ø65 M14 x1
M14 x1
25 25
20
50
0.02
61---- 0.01
4 x45°
R5
41
30
Ø20 Ø41.2 +-- 0.03
0
15
Ø9
195
95
14
Ø11
35
40 300
Ø80
10
50
RKP13250
Ø6.5
M12
ENERPAC Mod. RCH-123
23
3x15°
64
R2
0.8
0.8
R3 0.8
21°
Ø89 ---- 0.08

0.12
Ø40H8
Ø70
Ø54
Ø55
Ø83
Ø40
0.8
R2
R2
10 56
66
312
M18X1.5
M18X1.5
267
50 5x15° 0.8
0.8
15°
Ø40H8
R3
-- 0.2
-- 0
17min.
Ø19
30 RKP13240
30-10 PW110R-1
M13 Ø75
M14
Ø55 ---- 0.08
0.12
Ø50
5x45°
5x15
Tornito Ø
0.8
32,25
35
Ø10
60
63
87
74
15
14
R5
2 -- 0.2
0
48
59
12
R5
30
0.8
12
3x15°
0.8
M6
5
Ø20
Ø37.75 ++ 0.12
0.08
0.8
Ø40H7-n6 1/4”
Ø55 ---- 0.3
0.2
Ø44
Ø89
Ø99
RKP13230
M17 Ø45 ---- 0.05

0.10
0.8
M8x1.25
RKP13150
R2 5°
.5
M15
1.5x45°
15
30
0.8
44
14
75
3
6
7
1
1
68
0.8
1x45
30°
38
Ø6.5
0.8
Ø20.4-- 00.05
Ø38.5 ---- 0.1
0.2
Ø55 Ø43.6 + 00.05

Ø63
RKP13220
Ø65 RKP13140
M16
50
20
120± 0.1
=
120± 0.1
200
=
90
= = 840
930
RKP12980
PW110R-1 30-11
M18
R110
100
50
R1
5 5x45°
27.5±0.2
55 500
555
±0.1
Ø23
17
125
RKP13080
125
M19 0
M20 Ø30
Ø54,5 -- 0.1
3x45°
30
Ø30
cementazione
R35
Proteggere da
0.8
46
130
70
155
14 10
0.8
1.5 x45°
0.8
2,5 -- 00.2
0
0.8 R1
3 x15°
7
0.8
Ø54 + 00.1
10
Ø79
R1 0.8
Ø90 -- 0.15
RKP13020
0.8
49.5
89
RKP13030
M21 M22 M23 Ø64

Ø25
Ø25
Ø30
3x15°
3 x45°
50
2 x45°
50
50
cementazione
Proteggere da
cementazione
Proteggere da
150
150
cementazione
Proteggere da
150
180
213
169
2 x45°
R1
3-- 00.2
0
1.5x45°
.5
13
R7
1.5
R5
.5
0.8
10
0.8
R1
52
20 10
50
+ 0.15
-- 0.4
0.8
19
0.8 9
R2
Ø67
0.8
5x15°
3x15°
Ø35 ---- 0.08

0.12 RKP13000 Ø35
Ø50 RKP12990 Ø50 ---- 0.1
0.2
RKP13040
30-12 PW110R-1
M24 M25
Ø75
Ø158.5
Ø25 Ø158.5
Ø50 H7 20° Ø35

Ø30
3x45°
50
0.8
16
0.8
R3
113
Ø132 -- 0.3
0.5
129
cementazione
Proteggere da
117
R3
--
148
102
150
R5 20°
100
25
R3
8x15°
Ø40
233
Ø140
Ø50---- 0.08
0.12
0
Ø150
R1
3-- 00.2
Ø200 ±0.03
13
0.8
0.8 Ø95
75
70
Ø35
5x15°
0.8
Ø50 ---- 0.1

0.2
Ø56
Ø64 RKP13050 RKP13130
M26 Ø40 M27 Ø35

2x45°
2 x45°
120
175
1x45°
0.8
-- 0.2
-- 0.3
1
41
26
19
0.8 0.8
5.5
R3
5x15°
0.8
0
Ø139.5 -- 0.1
Ø153
10 15
0.8
25
Ø168
2x15°
Ø180 RKP13070
Ø39 0.8
Ø50 RKP13060
PW110R-1 30-13
PAGE INTERNATIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION STARTER MOTOR
REMOVAL OF STARTER MOTOR

Disconnect the cable from accumulator negative termi-
nal (–). 1
1 - Remove lower guard.
2 - Disconnect electrical cable (1).
3 - Remove screw (2) and starter motor (3). 1

2
3
RKPB5070
INSTALLATION OF STARTER
MOTOR
• To install, reverse the removal procedure.
Screws: 78.4–98 Nm
PW110R-1 30-15
REMOVAL AND INSTALLATION ALTERNATOR
REMOVAL OF ALTERNATOR
nal (–).
1 - Remove upper cover (1) (No. 5 screws) with exhaust

pipe (2).
2
1
RKPB6140
2 - Remove union (3) of the exhaust pipe.

1
3
RKPB5090
3 - Disconnect cable (4) and connector (5).
4 - Loosen bolts (6), (7) and (8) sufficiently to allow the al- 7
ternator (9) to rotate.
4
5 - Free the pulley from the fan-belt (10) and remove al-
ternator (9). 2
5
6
RKPB4881
INSTALLATION OF ALTERNATOR
• To install, reverse the removal procedure. 10
9
1
★ Check the union gasket of exhaust pipe.
2
★ Adjusting of the fan-belt (For details, see «20. TESTING
8
AND ADJUSTMENTS»).
RKPB4871
30-16 PW110R-1
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR

(Only for machines equipped with an air-conditioning unit)
nal (–). 1 2
1 - Connect the outlets (1) and (2) to the maintenance sta-
tion for air-conditioning units D1 and drain the cooling
fluid.
– 30
Quantity of fluid R134a: 1100 + 50 g
D1
RKPB6154
2 - Remove the clamp (3) and disconnect the connector

(4).
RKPB6160
3 - Loosen screw (5) and remove return (6) and delivery (7)
pipes. 1
6 7
5
8
12
RKPB6170
4 - Remove the fan guard (8). 2

5 - Loosen screws (9), (10) and (11) to leave free the com- 11
pressor (12).
9
12
10
RKPB6180
PW110R-1 30-17
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
6 - Release the pulley from belt (13) and remove bracket

(14).
14
7 - Remove the compressor (12). 3
12
13
RKPB6190
INSTALLATION OF THE
AIR-CONDITIONING UNIT
COMPRESSOR
1
Screw: 22.5–28.4 Nm
2
Screw: 22.5–28.4 Nm
3
★ Apply tension to the compressor belt.
(For detail, see «TESTING AND APPLYING TEN-
SION TO THE COMPRESSOR BELT».
1 - Connected the unit to the maintenance station D1 and

refill it.
– 30
Quantity of fluid: 1100 + 50 g
30-18 PW110R-1
REMOVAL AND INSTALLATION INJECTION PUMP
REMOVAL OF INJECTION PUMP

nal (–).
★ Close the cock (1) of separator (2) to prevent fuel leak- 2

age. 1
★ Plug removed or disconnected pipes to avoid impurity

entry.
RKPB1650
1 - Disconnect high pressure pipes (4) from injection pump

(3). 1
4
RKPB4861
2 - Disconnect from injection pump (3) fuel feeding pipes

6
(6) and return pipes (5). 2
5
3 - Disconnect pipes (8) and (9) from fuel feed-pump (7).
4 - Disconnect the engine stop solenoid (10) from injection

pump (3) and remove the complete unit. 3
3
10
9 7
8
RKPB5300
5 - Disconnect control cable (12) from accelerator lever

(11).
12 11
RKPB4960
PW110R-1 30-19
6 - Remove the bolt (13) and bracket of injection pump lu-

bricating pipe.
7 - Remove injection pump lubricating pipe (14).
13 14
RKPB4971
8 - Remove coolant tank (15).
9 - Remove fan guard (16).

16 15
RKPB6200
10 - Remove the inlet cover (17) to ignition gear system and

the filler oil plug (18).
4 18
16
17
RKPB1700
11 - Loosen and remove nut (19) and lock washer (20) of

pump driving gear (21). 5
★ Be careful not to let lock washer drop in the hous-
ing. 21
20
19
RKPA5611
30-20 PW110R-1
12 - Remove pump (3) driving gear (21).

★ Before removing pump driving gear, mark position
X2
compared to idling gear. 24
★ For removal, use a puller (X1) and tighten its
screws (X2) directly in the gear (21). 22
★ Be careful not to damage pump shaft thread.
★ During removal be careful not to let key drop (22) in
the housing.
21 X1
X2
RKP07801
13 - Remove nuts (23) (No. 4) and injection pump (3) with

relative OR rings (24).
6 3
23
RKPB4970
PW110R-1 30-21
INSTALLATION OF INJECTION PUMP

1
Feed and return pipes: 24.5–34.3 Nm
2
High pressure pipes: 24.5–34.3 Nm
3
★ Replace safety cotter pin.
4
Cover gasket: ASL800070 Injection pump
drive gear
Timing gear system cover bolts: 18 Nm
5
Alignment reference
★ Align marks between gears before installing pump
and nut.
Gear lock nut: 83.3–93.1 Nm Idling gear
6 RKP07811
Pump lock nuts: 35.2–43.1 Nm
1 - Check fuel injection timing.

(For details, see «20. TESTING AND ADJUST-
MENTS»).
30-22 PW110R-1
REMOVAL AND INSTALLATION INJECTION NOZZLE
REMOVAL OF INJECTION NOZZLE

1 - Loosen the clamps (1) and remove the high pressure
pipes (2) and fuel return pipes (3). 1
3
2 - Loosen the nuts (4) that secure the collar (5).
Remove the injector (6), the seat (7) and the protection
sleeve (8). 2
1
RKPB5030
INSTALLATION OF THE 5
INJECTION NOZZLES
1 4
High pressure pipe fittings: 24.5–35.3 Nm
Hose clamp screws: 9.8–11.8 Nm 6 8
2
7
Collar lock nuts: 9.8–11.8 Nm RKP07791
PW110R-1 30-23
REMOVAL AND INSTALLATION THERMOSTAT
REMOVAL OF THE THERMOSTAT

nal (–). 1
★ Drain the engine cooling liquid. 3
Cooling liquid: 18 2
1 - Disconnect the radiator hose (1) from the thermostat

cover (2).
2 - Remove the thermostat cover screws (3). 2

3 - Remove the gasket (4), the thermostat (5) and the ring
seal (6). RKPB1710
Replace all gasket and seals.
3
2
RKP12500
INSTALLATION OF
THE THERMOSTAT
1 - Refill the coolant liquid tank.
Coolant liquid: 18
2 - Start the engine at low idling to circulate the coolant liq-

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

minute, stop the engine and check or top up the level in
the container.
★ Check that there are no leaks.
2
Cover screws: 22–27.8 Nm
30-24 PW110R-1
REMOVAL AND INSTALLATION MUFFLER
REMOVAL OF THE MUFFLER

nal (–).
1 - Remove the cover (1) (No. 5 screws) together with the

exhaust pipe (2).
2
1
RKPB6140
2 - Loosen the clamps (3) and remove the protection (4).

4 7 3
Loosen the nuts (5) (No. 4) that fasten the muffler (6) to
the turbocompressor (7).
RKPB1720
3 - Loosen the screws (8) from the muffler support bracket

(9) and remove the muffler (6).
6
9
RKPB1402
INSTALLATION OF THE MUFFLER

★ Replace the sealing gasket.
PW110R-1 30-25
REMOVAL AND INSTALLATION TURBOCOMPRESSOR
REMOVAL OF THE TURBOCOMPRESSOR

nal (–). 4 2
1 - Remove the muffler. (For details, see «REMOVAL OF 3
THE EXHAUST PIPE MUFFLER»).
2 - Disconnect the pre-heat cable (1).
3 - Disconnect the turbocompressor (3) coupling sleeve (2)

from the suction manifold (4).
1
RKPB1721
4 - Loosen the screws (5) that secure the lubrication oil

drainage tube. 6
1
3
5 - Loosen the union (6) that secures the lubrication oil de-
livery tube.
6 - Loosen the nuts (7) that secure the turbocompressor (3)

and remove the turbocompressor. 7
RKPB1730
INSTALLATION OF THE
TURBOCOMPRESSOR
1
Flange screws: 8–9 Nm
30-26 PW110R-1
REMOVAL AND INSTALLATION CYLINDER HEAD
REMOVAL OF THE CYLINDER HEAD

nal (–).
★ Drain the cooling liquid.
Cooling liquid: 18 2
1
1
1 - Remove the engine hood.
(For details see: «REMOVAL OF ENGINE HOOD»).
2 - Remove cover (1) (No. 5 screws) together with the ex-

haust pipe (2). RKPB6140
3 - Remove the coolant tank (3).
4 - Only for machines equipped with an air-condition- 5

ing unit.
Remove the compressor.
(For details, see «REMOVAL OF THE AIR-CONDI- 4
TIONING UNIT»).
RKPB5921
5 - Remove hose (4) from the radiator (5) and disconnect

the heater pipes (6).
6 - Loosen the clamp (7).
RKPB5050
7 - Disconnect the water temperature sensor cable (8) and

the water temperature alarm sensor cable (9).
10
8 - Disconnect the alternator (11) support bracket (10).
11
8
RKPB5220
PW110R-1 30-27
9 - Disconnect the pre-heater cable (12) and remove the

support (13). 12 13
RKPB1751
10 - Disconnect the coupling sleeve (14) from the turbocom-

pressor (15). Loosen the screws (16) and remove the 14
suction manifold (17). 2 15
17
16
RKPB1722
11 - Remove the fuel filter (18).
12 - Disconnect the fuel return hose (19) from the injectors.
19
18
RKPB1760
13 - Disconnect the oil supply and drainage tubes (20) from

the turbocompressor. 20
3
20
RKPB1731
30-28 PW110R-1
14 - Disconnect the breather tubes (21), (22) and (23) from

the vapour chamber (24). 21
15 - Loosen the screw (25).
22
25
23
24
RKPB1770
16 - Remove the injectors (26).

(For details see: «REMOVAL OF THE NOZZLE INJEC-
TORS») 4 5
17 - Loosen the nuts (27) and remove the tappet cover (28).
6
27
26 28
RKPB1372
18 - Remove the valve rocker-arm (29).

★ Loosen the nuts and unscrew the tappets by 2-3 29
turns 32 31
7
19 - Take out the rocker arm control arms (30).
30
RKP10860
20 - Remove the cylinder head (32) screws (31) follow the

indicated sequence to loosen the screws 8
★ Sequence to be followed: see drawing. BOLT LOOSENING ORDER
Keep two positioning screws inserted and tight-

7 16 14 6
ened 2-3 turns. 1 9 18 12 4
3 11 17 10 2
5 13 15 8
RKP07820
PW110R-1 30-29
21 - Attach the cylinder head (32) to a hoist and apply ten-

sion to the hoisting cables.
Ensure that the cylinder head is detached from the

engine block and that all tubes and cables are dis-
connected.
Attach the hoisting cables to the lifting logs and the

muffler. Ensure that the cylinder head remains lev-
el while hoisting.
22- Remove the complete cylinder head (32) and place it on
a work-bench.
23 - Remove the turbocompressor.

(For details see: «REMOVAL OF THE TURBOCOM-
PRESSOR».
30-30 PW110R-1
INSTALLATION OF THE CYLINDER HEAD

1
★ Fill up the cooling circuit.
Coolant liquid: 18
★ Check carefully that there are no leaks.
2
Screws for intake line: Loctite 262
Screws for intake line:45--55 Nm
3
Flange screws: 8--9 Nm
4
High-pressure pipe fittings: 24.5--34.3 Nm
5
Collar lock nuts: 9.8--11.8 Nm
6
★ Check the condition of the seals of the tappet cover
and the O-rings of the fastening nuts.
Thoroughly clean the contact surfaces on the cyl-
inder heads.
Cover fastening nuts: 25±3 Nm
7
★ Check that the tappets are firmly engaged in their
rods and that the valve collars are correctly assem-
bled.
Rods - tappets: Engine oil
★ Start tightening the rocker-arm shaft from the center to-
wards the outside.
Screws and nuts for the rocker-arm shaft:
22.5--28.4 Nm
★ Adjust the valve clearances (For details, see «20.
TESTING AND ADJUSTMENTS»).
8
★ Install a new gasket.
Bolt and cylinder block threadings: Engine oil.
★ Tighten the screws, manually at first, and then in two BOLT TIGHTENING ORDER
stages, following the sequence indicated.
Cylinder head bolts.
12 3 5 13
First tightening: 88.3--98.1 Nm 18 10 1 7 15
Final tightening: 181.4--191.2 Nm
16 8 2 9 17
1 - Start the engine at low idling to circulate the coolant liq- 14 6 4 11
uid through all circuits.
2 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level in
the container. RKP07830
PW110R-1 30-31
REMOVAL AND INSTALLATION 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.
RKPB1280
3 - Remove the four screws (3) that secure the seat (No. 4).
★ Slide the seat forwards and backwards in order to
reach the screws.
3
4 - Remove the seat.
Seat: 32 kg
RKPB0940
INSTALLATION OF SEAT
30-32 PW110R-1
REMOVAL AND INSTALLATION CABIN
REMOVAL OF CABIN
ground, switch off the engine and remove the ignition
key.
1 - Disconnect the connector (1) and hose (2) from the
windshield-washer tank and remove all the clamps fix- 1
ing them.
3
2 - Remove screws (3), dashboard (4) and disconnect 4
heating pipe (5).
3
5
2
RKPB6210
3 - Move the back of the operator's seat completely forward

and remove the panel (7) fixing screws (6). 9
4 - Raise the panel (7), disconnect the heating hose (8)
from the diffuser (9) and remove the panel (7).
6 8
RKPB6220
Only for machine equipped with an air conditioning unit

5 - Remove screws (10). 11
11
6 - Raise air duct (11) and disconnect pipe (12).
7 - Lower completely the seat, remove screws (6) and hood
(7).
10
12
6
7 RKPB6230
8 - Remove knob (13) and (14), screws (15) and hood (16).
15 14
13
16
RKPB6240
PW110R-1 30-33
REMOVAL AND INSTALLATION CABIN
Only for machine equipped with an air conditioning unit

9 - Disconnect the connecter (17).
17
RKPB7630
10 - Remove the heater (19) screw (18).

18
11 - Remove clamps (20) and sleeve (21). 20
12 - Remove screws (22) (n°7).
21
13 - Remove the upper protection cap and mount the eye- 20
bolts (23).
19
RKPB6590
14 - Attach the eyebolts (23) to the hoisting tackle and re-

move the cabin.
Cabin: 220 kg 23
23
INSTALLATION OF CABIN
★ Make sure that the short screw (24) is placed on the
24
LH side.
RKPB1102
30-34 PW110R-1
REMOVAL AND INSTALLATION ENGINE HOOD
REMOVAL OF ENGINE HOOD

3
ground and switch off the engine.
1 - Detach the gas cylinder (1) from the engine hood (2).
2 - While holding up the engine hood (2) remove the

screws (3) that attach the hood to the hinges (4).
4
1
★ Mark the position of any shims.
Engine hood: 36 kg
1
2
RKPB6910
INSTALLATION OF ENGINE HOOD

1
★ Position any shims.
★ Check the centering and adjustment of the closing
hook (5).
Replace the cotter pins (6).

6
5
RKPB0950
PW110R-1 30-35
REMOVAL AND INSTALLATION CONDENSER UNIT
REMOVAL OF CONDENSER UNIT

(Only for machine equipped with an air conditioning unit)
nal (–). 1 2
1 - Connect the outlets (1) and (2) to the maintenance sta-
tion for air-conditioning units D1 and drain the cooling
fluid.
– 30
Quantity of fluid R134a: 1100 + 50 g D1
RKPB6154
2 - Loosen the knobs (3) and remove the hood (4).

4
RKPB6250
3 - Disconnect pipes (6) and (7) from condenser unit (5).

5
5
7
6
RKPB6260
4 - Disconnect pipes (6) and (9) from filter (8).
9
6
8
RKPB6270
30-36 PW110R-1
REMOVAL AND INSTALLATION CONDENSER UNIT
5 - Remove nuts (10). 1
10
5
10
RKPB6280
6 - Raise condenser unit (5), disconnect the connectors

(11) and remove the group. 5
11
11
RKPB6290
INSTALLATION
OF CONDENSER UNIT
1
Nut: 22.5–28.4 Nm
1 - Connect the unit to the maintenance station D1 and refill

it.
– 30
Quantity of fluid: 1100 + 50 g
PW110R-1 30-37
REMOVAL AND INSTALLATION FRONT HOOD
REMOVAL OF FRONT HOOD

2
1 - Detach the gas cylinder (2) from the support (1). 7
2 - Only for machine equipped with an air conditioning
unit:
remove the condenser unit. 1
(For detail see «REMOVAL OF CONDENSER UNIT»).
RKPB1800
3 - While holding up the engine hood (3), remove the

screws (4) that attach the hood to the hinges (5). 4
1
★ Mark the position of any shims.
Engine hood: 27 kg
3
5
RKPB1810
INSTALLATION OF FRONT HOOD

1
★ Position any shims.
★ Check the centering and adjustment of the closing
hook (6).
Replace the cotter pins (7).

6
RKPA5680
30-38 PW110R-1
REMOVAL AND INSTALLATION HEATING FAN UNIT
REMOVAL OF HEATING FAN UNIT

Disconnect the cable from accumulator negative termi- 2
nal (–).
1 - Disconnect clamp (1) and pipes (2) and (3) from the en- 3
gine and lower the terminals so as to thoroughly drain 1
the liquid from the heating radiator.
Cooling liquid: approx. 1.5
RKPB1754
2 - Move the back of the operator's seat completely forward

and remove the panel (5) fixing screws (4). 7
3 - Raise the panel (5), disconnect the heating hose (6)
from the diffuser (7).
4 6
5
RKPB6221
4 - Remove the knob (8) and (9), loosen the screw (10) and
remove the hood (11).
10 9
11
RKPB6241
5 - Remove the clamps (12) and the sleeve (13).

12
13
12
RKPB6591
PW110R-1 30-39
REMOVAL AND INSTALLATION HEATING FAN UNIT
6 - Move forward the seat and disconnect the heater con-

nectors.
7 - Remove the clamps (14) and disconnect the sleeve

(15).
15 14 RKP12930
8 - Disconnect the pipes (16), remove screws (17) and lat-

eral screws (18). 17
9 - Move backward the heating fan unit (19). 19
16
18 RKP12920
INSTALLATION OF
HEATING FAN UNIT
1 - Make sure that the heating cock is fully open.
2 - Fill up with coolant liquid.
Quantity of coolant liquid: approx. 6.5
3 - Start the engine to circulate the coolant liquid.
4 - Switch off the engine and top up the level.
30-40 PW110R-1
REMOVAL AND INSTALLATION AIR CONIDTIONING FAN UNIT
REMOVAL OF AIR CONIDTIONING FAN UNIT

(Only for machine equipped with an air conditioning unit)
nal (–).
1 - Drain the coolant liquid a level below that of the con-
necting pipes (2) and (3) between the engine and the 2
heating fan.
Cooling liquid: approx. 5 3
1
RKPB6300
2 - Connect the outlets to the maintenance station for air

conditioning unit D1 and drain the cooling fluid
– 30
Quantity of fluid R134a: 1100 + 50 g
3 - Disconnect clamp (1) and pipes (2) and (3) from the en-
gine and lower the terminals so as to throughly drain the
liquid from the heating radiator.
Cooling liquid: approx. 1.5

D1
RKPB6153
4 - Remove screws (4) fixing air conduct (5).

5
5 - Raise conduct air (5) and disconnect pipe (6). 5
6 - Move the back of the operator’s seat completely for-
ward, remove the screws (7) and the hood (8).
4
6
7
8 RKPB6231
7 - Remove the knobs (9) and (10), the screws (11) and the
hood (12).
11 10
12
RKPB6242
PW110R-1 30-41
8 - Remove the clamps (13) and the sleeve (14).
13
14
13
RKPB6592
9 - Disconnect the connectors (15) and (16).
16
15
RKPB6310
10 - Remove the plug (17) and disconnect the connectors

(18), (19) and (20).
★ Mark the position of connectors.
20
17 18 19
RKPB6320
11 - Remove the screw (21) retaining flange (22), discon-

nect the return pipe (23) and pipe (24). 1
23
22
21
24
RKPB6330
30-42 PW110R-1
12 - Loosen the clamps (25) and remove the pipes (26).
26 25
26
RKPB6340
13 - Remove screws (27), (28) and move backward the air

conditioning unit (29).
29
27
28
RKP12940
INSTALLATION OF
AIR CONDITIONING FAN UNIT
1 - Make sure that the heating cock is fully open.
2 - Fill up with coolant liquid.
Quantity of coolant liquid: approx. 6.5
3 - Start the engine to circulate the coolant liquid.
4 - Switch off the engine and top up the level.
1
★ Film the valve and union with anticondensate mas-
tic.
5 - Connect the unit to the maintenance station D1 and refill

it.
– 30
Quantity of fluid 1100 + 50 g
PW110R-1 30-43
REMOVAL AND INSTALLATION RADIATOR
REMOVAL OF RADIATOR
Completely eliminate all residual pressures in all cir-
cuits. (For details see: «20. TESTING AND ADJUST-
MENTS»). 2
1
Drain the engine coolant liquid.
Cooling liquid: 18
Hydraulic oil: 84 3
1 - Remove the cover (1) together with the exhaust pipe
(2). RKPB6141
2 - Remove the engine hood (3).

(For details see: «REMOVAL OF ENGINE HOOD»). 6
3 - Remove the coolant container (4) and the fan guard (5). 5
4 - Disconnect the engine coolant circuit hoses (7) and (8)
from the radiator (6). 7
8
RKPB5882
5 - Disconnect the hydraulic oil supply pipe (9) and the re-
turn pipe (10).
6 10
11 9
RKPB1820
7 - Loosen the radiator retaining screws (12) and remove

the radiator.
Radiator: 37 kg
12
RKPB1840
30-44 PW110R-1
REMOVAL AND INSTALLATION RADIATOR
INSTALLATION OF RADIATOR
1 - Refill the coolant liquid circuit.
Coolant liquid: 18
2 - Refill the hydraulic oil tank.
Hydraulic oil: 84
3 - Start the engine at low idling to circulate all the fluids and
to fill up the oil coolers.
4 - Stop the engine and top up all levels (coolant liquid and
hydraulic oil).
5 - Bleed the hydraulic circuits.

(For details see:
«20. TESTING AND ADJUSTMENTS»).
PW110R-1 30-45
REMOVAL AND INSTALLATION FUEL TANK
REMOVAL OF FUEL TANK

nal (–).
★ Turn the turret 45° towards the right.

1 - Remove the front hood (for details, see «REMOVAL OF
FRONT HOOD») and the bottom right guard of the tur-
ret.
2 - Remove the cap (1) of the fuel tank (2), open the tank
drainage cock (3), and drain the fuel.
3 - Disconnect the fuel suction pipe (4).

3
RKPB1651
4 - Disconnect the fuel return pipe (5) and the connector (6)
of the level gauge (7).
2
5
1
7
RKPB5890
5 - Disconnect the plate (8) that joins the tanks.
2 8
RKPB6350
30-46 PW110R-1
REMOVAL AND INSTALLATION FUEL TANK
6 - Hook the tank (2) to the hoisting equipment and slightly

put the rope under tension. 2
7 - Remove the screws and remove the tank.
Fuel tank: 47 kg
RKPB1870
INSTALLATION OF FUEL TANK

★ Fill the fuel tank and start the engine.
PW110R-1 30-47
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
REMOVAL OF HYDRAULIC OIL TANK

Release residual pressures from all circuits. (For de- 2
tails, see «20. TESTING AND ADJUSTMENTS»).
• Drain the hydraulic oil.
1
Quantity of oil: approx. 84
1 - Remove the fuel tank. (For details, see «REMOVAL OF

FUEL TANK»).
2 - Disconnect the return pipe (1) and (2).

RKPB5900
3 - Disconnect the drain pipes (3) and (4).
4 - With arm safety valve:

Disconnect the drain pipe (5) from safety valve.
4
5
3
RKPB6361
5 - Disconnect the coupling of the pump suction tube and

the pipe (6).
6 - Remove the bracket (7) of the solenoid valves.

6
7 - Hook the tank to the hoisting equipment and slightly put
the rope under tension.
RKPB1832
8 - Remove the bolts and the oil tank (8).
Oil tank: 67 kg 8
RKPB0743
30-48 PW110R-1
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
INSTALLATION OF HYDRAULIC OIL TANK

1 - Fill the hydraulic oil tank to maximum level.
While filling, bleed air from the main pump piston.

MENTS»).
Hydraulic oil needed: approx. 84
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 necessary,

top it up.
PW110R-1 30-49
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
REMOVAL OF ENGINE-PUMP GROUP

1
nal (–).
Release residual pressures from all circuits. (For de-

• Drain the engine coolant liquid.
Quantity of coolant liquid: 18

RKPB1652
• Close the feed cock of fuel tank (1).
1 - Remove the engine hood. (For details, see «REMOVAL

OF ENGINE HOOD»).
2 - Remove the top cover (3) complete with the exhaust 3

2
pipe (2).
RKPB6142
3 - Remove the rubber air filter elbow (4).
4 - Remove the rear lower protection.
5 - Disconnect from engine all connectors.
RKPB6370
6 - Disconnect the pipe (6) coming from the separator from

the fuel pump (5).
7 - Disconnect the return tube (8) from the fuel filter (7). 8
5
6 7
RKPB6600
30-50 PW110R-1
8 - Disconnect the cable (9) and the sheathing (10) of the

accelerator as well as the earth plait (11) from the en-
gine.
9 - Remove the radiator.

(For detail see «REMOVAL OF THE RADIATOR»).
10
9
11
RKPB1383
10 - Loosen the clamp (12) and disconnect the heating pipes

(13) from the engine.
12
13
RKPB1753
11 - Only for machine equipped with an air conditioning

unit. 12
Disconnected from engine the heating pipe (12) and
from air conditioning compressor the pipes (14), the
clamps (13) and (15). 14
15
12
13
RKPB6301
12 - Disconnect the flanges of the suction pipes and all de-

livery pipes (16) from pumps.
★ Mark the position of Load Sensing, Mode System
and servo-control feed pipes in order to avoid mix-
ing them up during installation. 16 16
16
RKPB1922
PW110R-1 30-51
13 - Hook the engine (17) to the hoisting equipment using

the specific brackets and slightly put the chains under 17
tension.
RKPB1931
14 -Remove the screws (18) (No. 4) of the engine supports

(19). 2 18 19
15 - Slowly lift the unit and remove the engine (17).
Engine - pumps: 550 kg
Ensure that the engine-pump group is not in any

way caught or fastened to the frame and that all
pipes and cables are disconnected.
RKP10712
INSTALLATION OF
ENGINE-PUMP GROUP

MENTS»).

2 - Fill the cooling circuit.
Coolant liquid needed: approx. 18

are no leakages.

top it up.
30-52 PW110R-1
REMOVAL AND INSTALLATION PUMP GROUP
REMOVAL OF PUMP GROUP

Release residual pressures from all circuits.
MENTS»). 1 2

1 - Remove the engine hood.
(For details, see «REMOVAL OF ENGINE HOOD»).
2 - Remove left and centre rear guards.
RKPB5210
3 - Disconnect the suction flanges and all delivery pipes
from the pumps (1) and (2).
★ Mark the position of Load Sensing, Mode System
and servo-control feed pipes in order to avoid mix-
ing them up during installation.
4 - Attach the pump group to a hoist keeping the cables un-
der slight tension. 3
★ Pass a harness under the gear pump to prevent tilt-
ing of the unit.
5 - Pull out the screws (3) and remove the pump group; dis-
engage the group from the coupling joint shifting it to
one side. 1
Pump group: approx. 97 kg
RKPB1940
INSTALLATION OF PUMP GROUP

1
★ Coat the coupling surfaces thinly.
Coupling surfaces: ASL800050

Pump check screws: Loctite 262
Pump check screws: 50±5 Nm
MENTS»).
Hydraulic oil: 84
are no leakages.
top it up.
PW110R-1 30-53
REMOVAL AND INSTALLATION ENGINE-PUMP COUPLING JOINT
REMOVAL OF ENGINE-PUMP COUPLING JOINT

ground and switch off the engine. 1
1 - Remove the piston pump.
(For details, see «REMOVAL OF PISTON PUMP»).
Half joint pump
2 - Loosen dowel pin (1) fixing half joint (2) in more stages
and alternatively. 1
★ Heat dowel pins to 85 –100 °C
2
3 - Remove pump half joint (2).
★ If necessary, use a puller. RKPB1950
Half joint on flywheel
4 - Remove bolts (3) and flywheel cover (4).

3
2
RKPB1960
INSTALLATION OF ENGINE-PUMP
COUPLING JOINT
1
Pump flange joint mounting bolts: Loctite 262
Pump flange joint mounting bolts: 50 Nm
2
Drive flange bolts: Loctite 262
Drive flange bolts: 50 Nm
1 - Fill up tank unit maximum level.
During the filling operation, bleed air from the piston
pump (For details, see «20. TESTING AND AD-
JUSTMENTS»).
Hydraulic oil: 84
2 - Start the engine to allow oil circulation in all systems and
check the seals.
3 - Stop the engine and, if necessary, restore oil level in the
tank.
30-54 PW110R-1
REMOVAL AND INSTALLATION GEAR-PUMP
REMOVAL OF GEAR-PUMP
• Drain the hydraulic oil. 2 3
1 - Disconnect the suction flange (1) and the delivery pipe

(2) from the pump. 1
1
RKPB1970
2 - Remove the bolts (3) and the pump (4), the joint (5) and
the gasket (6). 2
6
4
5
3 RKP10870
INSTALLATION OF GEAR-PUMP
1
★ Before connecting the suction flange, check the condi-
tion of the seal and keep it in its seat by applying grease
ASL800050.
Flange screws: 35±3.5 Nm
2
Joint: ASL800050
Pump fastening screws: 98–123 Nm

MENTS»).

are no leakages.
top it up.
PW110R-1 30-55
REMOVAL AND INSTALLATION SWIVEL JOINT
REMOVAL OF SWIVEL JOINT

tails, see «20. TESTING AND ADJUSTMENTS»). 1
Disconnect the lead from the negative (–) battery ter-
1
minal.
1 - Remove the distributor hood. (For details see «RE-
MOVAL OF FRONT HOOD»). 3
2 - Remove the cabin (For details, see «REMOVAL OF
CABIN»). 4
3 - Disconnect the tubes (1) on the lower side of the swivel
joint (2) and plug them. RKPB2750
★ Mark the tubes before disconnecting them, to avoid

errors when re-assembling.
4 - Disconnect the stay bolt (3) from the joint (2) and place it
6 2
to one side.
5 - Disconnect the bottom connectors (4).
6 - Disconnect the tubes (5) on the top of the joint (2) and 5
plug them. 1
★ Mark the tubes before disconnecting them, to avoid
errors when re-assembling.
7 - Disconnect from the electric box the connectors (6) of
5
cables coming out on the top portion of joint.
7
8 - Unscrew and remove the screws (7) (No. 4) of the swivel
joint. RKPB2760
9 - Hook the joint (2) to the hoisting equipment and remove

it. 2
Swivel joint: 54 kg
INSTALLATION OF SWIVEL JOINT

1
★ Before connecting the top pipes, introduce hydraulic oil
into the draining branch (branch 6).
1 - Start the engine and bleed air from the circuits by fol-
lowing the procedure given below:
a - Move the outriggers and blade (if mounted) several
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.
30-56 PW110R-1
REMOVAL AND INSTALLATION SWING MOTOR
REMOVAL OF SWING MOTOR

3
4
1 - Disconnect the supply (1), return (2), the brake release
pipe (3) and the drain line connection (4). 1
RKPB6133
2 - Remove the screws (5) and remove the motor (6).
RKPB6380
INSTALLATION OF SWING
MOTOR
1
★ Fill the motor with hydraulic oil through the top drain line
connection.
check the seals.
2 - Bleed the air from engine. (For details, see «20. TEST-
ING AND ADJUSTMENTS»).
PW110R-1 30-57
REMOVAL AND INSTALLATION SWING MACHINERY
REMOVAL OF SWING MACHINERY

2
1 - Drain the reduction gear hydraulic oil. 4
Hydraulic oil: 3.5
2 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»). 1
3 - Disconnect the feed pipes (1), the exhaust pipe (2), the
brake release pipe (3) and the drain line connection (4)
1 RKPB6133
4 - Remove the drain extension tube (5).

5 - Remove the check screws (6) (No. 12) of the reduction 7
gear (7). 2
6 - Fasten two screws into the holes opposite to each other
and remove the reduction gear 6
7 - Sling the complete assembly and remove it.
★ During removal, slowly lift the assembly and pay
particular attention not to damage the pipes or oth- 5
er parts.
Complete group: approx. 87 kg

RKPB6390
INSTALLATION OF THE
SWING MACHINERY
★ In order to centre the holes of the pins and of the fas-
tening screws, connect a hydraulic power unit “A” to the
hydraulic motor and slowly rotate the motor until the cor-
rect angle for the positioning of the reduction gear has
A
been obtained.
1
★ Fill with hydraulic oil through the breather (8).
RKPB6402
2
Screws: 294 Nm
check the seals.
2 - Bleed the air from engine. (For details, see «20. TEST-
ING AND ADJUSTMENTS»).
30-58 PW110R-1
DISASSEMBLY OF THE SWING MACHINERY

★ Before dismantling the swing machinery mark the po-
sition of the hydraulic motor (1) in relation to the flange 1
(2), in relation to the flange (2), in relation to the flange
(2) and ring gear (3) and gear housing (4). 2
5
3
RKP12550
1 - Remove the oil drain plug (5) and remove the screw (6)
and hydraulic motor (1).
1
5
6
RKPB6381
2 - Remove the screw (7) (No. 14) fixing flange (2).

7
RKPB6630
3 - Remove the flange (2).
RKPB6640
PW110R-1 30-59
4 -Take out the O-ring (8) from flange (2).

2
RKPB6650
5 - Remove 1st reduction sun gear (9).

9
RKPB6660
6 - Remove the planetary carrier (10).
10
RKPB6670
7 - Remove 2nd reduction sun gear (11).
11
RKPB2161
30-60 PW110R-1
8 - Take out the toothed ring (3).
RKPB6680
9 - Using levers, remove the planetary carrier (12).

12
RKPB6690
10 - Remove the O-ring (13) from gearbox housing (4).

13
RKPB2191
11 - Lift the staking of the ring nut (14).
15
14
RKPB2201
PW110R-1 30-61
12 - Using the special tool C1 and a dynamometric wrench,

remove the ring nut (14).
C1
RKPB6701
13 - Remove the spacer (16).
16
RKPB2222
14 - Using a puller, remove the swing pinion shaft (15) from

gearbox housing (4).
4 15
RKPB2231
15 - Remove the bearing inner ring (17).
17
RKPB2371
30-62 PW110R-1
16 - Remove the gearbox housing (4) from swing pinion

shaft (15)
4
15
RKPB2361
17 - Using a puller, remove the bearing outer ring (17) from

17
4
RKPB2241
18 - Using the special tool C2 and a press, remove the bear-

ing inner ring (18), the seal ring (19) and the spacer (20)
from swing pinion shaft (15). C2 19
15 20
19
18 20
RKPB2273
19 - Overturn the gearbox housing (4) and remove the seal

ring (21).
4
21
RKPB2251
PW110R-1 30-63
20 - Using a puller, remove the bearing outer ring (22) from

22
RKPB2261
30-64 PW110R-1
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 reduction

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
20
1 - Mount the spacer (20) on the swing pinion shaft (15).
★ Check that the chamfered part rests on the pinion.
20
15
RKPB2281
2 - Mount the metal sealing ring (19).

19
★ Take care to the orientation of seal ring.
19
RKPB2291
3 - Fill the metal sealing ring (19) with grease.
Metal sealing ring: ASL800050

19
RKPB2301
PW110R-1 30-65
4 - Apply a layer of grease over the inside bearing ring (22).
Bearing: ASL800050
22
RKPB2311
5 - Using the tool C3 and a press, drive the inside bearing

ring (19) down over the spacer (19).
C3
22
19
RKPB2323
6 - Using the tool C4 and a press, drive the outside bearing

ring (22) down over the gearbox housing (4). 22
C4
RKPB2331
7 - Using the same method as above, mount the outside

ring of the other bearing (17) in the gearbox housing.
C3
RKPB2342
30-66 PW110R-1
8 - Mount the sealing ring (21) in the gearbox housing (4).

21
21
RKPB2351
9 - Fill with grease the bearing (22) seat.

22
Bearing: ASL800050
22
RKPB7640
10 - Position the gearbox housing (4) over the swing pinion

(15).
4
15
RKPB2361
11 - Mount the inside bearing ring (17) on the swing pinion

(15).
17
15
RKPB2372
PW110R-1 30-67
12 - Using the tool C3 and a rubber hammer, drive the bear-

ing (17).
C3
RKPB2342
13 - Mount the spacer (16) over the swing pinion shaft (15).
In the case of replacing bearings (17) and (22) of

the swing pinion shaft (15) or the gearbox housing
(4), before continue to assembly check the rotation
torque of the swing pinion shaft. 16
(For detail see «Check rotation torque of pinion
shaft»).
15
RKPB2223
14 - Tighten the lock-nut (14).

★ Use a new lock-nut.
Lock-nut: Loctite 243
15
RKPB2381
15 - Use the special wrench C1 and a dynamometric wrench

to tighten the lock-nut (14).
C1
RKPB2391
30-68 PW110R-1
16 - Lock the position of the lock-nut (14) with 6 safety caulk-

ings, corresponding to the grooves in the pinion shaft
(15).
15
14
RKPB2401
17 - Lubricate the O-ring seating of the gearbox housing (4)

and mount the seal (13). 13
Seating: ASL800050
4
RKPB2191
18 -Install the 2nd sun gear groups (12).

12
RKPB2181
19 - Mount the toothed ring (3).

★ Check the position against the marks made before 3
dismantling.
RKPB2170
PW110R-1 30-69
20 - Mount the pinion (11) of the 2nd sun gear.
11
RKPB2161
21 - Mount the 1st sun gear (10).

10
RKPB2151
22 - Mount the pinion (9) of the 1st sun gear.

9
RKPB6660
23 - Lubricate the O-Ring seat and mount the O-Ring (8) in

8
the flange (2).
Seat: ASL800050
RKPB6710
30-70 PW110R-1
24 - Mount the flange (2) on the toothed ring (3).

★ Check the position.
RKPB6720
25 - Using a dynamometric wrench tighten the screws (7).

7
Screws: 85 Nm
RKPB6730
26 - Using a caliper verify the correct assembly of the gear-

box checking the axial quota X.
X= 28.9–29.5 mm
★ If the value is higher, reduce the sun gear (9) width
X
in the axial direction flattening the support plane 9
(reduction side).
★ If the value is lower, insert adjusting spacer be- 10
tween sun gear (9) and planetary carrier (10).
RKP12950
27 - Place the swing machinery (1), tighten the screws (6)

and mount the oil drain plug (5).
1
5
6
RKPB6381
PW110R-1 30-71
Check rotation torque of pinion shaft

1 - Position the special tool C2 on the bearing (17) and, with
press, apply a force of 2500–3060 kg.
2 - Using a dynamometric wrench, verify that the torque of

gearbox housing is 5–6 Nm C2
Gear housing: 5 –6 Nm
★ If the torque is higher, increase the thickness of
shim (16).
★ If the torque is lower, decrease the thickness of 16
shim (16).
17
RKP12961
30-72 PW110R-1
REMOVAL AND INSTALLATION CONTROL VALVE
REMOVAL OF CONTROL VALVE

ground and switch off the engine. 1 4
1
★ Mark all pipes before removal.

2
1 - Disconnect pipes in the following sequence: servo con-
trol pipes (1), feed pipes (2), return pipes (3), function 3
pipes (4) and LS pipes (5).
★ Plug all holes so as to keep out impurities.
5
RKPA5810
2 - Fit the unit with two eyebolts (6). (M8x1.25)

6
3 - Hook the unit (7) to the hoisting equipment and slightly
put the ropes under tension.
4 - Remove screws (8) (No. 3) and remove the control

valve. 1
Complete control valve: approx. 65 kg
7
RKPA5820
INSTALLATION OF CONTROL
VALVE 8
1
Control valve check screws: 190 Nm
Control valve check screws: Loctite 262
1 - Check the level of the tank; start the engine to allow oil to
circulate to all parts of the equipment. RKPB5700
Switch off the engine and top up the oil level.
2 - Bleed air from all parts of the equipment. (For details,

see «20. TESTING AND ADJUSTMENTS»).
PW110R-1 30-73
REMOVAL AND INSTALLATION REVOLVING FRAME
REMOVAL OF REVOLVING FRAME

minal.
1 - Remove the upper work equipment. 1
(For details, see «REMOVING UPPER WORK EQUIP-
MENT»). 2
2 - Remove the front hood. (For details, see «REMOVAL
2
OF FRONT HOOD»).
3 - Remove the cabin and the seat. (For details, see «RE-
MOVAL OF CABIN AND REMOVAL OF THE SEAT»).
4 - Remove the boom cylinder. (For details, see «REMOV-

RKPB2751
AL OF BOOM CYLINDER»).
5 - Disconnect all the lower tubes (1) from the swivel joint
(2) and plug them. Also plug the fittings left on the joint.
1
6
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.
5 7
7 - Start the engine and swing the revolving frame (4) until a
screw (5) in the rear extraction compartment of the track
frame (6) has been centred.
8 - Remove the screw (5).
RKPB0330
9 - Repeat the same operations for the other screws (No.
39).
Leave two screws in position for reasons of safety,

one at the front and one at the rear.
C
10 - Using the raising hooks B and C attach the revolving
frame to a hoisting tackle and apply slight tension to the
chains. 2 B
11 - Loosen and disengage the two screws, leaving them in-
serted in the bearing ring (7).
12 - Raise the revolving frame (4) slowly. 3

★ While raising the revolving frame, take great care
4
not to damage the swivel joint. RKPB6611
Revolving frame: approx. 4300 kg
3
4
RKP11260
30-74 PW110R-1
REMOVAL AND INSTALLATION REVOLVING FRAME
INSTALLATION OF REVOLVING FRAME

1
★ After connecting up all the hydraulic tubes, start the
engine and move all parts of the equipment several
times to bleed air from the circuits, while checking
for leakages.
★ Switch off the engine and check level of the hy- 8
draulic oil.
2 7
★ Align the two positions corresponding to the center-
ing pins (8), then assemble.
Sealant and swing circle platform gaskets: RKPA5850
ASL800050
Internal swing circle grease: approx. 25 kg
10
3 12
Revolving frame attachment screws
(without nut): Loctite 262 11
9
Installation Procedure
In order to swing the revolving frame for centering the
reference pins (8), and the pinion-swing circle coupling: 10
1 - Disconnect the feed pipes (10), the drain line connec-
tion (11) and the brake release tube (12) from the swing RKPB6134
motor (9).
★ Plug connections to avoid impurity entry.

2 - Connect a hydraulic power unit “A” and slowly rotate
the turret until correct centring is obtained.
3 - Insert the two screws left in the swing circle (7) and se-
cure them.
4 - Insert all the other screws (5).
5 - After having secured all the screws that joint the swing A
circle to the revolving frame, reconnect the delivery
tubes (10) of the swing motor (9), and the brake release
tube (12) and the drain line connection.
6 - Detach the hoisting tackle. RKPB6402
PW110R-1 30-75
REMOVAL AND INSTALLATION COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
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 hoist-
ing eyebolts (2).
4 - Attach the hoisting tackle and apply slight tension to the
cables.
5 - Using the tool A1, loosen the screws (3) and their safety
washers. 1 RKPB0860
6 - Remove the counterweight (4).

Counterweight: 1450 kg
2 2
4
RKPB0960
INSTALLATION OF
COUNTERWEIGHT
• To install, reverse the removal procedure. A
3
1
Counterweight screws: Loctite 262
Counterweight screws: 580 Nm

★ Carefully check that the vertical positioning meas-
urement «A» is 100±2 mm with respect to the re-
RKPB0880
volving frame.
30-76 PW110R-1
REMOVAL AND INSTALLATION SWING CIRCLE
REMOVAL OF SWING CIRCLE

1 - Remove the upper revolving frame. (For details, see
«REMOVAL OF UPPER REVOLVING FRAME»).
S
2 - Completely remove all contaminated grease. 3
3 - Remove the screws (1) that secure the swing circle (2).
1
2
RKPB0340
4 - Remove the swing circle (2) using a lifting equipment

“A”. 1
Swing circle: 124 kg A
2 S
RKPB0351
INSTALLATION OF
SWING CIRCLE
★ Before installing the swing circle, check the condition of
the central gasket (3).
For reasons of safety, when installing the swing circle,
insert two screws into the front and back holes in the
frame.
1
Before attaching the swing circle, check that the area
marked with an «S» is positioned on the right-hand side
of the chassis.
Attachment screws: Loctite 242
Lubricating grease: approx. 25 kg
PW110R-1 30-77
TRANSMISSION - REVERSER, DIRECTION INDICATOR AND
REMOVAL AND INSTALLATION HEADLIGHT DIPPER BEAM CONTROL GROUP
REMOVAL OF THE TRANSMISSION - REVERSER, DIRECTION INDI-

CATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Lower the work equipment until it rests on the ground
and stop the engine.
Disconnect the lead from the negative (--) battery ter-
minal.
1 - Take out check screws (1) (No. 2) and remove the front
guard (2) of the steering column. 2
RKPB6740
2 - Disconnect the connectors (3) and (4).
RKPB6750
3 - Remove the screws (5) (n° 2 alternate) and switches (6)

and (7).
7
5 6
RKPB6760
INSTALLATION OF THE
TRANSMISSION - REVERSER,
DIRECTION INDICATOR AND
HEADLIGHT DIPPER BEAM
CONTROL GROUP
30-78 PW110R-1
REMOVAL AND INSTALLATION R.H. PPC VALVE (BOOM-BUCKET)
REMOVAL OF R.H. PPC VALVE (BOOM-BUCKET)

ground and switch off the engine, and remove the start-
ing key. 4
2
1
minal.
1 - Loosen screws (1) and remove armrest (2).
3
2 - Loosen retaining screws (3) (n. 3) of R.H. console (4). 3
★ To remove the inside screw, lower the seat and
RKPB6770
push it right back.
3 - Disconnect the connectors (5), (6) and the PPC valve

connector (7).
★ Mark the position to avoid errors during the assem-
bly.
5 7
6
RKPB6420
4 - Detach the cover (8) from the R.H. console (4).
5 - Move backward the R.H. console. Disconnect hoses (9)

from the PPC valve (10) (n° 6 pipes) and plug them to 8
prevent entry of impurities. 1 10
★ Mark the position to avoid errors during assembly.
11
6 - Remove screws (11) and remove the PPC valve (10)
9
If there is a slack on the control lever, adjust the unit
(See «20: TESTING AND ADJUSTMENTS - Ad-
justment of manual control slacks»).
RKPB6430
PW110R-1 30-79
REMOVAL AND INSTALLATION R.H. PPC VALVE (BOOM-BUCKET)
INSTALLATION OF R.H. PPC VALVE (BOOM-BUCKET)

1
★ Check the positions carefully when reconnecting
the tubes.
P - Pressure T
P1
T - Unload
P1 - L.H. swing P4
P2 - Arm opening
P3 - R.H. swing P
P2
P4 - Arm closing
P3
1 - Start the engine to circulate the oil and check the seals. RKPB6440
30-80 PW110R-1
REMOVAL AND INSTALLATION L.H. PPC VALVE (ARM-SWING)
REMOVAL OF L.H. PPC VALVE (ARM-SWING)

minal.
1 - Remove the control heating knob (1) the fan control

knob (2) and loosen the nut (3).
4
2 - Disconnect the cover (4) from console.
2 3
1
5 3
RKPB6450
3 - Only for machine equipped with air conditioning

unit: remove the air conditioning control knob (6) and
loosen the retainer nut (7).
6
RKPB6460
4 - Remove the arm rest (9) fixing screws (8).
5 - Loosen screws (10) and remove L.H. console (5).

★ To remove the inside screw, lower the seat and
push it right back.
8
10
9
5
RKPB6470
PW110R-1 30-81
REMOVAL AND INSTALLATION L.H. PPC VALVE (ARM-SWING)
6 - Disconnect the six tubes (11) from the PPC valve (12)
and plug them to prevent entry of impurities.
★ Mark the positions to avoid errors during assembly.
1
7 - Remove screws (13) and remove PPC valve (9). 13
12
If there is a slack on the control lever, adjust the
unit. (See «20. TESTING AND ADJUSTMENTS -
Adjustment of manual control slacks»).
11
RKPB6480
INSTALLATION OF PPC VALVE

(ARM-SWING)
1 P1 T
★ Check the positions carefully when reconnecting
the tubes.
P - Pressure
T - Unload P2 P4
P1 - Arm closing P
P2 - L.H. swing P3
RKPB6490
P3 - Arm opening
P4 - R.H. swing
1 - Start the engine to circulate the oil and check the seals.
30-82 PW110R-1
REMOVAL AND INSTALLATION OUTRIGGER AND BLADE PPC VALVE
REMOVAL OF OUTRIGGER AND BLADE PPC VALVE

4 5
1 - Remove the cabin (For details, see «REMOVAL OF
CABIN»).
3 6
2
1
RKPB6500
1. Blade version
1 - Disconnect the tubes (1), (2), (3) and (4) and plug them. 12
★ Make an identifying mark on the pipes to avoid mix- 13
10
2 - Remove the screw (5) and the PPC valve (6).
2. Blade - stabiliser version 11 8

1 - Disconnect feed and exhaust pipes (7) and (8).
★ Make an identifying mark on the pipes to avoid mix-
7
2 - Remove pipes (9) and (10). 9
3 - Disconnect the tubes (11) RKPB6780
Make an identifying mark on the pipes to avoid mixing

them up during installation.
4 - Take out the screws (12) and remove the PPC valve
(13) for reconditioning or replacement.
INSTALLATION OF OUTRIGGER
AND BLADE PPC VALVE
1 - Start the engine to circulate the oil.
2 - Bleed air from the blade cylinder. (For details, see «20.
PW110R-1 30-83
REMOVAL AND INSTALLATION BOOM SWING PPC VALVE
REMOVAL OF BOOM SWING PPC VALVE

• Rotate the turret 90° to the left.

1 - Remove the bottom left casing (1).
1
RKP11052
2 - Disconnect the pipes (2) (No. 4 tubes) from the PPC val-
ve.
2
★ Place an identifying mark on the pipes to avoid mix-
2
2 3
3 - Remove the side connections (3).
3
3
RKPB6540
4 - Pull out the screws (4) and remove the pedal control (5)
with the operation pedal (6).
RKPB6790
INSTALLATION OF BOOM SWING

PPC VALVE
2 - Bleed the air from boom swing cylinder.(For details, see

«20. TESTING AND ADJUSTMENTS»).
30-84 PW110R-1
REMOVAL AND INSTALLATION TRAVEL AND 2nd BOOM PPC VALVE
REMOVAL OF TRAVEL AND 2nd BOOM PPC VALVE

• Rotate the turret 90° to the left.

1 - Remove the bottom left cover (1).
1
RKP11052
2nd BOOM
2 - Disconnect the pipes (2) (No. 4 tubes) from the pedal
control.
★ Place an identifying mark on the pipes to avoid mix-
ing them up during installation. 3
3 - Remove the connections (3) from the pedal control. 2
2
3
RKPB6560
2nd BOOM
4 - Pull out the screws (4) and remove the pedal control (5)
or (6) with the operation pedal. 6
5
RKPB6570
TRAVEL
INSTALLATION OF TRAVEL
AND 2nd BOOM PPC VALVE
6
2 - Bleed air from the front boom swing cylinder.

(See «20. TESTING AND ADJUSTMENTS»).
RKPB6800
PW110R-1 30-85
REMOVAL AND INSTALLATION BRAKE PUMP
REMOVAL OF BRAKE PUMP

Lower the work equipment completely until it rests it on
the ground and stop the engine. 1
Release all residual pressures from all circuits, and in
particular from the brake line. (See «20. TESTING AND
ADJUSTMENTS»).
1 - Disconnect the seven hoses (1) from the brake pump
and plug them. 1
3
★ Make an identifying mark on the hoses to avoid 1
2
mixing them up during installation.
2 - Disconnect the terminals of pressure switches (2) and
(3). 2
★ Make an identifying mark on the cables to avoid RKPB5810

3 - Remove the screws (4) locking support sensor (5) and
move away it.
4 - Remove the brake pump (7) and loosen three screws

(6).
5
7
4 6
RKPB5820
INSTALLATION OF THE“BRAKE
PUMP
1
★ Start the engine and bleed air from the brake lines.
2
★ After re-connection, make sure that the protective
sleeves are positioned correctly and firmly.
30-86 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT
REMOVAL OF THE STEERING UNIT

ground and stop the engine.
Release all residual pressures from all circuits.
MENTS»).
1 - Remove the LH guard (1) of the revolving frame.
1
RKP07970
2 - Disconnect the tubes (3) from the steering unit (2).

★ Make some identifying marks on the tubes before
disconnecting them, to avoid mixing up the posi- 4
tions when reconnecting.
2
RKPA8290
3 - Using the special wrench Q1, remove the screws that

fasten the steering unit group (2) to the steering column
(4).
★ In order to remove the front screws, attach the spe- 5
cial wrench Q1 to the steering unit (2) and move it
with a normal wrench inserted in the lower provided
Q1
between the cabin (5) and the revolving frame (6).
6 RKP09570
INSTALLATION OF THE
STEERING UNIT
1 - Start the engine and bleed air from the Load Sensing cir-
cuit (See «20. TESTING AND ADJUSTMENTS»).
RKPB0470
PW110R-1 30-87
DISASSEMBLY THE STEERING UNIT

Disassembly the body of the steering unit
1 - Loosen and remove the screws (1-3) that hold the cover 3
(2) in place (six screws plus one special screw). 1
RKPA7990
2 - Remove the cover (2) by sliding it sideways.
RKPA8000
3 - Raise the rotating gear (4) complete with the O-rings

(34). Also remove the spacer (5).
4
5
34
RKPA8010
4 - Remove the drive shaft (6).
RKPA8020
30-88 PW110R-1
5 - Remove the control lens (7).
RKPA8030
6 - Remove the threaded bush (8) of the safety valve.
RKPA8040
7 - Remove the O-ring (9).
RKPA8050
8 - Lift out the ball (10) of the check valve, and the pins (11)
and balls (12) of the anticavitation valves.
11
10
12
RKPA8060
PW110R-1 30-89
9 - While watching through the central hole of the spool, po-

sition the spool-bushing connecting pin horizontal-
ly.“Push the entire group (13) and the entire bearing
13
until they can be extracted from the body of the steering
unit (14).
14
RKPA8070
10 - Remove the outside ring (15), the inside ring (16), and
the roller bearing (17) from the spool. Also remove the
ring (33).
★ The inside ring (16) sometimes gets left in the body
of the steering unit. Make sure that it has been re- 33
moved.
16
15 17
RKPA8080
11 - Lift out the cross pin (18), the bushing (19) and the spool
(20).
★ Use the special cover-fastening screw (3) for total 19
extraction.
3
18
20
RKPA8090
12 - Slowly slide the spool (20) out of the bushing (19).
20
19
RKPA8100
30-90 PW110R-1
13 - Push the neutral position springs (21) and extract them

from the spool (20).
21
20
RKPA8110
14 - Remove the dust-guard washer (22) and the composite

leaktight seal (23) (O-ring + washer).
23
22
RKPA8120
15 - Remove the caps (24) from the safety valves.
24
RKPA8130
16 - Remove the cup springs (25).
25
RKPA8140
PW110R-1 30-91
17 - Remove the adjustment screws (26) (6 mm screw

wrench).
26
RKPA8150
18 - Extract the springs (27) and the two balls (28).

★ The valve seatings are fixed in the body of the
steering unit and cannot be removed.
27
RKPA8160
19 - Check that the dismantled pieces resemble those indi-

cated in the figure. 26
25
27
28 24
27 25
26
RKPA8170
Removal of the safety valve

20 - Remove the cap (29) and its gasket (30) (8 mm screw
wrench).
29
30
RKPA8180
30-92 PW110R-1
Disassembly the safety valve

21 - Remove the safety valve (31) and its washer (32).
22 - Make sure that the steering unit is completely disman- 31 32

tled.
NOTE
Cleaning
• Clean all the components with an aliphatic solvent
(white spirits or similar).
Inspections and substitutions
• Change all the cup springs and seals.
RKPA8190
• Inspect all the pieces and change those in a doubtful
state of wear.
PW110R-1 30-93
ASSEMBLY THE STEERING UNIT

★ Before assembly, lubricate all the components with hy-
draulic oil.
1 - There is only one possible and correct way to assemble a
of the spool (20) and bushing (19). “Assemble with the
three holes (a) of the bushing (19) opposite the slots (b) 20
in the spool (20). “Check that the holes in the bushing
are at least partially visible through the slots (b) in the 19
spool.
b
RKPA8200
2 - Insert the two flat springs (21a) in the seating and centre
them with respect to the diameter of the spool (20). In-
sert the four curved springs (21b) between the two flat
springs (21a) , arranged in pairs, and push them com-
pletely home.
21a
20
21b
RKPA8210
3 - Align the springs (21).
21
RKPA8220
4 - Insert the spool (20) into the bushing (19).

★ Make sure that the position between bushing and
spool is as described in phase 1 of the assembly in- 20
structions.
21 19
RKPA8230
30-94 PW110R-1
5 - Push the springs (21) and the spool (20) down together
until the springs are engaged in the seating of the bush-
ing (19).
21
20
19
RKPA8240
6 - Align the springs (21) with each other and centre them
with respect to the diameter of the bushing (19).
21
19
RKPA8250
7 - Install the ring (33) in the seating of the bushing (19).

★ The ring (33) should be free to rotate without inter-
fering with the springs (21).
19
33
RKPA8260
8 - Insert the cross pin (18).
18
RKPA8270
PW110R-1 30-95
9 - Assemble the thrust bearing according to the sequence

indicated at point 10.
16
17
15
RKPA8280
10 - Sequence for assembly the bearing.

15 - Outside ring 16
16 - Inside ring
17 - Needle bearing 17
19 - Bushing
15
20 - Spool
20
19
RKP09580
11 - Place the body of the steering unit (14) with the hole hor-
izontal.
Insert the guide of tool Q2 into the hole of the spool/
bushing group. 14
Q2
RKPA8300
12 - Lubricate the seal ring (23a) and the O-ring (23b) and
mount them on the push-rod of tool Q2.
23a Q2
23b
RKPA8310
30-96 PW110R-1
13 - Mount the tool Q2 and insert it in the guide already in-

serted in the hole of the steering unit.
23
Q2
RKPA8320
14 - Push the gasket (23) into the seating of the body of the
steering unit (14), assisting the movement with slight ro-
tatory movements.
14
RKPA8330
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
RKPA8340
16 - Insert the bushing/spool group (13) into the hole of the

steering unit (14).
Assist the insertion with slight rotatory movements.
★ Insert the group while keeping the cross pin hori-
zontal. 13
14
RKPA8350
PW110R-1 30-97
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
RKPA8360
18 - Rotate the body of the steering unit (14) until the central
hole is vertical.
Insert the ball (10) of the safety valve into the hole in-
dicated by the arrow.
10
14
RKPA8370
19 - Screw the valve threaded bush (8) into the hole in the
safety valve.
★ The upper part of the threaded bush should be low-
er than the surface of the body of the steering unit
(14). 8
14
RKPA8380
Assembly of the anticavitation valve

20 - Insert the balls (12) into the two holes indicated by the
arrows.
12
RKPA8390
30-98 PW110R-1
21 - Insert the pins (11) into the same holes.
11
RKPA8400
22 - Lubricate the O-ring (9) and mount it in the seating.
Mineral oil: viscosity approx. 500 cSt at 20 °C 9
RKPA8410
23 - Position the control lens (7) so that the holes corre-

spond to those in the body of the steering unit (14).
14
RKPA8420
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
6
steering column.
RKPA8430
PW110R-1 30-99
25 - Place the drive shaft in a vertical position and hold it

steady with the tool Q3.
Q3
RKPA8440
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).
4 34
Mineral oil: viscosity approx. 500 cSt a 20°C
RKPA8450
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 to 6
align the attachment holes.
4a
RKPA8460
28 - Install the spacer (5).
4b
RKPA8470
30-100 PW110R-1
29 - Mount the cover (2).
RKPA8480
30 - Insert the special screw (3) complete with washer in the

hole indicated in the figure.
RKPA8490
31 - Insert the six screws (1) complete with their cup springs.
Tighten the screws (1) crosswise with a torque of 30±6
Nm.
RKPA8500
32 - Position the dust-guard seal (22) in the body of the

steering unit (14).
22
14
RKPA8510
PW110R-1 30-101
33 - Press the dust-guard seal (22) into the body of the steer-
ing unit, using the tool Q4 and a plastic hammer.
Q4
22
RKPA8520
34 - Close the holes of the hydraulic couplings with plastic

caps to prevent the entry of impurities.
★ Push the caps on by hand, without using the ham-
mer.
RKPA8530
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: 50±1 Nm 14
32
RKPA8540
36 - Screw the cap (29) complete with washer (30), using an

8 mm. Screw wrench.
Cap: 50±1 Nm
29
30
RKPA8550
30-102 PW110R-1
Assembly of the safety valve

37 - Insert the balls (28) of the safety valves into the holes in-
28
dicated by the arrows.
RKPA8560
38 - Insert the springs (27) of the safety valves into the holes.
27
RKPA8570
39 - Screw the pressure adjustment screws (26) into the

holes.
26
RKPA8580
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
RKPA8590
PW110R-1 30-103
REMOVAL AND INSTALLATION PRIORITY VALVE
REMOVAL OF THE PRIORITY VALVE

(For details, see «20. TESTING AND ADJUST- 1
MENTS»).
1 - Disconnect the four tubes (2) and the priority valve (1).
2 - Remove screw (3) and washer.Remove the priority

valve (1).
RKPB5450
2 RKP11070
INSTALLATION OF THE
PRIORITY VALVE
1 - Start the engine and bleed air from the Load Sensing cir-
cuit. (See «20. TESTING AND ADJUSTMENTS»).
30-104 PW110R-1
REMOVAL AND INSTALLATION PRIORITY VALVE
DISASSEMBLY OF 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).
3 - Lift off the cap (2) complete with the aluminium washer
2
and the spring (3).
4 - Using a nylon plunger, extract the spool (4).

3
ASSEMBLY OF THE
PRIORITY VALVE
★ 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 4
1 - Insert the spool (4) using the nylon plunger to keep it
centred.
2 - Screw the cap (1) complete with its aluminium washer, RKP10200
into the PP port.
3 - Screw the cap (2), complete with its aluminium washer

and the spring (3) into the LS port.
4 - Tighten caps (2) and (1) firmly, and in that sequence.
Caps (1) and (2): 50±10 Nm
PW110R-1 30-105
REMOVAL AND INSTALLATION TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR

MENTS»).
1 - Remove the steps leading to the cabin (1).
RKPA8610
2 - Disconnect the front drive shaft (2) from the transmis-

sion (3). 1
3 2
RKPB2780
3 - Disconnect the supply tubes (4), the motor drainage

tubes (5) and the drainage tube. Plug the tubes and the
motor to prevent entry of impurities. 2
4 - Disconnect the connector (6).
5 - Loosen the four screws (8) that hold the motor (7).
6 - Place a hydraulic jack underneath the motor to support

it.
7 - Remove the screws (8).

6
RKPB2790
8 - With the help of levers and a soft-headed mallet, move

the motor (7) and slide the shaft off the transmission
7 4
coupling.
★ Take great care not to damage the coupling sur-
5
faces.
3
RKPB2721
30-106 PW110R-1
INSTALLATION OF THE TRAVEL MOTOR

1
Screws: 34÷41 Nm
2
★ Before connecting the drainage tube (5), fill the mo-
tor casing with hydraulic oil.
3
★ Carefully check the O-ring seal between motor and
transmission. If there are any doubts as to its con-
dition, change it.
Sealant: ASL800050
1 - Start the motor and travel both forwards and backwards

at low speed to bleed the system and to check the leak- 9
tightness of the tubing. 7
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 in-

spection or overhaul, before using the machine again
check:
1 - The setting of the automatic displacement control
system.
RKP09590
2 - The speed of the travel propeller shaft.
★ For test and adjustment procedures, see «20.
TESTING AND ADJUSTMENTS».
PW110R-1 30-107
DISASSEMBLY OF THE TRAVEL MOTOR

1 - Remove circlip (1) and spacer (2).
RKP09640
2 - Install two screws in gasket (3) holes and extract it using

pliers.
RKP09880
3 - Remove oil exchange valve (4).
RKP09600
4 - Remove recognition of travel direction device and au-

tomatic displacement device (5), guide pin (6), spring
(7), bushing (8) and spring (9).
Remove brake valve (35).
Remove safety valve (36) (No. 2).
9
8 3 3
7
5 6
RKP09610
30-108 PW110R-1
5 - Set the motor on a work bench, mark measure «A» of

minimum displacement adjusting screw (34) and re-
move it.
A
34
RKP09750
6 - Push positioning piston (10) until to bring the cylinder

barrel to position zero. 1
★ Mark the measure «B» of maximum displacement
adjusting screw.
RKP09760
7 - Mark position between motor case (11) and displace-

ment adjusting case (12), and after removed bolts (13) 12
(No. 8) remove the adjusting case. 13
11
RKP09620
8 - Remove screw (14) and piston (15) complete with gas-

kets. 15 16
Loosen locking screw (16) and positioning pin (17).
★ For an easy removal, make a pin (17) and screw
(16) heating at about 120°C.
14
17
RKP09780
PW110R-1 30-109
9 - Stop with threaded pin (18) a washer (19) and a nut (20)
the cylinder barrel in zero position.
Remove maximum displacement adjusting screw (21). 20 19
★ Threaded pin: M5x71
18
21
RKP09890
10 - Using a puller, remove the complete swing unit (22).
22
RKP09900
11 - Tighten the complete swing unit into a vice and remove

nut (20), washer (19) and threaded pin (18). 20
Remove cylinder barrel (23).
★ Use a vice provided with soft jaws. 19
18
23
RKP09910
12 - Loosen mounting bolts (24) of valve plate (25).
24
25
RKP09920
30-110 PW110R-1
ASSEMBLY OF THE TRAVEL MOTOR

1 - Tighten the swing unit (26) in a vice and install pistons
(27), valve plate (25) and screws (24).
24
27
26 25
RKP09930
2 - Install cylinder block (23).

★ Check that all components are oriented correctly
and in the right position.
RKP09790
3 - Block cylinder block (23) in vertical position using the

threaded pin (18), and washer (19) and nut (20).
★ Threaded pin: M5X71 20
19
18
23
RKP09940
4 - Install theplunger D on swing unit (22).

22
D
RKP09800
PW110R-1 30-111
5 - Heat the motor case (11) at 80°C and insert complete

swing unit.
11
RKP09810
6 - Lock cylinder barrel in zero position using maximum dis-

placement adjusting screw (21).
Loosen nut (20) used to lock cylinder barrel and remove
washer (19) and threaded pin (18).
Install O-ring gasket (28).
28
21
RKP09950
7 - Set valve plate (29) on cylinder barrel (23) and dowel it

with dowel pin of equipment B.
29
23
RKP09960
8 - Prepare equipment B assembling the travel motor com-

ponents as shown in the illustration.
452010 452269
083105
Position
for item
B
452271
083010
452271
452269 452021
452014
RKP09971
30-112 PW110R-1
9 - Assemble and set equipment B on motor case (11).

Check and bring to zero dial gauge when knob has been
rotated in counterclockwise direction till end of stroke.
B
11
RKP09981
10 - Rotate the knob for 4 turns in clockwise direction and

make sure with a caliper that the dial gauge has a clear-
ance of 2 mm and that pointer is in zero position.
★ This is the starting zero for checking.
RKP10030
11 - Rotate the knob in clockwise direction till end of stroke

and check the central pin (30) clearance value that cor-
responds to dial gauge indicated value.
★ Pin clearance: 0,2±0,05 mm B
★ If central pin clearance is not within the tolerance,
replace springs guide plate (31).
30 31
11
RKP10081
12 - Remove equipment B.
PW110R-1 30-113
13 - Assemble positioning piston (32) into the displacement

adjusting case (12).Assemble the positioning pin (17) 32 16
and locking bolt (16).
★ Use a new locking bolt.
★ Tighten the bolt to recommended tightening
torque.
17
RKP09820
14 - Assemble rings (33) into the piston (15).

Assemble complete piston on positioning piston (32)
and tighten the bolt (14).
33
★ Assemble rings (33) with opposed notch. 15
14
RKP09990
15 - Assemble displacement adjusting case (12) on pump

case (11) and tighten mounting bolts (13) (No. 8). 12
Restore the measures «A» and «B» of maximum (21) 13
and minimum (34) displacement adjusting bolts.
★ Align marks made on pump case and on displace-
ment adjusting case before the disassembly.
11
RKP09620
16 - Assemble the spring (9), bushing (8), spring (7), guide

pin (6) and the recognition travel direction device (5).As-
semble the safety valve (36) (No. 2).Assemble the
brake valve (35).
9
8 3 3
7
5 6
RKP09610
30-114 PW110R-1
17 - Assemble the oil exchange valve (4).
RKP09600
18 - Using the plunger C, fit the gasket (3), spacer (2) and cir-
clip (1). C
1 2
3
RKP09832
PW110R-1 30-115
REMOVAL AND INSTALLATION TRANSMISSION
REMOVAL OF THE TRANSMISSION

Release all residual pressures from all circuits (For de-
• Drain the transmission oil.
Transmission oil: approx. 1.6
1 - Remove the travel motor.

(See «REMOVAL OF TRAVEL MOTOR»).
1 2
2 - Disconnect the rear drive shaft (2) from the transmis-
sion (1). RKPB2781
3 - Disconnect the movement sensor (3) and the micros-

witch (4). 1 6
4 - Disconnect the gear-change tubes (4-5) and plug them.
★ Take some identifying marks on the tubes, to avoid
mixing up the position when reconnecting.
5 - Place a supporting jack underneath the transmission
(1).
5
6 - Loosen the screw (7) (No. 8) and remove complete 3
group. 2 4
★ Take great care not to damage the sensor (3) and
RKPB2742
the microswitch (4). 3
INSTALLATION OF THE
TRANSMISSION 1
1
★ Adjust the position of the transmission sensor.
MENTS»).
★ Position the protective sleeve with the cable outlet
pointing towards the ground to prevent accumula- 7
tions of water or condensates.
8
RKPB2840
2
Nuts: Loctite 242
Nuts: 49÷51 Nm
Surface: Loctite 510
3
★ Fill the transmission with lubricating oil.
Transmission oil: 1.6

1 - Start the engine to circulate the oil and, with the machine
stationary, put it into gear several times to bleed air from
the circuit.
30-116 PW110R-1
DISASSEMBLY OF THE TRANSMISSION
3
2 1 View of gear
cylinder control
4
5 6 8 29
16 44 31
23
22 7
21 24
35 30
18
17 36 32
19
20
13
12 26
14
34
11
10
38
9 28
37
27
39 25
33
38 41
40
RKP09631
1 - Unscrew and take out the gear control shaft (6).
RKPA8670
PW110R-1 30-117
2 - Remove the gear control cylinder assembly (7) and

guard plate (8).
7
8
RKPA8680
3 - Disassemble the gear control cylinder (7).

★ Check carefully the O-rings position. 7
★ Arrange the components in reassembly order.
RKPA8690
4 - Remove the breather (3) and mount the eyebolt (A).

Apply a slight tension to the chain an remove the screws A
fixing the gear box (B) to the axle (C).
B
C
RKPA8700
5 - Using a plastic hammer, remove the gear box (B).
RKPA8710
30-118 PW110R-1
6 - Remove the gear position microswitch (9), washer (10)

and O-ring (11).
10
11
RKPA8720
7 - Remove the screw (12), spring (13) and ball (14) for
neutral position.
14 13
12
RKPA8730
8 - Remove the flange (1) with oil seal (4) and spacer (5).
★ Note the spacers thickness.
RKPA8740
9 - Remove the nut (16).

★ To remove the nut (16) heat it at about 120°C.
★ Make unit cold before continuing in disassembly.
16 17
RKPA8750
PW110R-1 30-119
10 - Remove the ring (18) and the flange (17).
16 18
17
RKPA8760
11 - Remove the cover (19) complete with seal (20) and

thrust ring (22). X
★ Note that notch «X» must be turned upwards.
20
22
19
RKPA8770
12 - Remove the bolts (23) and lightly the cover (24).
23 24
RKPA8790
13 - Using some levers, force the cover (24) to divide it from

housing (25).
★ Prise the cover by the locating dowels.
★ Take great care not to ruin surfaces. 24
25
RKPA8800
30-120 PW110R-1
14 - Pull out gear (39), needle bearings (38) and distance

piece (40) from the cover (25).
39
40 25
38
RKPA8810
15 - Take out bearing (36).

★ Do not take out the bearing (36) if does not need re-
placement.
36
RKPA8820
16 - Remove the oil shield plate (41).

★ Operation to be carried on only if necessary.
41
RKPA8830
17 - Remove the bolts of cut flow housings (26) and (27).
27
RKPA8840
PW110R-1 30-121
18 - Remove the cut flow housing (27) and, in one time, the
hub (28) and the fork (29) complete with pads (30) and
transmission shaft (31).
29
27
31 28
RKPA8850
19 - Check sliding block (30), pin (32) and sliding coupling

(28) wear; replace if worn.
30
32
28
RKPA8860
20 - Using a plastic hammer, remove the output shaft (37)

with needle bearings (38), gear (33) and cut flow hous-
ing (26). 38
37
26
33
RKPA8870
21 - Remove the output shaft (37), gear (33), needle bearing

(38), distance piece (34) and bearing (21).
★ Replace worn or damaged components.
37 21
34
38
RKPA8880
30-122 PW110R-1
22 - Remove input shaft (35) from the cover (24).
35
24
RKPA8890
23 - Remove bearing (44) from carter (24).
24
44
RKPA8900
24 - Remove all the oil seal and clean and dry with accuracy
all the components before reassembling.
PW110R-1 30-123
ASSEMBLY OF THE TRANSMISSION

Removed gaskets and O-rings cannot be used again.
★ Check carefully that contact surfaces are not damaged.
★ Remove from contact surfaces each sealing residual.
★ Lubricate the coupling surfaces of bearings and seals.

4
Surfaces: ASL800050 44
1 - Install the bearing (44) into the casing (24) and fit seal 24 1
(4) and spacer (5) into the flange (1).
★ Lock the spacers into position using grease.
Spacers: ASL800050
RKPA8910
2 - Install the flange (1) onto the casing (24) and bolt it.
Flange surface: Loctite 510
Flange screws: 49–51 Nm

1
24
RKPA8920
3 - Lubricate the threaded portion of seal and fit the com-

plete shaft (35).
Seal: ASL800050 35
RKPA8930
30-124 PW110R-1
4 - Assemble the complete outlet shaft (37) and the flow

regulator casing (26) at the same time.
★ Stop assembly at approx. 5mm from the final po-
sition.
37
26
RKPA8940
5 - Provisionally fit cover (19) and screw it down.

★ Hold niche «X» turned to the top side of reduction
gear.
X
19
RKPA8950
6 - Install coupling (28), the complete fork (29) and the flow
regulator casing (27) all at the same time.
29
27
28
RKPA8851
7 - Bolt the assembly with screws.
Screws: Loctite 270
Screws: 25–26 Nm
RKPA8970
PW110R-1 30-125
8 - Install the needle bearings (38), the gear (39) and the
distance piece (34). 34
39 38
RKPA8960
9 - Coat the outer rim of the flow regulator plate (41).
Flow-regulator: Loctite 510
41
RKPA8980
10 - Fit the flow regulator plate (41) into the reduction gear
housing (25) turning the oil inlet (Y) upwards.
Place it 5–5.5 mm from the surface of the body.
41
Y
25
5ⴜ5,5mm
RKPA8990
11 - Fit the bearing (36) into the housing (25).
25
36
RKPA9000
30-126 PW110R-1
12 - Fit the housing (25) onto the casing (24) making sure to
centre the pins.
24
★ Apply sealant to the surface of cover.
★ Use a plastic hammer to mate.
Cover: Loctite 510
25
RKPA9010
13 - Bolt casing (24) and housing (25) with screws (23).
Screws: 48÷62 Nm
24
23
25
RKPA9020
14 - Lubricate the ball (14), spring (13) and the screw (12)
and install the neutral position assembly.
Ball and spring: ASL800050

14 13
Screw: 80–100 Nm 12
RKPA8730
15 - Fit the in-gear-position microswitch (9), the O-ring (11)

and washer (10).
Microswitch: Max. 54.2 Nm

9
10
11
RKPA8720
PW110R-1 30-127
16 - Hook transmission (B) to the hoisting equipment and fit

it onto axle (C ). Coat supporting surfaces.Bolt units with
the relative screws. B
Surfaces: Loctite 510

C
Screws: Loctite 270
Screws: 52–63 Nm Nm
RKPA9030
17 - Pull out screws and remove the provisionally fitted cov-

er (19).
19
RKPA9040
18 - Push the bearing (21) to end of travel.
21
RKPA9050
19 - Using a depth gauge, measure jut «A» of bearing (21)

on flange surface.
21
RKPA9060
30-128 PW110R-1
20 - Measure dimension «B» between the surface of the

cover (19) and the edge of the seat of bearing. Calculate
B
the required dimension of distance washers so as to
leave a slack of 0.2–0.3 mm, i.e.: 19
B – (A+0,2÷0,3)= dimension of distance washer.
19
RKPA9070
21 - Insert the required distance washers (22) in the cover

(19), greasing them to keep them in position.
Distance washers: ASL800050
X 19
22
RKPA9080
22 - Coat the supporting surfaces and fit the flange.

★ Keep niche «X» upwards.
Surfaces: Loctite 510
Screws: Loctite 270
Screws: 48–62 Nm
RKPA9090
23 - Fit the flange (17), the O-ring (18) and bolt them with the
nut (16).
Nut: Loctite 270 16
Nut: 260–300 Nm
17
RKPA9100
PW110R-1 30-129
24 - Assemble the gear control cylinder (7).

★ Carefully check position of O-rings. 7
RKPA8690
25 - Fit the protection plate (8) onto the transmission (B) af-
ter coating the surface touching the transmission.
Plate: Loctite 510
8
B
RKPA9110
26 - Install the gear control cylinder (7) complete with O-ring

and bolt it with the relative screws.
Screws: 49÷51 Nm
RKPA8681
27 - Run the gear control rod (6) and tighten.
Rod: Loctite 242
Rod: 24–26 Nm
RKPA8670
30-130 PW110R-1
REMOVAL AND INSTALLATION AXLE LOCKING CYLINDERS
REMOVAL OF AXLE LOCKING CYLINDERS

Lower the bucket (1) until level ground and make it lean
on the back.
(For details, see «20. TESTING AND ADJUST- 1
MENTS»).
1 - Bring the ignition key to the «I» position and operate the 2
axle release push-button; move the key to the «O»
3
(OFF) position and remove it.
2 - Disconnect the pipe (2) from the cylinder (1) and plug it.
3 - Loosen the screws (3).

RKPB2800
4 - Sling the cylinder (1) and remove the screws (3).
Cylinder: 32 kg
INSTALLATION OF
AXLE LOCKING CYLINDERS
1 - Start the engine, then lock and release the axle several
times to restore the circuit and check it is leak tight.
PW110R-1 30-131
REMOVAL AND INSTALLATION FRONT AXLE
REMOVAL OF COMPLETE FRONT AXLE

1 - Remove the cabin access steps (1) from both sides of
the machine.
RKPA8610
2 - Disconnect the drive shaft (32) from the axle (3).
RKPB2691
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
RKP09850
4 - Place a trestle (A) underneath the machine and some

blocks (B).
5 - Lower the machine slowly onto the blocks (B) and that
the wheels remain raised above the ground.
Lower the lower work equipment until it rests on the

B
Completely release all residual pressures from all
circuits, and in particular from the brake line. A
(For details, see « 20. TESTING AND ADJUST-
MENTS»).
RKPA9130
30-132 PW110R-1
6 - Mount the cage on the wheels group (5) and apply a

slight tension to the hoisting cables.
Using the dynamometric wrench B1, take off the nuts
and remove the entire wheel group.
Wheel group: 190 kg

4
RKPA9141
7 - Disconnect the tubes (5) from the steering cylinder and

plug both the tubes and the cylinder.
7
8 - Disconnect the brake-group tubes (6) and plug both the
tubes and the axle couplings.
9 - Remove the guard (7) the steering sensor.

★ Protect both the sensor and the connector with vi- 6
nyl bags and insulating tape.
5
RKPB2810
10 - Place a lifting platform (C) and some blocks (D) beneath

the axle. Raise this until the blocks are being forced up
against the arms of the axle (13).
★ The lifting platform should be capable of an excur-
sion of about 15 cm in descent.
8
D
C
RKPA9171
11 - Remove the axle (10) fixing screws (9).
12 - Lower the lifting platform (C) until the axle is free of the
chassis.
13 - Extract the axle (10).

9
Front axle: 380 kg
10
RKPB2692
PW110R-1 30-133
INSTALLATION OF FRONT AXLE

To install, reverse the removal procedure.
1 - Refill the axle with lubricating oil and check tightness.
2 - Start the engine to circulate the oil, recharge the accu-

mulators of the brake line, and check the leaktightness.
3 - Execute several complete steering manoeuvres.
4 - Bleed air from the front brake line.

5 - Stop the engine and check the level of the oil in the tank.
30-134 PW110R-1
REMOVAL AND INSTALLATION REAR AXLE
REMOVAL OF COMPLETE REAR AXLE

1 - Remove the cabin access steps (1) from both sides of
the machine.
RKPA8610
2 - Disconnect the drive shaft (3) from the axle (2).
3 2
RKPB2780
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
RKP09840
4 - Place a trestle (A) underneath the machine and some

blocks (B), roughly 15 cm high, at points corresponding
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

Release all residual pressures from all circuits in

particular from brake circuit. (For details, see « 20. A
RKPA9190
PW110R-1 30-135
6 - Mount the cage on the wheel group (4) and apply a slight
tension to the hoisting cables.
Using the dynamometric wrench A1, take off the nuts
and remove the entire wheel group.
Wheels group: 190 kg
7 - Remove the travel motor (for details, see «REMOVAL

OF TRAVEL MOTOR»).
RKPA9201
8 - Disconnect the tubes (5) of the braking units and plug

both pipes and cylinder. 5 6
8
9 - Disconnect the brake group tubes (6) and plug both the
5
tubes and the axle couplings.
10 - Disconnect sensor (8).

★ Protect both sensor (8) and connector (9) with vinyl
bags and tape.
9
7
RKPB2820
11 - Disconnect the steering cylinder tubes (5) and plug both

the tubes and the cylinder.
11
12 - Disconnect pipes (10) and (11) from transmission and
plug them.
★ Place an identifying mark on each tube to prevent
Disconnect the position sensor (12) and the micro-
switch (13). 10
12
13
RKPB2741
13 - Sling the axle (14) with ropes and hook it to a piece of

hoisting equipment. 17
14 - Loosen and take away the nuts (10), and plates (11) and
the fastening screws (12). 14
★ Loosen screws a little at a time and using the criss-
cross method.
15 - Lower the axle (14) and extract it. 16
Complete axle: 436 kg

15
RKPB2830
30-136 PW110R-1
INSTALLATION OF REAR AXLE

1 - Refill the axle with lubricating oil and check tightness.
2 - Start the engine to circulate the oil, recharge the accu-

mulators of the brake line, and check the leaktightness.
3 - Execute a few full steering manoeuvres.
4 - Bleed air from the rear brake line.

5 - Stop the engine and check the level of the oil in the tank.
PW110R-1 30-137
REMOVAL AND INSTALLATION AXLE
DISASSEMBLY OF AXLES
1. Planetary reduction
1
1 - Remove the securing screws (1) from the planetary car-
rier cover (2).
1
RKPB2910
2 - Disjoint the planetary carrier cover (2) from the steering

case (3) by alternatively forcing a screwdriver into the 3
appropriate slots.
RKPB2920
3 - Remove the complete planetary carrier cover (2).

2
RKPB2930
4 - Unloose and remove the tightening nuts (4) from the

crown flange (5).
5
4
RKPB2940
30-138 PW110R-1
5 - Remove the safety flange (6).
RKPB2950
6 - Using a puller, remove the complete crown flange (5) by

acting on the stud bolts.
5
RKPB2960
7 - Partially extract the hub (7) using a plastic hammer.

★ Alternately hammer on several equidistant points.
RKPB2970
8 - Remove the external bearing (8).

8
RKPB2980
PW110R-1 30-139
9 - By hand remove the complete hub (7).

7
RKPB2990
10 - Remove the pins and remove the steering case (3).

(For details, see «2. REMOVE THE COMPLETE
STEERING CASE»).
3
RKPB3000
11 - Remove the snap rings (9).
RKPB3010
12 - With the help of a puller, remove the planet wheel gears

(10).
★ Note down the assembly side of planet wheels. 10
RKPB3020
30-140 PW110R-1
13 - Remove the snap ring (12) from the crown (13).
12
13
RKPB3030
14 - Remove the crown flange (5).
RKPB3040
15 - Remove the sealing ring (14) from the hub (7).
14
RKPB3050
16 - Remove the internal bearing (15).
15
RKPB3060
PW110R-1 30-141
17 - Remove the external thrust blocks from the bearings (8)

and (15) forcing a pin-driver into the appropriate slots on
the hub (7).
★ Hammer in an alternate way so as to avoid crawling
or deformation of the thrust blocks.
RKPB3070
18 - Use a puller to remove the centring ring (16), the sealing

ring (17) and the bearing (18) from the steering case (3). 16
★ Note down the orientation of both centring ring (16)
and sealing ring (17). 17
16 17 18
18
RKPB3080
2. Steering case
1
1 - Remove the guard (1) and disconnect the articulation
pin (2). (See «5. STEERING CYLINDER»).
RKPB3090
2 - Sling the entire unit (7) and connect it to the hoist,

putting the rod under light tension.
7
RKPB3100
30-142 PW110R-1
3 - Unloose and remove the fitting screws (3) from the bot-
tom articulation pin (4).
★ Screws cannot be re-used.
3
RKPB3110
4 - Remove the bottom articulation pin (4) complete with

front sealing ring (5). 5
4
RKPB3120
5 - Unloose and remove the fittin screws (3) from the top ar-
ticulation pin (6).
RKPB3130
6 - Using two levers, remove the top articulation pin (6)

complete with front seal (5).
Pay attention not to damage the surfaces.
6
5
RKPB3140
PW110R-1 30-143
7 - Remove the complete steering case (7).
RKPB3150
8 - Using a puller for inner parts, remove the top bush (8)
and the bottom ball-bush (9).
RKPB3160
9 - Remove the articulation pins (4) and (6) and the front
sealing rings (5).
★ Note down the side for assembly. 5
4 6
RKPB3170
10 - If the ball cover (11) needs replacing, remove it from the

bottom articulation pin (4).
11
RKPB3180
30-144 PW110R-1
3. Cardan shaft
1 - Remove the steering case.
(For details, see «2. Steering case»).
★ For front axle: introduce compressed air (approx. 7
3
bar) in the braking circuit.
2
2 - Unloose and remove the top and bottom check nuts (2)
from the dowels (3).
RKPB3190
3 - Remove top and bottom check dowels (3).
RKPB3200
4 - Remove the u-joint (4).

★ To remove the u-joint use, if necessary, a plastic
hammer or a lever.
RKPB3210
5 - Remove the snap ring (5) from the bushing unit (6).
RKPB3220
PW110R-1 30-145
6 - Position the entire u-joint (4) under a press and remove

the complete bush (6).
4
RKPB3230
7 - Remove the snap ring (7) from the bearing (8).
8 - Use a puller to remove the bearing (8), the sealing ring

(9) and the O-ring (10).
★ Note down the assembly side of the ring (9).
7
8
8 9
10
RKPB3240
30-146 PW110R-1
4. Brakes
1 - Remove the swinging support (1) on the side opposite
the drive.
★ If the bushing (2) is worn and needs replacing, note 2 1
down the assembly side of the connection notch
"A".
RKPB3250
2 - Disconnect the pins of the steering bars from the steer-

ing case (See «5. STEERING CYLINDER»).
Only for rear axle

3
3 - Disconnect the negative brake cylinder.
4 - Sling the arm (3) to be removed and put the rod under
slight tension.
RKPB3260
5 - Unloose and remove the screws (4) and the washers (5)
that fix the arm (3) to the central body (6). 4 5 6
3
RKPB3270
6 - Remove the arm (3) together with the pack of the brak-
ing disks (7). Place the arm on a bench.
3
RKPB3280
PW110R-1 30-147
7 - Remove the braking disks (7) and note down their order
of assembly.
★ If the disks do not need replacing, avoid switching
their position.
8 - Extract the u-joint (17).
(For details, see «3. Cardan shaft»).
17
7
RKPB3290
9 - Remove the reversal springs (8) from the piston (9).

★ If the springs (8) are weak or deformed they must 8
be replaced. 9
8
RKPB3300
10 - Remove the pin screws (10) guiding the piston (9).
If the screws are to be replaced, note down the dif- 9

ferent colours for the different brake gap.
(See «3. Brake»)
10
RKPB3310
11 - Slowly introduce compressed air through the connec-

tion of the braking circuit in order to extract the entire pis-
ton.
Hold on to the piston as it may be suddenly ejected

and damaged.
9
RKPB3320
30-148 PW110R-1
5. Removal of steering cylinder

1 - Remove the centring sensor (1) of the steering piston
(2), if supplied. 1
2
RKPB3330
2 - Remove the safety cotter pins (3) from the articulation

pins (4) of the steering bars (5).
Dispose of used cotter pins.
6
3
RKPB3340
3 - Remove the castellated nuts (6) that lock the articula-

tion pins (4). 4
RKPB3350
4 - Disconnect the tapered pins of the articulation (4) from

the steering case (7) by means of a puller.
4 5
7
RKPB3360
PW110R-1 30-149
5 - If the connection of the steering bars includes a safety

collar (13), raise the border.
13
RKPB3370
6 - Disconnect left and right steering bars (5) from the pis-
ton (2).
2
RKPB3380
7 - Remove the securing screws (8) from the steering cyl-

inder (9). 9
RKPB3390
8 - Extract the cylinder (9) using a plastic hammer.
RKPB3400
30-150 PW110R-1
6. Disassembly of steering cylinder

1 - Remove the snap ring (1) from the cylinder head (2).
2
RKPB3410
2 - With the help of a plastic hammer, push the head (2) in-
side the cylinder (3).
★ The head should line up with the edge of the cyl- 3
inder.
RKPB3420
3 - With the help of a drift, apply pressure to the stop ring (4)
that is placed inside the cylinder (3) and extract the ring
using a screwdriver. 3
RKPB3430
4 - Hammer the piston (5) on the rear of the head (2) using
a plastic hammer. Continue hammering until the head
(2) is ejected from the cylinder (3).
5
3
2
RKPB3440
PW110R-1 30-151
5 - Disassemble the cylinder unit (3) by extracting first the

head (2), then the piston (5).
5
Note down the assembly side of the piston (5). The
bevelled part "A" of the piston is oriented towards
the head (2).
A RKPB3450
6 - Remove all seals, anti-extrusion rings and scraper rings

from head (2), cylinder (3) and piston (5).
★ All seals must be replaced every time the unit is dis-
assembled.
★ Particular attention must be paid not to damage the
seats of both seals and piston slide.
7. Hydraulic negative brake cylinder

1 - Insert pressure into cylinder (4) in order to release the
brakes.
★ If the machine hydraulic system cannot be used, 4
use an external manual pump.
RKPB3460
2 - Loosen and remove the external nut (7).
30-152 PW110R-1
3 - Release the pressure in the cylinder and disconnect the

pressure delivery tube.Remove the fulcrum pin (3) from 3
the cylinder (4).
RKPB3480
4 - Remove the snap ring (1) that checks the support (8)
and remove the distance piece (2).
8
1
RKPB3490
5 - Remove the cylinder assembly (4) complete with rod

(5), internal nut (6) and support (8). 4
6 5
RKPB3500
6 - Place cylinder (4) into a vice with the spring seat side
(10) engaged in it and, using a bar "D", loosen and re- D
move the cylinder unit (9) complete with piston (13) and
spring (12). 9
4 13
12
10
RKPB3510
PW110R-1 30-153
7 - Gently introduce the union piece of the cylinder unit (9)

so as to eject the piston (13).
Hold the piston as it may be forced out rapidly and

be damaged. 13 9
RKPB3520
8 - Remove seals (14) and guide ring (15) from the piston
(13). 15 14
★ Note down seals direction of assembly.
15 14
14
13
RKPB3530
9 - Only if necessary
Remove the guide ring (11) from the spring seat (10).
10
If the guide ring (11) is removed, it must be re-
placed.
11
RKPB3540
8. Differential
1 - Remove the complete arms. For detail, see
«CHECKING WEAR IN THE BRAKE DISKS».
RKPB3261
30-154 PW110R-1
2 - Mark the position of the ring nuts (1). Remove the fittin
screws (3) from the ring nuts (1).
3
1
RKPB3470
3 - Uniformly heat the ring nuts (1) up to a temperature of

80°C.
1
RKPB3550
4 - Apply tool M11 and remove the ring nuts.

★ Accurately clean the threaded portions on ring nuts
of body and cover.
M1
RKPB3560
5 - Remove the fittin screws (4) from the middle cover (5).
4 5
4
RKPB3570
PW110R-1 30-155
6 - Insert a screw-driver in the opposing slots then force

6
and remove the middle cover (5) and the complete dif- 5
ferential unit (6).
★ Support the pieces using a rod.
RKPB3580
7 - If the bearings need replacing, extract the external

thrust blocks of the bearings (7) and (8) from middle cov- 2 8
er (5) and central body (2).
★ Accurately check the O-ring (9).
7
5 9
RKPB3590
8 - Remove the top plug (10).

★ Top plug cannot be re-used. 10
RKPB3600
9 - Remove the fittin screws (11) from the crown (12).
11
12
RKPB3610
30-156 PW110R-1
10 - If the bearing need replacing, extract the bearing (7) and

remove the crown (12). 7
12
RKPB3620
11 - Remove the shim washer (13) and the planetary gear

(14). 13
14
RKPB3630
12 - If the bearing need replacing, extract the bearing (8)

from the differential carrier (15).
15
RKPB3640
13 - Remove the snap rings (16) from the two pins (17) of the
planet wheel gears (18).
16 17
RKPB3650
PW110R-1 30-157
14 - Insert tool M2 between the planet wheel gears (18).

M2
18 18
RKPB3660
15 - Force tool M2 in-between the planet wheel gears (18)

using two pin-drivers.
Make sure that tool M2 is perfectly lined up with the

pins (17) when locked.
15
17
RKPB3670
16 - Place the differential carrier (15) under a press, position

M4A
bush M3 and insert gudgeon M4A. Press M4A pin to M3
limit position.
M4A
17
15
RKPB3680
17 - Remove gudgeon M4A and bush M3.

★ In this condition the tool M2 contains pin (17). M4A
M3
RKPB3690
30-158 PW110R-1
18 - Remove tool M2 together with the pin (17) of the planet

wheel.
15
17
RKPB3670
19 - Leave the released planetary gear in position and again

lock tool M2. M2
20 - Repeat the operations for the extraction of the pin of the
2nd planet wheel (17).
21 - Repeat the operations for all other pins.

18 18
RKPB3660
22 - Remove tool M2 and remove the last two planet wheel

gears (18), the 2nd differential unit gear (14) and the rel-
ative shim washer (13) from the differential carrier. 14
13
15
RKPB3700
9. Bevel pinion
1 - Remove the complete arms and the differential unit.
(For details, see «4. BRAKE» and «8. DIFFEREN-
TIAL»).
PW110R-1 30-159
Only front axle

2 - If disassembly is awkward, heat the check nut (1) of the 2
flange (2) at 80 °C.
1
★ Heating is meant to unloose the setting of Loctite on
the nut (1).
RKPB3710
3 - Position tool M5A (or M5B), so as to avoid pinion rota-

tion. Unloose and remove the nut (1); also remove the
O-ring (3). M5A
RKPB3720
4 - Remove the flange (2) complete with guard (4) by

means of a puller.
RKPB3730
5 - Remove the swinging support (5)

5
RKPB3740
30-160 PW110R-1
6 - Remove the sealing ring (6).
RKPB3750
Only for rear axle

7 - Remove bearing (7) and ring (8). 8
7
RKP11080
For all axle

8 - Position wrench M6 onto the ring nut (9) and apply bar
hold M7 to the pinion (10).
Stop wrench M6 and rotate the pinion so as to release 9
and remove the ring nut (9).
★ If disassembly proves awkward, weld the ring nut at M7
approx. 80 °C.
M6
RKPB3760
9 - Apply blocks M8 and, with the help of a puller, extract

the pinion (10) complete with the internal bearing (11), 14
the distance piece (12) and shims (13). M8
★ The thrust blocks of the bearings remain in the cen-
tral body (14).
10
RKPB3770
PW110R-1 30-161
10 - Remove the pinion (10), shims (13) and distance piece

(12). 14
12
10
13
RKPB3780
11 - Using a puller and a press, remove the inner bearing

(11) from the pinion (10).
10
11
RKPB3790
12 - Remove the thrust block of the external bearing (15).
15
RKPB3800
13 - Insert a drift in the appropriate holes and remove the

thrust block of the internal bearing (11) as well as the
shim washers (16).
16
11
RKPB3810
30-162 PW110R-1
Only for rear axle

14 - Remove seal ring (17).
17
RKP11090
PW110R-1 30-163
ASSEMBLY OF AXLE
1. Bevel pinion
Only for rear axle

1 - Mount seal ring (17).
17
RKP11090
For all axle

2 - Using a surface plate, reset a centesimal comparator
and place it on the measurement ring M9 (with a thick-
ness of 30.2 mm).
Preset the comparator to approx. 2 mm.
M9
RKPB3880
3 - Bring the internal bearing (11), complete with its thrust

block, under the comparator.
Determine overall thickness "D" of the bearing checking
the discrepancy between this size and the size of the
measurement ring.
Press the thrust block in the centre and take several

measurements while rotating the thrust block.
11
RKPB3890
4 - Partially insert the thrust block of the external bearing

(15).
14
15
M10C
M10A
RKPB3900
30-164 PW110R-1
5 - Install tension rod M10C, measurement ring M9 and

front guide tool M10A on the thrust block of the external
bearing (15).
M10B M9 M10C M10A
15
RKPB3910
6 - Connect the tension rod to the press and move the

thrust block of the external bearing (15) into its seat.
Disconnect the press and remove the tension rod.
Before starting the next stage, make sure that the

thrust block has been completely inserted into its
seat.
RKPB3920
7 - Insert tool M11B complete with external bearing (15),

measurement ring M9 and gauged ring nut M11C.
Manually tighten.
M11C M9 M11B
15
RKPB3930
8 - Fit a centesimal comparator with long stem into bar

M11A; when the bar rests on two size- blocks of 57 mm,
reset the comparator.
M11A
9 - Preset the comparator to approx. 2 mm and reset.
RKPB3940
PW110R-1 30-165
10 - Lay bar M11A on gauged nut M11C and take the size
"A" at about 57 mm corresponding to the maximum di-
ameter of arms centring.
M11C
M11A A
RKPB3950
11 - Calculate size "B" which will be the first useful value for
calculating the size of the shims (16) that are to be in- M9
M11C
serted under the thrust block of the internal bearing (11).
R115
M11B
A
30.2 61
(61-A)+115+30.2=B B RKP11120
12 - Check the nominal size (X) marked on the pinion and

add or subtract the indicated variation (Y) so as to obtain
10
size "Z".e.g.:
Z=118 + 0,1= 118,1 X
Z=118 – 0,2= 117,8
RKPB3960
13 - Calculate size "C" which represents the second value

for calculating the size of the shims "S" that are to be
placed under the thrust block of the internal bearing
(11).
(16) S
D Z
C=Z+D C RKP11130
30-166 PW110R-1
14 - Calculate the difference between sizes "B" and "C" so

B-C=S
as to obtain the size "S" of the shim (16) that will go un- 16 S
der the thrust block of the internal bearing (11).
RKPB3970
15 - Insert shim "S" (16) and the thrust block of the internal
bearing (11) in the central body.
★ To hold shim "S" (16) in position, apply grease.
16
11
RKPB3980
16 - Position tool M10A and tension rod M10C.

Connect the tension rod to the press, fasten the thrust
block and then remove the tools.
★ Before going on to the next stage, make sure that
the thrust block has been completely inserted.
M10C M10A
RKPB3990
17 - Position tools M11C and M11B complete with tapered

bearings (11) and (15); manually tighten until a rolling
torque has been obtained.
M11C 11 15
M11B
RKPB4000
PW110R-1 30-167
18 - Insert the stem of a depth comparator in either side hole

of tool M11C; reset the comparator with a presetting of
M11C
approx. 3 mm.
RKPB4010
19 - Remove the comparator and release tools and bearings

from the central body.
20 - Re-install all and insert the distance piece (12) between M11C
11
bearings (11) and (15); manually tighten the whole 12 15
pack. M11B
RKPB4020
21 - Insert depth comparator into tool M11B-M11C and

measure variation "H" in relation to the zero setting per- H
formed back at point 18.
11 M11C
15
M11B
RKPB4030
22 - The variation is to be added to a set value of 0.12--0.13 H+0,12÷ 0,13=S1

mm, so as to obtain the size of shim "S1" (13) which will
be inserted between the external bearing (15) and the 13 S1
distance piece (12) and subsequently, to determine the
preload for the bearings.
RKPB3971
30-168 PW110R-1
23 - Position the internal bearing (11) and the pinion (10) un-
der a press; force the bearing onto the pinion.
10
11
RKPB4040
24 - Fit the pinion (10), shim "S1" (13) and distance piece
(12) in the main body (14). 14
★ The finer shims must be placed in- between the 12
thicker ones. 10
13
RKPB3780
25 - Insert the external bearing (15) in the central body in or-

der to complete the pack arranged as in the figure.
11 13 12 15
RKPB4050
26 - Connect the pinion (10) to the tie rod M12A and M12B;
connect the tie rod M12C to the press and block.
10
RKPB4060
PW110R-1 30-169
27 - Apply Loctite 242 (for the front axle) or Loctite 270 (for
rear axle) to the thread of the ring nut (9) and screw the
nut onto the pinion (10).
10
9
RKPB4070
28 - Apply special wrench M6 to the ring nut (9) and bar-hold

M7 to the pinion (10).
29 - Lock the wrench M6 and rotate the pinion using a dy-

namometric wrench, up to a minimum required torque M7
setting of:
★ front axle: 500 Nm
★ rear axle: 900 Nm
M6
RKPB4080
30 - Apply onto the pinion (10) the bar-hold "M13" and with
the help of a torque metre, check the torque of the pinion
(8).
M13
Torque: 120--170 Ncm
If torque exceeds the maximum value, then the size

of shim "S1" (13) between the bearing (15) and the
distance piece (12) needs to be increased.If torque
does not reach the set value, increase the torque
setting of the ring nut (9) in different stages to obtain
a maximum value of:
★ front axle: 570 Nm RKPB4090
★ rear axle: 1000 Nm
If torque does not reach the minimum value, then

the size of shim "S1" (13) needs to be reduced.
When calculating the increase or decrease in size

of shim "S1", bear in mind that a variation of shim
(13) of 0.01 mm corresponds to a variation of 60
Ncm in the torque of the pinion (10).
30-170 PW110R-1
31 - Remove blocks M8 (used for extracting the pinion) and

re-install the arms.
(For details, see Disassembly «9. BEVEL PINION»).
M8
RKPB4130
Only for front axle

5
32 - Lubricate the outer surface of the new sealing ring (6)
and fit it onto the central body (14) using tool M14.
33 - Install the swinging support (5).

★ Check that it is properly oriented.
RKPB3740
34 - Fit the flange (2) complete with the guard (4) and fasten
it. For keying the flange (2), use a plastic hammer if nec-
essary.
★ Make sure that the guard (4) is securely fastened
onto the flange and that it is not deformed.
2 4
RKPB4110
35 - Apply Loctite 242 to the threaded part of the pinion

(10).Position tool M5A (or M5B) and fasten it in order to
avoid rotation.Insert O-ring (3) the nut (1) and tighten it
using a dynamometric wrench.
Torque wrench setting: 280--310 Nm
Only for rear axle

36 - Mount ring (8) and bearing (7).
M5A
RKPB4120
PW110R-1 30-171
2. Differential
1 - Insert the shim washer (13) and the planetary gear (14)
in the differential carrier (15). 14
13
15
RKPB3700
2 - Position the shim washer (19) and the first planet wheel
gear (18). 18
Hold them in position using bar M4C.
19
M4C
RKPB4140
3 - With the help of gudgeon M4A, position the second

planet wheel gear (18) and the relative shim washer 18
(19).
M4A
19 15
M4C
RKPB4150
4 - Insert tool M2 between the two planetary gears (18).

Line up the entire unit by pushing bar M4C all the way M2
down until gudgeon M4A is ejected.
M4C
RKPB4160
30-172 PW110R-1
5 - Lock tool M2 behind the planet wheel gears (18).

After locking, remove bar M4C. M2
18 18
RKPB3660
6 - Fit the snap rings (20) onto the pins (17).

20 17
RKPB4170
7 - Place the differential carrier (15) under the press, po-

sition bush M3 and insert the planet wheel pin (17).
17 M3
RKPB4180
8 - Put gudgeon M4B on top of the planet wheel pin (17).

M4B
17
M3
M4B
17
RKPB4190
PW110R-1 30-173
9 - Press M4B pin all the way down.
M4B M3
M4B
17
15
RKPB4830
10 - Remove gudgeon M4B, bush M3 and fit the snap ring

(16) on the pin (17).
Make sure that the snap ring centres the seat and
that it rests on the surface of the differential carri- 16
er.Repeat the operations on the other planet wheel
pin or planet wheel axle.
17
RKPB4200
11 - Position the second planetary gear (14) in the differen-

tial carrier (15). 13
14
RKPB3630
12 - Position the shim washer (13) on the crown (12).

★ In order to hold the shim washer (13) in position, ap-
ply grease to it. 13
12
RKPB4220
30-174 PW110R-1
13 - Position the crown (12) on the differential carrier (15)

and lock it with screws (11) applied with Loctite 242.
Torque wrench setting for screws:128--142 Nm

11 12
★ Secure the screws using the cross-tightening
method.
15
RKPB4230
14 - Install the bearings (7) and (8) using tool M15.
M15 8
M15 7
RKPB4240
15 - If the bearings are replaced, insert the external thrust

2
blocks in the middle cover (5) and in the central body (2).
RKPB4250
16 - Position the differential unit (6) in the central body (2)

6
with the help of a bar and fit the middle cover (5). 5
★ Thoroughly check the state of the O-ring (9) and
make sure that the cover is fitted with the oil dis-
charge in the lower position.
RKPB3580
PW110R-1 30-175
17 - Lock the middle cover (5) with screws (4).

4
Torque wrench setting for screw: 23.8--26.2 Nm
5
★ If the ring nuts (1) are removed, spread them with
Loctite 242.
4
4
RKPB4260
18 - Tighten ring nuts on the crown side until clearance be-

tween pinion and crown is zero, then lock the crown; go
back 1/4–1/2 turn
M1
RKPB4270
19 - Pre-set the bearings by means of the ring nut situated

on the opposite side of the crown, so as to increase pin-
ion torque up to 140–210 Ncm.
M13
If bearings are not new, check the static torque; if
bearings are new, check the continuous torque.
RKPB4090
20 - Introduce a comparator with rotary key "A" through the

top plug hole (10).
Position the comparator on the centre of one of the teeth 12 A
of the crown (12), pre-set it to 1mm and reset it.
RKPB4290
30-176 PW110R-1
21 - Manually move the crown (12) in both directions in order

to check the existing backlash between the pinion and
the crown. A
RKPB4300
22 - Adjust the backlash between the pinion and the crown

by unloosing one of the ring nuts (1) and tightening the
opposite to compensate.
★ Normal backlash: 0.18–0.23 M1
★ Difference between MIN. and Max. clearance for
whole circumference should not exceed 0.09 mm.
RKPB4270
23 - Apply Loctite 242 to the screws (3), fit them into one of
the two holes and tighten. 10
Torque wrench setting: 23.8--26.2 Nm
3
24 - Fit the top plug (10) after applying repositionable joint-
ing compound for seals to the rims.
RKPB4310
25 - Re-install the complete arms.

For details, see Assembly «3. BRAKE».
RKPB3261
PW110R-1 30-177
3. Brake
14
1 - Accurately clean the piston (9) and the seats of slide and
12
seal.
11
2 - Replace the O-rings (11) and (12) and the anti-extrusion
rings (13) and (14); make sure that the assembly side is 13
correct.
Accurately check the positioning of the anti-extru-

sion rings (13) and (14).
3
9
RKPB4320
3 - Insert the stroke automatic regulation springs (15);

place them in line with the piston (9).
15
15 9
RKPB4330
4 - Lubricate the seals (11) and (12) and fit the piston (9)
into the arm (3).
Make sure that the piston seat fits into the stop pin A
(A) inside the arm.
RKPB4340
5 - Assist the insertion of the piston (9) by lightly hammer-

ing around the edge with a plastic hammer.
RKPB4350
30-178 PW110R-1
6 - Fit the pin screws (10) making sure that they are all of
the same colour.
9
White: 1 mm gap
Yellow: 0.75 mm gap
Blue: 0.5 mm gap
7 - Apply Loctite 270 to the thread.
Torque wrench setting: 5--7 Nm.
10
RKPB3310
8 - Fit the reversal springs (8) on the piston (9).

8
9
8
RKPB3300
9 - Slightly lubricate the braking disks (7) and fit them in the
arm following the correct sequence; orient them so that
the oil circulation holes and the marks "B" are perfectly
lined up.
B
★ When installing the steel discs, the slot corre-
sponding to the oil level cap should always be kept
free.
7
RKPB4360
10 - Check that the positioning of the sealing ring (16) on the

arm is intact; install the complete arm. Lock it into po-
sition using two facing screws (4) and washers (5).
16
RKPB3281
PW110R-1 30-179
11 - Check the flatness of the arms using tool M16 and finally
lock the arms with the screws (4) and the washer (5) us- M16
ing the cross-tightening method.
Torque wrench setting: 298 Nm
RKPB4370
30-180 PW110R-1
4. Hydraulic negative brake cylinder

15 14
1 - Install guide ring (15) and seals (14) onto the piston (13).
Carefully check seals assembly direction. 15 14

14
13
RKPB3530
2 - Lubricate the seals (14) and the inside of the cylinder

(9); introduce the whole piston (13) and move it to end of
stroke. 13 9
RKPB4380
3 - If guide ring has been removed, insert a new one (11)

into the seat of the spring.
Lubricate the guide ring. 10
11
RKPB3540
4 - Position the spring seat (10) in a vice and insert spring

(12).
Lubricate the thread. Assemble the whole cylinder (9).
12 9
10
RKPB4390
PW110R-1 30-181
5 - Screw the cylinder (9) into the spring seat (10) and lock
it using a bar "D". D
10
RKPB4400
6 - Apply Loctite 270 to the rod (5) and screw it in the piston
(13) as far as it will go.
RKPB4410
7 - Insert the pin of support (10) into the right-hand braking

lever. Fit the second distance piece (2) and snap ring
(1). 8
1
RKPB3490
8 - Install cylinder (4) complete with rod (5) and internal nut
(6) and external nut (7).
4
5
6
7
RKPB3461
30-182 PW110R-1
9 - Centre the hole of fulcrum pin (3). Apply Loctite 242 to

the pin thread, screw and tighten pin with a dynamo-
metric wrench set at 25–30 Nm.
RKPB4420
PW110R-1 30-183
5. Assembly of steering cylinder

1 - After applying grease, install the sealing ring (6) of the
shaft, the anti-extrusion ring (7) and the scraper ring (8) 3 6 7 8
inside the cylinder (3).
Thoroughly check that positioning of the anti-ex-

trusion ring (7) is correct.
RKP11140
2 - After applying grease, install the sealing ring (6) of the

shaft, the anti-extrusion ring (7) and the scraper ring (8)
in the head (2). 8 7 6 2
Thoroughly check that positioning of the anti-ex-
trusion (7) ring is correct.
RKP11150
3 - Fit the seal (9) onto the outside of the head (2).
1 - In order to facilitate assembly, apply grease to 2 9

the outer surface of the piston.
2 - Do not roll the seal (9) up.
RKP11160
4 - Prepare the piston (5) by fitting it with the guide ring (10),
the magnetic ring (11), the O-ring (12) and the seal (13).
11
13 10
1 - In order to facilitate assembly, apply grease.
2 - If a centring sensor is not fitted, then the mag-
netic ring (11) should be replaced by another
guide ring (10). 12 5
RKP11170
30-184 PW110R-1
5 - Apply tool M17 to the shaft on the opposite side of the

head (2) and centre it on the cylinder (3) so that it fits into M17
the piston (5).
★ Apply a little grease to seals and cylinder. 5
RKPB4430
6 - Push the piston (5) into the cylinder for 100 mm using a
plastic hammer.
5
3
RKPB4440
7 - Remove tool M17 and apply it to the opposite side of the

piston (5).
M17
5
2
RKPB4450
8 - Apply grease to head (2) seals, fit the head onto the pis-
ton (5) and push it into the cylinder (3) using a plastic
3
hammer.
2
★ Insert the head as to line it up with the edge of the
M17
cylinder.
5
RKPB4460
PW110R-1 30-185
9 - Insert the stop ring (4) ensuring that it fits into the seat of
the cylinder (3). 4
3
RKPB4470
10 - Apply pressure to the head using two screwdrivers or le-

vers until the head is fastened onto the stop ring (4).
RKPB4480
11 - Fit the snap ring (1) on the head (2).

2
Make sure that the snap ring (1) is securely fas-
tened in its seat.
If necessary, force it into its seat using a drift and a
hammer.
RKPB3410
30-186 PW110R-1
6. Install of steering cylinder

1 - Check that the O-rings (15) of the axle unit are in good 9
condition; lubricate the seats of the seals (15) and fit the
steering cylinder (9) into its seat.
RKPB4490
2 - Lock the cylinder by cross- tightening the screws (8).

9 8
RKPB4500
3 - Apply Loctite 242 to the thread and connect the steering

bars by screwing the terminals onto the piston stem. 13

★ Versions with coupling require that the rim of the ar-
ticulation (13) is riveted onto the surfaces of the pis-
ton stem.
RKPB4510
4 - Insert the pins (4) in the steering case (7) and lock into
position using a torque wrench setting of 260--290 Nm. 4
Find the position of the notching in relation to the hole of
the cotter pins and tighten the nut (6) further. 7
Check that rubber guards (A) are intact.
RKPB4520
PW110R-1 30-187
5 - Insert the cotter pins (3) and bend the safety stems.
Use new cotter pins.
6 3
RKPB4530
6 - Install the proximity (1) for checking piston (2) centring -

if applicable - and tighten the screws (10).
1
Torque wrench setting: 5--6 Nm 2
10
RKPB3331
Eliminate the action of the negative brake, if fitted.Apply

tools M18 to the hubs and lock them. M18
Using a level "B", check that tools are perfectly flat and
parallel to each other. M18
7 - Connect the sensor (1) to the inspection device accord-

ing to diagram
. RKPB4540
I max=0,80 A
NERO
BLACK
1
CONNETTORE
CONNECTOR
2 BLU
1 3
BLUE
--
4
BATTERIA
BATTERY
MARRONE
BROWN
+
2A
RKP11180
RKPB4550
30-188 PW110R-1
8 - Centre the piston by slowly moving it first in one direc-

tion then in the other and position it half way on the = =
stroke, which is determined by the switching on and off
of the signal lamp of the inspection device in the reversal
stage.
RKPB4560
9 - Inspect jut "C" on one side of the piston and note down
the size for checking later adjustments.
★ If cylinders come without a sensor, the centring of
C
the piston must be carried out on the basis of the
maximum stroke.
RKPB4570
10 - Without moving the piston, check front and rear size at

the edge of tools M18.
Max. difference: 0.6--0.7 mm
★ In order to check the rear size, rotate the bevel pin-
ion and check that tools M18 are flat.
M18
RKPB4580
11 - If necessary, adjust convergency without moving the

centring of the piston and adjust the length of the steer-
ing bars (5) or (14).
5 14
★ With a half turn of screw, the front size is reduced by
about 3 mm, whereas the rear one is increased by
about 3 mm.
RKPB4590
PW110R-1 30-189
7. Convergency adjustment
1 - Unloose the nuts (11) and screw them onto the ball-and-
socket joints (15). 15
11
RKPB4600
2 - Hold the articulations still and rotate the ball-and-socket

joints (15). Once the convergency has been adjusted, 15
lock the nuts (11). 11
Torque wrench setting for nuts: 298--328 Nm
RKPB4610
8. Cardan shaft
1 - Using tools M19 and M20, insert the sealing ring (9) and
the bearing (8) in the bush (6).
★ Carefully check the assembly side of the seal (12).
M19 M20
9 8
6 6
RKPB4620
2 - Fit the snap ring (7) on the bearing (8).
7
11
RKPB4630
30-190 PW110R-1
3 - Heat the bearing in oil at an approx. temperature of

100°C and fit the entire bush (6) on the u-joint (4).
RKPB4640
4 - Fit the check ring (5) on the bushing unit (6); also put the
O-ring (10) into position.
10
6
RKPB3221
5 - Insert the u-joint and tighten the top and bottom dowels
(3).
Torque wrench setting: Max. 15 Nm

3
★ For u-joint coming with a bush, centre the point of
the check dowels in the slot.
RKPB4650
6 - Apply Loctite 242 to the jutting parts of the dowels (3).
RKPB4660
PW110R-1 30-191
7 - Screw the check nuts (2) of the dowels (3) and lock them
using a dynamometric wrench.
Torque wrench setting: 122 Nm 2
RKPB4670
9. Steering case
1 - If the bottom articulation pin (4) has been extracted, po-
sition the pin under a press and fit the ball cover (11).
11
RKPB4680
2 - Fit the front sealing rings (5) onto the articulation pins (4)
and (6).
★ Carefully check that the rings are properly oriented 5
(5).
4 6
RKPB3170
3 - Lubricate the top bush (8) or the bottom ball bush (9)
and fit them into the fulcrum holes of the arm.
Use tools M21 and M22.
M21
8 M22
RKPB4690
30-192 PW110R-1
4 - Lubricate the terminal of the u-joint (10) and install the

steering case (7).
Pay due attention not to damage the dust cover rings
and the sealing rings. 7
RKPB3150
5 - Fit a new seal (5) onto the top articulation pin (6). Lu-
bricate and install the unit in the steering case. Position
the screws (3) and lightly tighten.
6 - Check the correct assembly side of the seal (5).

6
5
RKPB3140
7 - Fit a new seal (5) onto the bottom articulation pin (4). Lu-
bricate and fit the unit in the steering case. Position the 5
screws (3) and lightly tighten.
4
RKPB3120
8 - Check for the correct assembly side of the seal (5).
9 - Tighten the new fittin screws (3) of top and bottom ar- 3
ticulation pins in sequence using the cross tightening
method.
3
RKPB4700
PW110R-1 30-193
10 - Connect the articulation pin (2) (See «ASSEMBLY OF

STEERING CYLINDER»). 1
11 - Lubricate articulations with Molikote and fit the dust cov-
er (1).
RKPB3090
10. Planetary reduction

M23
1 - Lubricate the bushing (18) and the seat of the steering 3
case (3).
2 - Install the bushing (18), using tool M23.
18
RKPB4710
3 - Lubricate the outer surface of the sealing ring (17) and

centring ring (16); fit them into their seat using tool M24.
16 17 M24
RKPB4720
4 - Position the lower part of tool M25A and the thrust block
of the external bearing (8) under the press.
M25A
RKPB4730
30-194 PW110R-1
5 - Lubricate the seats of the bearings and position the hub

(7) on tool M25A; position the thrust block of the internal
bearing (15).
★ Check that the thrust block is correctly oriented.
15
M25A
RKPB4740
6 - Position the upper part of tool M25B and press the thrust
blocks into the hub (7) all the way down.
M25B
RKPB4750
7 - Fit the bearing (15) into the internal thrust block.
15
RKPB4760
8 - Apply a repositionable jointing compound for seals to

the outer surface of the sealing ring (14).
9 - Position the sealing ring (14) in the hub (7). 14

★ Check that the ring (14) is correctly oriented.
7
RKPB4770
PW110R-1 30-195
10 - Position tool M16 and press the sealing ring (14) into its
seat.
M26
14
RKPB4780
11 - Insert the flange (5) in the crown (13).
13
RKPB3041
12 - Insert the snap ring (12) in order to fix the flange (5) in
the crown (13).
★ Carefully check that ring (12) is properly inserted in
the slot of the crown (13).
12
13
RKPB4790
13 - With the help of tool M27, insert the planet wheel gears
(10) into the cover (2). M27
Accurately check the orientation.
10
RKPB4800
30-196 PW110R-1
14 - Lock the gears (10) into position by fitting the snap rings
(9).
RKPB3010
15 - Fit the steering case (3) onto the U-joint (19) and install
the articulation pins.
For pin assembly details, see Assembly «9. STEERING
CASE». 3
RKPB3000
16 - Connect the steering bars. (For details, see «6. AS-

SEMBLY OF STEERING CYLINDER»).
RKPB3091
17 - Install the hub (7).

7
RKPB2990
PW110R-1 30-197
18 - Install the external bearing (8).

★ Using a plastic hammer, drive the bearing to the 8
limit stop by lightly hammering around the edge.
RKPB2980
19 - Fit the complete crown flange (5).

★ In order to fasten the flange (5), use a plastic ham- 5
mer and alternately hammer on several equidistant
points.
RKPB4810
20 - Apply Tecnolube Seal 101 grease to the surface of the

safety flange (6) which touches the crown flange (5).
21 - Fit the safety flange (6). 6
RKPB2950
22 - Apply Loctite 242 to the studs and fit in the nuts (4).
RKPB4820
30-198 PW110R-1
23 - Cross tighten the nuts (4) in two stages.

4
Initial torque wrench setting: 120 Nm
Final torque wrench setting: 255--285 Nm
RKPB4210
24 - Fit the planetary carrier cover (2) onto the hub (3).
★ Check that the O-ring (20) is in good condition and 2
in position.
RKPB2930
25 - Lock the planetary carrier cover (2) by tightening the

screws (1).
1
Torque wrench setting for screws: 40--50 Nm
RKPB4280
PW110R-1 30-199
REMOVAL AND INSTALLATION REMOVAL OF BOOM CYLINDER (For 1-piece boom)
REMOVAL OF BOOM CYLINDER (For 1-piece boom)

Extend the arm fully and open the bucket completely.
Lower the work equipment until it is resting on the 2
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 - Remove the screw (2) and draw out the pin (3).
3
1 3
4 - Start the engine to retract the piston (4). 4
2
1
5 - Lower the cylinder (1) until it rests on a stand «A».
RKPA7160
★ To hold the piston rod in its fully retracted position
tie it with wire.
6 - Switch off the engine and release any residual hydraulic
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
7 - Disconnect the tubes (5 and 6) and plug them. Also plug
1
the holes in the safety valve to avoid entry of impurities.
8 - Remove pipe (7) and plug the cylinder port and the pipe
to keep out impurities.
9 - Remove the screw (8) and safety valve (9).
10 - Remove screw (10) and draw out the pin (11).
2 3 4 A
11 - Remove cylinder (1). RKPA7170
INSTALLATION OF BOOM
CYLINDER (For 1-piece boom) 10
1
★ Insert the spacers to a given clearance (distributed
on both sides of the cylinder rod) until a clearance of
1–2 mm is obtained.
2 11
When aligning the positions between hole and pin,
let the engine run at minimum idling. Do not insert RKPA7180
fingers into the hole to check the alignment.

3
Inside bushings: ASL800050
8
4 9
on both sides of the piston rod) until a clearance of
0.5–1 mm is obtained. 7
• Start the engine and bleed air from the cylinder. (For de-
★ After bleeding the air, check the oil level in the tank. 6
RKPB1582
30-200 PW110R-1
REMOVAL AND INSTALLATION BOOM CYLINDER (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.
★ The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
RKPA7200
3 - Put a sling round the RH 2nd boom cylinder (1) of the 2-

piece boom and remove the self-locking nut (2), the 1 1
screw (3) and the spacer (4). 1
4
4
2
5
5 3
RKPA7210
4 - Slide off the pin (5) that connects the RH 2nd boom cyl-
inder (1) to the 2-piece boom, until the piston rod is com-
pletely disconnected. 2 3 5
5 - Start the motor and retract the RH cylinder piston. 6
3
★ To secure the piston rod in this 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) until the cylinder (1) is free and re-
move it. 2 4
7
RKPA7220
8 - Put the boom cylinder (8) in a sling.
9 - Slide the pin (7) out until the boom cylinder piston rod (8)
is disconnected. 3 4
★ To hold the piston rod in its fully retracted position,
tie it with wire and switch off the engine.
8
10 - Start the engine and retract the piston.
7
11 - Lower the cylinder (8) and rest it on a stand (B).
B
RKPA7230
PW110R-1 30-201
REMOVAL AND INSTALLATION BOOM CYLINDER (For 2-piece boom)
12 - Disconnect the tubes (9) and (10) and plug them. Also
plug hole in the safety valve (11) to prevent impurities
from entering.
13 - Remove pipe (12) and plug the cylinder port and the 11 13
pipe to keep out impurities.
14 - Remove the screw (13) and remove safety valve (11). 12

9
10
RKPB1583
15 - Loosen the screws (14) and remove the pin (15).

2 3 4
16 - Remove the cylinder (8).
8 14
15
RKPA7240
INSTALLATION OF THE BOOM

CYLINDER (For 2-piece boom)
1
Self-locking nut: 118 Nm
2
3
run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.
4
0.5--1 mm is obtained.
5
on both sides of the cylinder) until a clearance of
• Start the engine and bleed the air from the cylinders (For
details, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the level of the oil tank.
30-202 PW110R-1
REMOVAL AND INSTALLATION 2nd BOOM CYLINDERS
REMOVAL OF 2nd BOOM CYLINDERS

1 - Fully extend the front work equipment, raise the boom
and 2-piece boom and position a supporting stand (A)
between them.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
RKPB0100
3 - Put a sling round the RH cylinder (1) of the 2-piece boom

and remove the self-locking nut (2), the screw (3) and 1 1
spacer (4). 1
4
4
2
5
5 3
RKPA7210
4 - Slide off the pin (5) that connects the RH cylinder (1) to
the 2-piece boom, until the piston rod is completely dis-
connected. 2 3 5
5 - Start the motor and retract the RH cylinder piston. 6
★ 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 remove it.
2 4 7
RKPA7220
8 - Put the boom cylinder (8) in a sling.
9 - Slide the pin (7) out to disconnect the boom cylinder pis-
ton rod (8). 2
10 - Start the engine and retract the piston.
★ To hold the rod in its fully retracted position, tie it 8
with wire and switch off the engine.
3 7
11 - Lower the cylinder (8) and rest it on a stand (B).
B
RKPA7230
PW110R-1 30-203
REMOVAL AND INSTALLATION 2nd BOOM CYLINDERS
12 - Repeat the procedure from points 3-7 to remove the LH

cylinder (9) of the 2-piece boom.
6
7
9
RKPA7250
INSTALLATION OF
2nd BOOM CYLINDERS
1
2
3
run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.
4
on both sides) until a clearance of 0.5--1 mm is ob-
tained for each cylinder.
5
• Start the engine and bleed the air from the cylinders (For
details, see «20. TESTING AND ADJUSTMENTS»).
★ After bleeding the air, check the level of the oil tank.
30-204 PW110R-1
REMOVAL AND INSTALLATION 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.
1 - Manoeuvre the bucket until its teeth are resting on the
ground, together with the arm.
3 - Switch off the engine, release pressure in the cylinder A
by moving the LH PPC valve lever several times.
1 3 RKPA7260
5 - Start the engine to retract the piston (4).

★ To hold the piston in its fully retracted position, tie
the rod with wire. 5
pressures. (For details, see «20. TESTING AND AD- 1
JUSTMENTS»).
4
7 - Disconnect the tubes (5) and plug them. 3
If a safety valve has been installed, disconnect the
tubes (6-7) from the valve.
2 3 4 2
★ 9 -Lift out the cylinder (1). RKPA7050
INSTALLATION OF
ARM CYLINDER
1
1--2 mm is obtained. 7
2
6
let the engine run at minimum idling. Do not insert RKPA5452
3
9 8
4 1
★ After bleeding the air, check the oil level in the tank.
RKPA7010
PW110R-1 30-205
REMOVAL AND INSTALLATION BUCKET CYLINDER
REMOVAL OF BUCKET CYLINDER

ground.
1 - Switch off the engine and release pressure in the cyl-
inder by moving the RH PPC valve lever several times. 2
2 - Remove the ring nut (2) and draw out the pin (3).
1 2 3
3 - Switch off the engine and retract the piston rod (4).
tie it with wire. 3
RKPA7690

JUSTMENTS»). 6
7
5 - Disconnect the hoses (5) and plug them. Also plug the
holes of the rigid tubes to avoid entry of impurities. 1
2 3 4
8 - Lift out the cylinder (1).
5
RKPA7270
INSTALLATION OF 5
BUCKET CYLINDER
6
1 7
1--2 mm is obtained.
2
do not insert fingers into the hole to check the align- RKPA7280
ment.
3
4
30-206 PW110R-1
REMOVAL AND INSTALLATION 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 45° and rest the work equip-
ment on the ground.
3 - Switch off the engine and move the PPC valve several
times to release all residual pressures.
4 - Remove the RH front guard (1) from the revolving frame

1
(2).
5 - Disconnect the tubes (3) from the cylinder and plug 2

them. Also plug the flanges (4) of the cylinder (5).
RKP11053
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 5
place a support beneath the cylinder.
4 4
8 - Remove the screw (7), draw out the pin (8) and detach
the piston rod from its support (9). 1 2
9 - Remove the screws (10) and draw out the stop (11) and
the pin (12). 2 3 4
10 - Slide the cylinder out partially from the front and, as 3
soon as possible, put it in a sling and lift it off.
★ During this operation take great care not to dent the
piston rod. RKPA5491
INSTALLATION OF BOOM SWING

CYLINDER
8
1
on both sides of the piston) until a clearance of 1--2
mm is obtained.
2
9
let the engine run at minimum idling. Do not insert RKPB0990
3
10
12
4
on both sides of the cylinder) until a clearance of 11
0.5--1 mm is obtained. 6
RKPA7290
PW110R-1 30-207
REMOVAL AND INSTALLATION CYLINDERS FOR OUTRIGGERS OR BLADE
REMOVAL OF CYLINDERS FOR OUTRIGGERS OR 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 dis-
engage the piston rod from the blade or from the out-
rigger. 1 2 3
5 - Start the engine and retract the piston rod (3).
★ Secure the totally retracted position by binding both RKP10050
sides of the piston rod with wire.

4
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
★ Take care not to distort the valve tube (8).
9 - Take out the screw (9) and remove the dowel (10). 3
1 2 3 2
10 - Take out the cylinder complete with valve.
1
RKPB2850
INSTALLATION OF
CYLINDERSFOR OUTRIGGERS 5
OR BLADE
1 4
★ Insert the spacers to a given clearance on both
sides of the piston.
6
2
When aligning the hole and pin, let the engine run at
minimum idling. Do not insert fingers into the hole to
RKPB2860
check the alignment.
3
7
4
★ Insert the spacers to a given clearance on both
sides of the piston.
★ After bleeding the air, check the level of oil in the
tank.
RKPB0140
30-208 PW110R-1
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
DISASSEMBLY OF WORK EQUIPMENT CYLINDERS

1. All cylinders
1 - Place the cylinder on the tool “A” and partially extract the
3
piston.
2 - Loosen the retaining screws of the flange (1) that se-
A 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).
★ Take great care not to damage the inside of the cyl-
inder.
4 - Slide the piston rod (5) out of the cylinder (3), complete
with the flange (1), the snap ring (4), the head (2) and the RKPA7313
piston (6).
2. Boom, bucket, boom swing and blade cylinders:
5 - Remove the screws (7) and remove the two half-flanges
1
(8). 4
2
4 6 7
RKPA7320
3. 2nd boom and arm cylinders
1 - Heat the end nut (10) to a temperature of 140--150 °C
2 - Only for arm cylinder: loosen and remove the safety 10

9
screw (9).
3 - Loosen and remove the nut (10). Use the tool and the
dynamometric tool A1.
★ Before continuing with the dismantling operations,
allow the piston rod to cool down.
RKPA7330
4. All cylinders
1 - Dismantle the assembly.
For the arm cylinder, first remove the thirteen brake

pin (12) retaining balls (11) (No. 12). 12
2 - Remove the seals from the piston rod.
11
RKPA7340
PW110R-1 30-209
ASSEMBLY OF THE WORK EQUIPMENT CYLINDERS

★ Take care not to damage the seals or the sliding sur-
faces.
3
★ Prepare each individual component before final assem- 2
bly.
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 a press. RKP07300 RKPA7350
2 - Mount the O-ring seal (3).

★ Use grease to hold the washer in place.
Sealant: ASL800050 6 5
7 1
4 2
2. Head assembly
1 - Mount the internal central retaining ring, positioning first

the O-ring (1) and then the sealing ring (2).
★ Make sure that the chamfered edge of the retaining 3 4
ring is turned towards the inside of the cylinder.
RKP08000
2 - Use the plier B, mount the lip seal (3).

★ Check that the lips are facing towards the inside of
the cylinder. 6 5 1 6 5 6
3 - Mount the guide rings (4). 7
4 - Mount the O-rings (5) and relative anti-extrusion rings
(6) on the outside of the head (7).
★ Check the position of the anti-extrusion rings (6).
4
3 2 4 RKP08010
1 2 B
7 2
RKPA7360
RKPA7371
30-210 PW110R-1
5 - Gauge the diameter of the internal seals, mounting the

group underneath a press and using the specific gaug-
ing knuckle pin C for the diameter of the piston rod.
RKPA7381
3. Assemblaggio pistone
1 - Using the suitable plunger D, mount the piston seal.

Mount in the correct sequence the rubber ring (1), the
external seal (2), and the anti-extrusion rings (3).
2 - Mount the guide rings (4).

1 2 D
3 - For the arm and 2nd boom piston only: Mount the O-
ring (5) and the anti-extrusion rings (6) for the sealing
between piston rod and piston.
RKPA7391
4 3 2 3 4
6 5 6
RKP08020
4 - Cauge the diameter of the seal (2) of the piston (7),

mounting the group under a press and use the specific
gauging ring E for the piston diameter.
7
RKPA7401
PW110R-1 30-211
4. Piston rod group assembly
1 - Mount on the end of the piston rod (1) the bushing F 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.
★ Check carefully the positioning of the head-retain-
ing flange.
3 - Remove the bushing F from the end of the piston.
F 3
RKPA7411
4 - Mount the O-ring (5) and the rings wear (6) in the end-
seating, for the sealing between the piston ring and pis- 5
ton.
★ For boom, arm and bucket 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).
RKPA7420
6 - For the arm piston only: mount the brake pin (9) and
slide the thirteen retaining balls (11) (No. 12) into the
hole (10).
8 12
7 - Mount the half-flanges (12) that hold the piston (8) in 10
place, and secure them with the screws (13).
Flange retaining screws: 49±5 Nm
13
11 9
For the arm and 2nd boom piston only: RKPA7430
1 - Mount the nut (14) that holds the piston (8) in place,
and tighten with the socket wrench and the dy-
namometric tool with multiplier A1.
Piston retaining nut: Loctite 262 8
Piston retaining nut: 14
Arm: 294±19.5 daNm
2nd boom: 343±28.4 daNm 15
Only for arm:

2 - Mount the safety screw (15).
Safety screws: Loctite 262
Safety screws: 88±8,8 Nm
RKPA7331
30-212 PW110R-1
5. Cylinder assembly
1 - Place the cylinder (1) and the piston rod group (2) on the 1 3
4
equipment A and align their axes. 2
2 - Lubricate the external seals and insert the piston (3) in
the cylinder (1).
Piston sealants: Grease ASL800050

★ Before inserting the piston, check that the seals are
not damaged and that they fit perfectly in their seat-
ings. 5
A
3 - Lubricate the external seals of the head (4) and insert it RKPA7312
completely into the cylinder (1).
Head sealants: Grasso ASL800050

★ Before inserting the head, check that the seals are
not damaged and that they fit perfectly in their seat-
ings. 8
6
4 - Using the plier G, position the snap ring (5) that holds
the head (4) in the cylinder seating.
★ Check that the snap ring is completely inserted in
the seating.
G
5 - Position the flange (6) that holds the head in place, and
secure it with the screws (7).
RKPA7461
★ Before positioning the flange, check that the O-ring
flange seal (8) is in its seating.
Flange blocking screws: 49±5 Nm

6
7
RKPA7470
PW110R-1 30-213
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 1-piece boom)
REMOVAL OF WORK EQUIPMENT

(For 1-piece boom)
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
1 3 6
4
4 - Start the engine to retract the piston (4).
2 1
RKPA7161
To hold the piston in its fully retracted position, tie it with wire.
5 - Lower the cylinder (1) until it comes to rest on blocks (A).
JUSTMENTS»).
7 - Disconnect the hoses (5) and plug them. Also plug the 1
rigid tubes.
8 - Put the equipment in a sling and apply slight tension to
the cables.
9 - Remove the screw (6) and the pin (7). Lift off the work
equipment (8). 3 4 A
Work equipment: 1300 kg RKPA7170
INSTALLATION OF WORK
EQUIPMENT
(For 1-piece boom)
1
★ Insert the spacers to a given clearance (distributed 5 5
mm is obtained.
2
When aligning the positions between holes and RKPA7480
pin, let the engine run at minimum idling. Do not in-

sert fingers into the hole to check the alignment.
3
4
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.
★ After bleeding the air, switch off the engine and
check oil level in the tank.
8
RKPB0150
30-214 PW110R-1
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 2-piece boom))
REMOVAL OF WORK EQUIPMENT

(For 2-piece boom)
Fully extend the arm and the 2-piece boom and com-
pletely curl up the bucket. Position a stand (A) (height
1.60 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 cir- A
cuits. (For details, see «20. TESTING AND ADJUST-
MENTS»).
RKPA7500
1 - Disconnect the boom cylinder (1) from the 2-piece

boom and rest it on a stand (B).
★ In order to disconnect the boom cylinder, it is nec-
essary to remove the RH cylinder of the 2-piece
boom. (See «REMOVAL OF 2-PIECE BOOM CYL- 2
INDERS 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
RKPA7530
2 - Disconnect the eight hoses (3) (No. 8) that control the

front work equipment cylinders, and plug them. Also
plug the union fittings of the hoses (4).
3
RKPA7520
3 - Put the boom (5) in a sling and apply slight tension to the
cables.
★ Pass the cables through the rigid tubes to avoid dis-
5
tortion.
7
4 - Remove the screws (6) and take out the pin (7).
2 3 4
5 - Raise the boom (5) until it is disengaged from the swivel
support (8) and take away the stand (A).
6
Work equipment: 1650 kg

A 8
RKPA7510
PW110R-1 30-215
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 2-piece boom)
6 - Swing the group to the side of the machine and rest the
boom on a stand (C).
5
RKP08030
INSTALLATION OF THE
WORKEQUIPMENT
(For 2-piece boom)
1
★ Insert the spacers (distributed on both sides of the
top of the cylinder) until a clearance of 1--2 mm is
obtained.
2
When aligning the positions between holes and
3
4
★ Insert the shims (distributed on both sides of the top
of the piston rod) until a clearance of 1--2 mm is ob-
tained.
• Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
★ After bleeding the air, switch off engine and check
oil level in the tank.
30-216 PW110R-1
REMOVAL AND INSTALLATION BUCKET
REMOVAL OF BUCKET
Lower the bucket to the ground, resting with its back on
a flat surface. 7
1 - Take out the safety pin (1) and the connecting pin (2) be-
4
tween bucket (3) and tie-rod (4). 6
1 2 3 2
2 - Take out the safety pin (5) and the pin (6) that connects 5
the bucket to the arm (7).
2 3 4 1 3
RKPA7540
INSTALLATION OF BUCKET
1
★ Insert the spacers to a given clearance between
bucket (3) and tie-rod (4).
2
When lining up the hole and the pin, let the engine
turn at low idling speed. Do not insert fingers into
the holes to check alignment.
3
4
★ Insert the spacers 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.
PW110R-1 30-217
REMOVAL AND INSTALLATION 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 optional

front equipment, disconnect the boom (or the 2-piece
boom), the tubes (1) and remove the supports (2)..
2
RKPA7550
4 - Loosen the ring nut (3) and pin (4) and remove the thrust
lever (5). 1 2
3
4
RKPA7560
5 - Raise the boom and bring the arm (6) into a vertical po-
sition and then lower it to the ground.
6
RKP09740
6 - Switch off the engine and release residual pressures.

10 7
7 - Put the arm cylinder (7) in a sling, remove the screw (8) 9
and take out the pin (9).
8 -Start the engine and fully retract the piston (10). 3

tie it with wire.
8
RKPA7570
30-218 PW110R-1
9 - Rest the cylinder (7) on a block (A).
10 - Switch off the engine. 7
A
RKPA7580
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). 4
12
11
RKPA7590
13 - Take out the screw (13) and pull out the pin (14).
14 - Lift off the arm (6). 6

Arm L=1850: 178 kg
Arm L=2000: 200 kg
Arm L=2300: 223 kg
14
13
RKPA7600
15 - Start the engine and, for reasons of safety, lower the

boom or 2-piece boom until it rests on the ground.
RKPB0890
PW110R-1 30-219
INSTALLATION OF ARM
1
★ Insert shim.
2
pin, do not insert fingers into the hole to check the
alignment.
3
mm is obtained.

sert fingers into the holes to check the alignment.
4
on both sides) until a clearance of 0.5--1 mm is ob-
tained.

do not insert fingers into the holes to check the
alignment.
30-220 PW110R-1
REMOVAL AND INSTALLATION 2nd BOOM
REMOVAL OF 2nd BOOM

1 - Remove the bucket, the bucket cylinder, the arm cylin-
der and the arm. For details see:
• REMOVAL OF BUCKET
• REMOVAL OF BUCKET CYLINDER 1
• 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.
RKPB0891
3 - Put a sling round the RH cylinder (2) of the 2-piece boom

and remove the nut (3), the screw (4) and the shim (5). 2 2
1
4 - Slide out the pin (6) that connects the RH cylinder (2) to
the 2-piece boom (1) until the piston rod is completely
5
disconnected. 2 3 5
3
6 4
RKPA7211
5 - Start the engine and completely retract the piston rod of

the RH cylinder.
★ 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, leaving
the boom tied up.
7 - Repeat these operations from point 3 to point 6 in order

to disconnect the LH cylinder (7). 2 3
RKPA7221
8 - Hook the 2-piece boom to the hoisting tackle.
9 - Remove the screws and take out the pin (8).

2 3 4
10 - Take off the 2-piece boom. 8
2-piece boom: 278 kg
7
RKPA7610
PW110R-1 30-221
REMOVAL AND INSTALLATION 2nd BOOM
INSTALLATION OF 2nd BOOM

1
2
3
4
• Insert the spacers (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 ADJUSTMENTS»).
check the oil level in the tank.
30-222 PW110R-1
REMOVAL AND INSTALLATION BOOM (For 1-piece boom)
REMOVAL OF BOOM (For 1-piece boom)

1 - Remove the arm.
(For details, see «REMOVAL OF ARM»). 2
2 - Remove the arm cylinder.
(For details, see «REMOVAL OF ARM CYLINDER»).
3 - Start the engine and lower the boom to the ground.
4 - Switch off the engine and move the PPC valve several
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 3
1
7 - Start the engine and fully retract the piston (4). 2
RKPA7162
tie it with wire.

8 - Switch off the engine and release all pressures. (For de-
9
9 - Lower the piston until it is resting on blocks (A).
10 - Remove the overload sensor. (For details, see «RE-
1 8
MOVAL OF OVERLOAD SENSOR»).
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). RKPA7171
Boom: 405 kg 3 4
(For 1-piece boom)
1
2
7 7
3
4
on both sides of the boom) until a clearance of
0.5--1 mm is obtained. 6 6
• Start the engine to circulate the oil and bleed air from the
cylinders.
check the oil level in the tank. RKPA7481
PW110R-1 30-223
REMOVAL AND INSTALLATION BOOM (For 2-piece boom))
REMOVAL OF BOOM (For 2-piece boom)

1 - Remove the bucket, the bucket cylinder, the arm cylin-
der, 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 se-
cure it with the proper screws. 2 1
3 - Manoeuvre the boom (2) until the fulcrum pin is resting
on a stand (A), 1.60 m high.
A
4 - Switch off the engine and release any residual pres-
sures in the boom cylinder.
3
5 - Remove the 2-piece boom cylinders (3) and let the
boom cylinder (4) rest on a stand.
4
RKPB0180
6 - Remove the overload sensor. (For details, see «RE-

MOVAL OF OVERLOAD SENSOR»).
7
6
7 - Disconnect the six connecting hoses of the front work 5
equipment cylinders (5) (No. 6) and the two tubes (6) of
the optional equipment (No. 2).
★ Plug the hoses and rigid tubes to prevent entry of
impurities.
RKPA7521
8 - Take out the four screws (7) (No. 4) and lift away the
complete rack of tubes. 7
RKPA7440
30-224 PW110R-1
REMOVAL AND INSTALLATION BOOM (For 2-piece boom))
9 - Screw four M10 UNI 2947 eyebolts (8) as far as they will
go into the holes of the rack of tubes.
10 - Attach the hoisting tackle to the eyebolts and apply 8 10

slight tension to the cables.
11 - Take out the screws (9) and remove the pin (10).
12 - Lift away the entire boom (2).
Boom: 314 kg 2
9
RKPB0900
(For 2-piece boom)
1
2
Do not insert fingers in the holes in order to check
the alignment.
3
★ Insert spacers 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.
check the level in the oil tank.
PW110R-1 30-225
REMOVAL AND INSTALLATION SWING SUPPORT
REMOVAL OF SWING SUPPORT

Extend the work equipment fully and rest it on the
ground.
1 - Remove the front work equipment. (For details see
«REMOVAL OF WORK EQUIPMENT»). 1
2 - Remove the boom cylinder (For details, see «REMOV- A
AL OF BOOM CYLINDER»).
3 - Take out the screws and remove the pins (4).

4 5
4 - Attach the swing bracket (1) to the hoisting hook “A” and
apply slight tension to the cable.
RKPB2111
5 - Place a jack (3) beneath the lower pin (2).

6 - Take out the retaining screws and pull out the pin (2).
1
7 - Take out the retaining screws and, with the help of a le-
ver, pull out the upper pin (4). 2
8 - Lift out the swing bracket (1). 3
2
Swing bracket: 230 kg
5
9 - If necessary, replace bushings (5).
3
RKPA7651
INSTALLATION OF SWING
SUPPORT
1
Lower pin: ASL800050
2 4
Upper pin: ASL800050
3
★ Insert the adjustments to a given clearance be-
tween the chassis and the support.
RKPA7660
Unità di misura: mm
Pos. Code No. Thickness Quantity
1 21D-09-39140 5 2
2 21D-09-39130 0.5 2 2
5
4
on both sides of the eyes piston) until a clearance of
2
5
When aligning the positions between hole and pin, run 5
the engine at idling.Do not introduce hand fingers in the
holes to check the alignment. 1
RKP07491
30-226 PW110R-1
REMOVAL AND INSTALLATION BLADE AND OUTRIGGERS
REMOVAL OF BLADE AND OUTRIGGERS

1 - Raise the blade (1) or the outriggers (2) and place
blocks (A) under the arms (3); Lower the equipment until 1
the arms rest lightly on the blocks.
A
RKPB0210
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).
1 2 3
4
4 - Remove the blade (1) or the outriggers (2).
Blade: 217 kg
Outrigger: 42 kg
A
2
RKPB0220
INSTALLATION OF BLADE AND

OUTRIGGERS
1
Internal bushings: ASL800050
2
Do not insert fingers into the holes to check on
alignment.
3
★ Insert the shims on both sides of the arm, in order to
obtain a clearance of 0.5–1 mm.
PW110R-1 30-227
REMOVAL AND INSTALLATION BLADE AND OUTRIGGER ARMS
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).
1 2 3
3 - Start the engine and retract the piston (3). Stop the en-
gine. 2
3
1
RKPB0230
4 - Attach the arm (4) to the hoisting equipment and apply

slight tension to the cables. 5
5 - Take out the screw (5) and remove the dowel (6). 6
6 - Remove the arm (4).
1 2 3
Arm: 100 kg 4
RKPB0240
INSTALLATION OF BLADE AND

OUTRIGGERS ARMS
1
Internal bushings: ASL800050
2
★ Do not insert fingers into the holes to check on
alignment.
3
★ Insert the shims on both sides of the arm, in order to
obtain a clearance of 0.5–1 mm.
30-228 PW110R-1
STANDARD MAINTENANCE
P.T.O. ........................................................................ 2 Swivel joint ...............................................................33

Front axle................................................................... 3 Travel motor .............................................................34
Transmission ............................................................. 8 Travel motor brake valves ........................................35
Rear axle ................................................................. 10 Servocontrol feed unit ..............................................36
Swing circle ............................................................. 16 PPC valves...............................................................37
Swing machinery ..................................................... 18 Blade safety valve ....................................................39
Hydraulic pump........................................................ 20 Cylinders ..................................................................40
Control valve............................................................ 22 Work equipment .......................................................42
Swing motor............................................................. 32
PW110R-1 40-1
STANDARD MAINTENANCE P.T.O.
P.T.O.
44–54 Nm
85 Nm
70 Nm
44–54 Nm
RKP05341
40-2 PW110R-1
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
DIFFERENTIAL
24–26 Nm 128–142 Nm
with Loctite 242 A with Loctite 242
Loctite 242
24–26 Nm
A 1 2
500–570 Nm 1
with Loctite 242
Section B - B
280–310 Nm
with Loctite 270 B
35–50 Nm
35–50 Nm
3
Unit: mm
No. Check item Criteria
Remedy
Standard clearance Clearance limit
Backlash of crown wheel
1
and pinion
0.18–0.23 – Adjust
Tightening torque of slew

2 differential 120–170 Ncm
Adjust
3 Tightening torque of slew 20–40 Ncm
pinion (w/o seal)
PW110R-1 40-3
BRAKES
A
3
A
Section A - A
283–312 Nm
35–50 Nm
2
5–7 Nm
with Loctite 270
RKP05581
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installated Installated Free Installated
1 Returning spring
length length load length load
– – – – –
Standard thickness Min. thickness
2 Disk thickness Replace
– 4.5
Standard clearance Max. clearance
3 Disk clearance Adjust
0.75 –
40-4 PW110R-1
FINAL DRIVE
128–142 Nm
1
60–70 Nm 1st tightening: 120 Nm

with Loctite 242 2nd tightening: 255–285 Nm
with Loctite 242
Tecnolupe seal 101
40–50 Nm
128–142 Nm
RKP05590
Unit: mm

1 Hub torque (with sealing ring) Adjust
5–25
PW110R-1 40-5
STEERING CYLINDER
240–270 Nm
with Loctite 242
116–128 Nm
RKP05670
Unit: mm
Tolerance
Standard Clearance
Standard size
Clearance between shaft clearance limit
1 and bushing Shaft Hole Replace
45 – – – –
40-6 PW110R-1
STEERING AND CONVERGENCY ANGLE
28° 28
A A
47.2
Detail B
260–290 Nm
Section A - A
1920±1
1000
1000
87.7 87.7
1920±1
RKP05663
PW110R-1 40-7
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
25 Nm
A
49–51 Nm
with Loctite 510
B
B
35–50 Nm
A 49–51 Nm
49–51 Nm
35–50 Nm
24–26 Nm
30 Nm
80–100 Nm
40-8 PW110R-1
STANDARD MAINTENANCE TRANSMISSION
Loctite 510
Loctite 510
280–310 Nm 2
with Loctite 310
49–51 Nm
with Loctite 242
Loctite 510 Loctite 510
25–26 Nm RKP05620
Unit: mm

1 Bearing clearance
0.25–0.35 – Adjust
2 Bearing clearance 0.20–0.30 –
PW110R-1 40-9
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
DIFFERENTIAL
24–26 Nm
with Loctite 242 128–142 Nm
A with Loctite 242
Loctite 242
24–26 Nm
A 1 2
1
Section B - B
B
35–50 Nm
35–50 Nm
3 900–1000 Nm
with Loctite 270 RKP05571
Section A - A
Unit: mm
Remedy
Backlash of crow wheel
1
and pinion
0.18–0.23 – Adjust

2 120–170 Ncm
differential
Adjust
3 20–40 Ncm
pinion (w/o seal)
40-10 PW110R-1
BRAKES
A
3
A
Section A - A
283–312 Nm
35–50 Nm Section B - B
2
5–7 Nm
with Loctite 270
B A B
1
35–50 Nm
with Loctite 270 RKP05601
Unit: mm
Free Installated Installated Free Installated
1 Returning spring
– – – – –
Standard thickness Min. thickness
2 Disk thickness Replace
– 4.5
Standard clearance Max. clearance
3 Disk clearance Adjust
0.75 –
PW110R-1 40-11
PARKING BRAKE AND CYLINDER
25–30 Nm
with Loctite 242
24–26 Nm
20–25 Nm
20–25 Nm
3 a
50–60 Nm
RKP05630
Unit: mm
Free Installated Installated Free Installated Replace if
1 Returning spring damage or
deformed
– – – – –
2 Clearance with 10 kg force 0 – Set
Check
3 Piston jut 4–5 brake
–
thickness
and adjust
40-12 PW110R-1
FINAL DRIVE
128–142 Nm
1
60–70 Nm 1st tightening: 120 Nm

with Loctite 242 2nd tightening: 255–285 Nm
with Loctite 242
Tecnolupe seal 101
40–50 Nm
128–142 Nm
RKP05590
Unit: mm

1 Hub torque (with seal) Adjust
5–25
PW110R-1 40-13
STEERING CYLINDER
240–270 Nm
with Loctite 242
116–128 Nm
RKP05640
Unit: mm
Tolerance
Standard Clearance
Standard size clearance limit
Clearance between shaft
1 Shaft Hole Replace
and bushing
45 – – – –
40-14 PW110R-1
STEERING AND CONVERGENCY ANGLE
28 28
A A
47.2
Detail B
260–290 Nm
Section A - A
1920±1
1000
1000
87.7 87.7
1920±1
RKP05651
PW110R-1 40-15
STANDARD MAINTENANCE SWING CIRCLE
SWING CIRCLE
290 Nm
Section C - C
Section A - A
1
290 Nm
Section B - B
D
290 Nm
A
D
314 Nm
C
C
Section D - D
B
B
Section E - E
A E
RKP12461
Unit: mm
Remedy
1 Axial clearance
0.3–1.2 3 Replace
40-16 PW110R-1
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE SWING MACHINERY
SWING MACHINERY
3
49 Nm 85 Nm
1000±50 Nm
with Loctite 243
1
294 Nm
ASL800050
6
RKP12310
40-18 PW110R-1
STANDARD MAINTENANCE SWING MACHINERY
Unit: mm

Backlash between No. 2
1
planetary gear and housing
Backlash between No. 1

2
planetary gear and housing
Backlash between
3 No. 1 sun gear and
No. 1 planetary gear
Replace
Backlash between
4 No. 2 sun gear and
No. 2 planetary gear
Backlash between swing

5
pinion and swing circle gear
Standard size Size limit

Wear of swing pinion shaft
6 surface contacting with oil seal
PW110R-1 40-19
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
66.2 ± 7.4 Nm 11.25 ± 1.45 Nm
68.6 ± 9.8 Nm 30.5 ± 3.5 Nm
66.2 ± 7.4 Nm 17.2 ± 2.5 Nm
110.3 ± 12.3 Nm
View Y
13.25 ± 1.45 Nm 144.55 ± 12.25 Nm 100.45 ± 12.25 Nm
RKP03731
40-20 PW110R-1
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
A
C B
D A
AA AA
O O
N N
M M
L L
K K
J J
H H
G G
F F
P
E E xx
BB BB
C D A
Pu
P B
9.8–12.7 Nm 29.4–39.2 Nm
1 3
4 2
1st tightening: 19.6–29.4 Nm View A

2nd tightening: 39.2–49 Nm Tightening following
3rd tightening: 58.8–73.5 Nm 1-2-3-4 order
in 3 times
View B RKP03281
40-22 PW110R-1
39–49 Nm 39–49 Nm
39–49 Nm 39–49 Nm
39–49 Nm 39–49 Nm
107.8–147 Nm
RKP03291
Section A - A
Unit: mm
Cooler by-pass Free length Installed Installed Free length Installed

1 Replace
valve spring x O.D. length load x O.D. load
– 33 231.4 N – –
PW110R-1 40-23
1 1
1 1
1 1
1 1
1 1
1 2
1 3
2 2
1 1
3 3
RKP03371
Section B - B
Unit: mm

Spool return spring
(Work equipment, swing
Free length Installed Installed Free length Installed
1 boom, arm, bucket,
x O.D. length load x O.D. load
boom swing, blade,
travel, equipment)
– 40.5 34.7 N – – Replace
Spool return spring
2 – 40.5 54.6 N – –
(Arm)
Spool return spring

3 – 40.5 4.9 N – –
(Boom, swing)
40-24 PW110R-1
118–162 Nm
1
1
4
2
RKP03301
Section C - C
Unit: mm
1 Pressure compensation Free length Installed Installed Free length Installed

valve spring x O.D. length load x O.D. load
– 14.5 13.72 N – –
Replace
Pressure compensation
2 valve spring (boom) – 21.5 55.9±3 N – –
3 Spool (boom raise at joining – 36 238.3 N – –

pump discharge)
Flow compensation valve
4 – 20 27.6 N – –
spring (boom)
PW110R-1 40-25
24.5–34.3 Nm
58.8–78.5 Nm
RKP03311
Section D - D
Unit: mm
1 Check valve spring Free length Installed Installed Free length Installed
Replace
– 22 3.92 N – –
Check valve spring
2 – 11.5 13.7 N – –
(Swing)
40-26 PW110R-1
107.8–147 Nm
1
49–59 Nm
Section BB - BB RKP02823
19.6–27.4 Nm 65.7–85.3 Nm
with Loctite 638
Section E - E RKP02813
Unit: mm

1 Lift check valve spring Replace
– 46.4 138 N – –
PW110R-1 40-27
34–44 Nm
88.3–107.9 Nm
34–44 Nm
19.6–27.5 Nm
34–44 Nm
RKP02843
Section AA - AA
39–49 Nm
49–59 Nm
Section F - F RKP02833
40-28 PW110R-1
RKP02853
Section G - G
14.7–19.6 Nm 14.7–19.6 Nm
with Loctite 638 with Loctite 638
Section H - H RKP02863
14.7–19.6 Nm 14.7–19.6 Nm
with Loctite 638 with Loctite 638
RKP02873
Section J - J
PW110R-1 40-29
14.7–19.6 Nm
with Loctite 638
RKP02883
Section K - K
14.7–19.6 Nm
with Loctite 638
RKP03321
Section L-L
14.7–19.6 Nm
with Loctite 638
Section M-M RKP03331
40-30 PW110R-1
14.7–19.6 Nm
with Loctite 638
RKP03341
Section N-N
14.7–19.6 Nm
with Loctite 638
20–25 Nm
RKP03351
Section O-O
147–186 Nm
RKP03361
Section P-P
PW110R-1 40-31
STANDARD MAINTENANCE SWING MOTOR
SWING MOTOR
A
108–142 Nm
58.8–78.4 Nm
34.3–44.1 Nm
2
Unit: mm
1 Suction valve spring Free length Installed Installed Free length Installed
x O.D. length load x O.D. load Replace
– 11.5 0.9 N – –
2 Shuttle valve spring – 19.5 1.8 N – –
40-32 PW110R-1
STANDARD MAINTENANCE SWIVEL JOINT
SWIVEL JOINT
RKP03790
Unit: mm
Standard Standard Clearance
Tolerance
size clearance limit
Clearance between – 0.02
1 Shaft Replace
shaft and rotor – 0.05
85 0.12–0.20 0.25
+ 0.10
Hole
+ 0.15
PW110R-1 40-33
STANDARD MAINTENANCE TRAVEL MOTOR
TRAVEL MOTOR
__________ Nm
2 __________ Nm
1
3
__________ Nm _______ Nm
A __________ Nm
__________ Nm
__________ Nm
Section A - A
RKP11201
Unit: mm
Free Installed Installed Free Installed

1 Valve guide retain spring
– – – – –
2 Measure piston spring – – – – –
3 Centre spring of cylinder unit – – – – –
40-34 PW110R-1
STANDARD MAINTENANCE TRAVEL MOTOR BRAKE VALVES
TRAVEL MOTOR BRAKE VALVES
1 2 200 Nm
20 Nm
100 Nm
20 Nm
600 Nm
200 Nm
650 Nm
10 Nm 4
RKP04560
Unit: mm
Free Free
1 Pilot valve spring length Installed Installed Installed
length
length load load
xØe xØe
– – – – –
Replace
2 Main valve spring – – – – –
3 Piston return spring – – – – –
4 Single-acting valve spring – – – – –
5 Check valve spring – – – – –
PW110R-1 40-35
STANDARD MAINTENANCE SERVOCONTROL FEED UNIT
SERVOCONTROL FEED UNIT
3 22.0±4.9 Nm 29.4±4.9 Nm
9.8±2 Nm
1 2 9.8±2 Nm 4
66.2±7.3 Nm
RKP04091
Unit: mm
Free Installed Installed

Free
Installed
1 Pilot valve spring length length load
length
load
xØe xØe
19.2x7.2 16.1 19.6 N – 17.7 N Replace
2 Reduction box pilot valve spring 16.5x7.2 12.7 20.6 N – 18.6 N
3 Spring 71x18 59 199.8 N – 186.2 N
4 Relief valve spring 16.1x7.8 13.4 61.7 N – 58.8 N
40-36 PW110R-1
STANDARD MAINTENANCE PPC VALVES
PPC VALVES
BOOM, ARM, BUCKET, SWING
1 2
3 3
RKP12670
Unit: mm
Centering spring Free length Installed Installed Free length Installed

1
(for P2 and P4 port) x O.D. length load x O.D. load
Replace
Metering spring
2
(For P1 and P3 port)
3 Checking spring
PW110R-1 40-37
STANDARD MAINTENANCE PPC VALVES
BLADE
Unit: mm

1 Centering spring
Replace
2 Metering spring
40-38 PW110R-1
STANDARD MAINTENANCE BLADE SAFETY VALVE
BLADE SAFETY VALVE
83 Nm
75 Nm
33 Nm
RKP04580
Unit: mm
Free Free
1 Check valve spring length Installed Installed Installed
length load length load
Replace
xØe xØe
16.5 11.12 2.465 kg 13.5 1.1 kg
PW110R-1 40-39
STANDARD MAINTENANCE CYLINDERS
CYLINDERS
BOOM - BUCKET, BOOM SWING, OUTRIGGERS OR BLADE
1
49 Nm
49 Nm
RKP04370
ARM
1 88 Nm with Loctite 262
49 Nm 2940±196 Nm
with Loctite 262
RKP04360
2-PIECE BOOM
3430±284 Nm
1 with Loctite 262
49 Nm with Loctite 262
RKP04350
40-40 PW110R-1
STANDARD MAINTENANCE CYLINDERS
Unit: mm
Tolerance Standard Clearan-

Standard
Cylinder clearance
size ce limit
Shaft Hole
– 0.03 0 0.030
Boom 70 0.326
– 0.06 + 0.166 0.226
– 0.05 0 0.025
2-piece boom 50
–0.025 + 0.166 0.216
0.316
Clearance
1 between
piston rod – 0.03 0 0.030
Arm 60
– 0.06 + 0.166 0.226
0.326
and cylinder head
– 0.03 0 0.030
Bucket 60 0.326
– 0.06 + 0.166 0.226
– 0.03 0 0.030
Boom swing 60
– 0.06 + 0.166 0.226
0.326
Outriggers or 60
– 0.03 0 0.030
0.326
blade – 0.06 + 0.166 0.226
– 0.060 + 0.1 + 0.16

Boom 60
– 0.106 +0.146 + 0.252 1
– 0.050 + 0.08 + 0.13

2-piece boom 50
– 0.089 + 0.119 + 0.208
1
– 0.050 + 0.08 + 0.13

Clearance Arm 50
– 0.089 + 0.119 + 0.208
1
2 between
cylinder head
bushing and pin – 0.050 + 0.08 + 0.13
Bucket 50
– 0.089 + 0.119 + 0.208 1
– 0.050 + 0.08 + 0.13

Boom swing 50
– 0.089 + 0.119 + 0.208
1
Outriggers or 50
– 0.050 + 0.08 + 0.13
1
blade – 0.089 + 0.119 + 0.208
– 0.060 + 0.1 + 0.16

Boom 60
– 0.106 +0.146 + 0.252 1
– 0.060 + 0.1 + 0.16

2-piece boom 60
– 0.106 +0.146 + 0.252
1
– 0.050 + 0.08 + 0.13

Clearance Arm 50 1
– 0.089 + 0.119 + 0.208
between
3
cylinder bottom
bushing and pin – 0.050 + 0.08 + 0.13
Bucket 50
– 0.089 + 0.119 + 0.208
1
– 0.050 + 0.08 + 0.13

Boom swing 50
– 0.089 + 0.119 + 0.208
1
Outriggers or 50
– 0.050 + 0.08 + 0.13
1
blade – 0.089 + 0.119 + 0.208
PW110R-1 40-41
STANDARD MAINTENANCE WORK EQUIPMENT
WORK EQUIPMENT
1-PIECE BOOM
D
G
A B
7 6 4 5 3
Section A - A Section B - B Section C - C
Section D - D Section E - E Section F - F
40-42 PW110R-1
Section G - G
RKP05741
Unit: mm
Tolerance
Standard Standard Tolerance
Clearance between swing size clearance limit
1 bracket-to-revolving Shaft Hole
frame mounting and pin bushing
– 0.072 + 0.145 0.271–
100 0.8
– 0.126 + 0.044 0.116
Clearance between boom-to-swing – 0.060 + 0.047 0.107–

2 60 0.8
bracket mounting pin and bushing –0.106 + 0.127 0.233
Clearance between boom-to-arm – 0.060 + 0.047 0.107–

3 mounting pin and bushing
60
–0.106 + 0.127 0.233
0.8
Clearance between bucket cylinder-to- – 0.050 + 0.095 0.184–

4 50 1
link mounting pin and link bushing – 0.089 + 0.016 0.066
Replace
5 Clearance between arm-to-link 50

– 0.050 + 0.095 0.184–
1
mounting pin and bushing – 0.089 + 0.016 0.066
Clearance between bucket-to-arm – 0.050 + 0.095 0.184–

50
– 0.089 + 0.016 0.066
1
Clearance between bucket-to-link – 0.050 + 0.095 0.184–

7 50 1
8 Clearance between bushing and 50

– 0.050 + 0.095 0.184–
1.5
connecting pin of outrigger – 0.089 + 0.016 0.066
9 Clearance between bushing and 50

– 0.050 + 0.095 0.184–
1.5
bracket pin – 0.089 + 0.016 0.066
PW110R-1 40-43
WORK EQUIPMENT
2-PIECE BOOM
D
H
F
F
A B
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
40-44 PW110R-1
9 10
Section G - G Section H - H RKP05751

Unit: mm
Tolerance
Standard Standard Tolerance
Clearance between swing size clearance limit
1 bracket-to-revolving frame Shaft Hole
mounting and pin bush1ing
– 0.072 + 0.145 0.271–
100 0.8
– 0.126 + 0.044 0.116
Clearance between boom- to-swing – 0.060 + 0.047 0.107–

2 60 0.8
bracket mounting pin and bushing –0.106 + 0.127 0.233
Clearance between boom-to-arm – 0.060 + 0.047 0.107–

60
–0.106 + 0.127 0.233
0.8
Clearance between bucket – 0.050 + 0.095 0.184–

4 cylinder-to-link mounting pin 50
– 0.089 + 0.016 0.066 1
and link bushing
Replace
5 Clearance between arm-to-link 50
– 0.050 + 0.095 0.184–
1
Clearance between bucket-to-arm – 0.050 + 0.095 0.184–

6 50 1
7 Clearance between bucket-to-link 50

– 0.050 + 0.095 0.184–
1
Clearance between bushing and – 0.060 + 0.047 0.107–

8 connecting pin of 2nd boom
60
–0.106 + 0.127 0.233
0.8

9 50 1
connecting pin of outrigger – 0.089 + 0.016 0.066

10 60 1
bracket pin –0.106 + 0.127 0.066
PW110R-1 40-45

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

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

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

The affected pages are indicated by the use of the

● Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised or

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

00-1 10-17 10-58 10-99 10-140

Time of Time of Time of Time of Time of

20-37 30-25 30-89 30-153 30-217

IMPORTANT SAFETY NOTICE

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

Symbol Item Remarks

10 - 3 Weight of parts or systems.

Parts to be coated with adhe-

REVISED EDITION MARK

1. If a part cannot be smoothly removed from the ma-

The allowable load value is estimated to be one-

STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

6 1 10 8 0.96±0.1 9.5±1 1.3±0.15 13.5±1.5

8 1.25 13 6 2.3±0.2 23±2 3.2±0.3 32.2±3.5

10 1.5 17 8 4.6±0.5 45±4.9 6.5±0.6 63±6.5

12 1.75 19 10 7.8±0.8 77±8 11±1 108±11

14 2 22 12 12.5±1 122±13 17.5±2 172±18

16 2 24 14 19.5±2 191±21 27±3 268±29

18 2.5 27 14 27±3 262±28 37±4 366±36

20 2.5 30 17 38±4 372±40 53±6 524±57

22 2.5 32 17 52±6 511±57 73±8 719±80

24 3 36 19 66±7 644±70 92±10 905±98

27 3 41 19 96±10 945±100 135±15 1329±140

30 3.5 46 22 131±14 1287±140 184±20 1810±190

33 3.5 50 24 177±20 1740±200 250±27 2455±270

36 4 55 27 230±25 2250±250 320±35 3150±350

39 4 60 ---- 295±33 2900±330 410±45 4050±450

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

1/2” - 20 17 2.6±0.5 25.5±4.9

9/16” - 18 17 4±0.5 39.2±4.9

3/4” - 16 22 6.7±2 65.7±19.6

7/8” - 14 27 8±2 78.5±19.6

1.1/16 - 12 32 9.7±3 95.15±29.4

1.5/16 - 12 38 17±3 166.7±29.4

1.5/8 - 12 50 20±5 196.2±49

Thread diameter Width across flats TIGHTENING TORQUE

9/16” - 18 17 2.3–2.5 23–25

11/16” - 16 22 3.4–3.9 33–38

13/16” - 16 24 5.2–5.8 51–57

1.3/16 - 12 36 12.2–13.3 120–130

1.7/16 - 12 41 15.3–17.3 150–170

1.11/16 - 12 50 18.4–20.4 180–200

Nomenclature Code Applications

Used by itself on mounting flat surface

Used by itself on mounting flat surface

CLASSIFICATION BY COLOUR AND CODE