CONTENTS

WB97S-2
No. of page
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING AND ADJUSTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
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GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions written on the decals which
are suck on the machine.
2. When carrying out any operation, always wear sa-
fety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
. Always wear safety glasses when hitting parts
with a hammer.
. Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a trai-
ned, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other clo-
thes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on
the controls in the operator's compartment.
5. Keep all tools in good condition and learn the cor-
rect way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor.
Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chine on hard, level ground, and block the wheels
to prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or
any other work equipment to the ground. If this
is not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
to lock all the control levers and hang warning
sign on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before star-
ting work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting
on or off the machine.
Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
cuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.
00-5
WB97S-2
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu Utility and describe in this manual are
both effective and safe methods of operation. Some of these operations require the use of tools specially
designed by Komatsu Utility for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this ma-
nual. The cautions accompanying these symbols should always be carefully followed. If any danger ari-
ses or may possibly arise, first consider safety, and take necessary steps to face.
SAFETY
13. Before starting work, remove the leads from the
battery. Always remove the lead from the negative
( ) terminal first.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
. When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.
24. Take sure when removing or installing tracks of in
particular rubber tracks. When removing the
track, the track separates suddenly, so never let
anyone stand at either end of the wheel.
00-6
WB97S-2
00-7
WB97S-2
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-
curate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into
the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understan-
ding 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.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your Komatsu Utility distributor for the latest information.
VOLUMES
Shop manual are issued as a guide to carry out re-
pairs. These various volumes are designed to avoid
duplicating the same information.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will
be sent to Komatsu Utility distributors.
Get the most up-to-date information before you start
any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show you how to read the pa-
ge number.
Example
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num-
ber.
Fle as in the example.
Example:
10-4
10-4-1
10-4-2
10-5
] Added pages
REVISED EDITION MARK
(1 2 3 ....)
When a manual is revised, an edition mark is recor-
ded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVI-
SED PAGES between the title page and SAFETY pa-
ge.
SYMBOLS
In order to make the shop manual greatly chelpful,
important points about safety and quality are marked
with the following symbols.
Symbol Item Remarks
Safety
Special safety precautions are ne-
cessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under inter-
nal pressure.
Caution
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Weight
Weight of parts or systems.
Caution necessary when selecting
hoisting wire, or when working po-
sture is important, etc.
Tightening
torque
Parts that require special attention
for the tightening torque during as-
sembly.
Coat
Parts to be coated with adhesives
and lubricants etc.
Oil, water
Places where oil, water or fuel
must be added, and their quantity.
Drain
Places where oil or water must be
drained, and quantity to be drai-
ned.
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
00-8
WB97S-2
Item number (10. Structure and
Function)
Consecutive page number for each
item.
10 - 3
Heavy parts (25 kg or more) must be lifted
with a hoist etc. In the Disassembly and As-
sembly section, every part weighing 25 kg or
more is clearly indicated with the symbol
1. If a part cannot be smoothly removed from the
machine by hoisting, the following checks should
be made:
. Check for removal of all bolts fastening the part
to the relative parts.
. Check for any part causing interference with
the part to be removed.
2. Wire ropes
1) Use adequate ropes depending on the weight
of parts to be hoisted, referring to the table be-
low:
WIRE ROPES
(Standard S or Z twist ropes
without galvanizing)
Rope diameter (mm) Allowable load (tons)
10
11.2
12.5
14
16
18
20
22.4
30
40
50
60
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
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 hoist-
ing, and a serious accident can result.
Hooks have maximum strength at the middle
portion.
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
Slinging with one rope may cause turning of
the load during hoisting, untwisting of the ro-
pe, or slipping of the rope from its original
winding position on the load, which can cau-
se dangerous accidents.
4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles.
The table below shows the variation of allowa-
ble load (kg) when hoisting is made with two ro-
pes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150.
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
00-9
WB97S-2
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
00-10
WB97S-2
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of Di-
sassembly and Assembly.
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Thread diameter
of bolts
(mm)
Pitch of
bolts
(mm)
Width across flat
(mm)
kgm Nm kgm Nm
6
8
10
12
14
1
1.25
1.5
1.75
2
10
13
17
19
22
5
6
8
10
12
0.96w0.1
2.3w0.2
4.6w0.5
7.8w0.8
12.5w1
9.5w1
23w2
45w4.9
77w8
122w13
1.3w0.15
3.2w0.3
6.5w0.6
11w1
17.5w2
13.5w1.5
32.2w3.5
63w6.5
108w11
172w18
16
18
20
22
24
2
2.5
2.5
2.5
3
24
27
30
32
36
14
14
17
17
19
19.5w2
27w3
38w4
52w6
66w7
191w21
262w28
372w40
511w57
644w70
27w3
37w4
53w6
73w8
92w10
268w29
366w36
524w57
719w80
905w98
27
30
33
36
39
3
3.5
3.5
4
4
41
46
50
55
60
19
22
24
27

96w10
131w14
177w20
230w25
295w33
945w100
1287w140
1740w200
2250w250
2900w330
135w15
184w20
250w27
320w35
410w45
1329w140
1810w190
2455w270
3150w350
4050w450
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
. Nm (Newton meter): 1 Nm = 0.102 kgm
STANDARD TIGHTENING TORQUE
00-11
WB97S-2
Superficie di tenuta Sealing surface
2. TIGHTENING TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter
of nut part
(mm)
Width across flats
of nut part
(mm)
TIGHTENING TORQUE
kgm Nm
1/2" - 20
9/16" - 18
3/4" - 16
7/8" - 14
1.
1
/16
"
- 12
1.
5
/16
"
- 12
1.
5
/8
"
- 12
22
33
17
17
22
27
32
38
50
27
41
2.6w0.5
4w0.5
6.7w2
8w2
9.7w3
17w3
20w5
8w2
20w5
25.5w4.9
39.2w4.9
65.7w19.6
78.5w19.6
95.15w29.4
166.7w29.4
196.2w49
78.5w19.6
196.2w49
Thread diameter
of nut part
(mm)
Width across flats
of nut part
(mm)
TIGHTENING TORQUE
kgm Nm
9/16" - 18
11/16" - 16
13/16" - 16
1" - 14
1.
3
/16
"
- 12
1.
7
/16
"
- 12
1.
11
/16
"
- 12
2" - 12
17
22
24
30
36
41
50
57
2.3 2.5
3.4 3.9
5.2 5.8
8.2 9.2
12.2 13.3
15.3 17.3
18.4 20.4
20.4 24.4
23 25
33 38
51 57
80 90
120 130
150 170
180 200
200 240
00-12
WB97S-2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
Nomenclature Code Applications
Adhesives
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
ASL800020
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
Loctite 242
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Loctite 270 Used for high resistant locking and for sealing threaded parts, bolts and stud bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Loctite 573
Used for sealing rather exact plane surfaces when the option of possible future
dismantling is required.
Loctite 601
Used for high resistant locking of mechanical components that can be removed
only after heating
Loctite 675
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Gasket sealant
ASL800060
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
tings in hydraulic circuits of less than 50 mm in diameter.
Loctite 510
Used by itself on mounting flat surface
(Clearance between surfaces within 0.2 mm)
Loctite 518
Used by itself on mounting flat surface
(Clearance between surfaces within 0.5 mm)
Antifriction compound
(Lubricant including
Molybdenum disulfide)
ASL800040
Applied to bearings and taper shaft to facilitate press-fitting and to prevent stic-
king, burning or rusting.
Grease
(Lithium grease)
ASL800050
Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Vaseline Used for protecting battery electrode terminals from corrosion.
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
00-13
WB97S-2
ELECTRIC
n the wiring diagrams various colours 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
Nominal
number
Copper wire
Cable O.D.
(mm)
Current rating
(A)
Number
strands
of strands
(mm)
Cross section
(mm
2
)
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.32 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 14.00 160
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A-B A-G A-N A/N A-R A/R A-V A/V
Colour Light blue Light blue - White Light blue - Yellow Light blue - Black Light blue - Red Light blue - Green
Code B B-G B-N B/N B-R B/R B/V
Colour White White - Yellow White - Black White - Red White - Green
Code C C-B C/B C-L C-N
Colour Orange Orange - White Orange - Blue Orange - Black
Code G G-N G/N G-R G-V
Colour Yellow Yellow - Black Yellow - Red Yellow - Green
Code H H-L H-N H/N H-R
Colour Gray Gray - Blue Gray - Black Gray - Pink
Code L L-B L/B L/N L-G
Colour Blue Blue - White Blue - Black Blue - Yellow
Code M M-B M-N M/N M-V
Colour Brown Brown - White Brown - Black Brown - Green
Code N
Colour Black
Code R R-G R-N R/N R-V
Colour Red Red - Yellow Red - Black Red - Green
Code S S-N S-G
Colour Pink Pink - Black Pink - Yellow
Code V V-B V-N V/N
Colour Green Green - White Green - Black
Code Z Z-B Z/B Z-N Z/N
Colour Violet Violet - White Violet - Black
COMPOSITION OF THE COLOURS
The coloration of two-colour wires is indicated by the composition of the symbols listed.
Example: G-V = Yellow-Green with longitudinal colouring.
G/V = Yellow-Green with transversal colouring.
WEIGHT TABLE
00-14
WB97S-2
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB97S-2
From serial no. 97SF10001-
Engine assembly - Muffler - Exhaust pipe 410
Radiator - exchanger 37
Hydraulic tank (without hydraulic oil) 77
Fuel tank (without fuel) 73
Front counterweight 300
Engine hood 27
Cab (without seat) 595
Seat 34
Engine - gear-box - pump group 740
Piston pump 38
Transmission 230
Front axle 530
Rear axle 540
Front wheel
Rear wheel
163
163
2-spool control valve 24
3-spool control valve 30
Front work equipment assy.:
. Boom
. Shovel
. Fulcrum lever
. Tilt lever
. Raise cylinder
. Tilt cylinder
960
370
427
13x4
48x2
40x2
45x2
Backhoe
Work equipment assy.:
. with standard arm
. with long arm
. with jig arm
850
885
1030
Boom 323
Arm 213
Long arm 245
Boom swing bracket 133
Backframe 237
6-spool control valve 47
7-spool control valve 53
8-spool control valve 59
Jig arm 392
Outriggers 57
Boom cylinder 78
Arm cylinder 69
Bucket cylinder 49
Outrigger cylinder 42
Swing cylinder 30
Standard bucket 156
TABLE OF OIL AND COOLANT QUANTITIES
00-15
WB97S-2
RESERVOIR
KIND OF
FLUID
AMBIENT TEMPERATURE CAPACITY ( <)
20 10 0 10 20 30C
Specified Refill
Crankcase sump
OIL
. API CD
8.6 8.6
Hydraulic circuit
OIL
. API CD
150 92
Front axle
. differential
OIL
. UTTO FLUID
10.5 10.5
. final red. gear
(each)
1.3 1.3
Rear axle:
. differential
9 9
. final red. gear
(each)
1.3 1.3
Hydraulic
transmission
OIL
. GM DEXRON
t
II D
(DEXRON
t
is a registe-
red trademark of General
Motors Corporation)
19 16
Braking
system
0.8 0.8
Fuel tank
DIESEL OIL 130
Engine coolant
system
WATER+
ANTI-FREEZE
18
WATER 18
PERMANENT
LIQUID
18
] ASTM D975 N. 1
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: USA Military Specification
CCMC: Common Market Constructors Committe
First filling quantity: total quantity of oil, including the oil for the components and pipes.
Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and mainte-
nance operations.
SAE 10W
SAE 20W-20
SAE 30
SAE 40
SAE 10W-30
SAE 10W-30
]
ASTM D975 N. 2
00-16
WB97S-2
NOTE:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic mainte-
nance 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 hy-
draulic circuit of equipment and for reductions.
10-1
WB97S-2
STRUCTURE AND FUNCTION
Power train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control valve block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering system (4WS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Shovel control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Backhoe control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CLSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Solenoid valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Safety valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Brake pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Shovel cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Backhoe cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Air-conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
How the air-conditioning unit functions. . . . . . . . . . . . . . 84
Electrical circuit diagram (1/7). . . . . . . . . . . . . . . . . . . . . . . . 85
Electrical circuit diagram (2/7). . . . . . . . . . . . . . . . . . . . . . . . 87
Electrical circuit diagram (3/7). . . . . . . . . . . . . . . . . . . . . . . . 89
Electrical circuit diagram (4/7). . . . . . . . . . . . . . . . . . . . . . . . 91
Electrical circuit diagram (5/7). . . . . . . . . . . . . . . . . . . . . . . . 93
Electrical circuit diagram (6/7). . . . . . . . . . . . . . . . . . . . . . . . 95
Electrical circuit diagram (7/7). . . . . . . . . . . . . . . . . . . . . . . . 97
DESCRIPTION
. The driving power for the engine (1) is transmitted
through the flywheel to the converter (2).
The converter (2) uses hydraulic oil to convert the
torque transmitted by the engine (1) into driving po-
wer. The converter (2) transmits motion to the drive
shaft of the transmission (3) and to the drive shaft
of the hydraulic pump (4).
. The transmission (3) has two hydraulically-activa-
ted clutches that can be selected by an electrical-
ly-controlled gear selector. It also has manual gear
selection (four forward gears and four reverse
gears).
. The driving power is transmitted from the transmis-
sion flanges (3) to the front (5) and rear (6) axles
through the Cardan drive shafts (7 and 8).
. The driving power transmitted to the front (5) and
rear (6) axles is reduced by the differentials and
then transmitted to the planetary gear through the
differential shafts.
POWER TRAIN
10-2
WB97S-2
RKZ04450
1 2
3 4
5
6
8
7
Gears Transmission Differential Planetary Total
1
st
gear 4.374
2.75 6.923
83.273
2
nd
gear 2.436 46.377
3
rd
gear 1.232 23.455
4
th
gear 0.651 12.394
10-3
WB97S-2
4
10
RKZ04460
6
9
8
7
5
2
3
1
1. Diesel engine
2. Convertor
3. Transmission
4. Hydraulic pump
5. Front axle
6. Rear axle
7. Front Cardan drive shaft
8. Rear Cardan drive shaft
9. Rear wheels
10. Front wheels
Diagram of the power train
1. Engine
2. Convertor
3. Transmission
4. Hydraulic pump
5. Rear flange
6. Front flange
TRANSMISSION
10-4
WB97S-2
RKZ04470
1
2
3
4
6
5
Z=37
Z=27
Z=27 Z=37
Z=58
Z=17
Z=51
Z=59
Z=41
Z=30
Z=58
Z=44 Z=30
Z=45
1. 1
st
gear antishock valve
2. 1
st
gear filling pressure sensor (C08)
3. 1
st
gear clutch solenoid valve (C23)
4. 3
rd
gear filling pressure sensor (C10)
5. 3
rd
gear antishock valve
6. 3
rd
gear clutch solenoid valve (C25)
7. Forward clutch proportional solenoid valve (C22)
8. Reverse clutch proportional solenoid valve (C21)
9. 4
th
gear filling pressure sensor (C11)
10. 4
th
gear clutch solenoid valve (C26)
11. 4WD disengagement clutch solenoid valve (C27)
12. 2
nd
gear filling pressure sensor (C09)
13. 2
nd
gear antishock valve
14. 2
nd
gear clutch solenoid valve (C24)
15. Oil pressure sensor (alarm) (C07)
16. Control valve group
17. Delivery filter (10 mm)
18. Check valve: set 23 26 bar
19. Plug
20. By-pass filter valve: set 3.45 bar
21. Pressure control
22. Pump
23. Engine
24. Suction filter (250 mm)
25. Convertor pressurization valve: set 5.5 bar
26. Convertor
27. Exchange
28. Transmission oil temperature sensor
Hydraulic Convertor-Transmission Circuit Diagram
10-5
WB97S-2
RKZ03030
13
12
11
10
8
7
6
3
1 2
4
5
28
26
27
23
23
23
24
25
21
20
17
16
15
14
18
19

3
,
5
Albero lato posteriore
Albero conduttore
Albero comando
trasmissione
9
Rear shaft
Drive shaft
Transmission shaft
a. From the oil cooler
b. To the oil cooler
c. To the solenoid valve group ST1 (Port P)
d. From the solenoid valve group ST1 (Port T)
1. Control valve group
2. Convertor
3. Filter
4. Plug
5. Plug
6. Suction filter
7. Oil temperature sensor (C16)
8. 4
th
gear filling pressure sensor (C11)
9. 1
st
gear filling pressure sensor (C08)
10. Speedmeter sensor (C02)
11. 3
rd
gear filling pressure sensor (C10)
12. 2
nd
gear filling pressure sensor (C09)
TRANSMISSION
Views
10-6
WB97S-2
RKZ04250
Vista X
A
7
A
1 2
8
X
3
B
12
11
10
B
6
5 9
a
b c
d
4
View X
1. Hydraulic pump drive shaft
2. Propeller shaft
3. Reverse gears idler shaft
4. Drive shaft
5. Driven shaft
6. Flange
7. Rear output shaft
8. Front output shaft
9. 4WD engagement device
10. Flange
10-7
WB97S-2
RKZ04270
1
2 3
4
5
7
6
9
Sezione A - A
10
8
Section AA
Drive shaft for forward and reverse movement
Drive shaft
DRIVE SHAFTS
10-8
WB97S-2
RKZ03070
1
a
5
2
b c
3 4
6
RKZ03090
1
a
2
3
5
4
a. Port commanding reverse clutch
b. Port commanding forward clutch
c. Lubrication port
1. Reverse gear clutch (Z=37)
2. Forward gear clutch (Z=37)
3. Reverse clutch piston
4. Forward clutch piston
5. Thrust ring
6. Driven shaft
a. Drive gear for 2
nd
gear
1. Drive gear 3
rd
gear (Z=45)
2. Drive gear 2
nd
gear (Z=30)
3. Drive gear 4
th
gear (Z=58)
4. Drive gear 1
st
gear (Z=17)
5. Control piston 2
nd
gear
Driven gear shaft
Front shaft and 4WD
10-9
WB97S-2
RKZ04280
1
a
c
6
8
b
2
3
4
5
7
9
RKZ04290
1
6
a
2
3
5
4
a. Port commanding 4
th
gear
b. Port commanding 3
rd
gear
c. Port commanding 1
st
gear
1. Driven gear for 3
rd
gear (Z=44)
2. Driven gear for 2
nd
gear (Z=58)
3. Driven gear for 4
th
gear (Z=30)
4. Drive gear for 4WD (Z=51)
5. Driven gear for 1
st
gear (Z=59)
6. Control piston 1
st
gear
7. Control piston 4
th
gear
8. Control piston 3
rd
gear
9. Speedmeter disc
a. 4WD disengagement command port
1. Front output shaft
2. 4WD disengagement command piston
3. 4WD driven gear
4. Rear output shaft
5. Piston (No. 3)
6. Spring
CONTROL VALVE BLOCK
10-10
WB97S-2
ELECTRICAL COMPONENT
1. C24 - 2
nd
gear clutch solenoid valve
2. C27 - 4WD disengagement clutch solenoid valve
3. C26 - 4
th
gear clutch solenoid valve
4. C21 - Reverse clutch proportional solenoid valve
5. C22 - Forward clutch proportional solenoid valve
6. C25 - 3
rd
gear clutch solenoid valve
7. C23 - 1
st
gear clutch solenoid valve
8. C07 - Oil pressure sensor (alarm)
CHECK POINT
a. 2
nd
gear pressure
b. Torque converter pressure
c. 4WD disengagement pressure
d. 4
th
gear pressure
e. General oil clucth pressure
f. Reverse clucth pressure
g. Forward clucth pressure
h. 3
rd
gear pressure
l. 1
st
gear pressure
RKZ03100
b
7 6 5 4 3 2 1
8
e f
g
a c d h l
10-11
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
1. Planetary gear
2. Ring bevel gear (Z=31)
3. Bevel gear
4. Lock nut
5. Half-axle
6. Pin
7. Differential housing
8. Spacer
9. Bearing
10. Seal
11. Flange
12. Lock nut
13. Bearing
14. Bevel pinion (Z=13)
15. Pin
16. Oil drain plug
FRONT AXLE
Differential
10-12
WB97S-2
RKZ04260
2
1
3
1
4
5
6
7
8
9
10 11
12
13
14
15
16
1. Planetary carrier
2. Planetary
3. Ring gear
4. Ring gear carrier
5. Wheel hub
6. Seal
7. Pin
8. Shim
9. Protection
10. Bushing
11. Seal
12. Axle body
13. Bearing
14. Joint
15. Pin
16. Protection
17. Seal
18. Bearing
19. Snap ring
20. Steady pin
21. Stud bolt
22. Plug
Final reduction-Joint
10-13
WB97S-2
RKZ04300
2
3
21 4 5
6
9
8
10
11
7
12
13
14
14
16 17 18 19 20
22
1
1. Steady pin
2. Oil refilling plug
3. Oil drain plug
4. Nut
5. Adjustment screw
6. Nut
7. Bushing
8. Bushing
Port a - From the steering unit (Port L)
Port b - From the steering unit (Port R)
Steering cylinder
10-14
WB97S-2
RKZ04380
A
7
8
A
A
a b
B
B
4
Sezione A - A
1
2 3
5
6
Particolare A Sezione B - B
Section AA Section BB Detail A
1. Bearing
2. Planetary gear
3. Bevel gear
4. Ring bevel gear
5. Differential housing
6. Lock nut
7. Half-axle
8. Pin
9. Bearing
10. Lock nut
11. Seal
12. Flange
13. Spacer
14. Bevel pinion (Z=13)
15. Differential housing
16. Friction disc
17. Steel disc
REAR AXLE
Differential
10-15
WB97S-2
RKZ04400
1 2 3 4 5 6
7 7
8
9
10
12
11
13
14
15 17 16
1. Support
2. Planetary gear
3. Crown
4. Support
5. Hub
6. Gasket
7. Pin
8. Washer
9. Protection
10. Bushing
11. Gasket
12. Axle body
13. Bearing
14. Joint
15. Pin
16. Protection
17. Gasket
18. Bearing
19. Ring
20. Centering pin
21. Stud
22. Plug
Final Reduction
10-16
WB97S-2
RKZ04410
2
3
21 4 5
6 9 8
10
11
12
13
14
14
16 17 18 19 20
22
1
7
1. Spring
2. Bushing
3. Parking brake control rod
4. Bleeder valve
5. Parking brake lever
6. Parking brake control cam
7. Brake disk
8. Bushing
9. Service brake piston
10. Pressure disk
11. Center reaction plate
12. Spacer
Brakes
10-17
WB97S-2
RKZ04420
2
3 1
A
4 5
6
10 11 7
12 8
9
Particolare A
Detail A
1. Steering cylinder
2. Nut
3. Screw
4. Nut
c Port - From ST2 solenoid valve group (A port)
d Port - From ST2 solenoid valve group (B port)
e Port - From brake pump
Steering cylinder
10-18
WB97S-2
RKZ04440
A
A
A
c d
e e
2
Sezione A - A
1
3
4
Particolare A
Section AA
Detail A
1. Engine
2. Pump (P2)
3. Tank
4 Priority valve
5. Control valve
6. Steering unit
7. Steering wheel
8. ST2 Solenoid valve group:
Y1: Rear steering cut out
Y2: Front/rear steering
Y3: Phase coincidence steering
Y4: Crab steering
9. Front axle steering cylinder
10. Rear axle steering cylinder
DESCRIPTION
. The steering system is completely hydraulic. The
oil required, supplied by the pump (2) driven by
the motor (1), is sent to the priority valve (4) which
functions by Load Sensing, and sends the neces-
sary quantity of oil to the steering system (6), even
when other oleodynamic components supplied by
the same circuit are in operation. The oil passes
from this group (6) into the steering cylinders (9)
and (10).
The solenoid valve group (8) can switch the oil flow
to provide three types of steering:
1 - 2 wheels steering
Steering condition in which the rear axle is ex-
cluded.
2 - 2 wheels steering and 2 wheels counter-
steering. Steering condition in which rear
steering is activated and the direction of the
rear wheels is contrary to that of the front
wheels.
3 - 4 wheels steering in the same direction.
Steering condition in which rear axle steering
is activated and the direction of the rear
wheels agrees with that of the front wheels.
. The hydraulic power supplied by the pump (2) is
transferred to cylinders (9) and (10) and transfor-
med into mechanical steering power.
STEERING SYSTEM (4WS)
10-19
WB97S-2
9
b
a
B
A
P T
5
7
6
Y2
L R
T
Y4
Y3 Y1
8
B
A
c
d
C
D
10
RKZ04480
DLS
3
2
4
1
P
STEERING TO THE RIGHT
Turning the steering wheel (7) clockwise causes rota-
tion of the steering metering group (6) and prepares
the control valve (port R) to send oil through line e di-
rectly into chamber b of the cylinder (9); the pressuri-
zed oil moves the piston which then steers the
wheels.
The oil in chamber a of cylinder (9) is impelled into line
f to solenoid valve group and thence into line g which
is coupled to the control valve of the steering group (6)
(port L); from the control valve the oil passes out of
Port T and drains into the tank (3).
STEERING TO THE LEFT
Turning the steering wheel (7) anti-clockwise causes
rotation of the steering metering group (6) and prepa-
res the control valve (port L) to send oil through line g
to solenoid valve group and thence through line f, into
chamber a of the cylinder (9); the pressurized oil mo-
ves the piston which then steers the wheels.
The oil in chamber b of cylinder (9) is impelled into line
e which is coupled to the control valve of the steering
group (5) (port R); from the control valve the oil passes
out of Port T and drains into the tank (3).
OPERATION
1 - Steering with front wheels, only.
10-20
WB97S-2
Y2
Y4 Y3
Y1
RKZ04490
9
A B
a
b
e
f
L
R P
T
7
4
6
3
2
5
g
Y2
Y4 Y3
Y1
RKZ04500
9 a
b
e
f
L
R P
T
7
4
6
3
2
5
g
A B
STEERING TO THE RIGHT
Turning the steering wheel (7) clockwise causes rota-
tion of the steering metering group (6) and prepares
the control valve (port R) to send oil through line e di-
rectly to chamber b of cylinder (9).
The pressurized oil moves the piston of cylinder (9)
which in turn steers the wheels while simultaneously
impelling the oil in chamber a (at the same pressure
as chamber b, through lines f - h into chamber d of cy-
linder (10).
The oil in chamber c of cylinder (9) is impelled through
lines i and g to the control valve of the steering group
(port L) from which it passes (port T) to drain into the
tank (3).
STEERING TO THE LEFT
Turning the steering wheel (7) anti-clockwise causes
rotation of the steering metering group (6) and prepa-
res the control valve (port L) to send oil (through line g)
to solenoid valve group and thence through line i into
chamber c of cylinder (10).
The pressurized oil moves the piston of the cylinder
(10) that steers the wheels and at the same time im-
pels the oil in chamber d (at the same pressure as
chamber c), through lines h and f into chamber a of
cylinder (9).
The oil in chamber b of cylinder (9) is impelled through
line e to the control valve of the steering group (port
R), from which it passes (port T) to drain into the tank
(3).
2 - Steering with 2 wheels steering and 2 wheels countersteering
10-21
WB97S-2
Y2
Y4 Y3
Y1
RKZ04510
9
A B
a
b
e
f
L
R P
T
7
4
6
3
2
5
g
D C
10
c d
h
i
Y2
Y4 Y3
Y1
RKZ04520
9
A B
a
b
e
f
L
R P
T
7
4
6
3
2
5
g
D C
10
c d
h
i
STEERING TO THE RIGHT
Turning the steering wheel (7) clockwise causes rota-
tion of the steering metering group (6) and prepares
the control valve (port R) to send oil through line e into
chamber b of cylinder (9).
The pressurized oil moves the piston of cylinder (9)
which in turn steers the wheels while simultaneously
impelling the oil in chamber a (at the same pressure
as chamber b) through lines f and i into chamber c
of cylinder (10).
The oil in chamber d of cylinder (10) is impelled
through lines h and g to the control valve of the stee-
ring group (5) (port L) from which it passes (port T) to
drain into the tank (3).
STEERING TO THE LEFT
Turning the steering wheel (7) anti-clockwise causes
rotation of the steering metering group (6) and prepa-
res the control valve (port L) to send oil (through line g)
to solenoid valve group and then through line h into
chamber d of cylinder (10).
The pressurized oil moves the piston of the cylinder
(10) that steers the wheels while simultaneously impel-
ling the oil in chamber c (at the same pressure as
chamber d) through lines i and f into chamber a of
the cylinder (9).
The oil in chamber b of cylinder (9) is sent through line
e to the control valve of the steering group (port R)
from which the oil passes (port T) to drain into the tank
(3).
3 - Steering with 4 wheels steering in the same direction
10-22
WB97S-2
Y2
Y4 Y3
Y1
RKZ04530
9
A B
a
b
e
f
L
R P
T
7
4
6
3
2
5
g
D C
10
c d
h
i
Y2
Y4 Y3
Y1
RKZ04540
9
A B
a
b
e
f
L
R P
T
7
4
6
3
2
5
g
D C
10
c d
h
i
a. Port L - To the steering cylinder (Port a)
b. Port R - To the steering cylinder (Port b)
c. Port T - To the hydraulic oil tank
d. Port P - From control valve (Port D)
e. Port LS - From control valve (Port DLS)
TECHNICAL DATA
Steering unit type: OSPC160LS
Delivery: 16 ,/min
OPERATION
. The steering unit is composed of a control valve
and a rotating oil dispenser, and is of the hydrosta-
tic type.
. When the steering wheel is turned, the control val-
ve sends oil from the pump P2 (by means of the ro-
tating oil dispenser) of the steering cylinder. The ro-
tating dispenser ensures that the volume of oil sup-
plied to the cylinder is proportionate to the angle of
rotation of the steering wheel.
. In the event of malfunction, the oil dispenser will
function automatically as a hand-pump, thus gua-
ranteeing emergency steering.
STEERING UNIT
10-23
WB97S-2
RKP03740
L
T
R
P
LS
a e b
c
d
1. Delivery variation group
2. Working mode selection solenoid valve (Y1)
3. Delivery control valve
a. Port L1 - To the intake flange (Spool Port)
b. Port B - To the shovel control valve (Port P)
c. Port X2 - From the shovel control valve
(Port LS)
d. Port L - To the hydraulic oil tank
e. Port S - To the hydraulic oil tank
HYDRAULIC PUMP
10-24
WB97S-2
3 A
A
B B
D
RKZ00401
b
e
a
c
d
D
2
1
1. Seal
2. Bearing
3. Central spring
4. Bearing
5. Control rod
6. Swash plate
7. Positioning piston
8. Spring
9. Cylinder block
10. Positioning piston
11. Piston
12. Guide shoe
10-25
WB97S-2
RKZ00380
10
11 12
7 8 9
6
2
1
5
4
3
C C
Sezione B - B
Sezione A - A
Section AA
Section BB
POWER GOVERNOR
1. Spring
2. Piston rod
3. Bushing
4. Initial adjustment spring
5. Spring
6. Pressure cut calibration screw
7. Initial adjustment calibration screw
PC VALVE
8. Spool
9. Spring (internal)
10. Spring (external)
LS VALVE
11. External spring
12. Internal spring
13. Throttles
14. Throttles
15. Spool
10-26
WB97S-2
RKZ00640
Sezione C - C
Sezione D - D
1
4
6
5
11 12 13
14
15
3
10
7
9 8
2
Section CC
Section DD
FUNCTION
. The rotation and torque transmitted to the pump
shaft is converted into hydraulic energy and pres-
surized oil is delivered according to the load requi-
rements.
. The amount of oil delivered can be modified by
changing the angle of the swash plate.
STRUCTURE
. The cylinder block (6) is supported and connected
to the shaft (1) by the spline a and the shaft (1) is
supported by the front and rear bearings.
. The tip of the piston (6) is ball-shaped. The shoe (4)
is caulked to it to form one unit in such a way that
the piston (5) and the shoe (4) together form a sphe-
rical bearing.
. The swash plate (3) has a flat surface A and the
shoe (4) remains pressed against this surface while
sliding in a circular movement.
The swash plate brings highly pressurized oil onto
the cylindrical surface B fashioned in the pump bo-
dy (2), which means that the swash plate (3) slides
on a hydrostatically-supported bearing.
. The pistons (5) perform their relative movements in
an axial direction, inside cylindrical chambers fas-
hioned in the cylinder block (6).
. The oil is brought up to pressure in the chambers of
the cylinder block (6) by the rotatory movement of
the block itself. The areas of pressure and suction
are determined by the swash plate (7).
The surface of the swash plate is so designed that
the oil pressure always remains within acceptable
limits.
The oil in each chamber is drawn in and discharged
through holes in the valve plate (7).
10-27
WB97S-2
RKZ01120
1
2 3 4 5 6 7
B A
a
OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the
shaft (1) and the shoe (4) slides on the flat sur-
face A. The swash plate (3) moves along the
cylindrical surface B. The angle a formed
between the center line of the shaft (1) and
the center line X of the swash plate (3) chan-
ges, thus modifying the axial position of the pi-
stons in relation to the cylinder block.
The angle a is known as the swash plate an-
gle.
2 - When the center line X of the swash plate (3)
maintains the angle a in relation to the cen-
ter line of the shaft (1), and hence also of the
cylinder block (6), the flat surface A acts as a
cam for the shoe (4). As the piston (5) rotates
and slides inside the cylinder block (6), it the-
refore creates a difference between the volu-
mes C and D which provokes intake and di-
scharge of the oil in quantities equal to the dif-
ference between the volumes (D C=delive-
ry).
In other words, as the cylinder block (6) rota-
tes, chamber D loses volume while the volume
of chamber C is increased, thus provoking an
intake of oil.
(The figure indicates the state of the pump
when the intake of chamber D and the delivery
of chamber C have been completed).
3 - When the center line X of the swash plate (3)
and the center line of the cylinder block (6)
are perfectly aligned (the swash plate angle
a=0), the difference between the volumes
C and D within the cylinder block (6) becomes
0 and the pump does not take in or deliver any
oil. (In practice the swash plate angle a ne-
ver becomes=0)
4 - In other words, pump delivery is directly pro-
portional to the swash plate angle a.
10-28
WB97S-2
RKZ01100
5 6 1
4
3 A D
B C

X
RKZ01110
2
5 D
C
X
= 0
2. Control of Delivery
. As the swash plate angle a grows larger, the
difference between volumes C and D increases,
and the delivery Q also increases.
The swash plate angle is modified by servo-pi-
stons (8) and (9).
. The servo-piston (8) moves in a reciprocating li-
near motion ( ) caused by pressure signals
from the PC and LS valves.
The linear movement is transmitted to the
swash plate (3), which is supported by the cylin-
drical surface of the cradle (7). The swash plate
therefore has a semi-circular reciprocating mo-
vement ( ).
. The surfaces of the servo-pistons receiving the
pressures PP and LS are dissimilar. The delive-
ry pressure PP of the main pump is always pas-
sed into the smaller (upper) pressure chamber,
whereas the pressure PEN coming from the LS
valve is passed into the larger (lower) pressure
chamber.
The movement of the servo-piston is governed
by the relationship between pressures PP and
PEN, as well by the proportions between the sur-
faces (larger and smaller) of the servo-piston.
10-29
WB97S-2
RKZ01130
C
2 3
8
D

9
SERVO-PISTON
1. Spring
2. Servo-piston
3. Servo-piston
LS VALVE
4. Piston
5. Spring
PC VALVE
6. Servo-piston
7. Spring
2. PC VALVE, LS VALVE SERVO-PISTON
10-30
WB97S-2
RKZ01140
Distributore
4
6
5
7
1
3
2
All'utilizzo
Control valve
To the actuator
LS VALVE
FUNCTION
. The LS valve controls the pump delivery according
to the stroke of the control valve level, i.e., in func-
tion of the delivery demands made by the actua-
tors.
. The LS valve detects the actuator's delivery needs
by means of the differential pressure DPLS existing
between the pump delivery pressure PP and the
pressure PLS coming from the control valve. This
reading permits control of the main pump delivery
Q.
(PP, PLS and DPLS are, respectively, the pump
pressure, the Load Sensing pressure, and the diffe-
rence in pressure between these two values).
. In other words, the LS valve detects the pressure
difference DPLS generated by the passage of the
oil flow through the surface freed by the control val-
ve spool, and controls the pump delivery Q so as to
keep the pressure drop constant.
. It can therefore be assumed that the pump delivery
is proportional to the demands made known by the
control valve.
10-31
WB97S-2
. The pressure PLS of the LS coming from the control
valve outlet passes into chamber a of the spring of
the LS valve. The pressure PP of the pump passes
into chamber b of the opposite side.
. The piston rod movement (4) is determined by the
combination of the force generated by the pressure
PLS, the force of the spring (6) and the force gene-
rated on the side opposite the piston rod by the
pressure PP.
. Before the engine is started the servo-piston (3) is
pushed to the right by the spring (1) (corresponding
to the maximum angle of the swash plate).
. If all the control valve spools are in their NEU-
TRAL position when the engine is started, the
pressure PLS of the LS will remain at 0 bar (0 bar)
because no oil is flowing through the control valve.
At the same time the pump pressure PP increases
and is maintained at a value of about 21 bar (21.3
kg/cm
2
).
. For this reason the piston (4) is thrust to the right
( ) and a passage is formed between the delivery
lines c and d. This opening enables the pump pres-
sure PP to enter chamber X of the servo-piston (3).
. Although the pump pressure PP is always passed
into chamber Y of the servo-piston (2), since the for-
ce exerted by that pressure on piston (3) exceeds
the force exerted on piston (2), the servo-piston
(1) moves to the right ( ), i.e. towards the side
of the minimum angle of the swash plate.
OPERATION
1. When the control valve is in a NEUTRAL position.
10-32
WB97S-2
RKZ01150
All'utilizzo
T PLS
PP
PP
Min Max
Distributore
c
4
b
d
a
6
1
2
3
Y
X
M
To the actuator
Control valve
2. When a control valve lever is activated
. When the control valve lever is moved out of its
NEUTRAL position, the opening f is determined, al-
lowing an LS signal to be generated.
. Until the DPLS generates a force less than the force
exerted by the spring (6) on the spool (4), the sy-
stem will remain stable.
When the opening f is such as to provoke a reduc-
tion in DPLS, the spool (4) moves to the left ( ) to
form a passage between delivery lines d and e. The
chamber X loses pressure and the servo-piston
causes the swash plate to move towards maximum
displacement.
. Equilibrium is re-established in the system when
the pressure DPLS generates on the spool (4) the
difference in force exerted by the spring (6), and
the passage between delivery lines c and d is re-
opened.
10-33
WB97S-2
RKZ01160
c
4
b
d
a
6
1
2
3
Y
X
PP
M
Min Max
T
PLS
PP
e
All'utilizzo
Distributore
To the actuator
Control valve
3. When the control valve opening is at its maximum (lever at the end of its stroke)
. When the control lever is moved to full stroke, in
other words, when the spool opening reaches its
maximum, the difference between the pump pres-
sure PP and the LS pressure PLS becomes smaller
(differential pressure DPLS).
. The LS pressure PLS introduced into the chamber a
of the LS valve becomes about the same as the
pump pressure PP and the piston (4) is moved to
the left ( ) by the combined forces generated
by the pressure PLS and the spring (6).
The piston movement closes the delivery line c and
forms a passage between lines d and e.
. The pressurized oil present in the chamber X of the
servo-cylinder (3) flows through the lines d and e
and reaches the pump drainage chamber, so that
the pressure in chamber X of the servo-cylinder
(1) becomes equal to the drainage pressure.
. The servo-piston (3) is thus moved to the right ( )
by swash plate movement due to the pressure PP in
the chamber Y of the servo-cylinder (2).
In other words, it is drawn in the direction of the in-
crease in angle of the swash plate.
10-34
WB97S-2
RKZ01160
c
4
b
d
a
6
1
2
3
Y
X
PP
M
Min Max
T
PLS
PP
e
All'utilizzo
Distributore
To the actuator
Control valve
4. When the spool makes very small movements (fine-control)
. When the control valve lever moves in very small
increments towards the NEUTRAL position, i.e.
when the control valve opening f diminishes, the
differential pressure DPLS between the pump pres-
sure PP and the LS pressure PLS increases.
. If the differential pressure DPLS generates on the
spool (4) a difference in force that exceeds the for-
ce exerted by the spring (6), the spool moves to the
right ( ) and a passage is formed between the de-
livery lines c and d. The pressure PP is introduced
into the chamber X and the swash plate moves to-
wards its minimum angle.
. When the control valve lever performs small move-
ments towards the position of maximum opening,
i.e. when the opening f of the control valve increa-
ses, the differential pressure DPLS diminishes.
. If the differential pressure DPLS generates on the
spool (4) a force difference that does not exceed
the force exerted by the spring (6), the spool (4) mo-
ves to the left ( ) and a passage is formed bet-
ween the delivery lines d and e.
The chamber X loses pressure and the servo-piston
provokes a movement of the swash plate towards
maximum displacement.
. Equilibrium is re-established in the system when
the pressure DPLS generates on the spool (4) the
difference in force exerted by the spring (6), and
hence the passage between delivery lines c and
d is also re-opened.
10-35
WB97S-2
RKZ01170
c
4
b
d
a
6
1
2
3
Y
X
PP
M
Min Max
T
PLS
PP
e
All'utilizzo
Distributore
f
To the actuator
Control valve
5. When pump flow matches the demands of the control valve
. Let A1 be the surface of the servo-piston (3), A2 the
surface of the servo-piston (2), PEN the pressure ac-
ting on the piston (1) and PP the pressure acting on
the piston side (2).
. When pump delivery reaches the quantity deman-
ded by the control valve, the pump pressure PP in
chamber b of the LS valve is in equilibrium with
the combined forces of the LS pressure PLS in
chamber a, and the force exerted by the spring (6).
Once equilibrium has been reached the piston (4)
stops in the central position.
. In this condition the passage from chamber c to
chamber d remains only slightly open in order to
maintain pressure in chamber d.
A flow of oil is introduced into the servo-cylinder (3)
at a pressure that balances the force generated by
the pump pressure PP in the cylinder (2)
(PEN x A1=PP x A2).
. The stability of the equilibrium is guaranteed by a
flow stabilized by the throttle g.
. The force of the spring (6) is regulated so that the
piston (4) is in equilibrium when
PP PLS=DPLS=18 bar (18.4 kg/cm
2
).
. In practice, the pump flow is made proportional to
the section of the opening of the control valve,
which maintains the differential pressure
DPLS=18 bar (18.4 kg/cm
2
).
10-36
WB97S-2
RKZ01180
A1
A2
c
4
b
d
a 6
1
2
3
Y
X
PP
M
Fermo
T
PLS PP
e
PEN
PP
All'utilizzo
g
Distributore
To the actuator
Control valve
Hold
PC VALVE
FUNCTION
. The PC valve performs an approximate power
check, and ensures that the hydraulic horse-power
absorbed by the pump does not exceed the horse-
power delivered by the endothermal engine.
This is achieved by limiting the pump delivery Q in
function of the delivery pressure PP, even if the LS
valve requests an increase in delivery Q due to the
larger section freed by the control valve spool, in
the presence of high pressure pump delivery.
. In other words, when during operation the delivery
Q increases and the delivery pressure PP also in-
creases simultaneously, the PC valve reduces the
pump delivery Q. When the delivery pressure PP
decreases, the PC valve increases the pump flow.
. The relationships between the pump delivery pres-
sure PP and the delivery Q are shown in the dia-
gram.
10-37
WB97S-2
RKP01180
Pressione pompa
P
o
r
t
a
t
a

p
o
m
p
a

Q
PP
P
u
m
p
d
i
s
c
h
a
r
g
e
a
m
o
u
n
t
Q
Pump discharge pressure PP
OPERATION
1. When the load on the actuators is heavy (high pump delivery pressure)
. When a higher delivery is required, the LS valve re-
ceives a signal from the control valve to bring the
pump up to maximum displacement.
When the swash plate moves it also moves the bus-
hing (2) joined to it (by the pin (1)), which releases
the spring (3). As the pressure of the actuators in-
creases, pressure also increases in the delivery li-
ne c. When the calibrated setting of the spring (3)
is reached, the piston rod (4) is thrust to the left
( ) and the passage between chamber b and
the pump drainage chamber a is opened.
. The opening of the passage between the chambers
b and a generates a flow of oil and hence, due to
the calibrated hole (6), a DP is generated between
chambers f and g at the sides opposite the spool
(5). (DP=PP PPC)
. When the value of PP exceeds the value of the
spring loading (7) the spool (5) moves to the right
( ), opening the passage between the delivery li-
nes d and e and sending the pump pressure PP to-
wards the servo-cylinder (8).
. The pressure PP introduced into chamber X of the
cylinder (8) pushes it towards the minimum angle
of the swash plate ( ).
10-38
WB97S-2
RKZ01190
T
PEN
PP
LS
5
7
Max
PP
Min
M
PPC
PPC
p
6
f
e
d
g
3 a b 4
2 1
8 X
All'utilizzo
c
Distributore
To the actuator
Control valve
2. When equilibrium has been reached
. When the piston (8) is pushed to the left ( ) the
bushing (2) is also moved.
The oil flow between the chambers b and a is redu-
ced and the PPC pressure tends to approach the PP
pressure value.
The DP decreases and the spool (5) is pushed to
the left ( ) by the force of the spring (7).
. Equilibrium is reached when the force generated by
the PP pressure, the force generated by the PPC
pressure, and the force of the spring (7) are all ba-
lanced. (The force generated by PP=the force ge-
nerated by the PPC+ the spring force (7)).
. In this condition the passage from chamber d to
chamber e remains only slightly open in order to
maintain pressure in chamber e. A flow of oil is in-
troduced into the cylinder (8) at a pressure that ba-
lances the force generated by the pump pressure
PP acting on the cylinder (9). (PEN x A1=PP x A2)
. The stability of this equilibrium is generated by a
continuous stabilized flow from the throttle (10).
10-39
WB97S-2
RKZ01200
A1
A2
5
7
PP
Fermo
M
PPC
PPC
p
6
f
e
d
g
a b 4 2
8 X
PEN PP
LS
9
10
c
All'utilizzo
Distributore
To the actuator
Control valve
Hold
3. When the load on the actuators decreases (pump delivery pressure drops)
. When the load on the actuators diminishes and the
pump delivery pressure PP drops, the PPC. pressu-
re also drops.
. The reduction in the PPC causes the spool (4) to
move and the passage between chambers b, d
and a is closed.
The PPC pressure and the PP pressure of the pump
are equalised due to the interruption of the oil flow
through the calibrated hole (6) and hence the DP
becomes zero (DP=PP PPC=0).
. The spring (7) pushes the spool (5) to the left ( ),
closing the passage between the chambers d and e
and opening the passage between chambers e and g.
. The pressurized oil present in chamber X of the
servo-cylinder (8) passes through chambers e and
g and reaches the pump drainage chamber, so that
the pressure in chamber X of the servo-cylinder (7)
becomes equal to the drainage pressure.
. Therefore the servo-piston (7) is caused to move by
the PP pressure in chamber Y of the servo-cylinder
(9), i.e. in the direction of the increase in the angle
of the swash plate.
10-40
WB97S-2
RKZ01210
5
7
PP
Fermo
M
PPC
PPC
6
e
d
a b 4
8 X
PEN PP
LS
c
g
9 Y
All'utilizzo
Distributore
To the actuator
Control valve
Hold
4. The function of the spring
. The loading on the springs (3) and (11) of the PC
valve changes in proportion to the angle of inclina-
tion of the pump swash plate.
. The compression of the spring (3) varies with the
movements of the servo-piston (8).
. When the piston (8) moves to the left ( ) the
spring (3) is compressed.
If the piston (8) moves even further to the left ( ),
the spring (11) comes into action to increase the
loading.
In other words, the overall loading of the springs is
varied by the piston (8), which either compresses or
releases them.
. The pump absorption torque curve, which indicates
the relationship between the pump delivery pressu-
re PP and the delivery Q, is a broken line (as illu-
strated in the diagram).
10-41
WB97S-2
T
PLS PP
LS
RKZ01220
8
3 11 4
All'utilizzo
Distributore
M
To the actuator
Control valve
RKZ01240
Pressione pompa
P
o
r
t
a
t
a

p
o
m
p
a

Q
Molla (3) + molla (11)
Molla (3)
PP
P
u
m
p
d
i
s
c
h
a
r
g
e
a
m
o
u
n
t
Q
Pump discharge pressure PP
Spring (3)+spring (11)
Spring (3)
. The position in which the piston (8) stops, i.e. the
pump absorption torque, is determined by the posi-
tion in which the PPC pressure applied to the spool
(4) is balanced by the force exerted by the springs
(3) and (11).
. In practice, as the pump delivery pressure PP in-
creases, the delivery Q decreases, and as the pres-
sure PP diminishes the pump delivery Q increases.
10-42
WB97S-2
WORKING MODE SOLENOID VALVE
FUNCTION
. Calibration of the pump absorption torque is nor-
mally performed for the working mode E.
When the solenoid valve of the working mode is
commutated the absorbed power of the pump is in-
creased, as indicated by the working mode curve.
OPERATION
1. WORKING MODE E (Economy)
. During normal operation (Working mode E), the PC
valve intervenes when a DP1 is generated equal to
the loading on the spring (4).
. The DP1 is generated by the calibrated hole (3) in
the spool of the PC valve (2) when, at a determined
pump delivery pressure P1, the valve (1) puts the
delivery line a into discharge, thus generating a
flow F1 in the delivery line a.
10-43
WB97S-2
RKZ01250
P
o
r
t
a
t
a

p
o
m
p
a

Q
Pressione pompa PP
Working mode P
Working mode E
P
u
m
p
d
i
s
c
h
a
r
g
e
a
m
o
u
n
t
Q
Pump discharge pressure PP
RKZ01230
P1
a
3
4
2
5
1
6
2. WORKING MODE P (Power)
. When the solenoid valve (6) is commutated (Wor-
king Mode P) the pressurized oil coming from the
pump changes its route and passes through the
throttle (5), which has a larger diameter than the ca-
librated hole (3).
. Because the throttle (5) has a larger diameter, the
DP2 generated is less than is needed to overcome
the force generated by the spring (4). The spool
of the PC valve (2) is therefore pushed to the left
( ) by the force of the spring (4).
. This shift obliges the pump to increase displace-
ment and hence the delivery (See PC VALVE: 3.
When the load on the actuators decreases third
paragraph).
. The increase in flow causes an increment of the
DP2 which, when the loading value of the spring
is reached, allows the spool to shift to the right
( ).
. The pump starts to work in normal fashion once
again, and all the valves recommence normal func-
tioning.
10-44
WB97S-2
RKZ01320
P2
3
4
2
5
1
6
HYDRAULIC CIRCUIT
10-45
WB97S-2
S L1 L
B
X1 X2
Arm Bucket
DLS
T P
Hammer Arm Boom swing L.H. outrigger Bucket Boom
Additional
equipment
L R
RKZ04561
Rear axle
Solenoid valve
group ST2
R.H. outrigger Jig arm
Front axle
Y1
Y2
Y3
Y4
P
T
B
A
21
bar
245
bar
235
bar
240
bar
5 bar
5 bar
230
bar
-5
0
200
bar
DLS
P
T
LS D
B1 A1 B2 A2 B3 A3
b
a
b
a a
T B A T T B A T
b
A8 B8 A7 B7
B T
A B T T
b
a
b
a
b
a
A6 B6
A
B
T
T
A5 B5
b
a
A4 B4 A3 B3
b
a
b
a
A B T T A T
A2 B2
b
a
A1 B1
b
a
A T
LS1 M P2 T1
P T
LS T
T2
C
230
bar
235
bar
175
bar
240
bar
175
bar
305
bar
235
bar
245
bar
235
bar
165
bar
A B
D C
o
SHOVEL CONTROL VALVE
2-Spool
10-46
WB97S-2
1 2
b
e
f
A
A
C
C
D
D
a
B
B
RKZ01080
g
h
c d
Sezione A - A
Sezione B - B
6
4
5
3
Section AA
Section BB
a. Port D - To the hydraulic steering unit (Port P)
b. Port A2 - To the bucket cylinders (Head side)
c. Port A1 - To the shovel-raising cylinders
(Base side)
d. Port LS - To the pump (Port X2)
e. Port T - To the hydraulic oil tank
f. Port P - From the pump (Port B)
g. Port B1 - To the shovel-raising cylinders
(Head side)
h. Port B2 - To the bucket cylinders (Base side)
1. Plug
2. Plug
3. Ball
4. Spring
5. Priority valve piston rod
6. Priority valve spring
1. Plug
2. Raising command spool
3. Spool return spring
4. Compensator
5. Antishock/anticavitation valve
6. Bucket dump command spool
7. Spring
8. Check valve
10-47
WB97S-2
6
5
5
RKZ00660
Sezione C - C
Sezione D - D
E
E
Sezione E - E
E
E
4
1
3
2
3
4
7
8
8
7
Section CC
Section DD
Section EE
a. Port D - To the hydraulic steering unit (Port P)
b. Port A3 - To the auxiliary equipment (Left side)
c. Port A2 - To the bucket cylinders (Head side)
d. Port A1 - To the shovel-raising cylinders
(Base side)
e. Port LS - To the pump (Port X2)
f. Port T - To the hydraulic oil tank
g. Port P - From the pump (Port B)
h. Port B1 - To the shovel-raising cylinders
(Head side)
i. Port B2 - To the bucket cylinders (Base side)
l. Port B3 - To the auxiliary equipment
(Right side)
1. Plug
2. Plug
3. Ball
4. Spring
5. Priority valve piston rod
6. Priority valve spring
7. Plug
3-Spool control valve
10-48
WB97S-2
1 2
a c
f
g
A
A
B
C
C
D
D
B
b
E
E
RKZ01070
h
i
Sezione A - A
Sezione B - B
d e
l
6
4
5
3
7
Section AA
Section BB
1. Plug
2. Raising command spool
3. Spool return spring
4. Spring
5. Ball
6. Ball
7. Compensator
8. Antishock/anticavitation valve
9. Bucket dump command spool
10. Spool return spring
11. Optional equipment command spool
12. Spring
13. Check valve
10-49
WB97S-2
8
9
2
1
1
8
8
8
7
15
15
F
RKZ00691
Sezione C - C
Sezione D - D
F
F
Sezione F - F
Sezione E - E
F
F
11
10
7
5
6
3
4
14
14
7
12
13
F
Section CC
Section DD
Section EE
Section FF
a. Port D - To the hydraulic steering unit (Port P)
b. Port A3 - To the auxiliary equipment (Left side)
c. Port A2 - To the bucket cylinders (Head side)
d. Port A1 - To the shovel-raising cylinders
(Base side)
e. Port LS - To the pump (Port X2)
f. Port T - To the hydraulic oil tank
g. Port P - From the pump (Port B)
h. Port B1 - To the shovel-raising cylinders
(Head side)
i. Port B2 - To the bucket cylinders (Base side)
l. Port B3 - To the auxiliary equipment
(Right side)
1. Plug
2. Plug
3. Ball
4. Spring
5. Priority valve piston rod
6. Priority valve spring
7. Plug
3-spool control valve (with return to dig)
10-50
WB97S-2
1
2
a
c
f
g
A
A
C
C
D
D
b
E
E
B
B
RKZ01090
h
i
d e
l
Sezione A - A
Sezione B - B
6
4
5
3
7
Section AA
Section BB
1. Plug
2. Raising command spool
3. Spool return spring
4. Spring
5. Ball
6. Ball
7. Compensator
8. Antishock/anticavitation valve
9. Bucket dump command spool
10. Spool return spring
11. Coil
12. Optional equipment command spool
13. Spring
14. Check valve
10-51
WB97S-2
8
9
2
1
1
8
8
8
7
15
15
F
RKZ00691
Sezione C - C
Sezione D - D
F
F
Sezione F - F
Sezione E - E
F
F
11
10
7
5
6
3
4
14
14
7
12
13
F
Section CC
Section DD
Section EE
Section FF
a. Port P - From the pump (Port B)
b. Port T - To the hydraulic oil tank
c. Port B1 - To the arm cylinder (Base side)
d. Port B2 - To the arm LH swing cylinder
(Base side)
e. Port B3 - To the RH outrigger cylinder
(Base side)
f. Port B4 - To the LH outrigger cylinder
(Base side)
g. Port B5 - To the bucket cylinder (Base side)
h. Port B6 - To the boom cylinder (Head side)
i. Port C - To the backhoe backframe lock
cylinders
l. Port A6 - To the boom cylinder (Base side)
m. Port A5 - To the bucket cylinder (Head side)
n. Port A4 - To the LH outrigger cylinder
(Head side)
o. Port A3 - To the RH outrigger cylinder
(Head side)
p. Port A2 - To the RH boom swing cylinder
(Base side)
q. Port A1 - To the arm cylinder (Head side)
r. Port T1 - To the hydraulic oil tank
s. Port LS - To the pump (Port X2)
BACKHOE CONTROL VALVE
6 Ports
10-52
WB97S-2
RKZ00230
Sezione A - A
Sezione B - B
1
2
3
4
5
6
3
A
A
B
B
C
C
D
D
D
D
E
E
F
F
L
H
H
L
G
G
c
q
i
l
a
d
e f g h
b
m n o p
r
s
Section AA
Section BB
1. Ball
2. Backhoe backframe lock solenoid valve
3. Antishock/anticavitation valve
4. Boom command spool
5. Spool return spring
6. Compensator
7. Bucket command spool
8. Anticavitation valve
9. Plug
10. Outrigger command spool
11. Boom swing command spool
12. Arm command spool
13. Spring
14. Check valve
10-53
WB97S-2
RKZ00760
Sezione C - C
Sezione D - D Sezione E - E
Sezione F - F
Sezione G - G
G
G
G
G
G
G
G
G
9
8
3
7
3
6
3
11
5
6
9
9
10
5
12
6
3
5
13
13 14
14
5
6
Section CC Section DD Section EE
Section FF
Section GG
10-54
WB97S-2
RKZ00790
Sezione H - H
Sezione L - L
4 5
2
3
1
Section HH
Section LL
1. Valve
2. Spring
3. Plug
4. Pressure cut-out valve
5. Unloading valve
10-55
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
a. Port B7 - To the jig arm cylinder (Base side)
b. Port A7 - To the jig arm cylinder (Head side)
c. Port B7 - To the side digging boom cylinder
(Base side)
d. Port A7 - To the side digging boom cylinder
(Head side)
e. Port B7 - To the hydraulic hammer (Left side)
7-spool control valve
10-56
WB97S-2
RKZ00240
a
b
A
A
For jig arm
RKZ00250
B
B
c
d
Side digging boom
RKZ00260
C
C
e
For Hammer
1. Anticavitation valve
2. Jig arm command spool
3. Spool return spring
4. Plug
5. Compensator
6. Anti-shock/anticavitation valve
7. Side digging boom command spool
8. Hammer command spool
10-57
WB97S-2
RKZ00960
Sezione B - B
Sezione C - C
Sezione A - A
4
6
4
5
6
7
3
8
5
6 3
5
1
2
3
Section AA
Section BB
Section CC
a. Port B7 - To the hydraulic hammer (L.H. side)
b. Port B8 - To the jig arm cylinder (Base side)
c. Port A8 - To the jig arm cylinder (Head side)
d. Port B7 - To the side digging boom cylinder
(Base side)
e. Port A7 - To the side digging boom cylinder
(Head side)
8-spool control valve
10-58
WB97S-2
RKZ00270
a b
c
For hammer and jig arm
RKZ00280
d
e
b
c
For side digging boom and jig arm
1. DESCRIPTION
CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has the following characteristics:
a) High precision control that is independent of the load applied to the movement;
b) High precision control of digging action even during delicate manoeuvres;
c) Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the
shuttles;
d) Energy savings guaranteed by control of pump delivery.
STRUCTURE
. The CLSS system includes the variable flow pump, the control valve and the working equipment.
. The pump includes the main pump, the TCC valve and the LS valve.
CLSS
10-59
WB97S-2
RKZ01710
Attrezzature di lavoro
Distributore
Valvola TCC
Valvola LS
Pistone di
controllo
PLS
PP
Pistone di
controllo
Attachment
Control valve
TCC Valve
LS Valve
Piston
Piston
2. OPERATING PRINCIPLES
1. Control of the angle of the pumping plate.
. The angle of the swash plate (and hence the pump delivery) is controlled in such a way that the differential pres-
sure DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve
towards the actuator is maintained at a constant value. (DPLS=pump delivery pressure PP pressure PLS of de-
livery to the actuator).
. If the differential pressure DPLS becomes lower than the set pressure of the LS valve, the angle of the swash
plate increases (delivery increasing).
If the differential pressure DPLS increases, the angle of the swash plate decreases.
H For details about this movement, see the description of the HYDRAULIC PUMP.
10-60
WB97S-2
Attrezzatura di lavoro
Distributore
Mandata pompa
Pistone di
posizionamento
POMPA
Pistone di
posizionamento
Valvola TCC
Valvola LS
Alta
pressione
Alta
pressione
RKZ01720
Attachment
Control valve
Pump delivery
Piston
PUMP
Piston
TCC Valve
High
pressure
LS Valve
High
pressure
2. Pressure compensation control
. The pressure compensation valves are installed downstream from the control valve in order to balance the dif-
ferential pressure between the loads..
When two or more movements (cylinders) are activated simultaneously, the pressure differences DP between the
delivery at the control valve inlet and outlets of the control valve are compensated by these valves.
We obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
10-61
WB97S-2
Carico
Utilizzo Utilizzo
Carico
Compensatore Compensatore
S1 S2
POMPA
P
P
RKZ01730
Load
Actuator
Load
Actuator
Pressure
compensation
valve
Pressure
compensation
valve
PUMP
3. Unloading valve
FUNCTION
1. When the control valve is in NEUTRAL position, the flow Q of the pump (due to the swash plate being in the
minimum angle position) is sent to the control valve.
In these conditions, the pump delivery pressure PP is regulated to 21 bar (21.4 kg/cm
2
) by the spring (2) inside
the valve.
(LS signal with pressure PLS=0 bar (0 kg/cm
2
))
OPERATION
When the control valve is in NEUTRAL position.
. On the two surfaces of the shuttle (1), the pump
pressure PP acts on the right-hand side, while the
LS signal with pressure PLS acts on the left-hand si-
de.
. Because no LS signal is generated with a pressure
PLS, when the control valve is in NEUTRAL posi-
tion, only the pump delivery pressure PP regulated
by the compression of the spring (2), acts on the
shuttle (1).
. While the pump delivery pressure PP increases un-
til it compensates for the loading on the spring (2)
(21 bar (21.4 kg/cm
2
)), the shuttle (1) moves to
the left ( ) and the PP circuit is put into communi-
cation with the tank circuit T.
. This system ensures that the pump delivery pressu-
re PP stays regulated at 21 bar (21.4 kg/cm
2
).
10-62
WB97S-2
RKZ01740
1 2
PLS
T
PP
2. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less
than the delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is re-
gulated by the pressure PLS+21 bar (21.4 kg/cm
2
).
Because the unloading valve opens when the differential pressure between the pump delivery pressure PP and
the PLS LS pressure becomes equivalent to the loading of the spring (2) (21 bar (21.4 kg/cm
2
)), the differential LS
pressure DPLS del LS becomes 21 bar (21.4 kg/cm
2
).
OPERATION
Final control of control valve
. When final control are performed with the control
valve, a pressure PLS is generated that pressurizing
the spring chamber, acts on the left-hand extremity
of the valve (1).
The actuator pressure is introduced into the LS cir-
cuit and then into the spring chamber.
As a result, the pump pressure PP tends to increa-
se.
. When the differential pressure between the pump
delivery pressure PP and the LS pressure PLS has
the same value as the loading on the spring (2)
(21 bar (21.4 kg/cm
2
)), the shuttle (1) moves to
the left ( ) and the pump circuit PP puts itself into
communication with the tank circuit T.
Consequently the exceeding pump delivery Q, rela-
tive to the actuator request, is sent to the tank cir-
cuit.
. The pump delivery pressure PP is regulated by the
combination of the pressure provided by the spring
(21 bar (21.4 kg/cm
2
)) and by the LS pressure PLS,
i.e. when the pressure differential DPLS reaches the
value of 21 bar (21.4 kg/cm
2
).
10-63
WB97S-2
RKZ01750
1 2
PLS
T
PP
3. When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the
control valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the ac-
tuators.
OPERATION
When the control valve is in use
. When the control valve shuttle is operated to exe-
cute a bigger stroke, the opening section of spool
becomes bigger and consequently the controlled
delivery.
Because the control valve passage is large, the dif-
ference between the LS pressure PLS and the pump
delivery pressure PP is reduced up to 16 bar (16.3
kg/cm
2
) (LS pump valve setting).
. Because the differential pressure between the
pump delivery pressure PP and the LS pressure
PLS is not equal to the pressure given by the spring
loading (2) (21 bar (21.4 kg/cm
2
)), the shuttle (1) is
pushed to the right ( ) of the spring (2).
. The result is that the connection between the pump
delivery circuit PP and the tank circuit T is excluded
and the entire pump delivery Q is sent to the actua-
tors.
10-64
WB97S-2
RKZ01760
1 2
PLS
T
PP
4. Introduction of the LS pressure
. The LS pressure is the pressure generated by external forces acting on the actuators at the outlet of the control
valve.
OPERATION
. When the shuttle (1) is activated, the pump
pressure PP starts to flow into the actuator cir-
cuit A through the duct b.
. At the same time the compensator (2) moves
upwards ( ) so that the flow controlled by spool
(1) can flow towards the actuator A.
Check valve (4) do not allow any flow up to when
pressure in chamber c is higher than pressure
in chamber b.
Pressure downstream spool (1) flows in the PLS
circuit downstream the compensator valve
throught the orifice d.
. The PLS circuit of the LS is thus in communica-
tion with the tank circuit T by means of the LS
decompression valve (3). (See the description
of the LS decompression valve).
. The system stabilizes when a pressure differen-
ce of 18 bar (18.3 kg/cm
2
) is generated across
the shuttle (1) between pump pressure PP and
PLS pressure.
10-65
WB97S-2
RKZ01780
2
3
A
b
PP
1
Alla pompa
4
c
d
To the pump
INTRODUCTION
The flow sent to each actuator is controlled by the opening area of each spool.
While performing complex control, in traditional control valves the difference between actuators pressure might cau-
se sudden and unexpected movements acceleration in those actuators operal at lower pressure.
The adoption of the pressure compensation valve allow to control those situation guaranting the proportionality bet-
ween each actuator
FUNCTION
Compensation of actuator deliveries occurs when, during the simultaneous activation of two or more movements,
the pressure of one actuator drops lower than that of the other, and pump delivery, if not controlled, tends to be
supplied the actuator operating at lower. (In the diagram the actuator on the right is requesting higher pressure).
OPERATION
1. When activating an actuator at a pressure lower than the one already working.
(While operating actuator A starts operating actuator B)
. Until the pressure PBV downstream from the shuttle
(1) reaches the same value requested by actuator
B, no oil passes.
. When the pressure requested by actuator B is ex-
ceeded, movement can commence. This creates
a flow that adding to the one controlled by spool
(3) reduces the pressure upstream of spool (1)
and (3) and therefore the DP between PLS and PP.
. The pump compares the delivery pressures PP and
PLS and senses that the difference DP<18 bar
(18.3 kg/cm
2
). This variation in DP causes an in-
crease in oil flow increasing the swash plate angle.
(For the detail see Hydraulic pump).
. Until the pump does not realize a DP of 18 bar (18.3
kg/cm
2
), i.e. until the increase in oil flow compensa-
tes the requirements of the two actuators, the pump
will continue to increase delivery.
. DP of 18 bar (18.3 kg/cm
2
) will stabilize as soon as it
is restored to.
. The compensator (2) is moved upwards by the oil
flow and stops when the aperture between the
chambers a and b reduces the passage sufficiently
to reduce the pressure in chamber a to be sent to
the actuator.
5. DELIVERY COMPENSATION
10-66
WB97S-2
RKZ02310
A B
PA
PAV
PP
PBV
PB
PLS
C
d
4
3
1
b
a
2
2. When a low pressure actuator needs to work at a higher pressure than the other
. If the actuator B needs to work at a higher pressure
(PB>PA), the pressure PB will start to increase.
. Since pressure PB is increasing, the compensator
(2) moves upwards to restore the DP between the
chambers a and b, and therefore the DP does not
vary upstream or downstream from the shuttle (1).
. When pressure PB exceeds pressure PA, the com-
pensator (2) is fully open and the pressure PB is in-
troduced into the LS circuit.
. The increase in pressure in the LS circuit obliges
the pump to increase delivery until the DP is resto-
red to 18 bar (18.3 kg/cm
2
).
. Simultaneously the increase in pressure upstream
from the shuttle (3) generates an increase in DP up-
stream and downstream from the shuttle.
(PAV<PLS<PP)
. Because the pressure PLS which is equal to the
pressure PB acts on the upper side of the compen-
sator (4), and since the pressure PAV is lower, the
compensator (4) is pushed downwards.
. The compensator stops when the aperture between
the chambers c and d generates a reduction of the
passage sufficient to reduce the pressure to be
sent to the actuator, and to increase the pressure
PAV until the DP is restored to the 18 bar (18.3 kg/
cm
2
) necessary for equilibrium.
10-67
WB97S-2
RKZ02320
A B
PA
PAV
PP
PBV
PB
PLS
C
d
4
3
1
b
a
2
3. When an increase in delivery is required by an actuator
. When an increased delivery is required by actuator
A, i.e. when the shuttle (3) is asked to execute a
bigger movement, the section of the aperture in-
creases.
. The increase in aperture provokes a drop in DP bet-
ween the two sides of the shuttles (2) and (3), be-
cause the flow, which has remained unchanged un-
til now, is divided between both the actuators.
. At the same time the pump senses the variation in
DP and increases the oil flow until the DP is restored
to DP of 18 bar (18.3 kg/cm
2
) between the two sides
of the shuttle (1) and the compensator (4) changes
position in order to restore the DP upstream and
downstream from the shuttle (3).
10-68
WB97S-2
RKZ02330
A B
PA
PAV
PP
PBV
PB
PLS
C
d
4
3
1
b
a
2
FUNCTION
. The Load Independence Flow Divider (LIFD) intervenes automatically when the oil-flow requested by the actua-
tors exceeds the maximum delivery guaranteed by the pump.
In this case, the oil-flow is divided between the various actuators in proportion to their requirements.
OPERATION
. When, during the simultaneous operation of more
than one actuator, one of them needs a higher
pressure and the characteristics of the pump are
exceeded, the pump guarantees a delivery limited
by its calibration curve.
. At this point less oil than requested is distributed to
all the actuators.
. Because the sections of the apertures remain un-
changed, the pressure upstream and downstream
from the shuttles drops. Since the position of the
compensator (4) is determined by the pressure of
the LS signal, by the pressure PBV downstream
from the shuttle (3) and by the flow of oil needed
for the movement, the compensator is pushed
downwards by the higher pressure in the upper
chamber until the pressure PBV downstream from
the shuttle becomes equal to the pressure PAV
downstream from the shuttle (1). This equalizes
the pressure DP of the shuttle (1).
. Thus the flow of each actuator is reduced by a per-
centage equal to the reduction or absence of pump
delivery.
. In other words, when the request for performance is
excessive, the system can nevertheless guarantee
proportionality and graduality for the movements in
any load conditions.
. If an increase in delivery is requested, rather than
an increase in pressure, and the characteristics of
the pump are exceeded, the system will function
in the same way as described for the above case.
6. LIFD CONTROL SYSTEM
10-69
WB97S-2
RKZ02340
PCV
PBV PAV
A B C
6 4
2
5
3 1
DESCRIPTION
The LS decompression valve is a throttle that continuously releases a small quantity of oil from the LS circuit and
that, when the shuttles are brought back to a neutral position, releases the residual LS pressure.
This continued flow renders the PLS pressure increment more gentle and gradual, and increases stability and control
during the phases of reducing the LS pressure.
OPERATION
. When the LS pressure reaches chamber a of the
valve, it generates a force that opposes the force
of the spring (2).
. Until the force generated by the LS pressure ex-
ceeds the force of the spring (2) (LS pressure low)
the shuttle (1) remains at rest and oil flows
through the calibrated orifice a in the tank circuit.
. When the force generated by the LS pressure ex-
ceeds the force of the spring (2), the shuttle is pus-
hed upwards ( ) and the passages c are closed.
Oil continues to flow into the chamber d until the
force generated by the pressure contained in
chamber d, together with the force of the spring
(2), exceeds the force generated by the LS pressu-
re.
. The shuttle is pushed downwards ( ) and passage
c is opened.
. The system is in equilibrium (i.e. the shuttle is at
rest), when the quantity of oil allowed to flow into
the tank circuit is equivalent to the quantity that ge-
nerates a pressure difference DP such that
(PLSxS)=[(PLS1xS)+F] where:
PLS= LS pressure
PLS1= LS pressure contained in chamber d
S= section of the shuttle
F= force of the spring.
7. LS DECOMPRESSION VALVE
10-70
WB97S-2
RKZ02350
c
a
d
2
b
RKZ02360
1,3
P (bar)
Q (/ min)
0,8
0 20 250
DESCRIPTION
The function of the pressure cut-off valve is to regulate the maximum pressure of the Load Sensing signal and hen-
ce also the pressure of the pump.
OPERATION
. The pressurized oil of the LS reaches the chamber
a of the valve.
. When the force generated by the LS pressure on
the valve (1) exceeds the force of the spring (2),
the valve (1) is pushed upwards ( ) opening the
passage between the chamber a and the tank cir-
cuit.
8. PRESSURE CUT-OFF VALVE
10-71
WB97S-2
RKZ01770
1
2
1
b
a
FUNCTION
The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic components. Di-
stribution is determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from
the pump, the pressure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is such
as to guarantee that delivery to the steering unit will always correspond to the actual need.
9. PRIORITY VALVE (ONLY FOR THE 2-3 SPOOL CONTROL VALVE)
10-72
WB97S-2
RKZ02370
P
LS
P
Agli utilizzi
DLS D
To the actuator
1. EV4 - Backhoe boom locking
a. Port 3 - To the transmission
b. Port 1 - From the transmission
c. Port 2 - Boom-locking cylinder
SOLENOID VALVE
Solenoid valve block ST1
Differential locking - backhoe boom locking
10-73
WB97S-2
RKZ04640
a
b
c
1
1. Y1 Rear steering cut out
2. Y2 Front/rear steering
3. Y3 Phase coincidence steering
4. Y4 Crab steering
5. Blocks connection
a. T Port - To front steering cylinder (b Port)
b. A Port - To rear steering cylinder (c Port)
c. P Port - From steering unit (Port r)
d. B Port - To rear steering cylinder (d Port)
Solenoid valve group ST2
10-74
WB97S-2
RKP03670
1 4
a b
c
d
5
A T
P B
2 3
10
8
6
4
2
0
0 20 40 60 80
Measured at V=41 mm
2
/s e t=50C
5 3
RKP04501
D
i
f
f
e
r
e
n
t
i
a
l

p
r
e
s
s
u
r
e

p

(
b
a
r
)
Amount Q (/ min)
6 9
10
8
6
4
2
0
0 20 40 60 80
Measured at V=41 mm
2
/s e t=50C
RKP04511
D
i
f
f
e
r
e
n
t
i
a
l

p
r
e
s
s
u
r
e

p

(
b
a
r
)
Amount Q (/ min)
RKZ04571
Y3
Y4
Y1
Y2
Direction of travel
c
d
rear
cylinder
Shovel raise
a. Port Y - to the raising cylinders (Head side)
b. Port A - From the shovel control valve (Port A1)
c. Port X - To the raising cylinders (Base side)
d. Port B - From the shovel control valve (Port B1)
Bucket Dump
a. Port Y - To the dump cylinders (Head side)
b. Port A - From the shovel control valve (Port B2)
c. Port X - To the dump cylinders (Base side)
d. Port B - From the shovel control valve (Port A2)
Boom
a. Port Y - To the boom cylinder (Head side)
b. Port A - From the backhoe control valve
(Port A6)
c. Port X - To the boom cylinder (Base side)
d. Port B - From the backhoe control valve
(Port B6)
Arm
a. Port Y - To the arm cylinder (Head side)
b. Port A - From the backhoe control valve
(Port B1)
c. Port X - To the arm cylinder (Base side)
d. Port B - From the backhoe control valve
(Port A1)
CHARACTERISTICS
Safety valve calibration
Shovel dump: 230 bar
Boom: 350 bar
Arm: 230 bar
SAFETY VALVE
10-75
WB97S-2
a
b
c
d
A
A RKZ00850
1. Plug
2. Check valve spring
3. Check valve
4. Check valve spring
5. Check valve
6. Plug
7. Protection
8. Over-ride screw (Safety)
9. Spool
10. Safety valve spring
11. Safety valve
12. Spool
13. Spring
14. Housing
15. Plug
H The drawing represents the boom safety valve
10-76
WB97S-2
RKZ01050
Sezione A - A
1
2
3 4
6
5
7
8
9 10 11 12 13 14
15
Section AA
1. Pump body
2. Main piston
3. Seal
4. Differential piston
5. Spring
6. Pump spring
7. Spring
8. Check valve
9. Ball
10. Seal
11. Pin
12. Seal
13. Seal
14. Seal
15. Ball
16. Spring
17. Seal
CHARACTERISTICS:
Stroke: 36 mm
Displacement: 15 28 cc
Max. pressure: 150 bar
BRAKE PUMP
10-77
WB97S-2
RKZ00932
1
10 11 12 13
14
15 16
17
9
7
8
2
3 4 5
6
RAISING CYLINDER
DUMPING CYLINDER
CHARACTERISTICS
Cylinder Raising Dumping
Piston rod diameter 50 50
Internal cylinder diameter 85 85
Piston stroke 730 755
Max. cylinder length 1880 2145
Min. cylinder length 1150 1390
Key size for piston
safety nut
55 55
SHOVEL CYLINDERS
10-78
WB97S-2
RKZ00300
4 6 5
1
3 2 7
8
RKZ00310
4 6 5
1
3
2
7
8
1. Bushing, base side
2. Cylinder
3. Nut
4. Piston seal
5. Piston
6. Piston rod
7. Cylinder
8. Bushing, head side
BOOM
ARM
BUCKET
BACKHOE CYLINDERS
10-79
WB97S-2
RKZ00200
4
1
3
2
7
8
6 5
9
10 11
RKZ00220
4
1
3
2
7 8 6 5 9
10
RKZ00290
4
1
3
2
7 6 5 8 9
1. Head bushing, piston rod side
2. Piston rod
3. Cylinder head
4. Cylinder
5. Piston
6. Piston ring
7. Guide ring
8. Cushion plunger
9. Bottom bushing
10. Dowel bolt
11. Ball-bearings (9)
1. Head bushing
2. Piston rod
3. Cylinder head
4. Cylinder
5. Bushing
6. Piston ring
7. Guide ring
8. Piston
9. Nut
10. Bottom bushing
1. Head bushing
2. Piston rod
3. Cylinder head
4. Cylinder
5. Piston
6. Piston ring
7. Guide ring
8. Nut
9. Bottom bushing
OUTRIGGERS
BOOM SWING
ARM (for side digging boom)
10-80
WB97S-2
RKZ00410
4 1 3
2
7 6 5 8
RKZ00361
4 1 3 2
6
5
7
10 11 12 9 8
11 10 RKZ00210
3
1
3
2
7
5 4
8
6
9
1. Piston rod
2. Cylinder head
3. Cylinder
4. Spacer
5. Piston ring
6. Guide ring
7. Piston
8. Nut
1. Retaining ring
2. Throttling ring
3. Piston rod
4. Cylinder
5. Swing bushing
6. Cylinder head
7. Head bushing
8. Piston
9. Guide ring
10. Piston ring
11. Spacer
12. Cushion plunger
1. Head bushing
2. Cylinder head
3. Throttling ring
4. Piston ring
5. Guide ring
6. Nut
7. Bearing
8. Piston
9. Piston
10. Piston rod
11. Cylinder
SIDE DIGGING BOOM
JIG ARM
10-81
WB97S-2
1
2
RKZ00390
3 4 5 6 7 8 9 10
11
1 2 3 5 4 6 7 7 8
RKZ04580
1. Head bushing
2. Piston rod
3. Ring nut
4. Gasket
5. Cylinder head
6. Cylinder
7. Piston ring
8. Ring
9. Nut
10. Bottom bushing
11. Spacer
1. Head bushing
2. Piston rod
3. Cylinder head
4. Cylinder
5. Piston
6. Piston ring
7. Guide ring
8. Bottom bushing
CHARACTERISTICS
Cylinder Boom
Arm
Bucket
Standard
With side
digging boom
Piston rod diameter 60 60 60 60
Internal Cylinder diameter 120 110 110 95
Piston stroke 849 920 910 765
Max. cylinder length 2050 2175 2170 1850
Min. cylinder length 1040 1255 1260 1085
Key size for piston
safety nut
65 55 55 55
CHARACTERISTICS
Cylinder Outriggers Boom swing Side digging boom Jig arm
Piston rod diameter 40 50 45 40
Internal Cylinder diameter 80 100 85 70
Piston stroke 635 230 365 1140
Max. cylinder length 1690 319 830 2590
Min. cylinder length 1055 89 565 1450
Key size for piston
safety nut
46 46
10-82
WB97S-2
1. Compressor
2. Condenser
3. Drying-filter tank
4. Safety pressure
5. Expansion valve
6. Evaporator
7. Thermostatic clutch control sensor
8. Air-circulation fan in cab
9. Air conveyor
TECHNICAL DATA
. Operating pressure in circuit with engine at 2500
rpm and ambient temperature at 25 30C:
Normal pressure: 15 17 bar
Low pressure: 1.6 1.8 bar
. Safety pressures:
High pressure: 26 bar
Low pressure: 2.5 bar
. Coolant fluid: R134a
. Quantity of coolant: 970w15 g
AIR-CONDITIONING UNIT
10-83
WB97S-2
RKZ03130
4
3
5
2
1
6
7
9
1a
8
Low pressure steam
Low pressure liquid/steam
High pressure steam
High pressure liquid
INTERIOR OF CAB
AIR AT AMBIENT TEMPERATURE
The compressor (1) is driven directly by the engine
shaft by means of a belt, and made to rotat by a pulley
fitted with an electromagnetically-engaged clutch (1a).
A thermostatic sensor (7) controls the engagement
and disengagement of the clutch. It disengages the
clutch when the evaporator reaches the lower tempe-
rature limit and engages the clutch when the evapora-
tor reaches the upper temperature limit.
The coolant fluid (in gaseous phase) is drawn into the
compressor where it is subjected to compression and
an intense heating process. In these conditions the
fluid is then sent into the condenser (2) where, due
to the heat extracted by ambient temperature air flo-
wing over fins, it reaches condensation temperature,
and passes into a high-pressure liquid state.
Subsequently the coolant passes into the drying-filter
group (3) which performs three functions: it filters out
impurities, absorbs any moisture present in the circuit
and, finally, also functions as a reserve tank.
The coolant in its liquid state is then transferred to the
evaporator (6), first passing through an expansion val-
ve (5). The task of this valve is the constant metering
of the quantity of fluid in order to maintain optimum
evaporation.
In the evaporator the coolant fluid is subjected to ex-
pansion, bringing it up to the critical evaporation point
at a temperature of approximately 8C.
The flow of air generated by centrifugal fan (8) which
passes through the evaporator (6) at ambient tempera-
ture is considerably warmer than 8C. For this rea-
son it yields heat to the coolant fluid, bringing it up
to boiling point and complete evaporation.
On leaving the evaporator (6) the coolant is drawn on-
ce more into the compressor (1) and a new cycle com-
mences.
The yielding of heat from the atmosphere in which the
evaporator is positioned leads to the condensation of
the water suspended in the air, and hence to dehumi-
dification. The condensate is deposited on the evapo-
rator fins where, if a temperature higher than 0C is
not maintained, it freezes and inhibits the functioning
of the evaporator.
The task of keeping the temperature of the evaporator
above 0C (and thus within the optimum limits for heat
exchange) is entrusted to a thermostatic sensor (7).
The condensate that forms on the evaporator fins (6)
also contains dust, pollens and particles suspended
in the air. Continual condensation therefore effectively
purifies the air, and the droplets of condensate are di-
scharged to the exterior.
A fixed quantity of anti-freeze oil is also introduced into
the circuit, with the function of lubricating all the me-
chanical parts of the unit. A percentage of this oil cir-
culates constantly throughout the unit in nebulized
form, lubricating the compressor (pistons and bea-
rings) and the expansion valve.
A pressure switch (4) has been inserted in the electri-
cal control circuit to protect the unit in the case of a
lack of coolant fluid or if the quantity becomes insuffi-
cient due to leakages. This switch will inhibit the enga-
gement of the electromagnetic clutch and hence the
functioning of the air-conditioning unit.
HOW THE AIR-CONDITIONING UNIT FUNCTIONS
10-84
WB97S-2
ELECTRICAL CIRCUIT DIAGRAM (1/7)
10-85
WB97S-2
X4
6
X4
4
X4
10
X4
2
X4
9
X4
1
X4
11
L
2
3
D
1
6
L
1
3
12
2.5
1
2.2
9
4.12
10
2.19
8
3.12
4
4.18
3
3.6
11
2.2
R
/N
1
H
/N
1
X17
3
t_
P4
-
S i
+
X17
14
X
S
6
X
S
5
q
P3
-
S
+
i
X17
9
R/N1
3.1
X4
3
X4
5
X4
8
G
1
V
-
B
1
A
-
G
1
X8
5
X8
7
X8
3
X8
11
R
/N
1
X8
12
D19
7
3.9
D
1
8
D
1
7 +15
F3A
7.5A
R25
1/4W
+15
F7C
7.5A
X8
2
Z
/N
1
X8
9
X8
6
X8
8
+30
+15
X8
10
D
2
0
K4 86 87a 87
85 30
D5
R3
1/4W
X17
8
X4
7
L6
D
1
2
A
-
N
1
.5
10 8
+15 +15
V
-
B
1
H
/N
1
1 4 3
X10
1
X10
4
X10
2
t
R32
p
S22
HA1
X10
6
31
2.1
N
1
.5
N
1
.5
N
1
N
1
S
1
2
X1
7
D
1
0
X1
5
B/V1
2.4
X10
3
t
S21
X21
2
X21
1
X21
3
R31
S24
B
/V
1
B
/N
1
13
4.15
2
4.18
B
-
R
1
Z
-
N
1
X1
6
X1
9
L4
B-N1
X1
11
Z
-
B
1
R
-
N
1
.5
N
1
p
S23
N
1
V
1
R4
1/4W
L
2
5
F3B
R13
R6
1/4W
L3
F7A
7.5A
R23
1/4W
XS
1
XS
4
rpm
P1
-
S i
+
H8
X
1
7
2
V
1
6 5
H4 H5 H6 H7
S
1
1 11 13 12
H1 H2
N
1
.5
A
2
.5
3 4
G2.5
M
-
V
1
H3
4
R
-
N
1
.5
X
1
0
5
A-R1
3 4
X
T
1
1 2
KT1
5
3
S
5
3
M
3
1
1
5
A-R1
2.19
M
-
V
1
R
-
V
1
M
-
V
1
10
R
-
V
1
3
X
1
0
12
X
1
8
5 4
X
A
D
l
4
X
T
2
1
KT2
5
3
S
1
5
5
3
M
3
1
2
X
1
9
4 5
X10
9
X10
11
X
1
0
7
R
-
V
1
M
-
V
1
A
2
.5
A
2
.5
Z
/B
1
X17
7
X15
2
R6
X15
1
L4
2.13
AL KIT
G
2
.5
B
-
R
1
X11
2
X14
2
R
4
L
4
X
1
2
2
X10
13
L
4
X
1
3
l
A
-
V
1
X
1
0
8
X
1
4
1
L
4
A
-
V
1
COND.
R
4
R
4
R
4
X11
1
X12
1
R
6
G
2
.5
R1
ST
OFF ACC
S6
R1 ACC BR R2 C
B
A
-
V
1
G
1
M
1
K03
86 87
85 30
B1.5
B1.5
X16
A
B
3
R30
2
Y0
1
M10
G2.5
K01
86 87
85 30
K02
86 87
85 30
N
1
N
1
N
1
Z
-
B
1
G
2
.5
R
1
0
R50
FUG4
70A
FUG3
30A
X
A
-
X
A
l
U
3
G
G2
30
D+
W
31
M
M1
30 50
FUG1
60A
G1
12Vcc
FUG2
80A
R
5
0
N
5
0
G
/N
1
R
-
V
1
B
/R
1
M
-
V
1
Z
/B
1
-
Z
/N
1
B
-
N
1
h
P2
-
S i
+
X
1
7
X
1
7
X
1
7
X
1
7
X
1
7
X
1
7
X
1
7
X
1
5
X
1
5
X
A
D
X
T
2
X
T
2
X
1
0
X
1
8
X
1
9
X
T
1
X
T
1
X
T
1
XAM XAM
X16 XAM
X1 X1 X1 X1 X1 X1
1/4W 7.5A
D13
D
1
1
N
1
N1
N
1
.5
N1.5
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
G1
G
1
S1
S
1
Z-N1
Z
-
N
1
A
-
G
1
A-G1
V
-
B
1
V-B1
A
-
V
1
A-V1
V
-
N
1
V-N1
R1
R
1
.5
R1.5
B
-
N
1
B-N1
3.18
R/N1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RKZ04590
COMPONENTS
G1 Battery
G2 Generator
H1 Preheating warning light
H2 Generator warning light
H3 Engine water high temperature
warning lamp
H4 Air filter warning lamp
H5 Hydraulic oil filter warning lamp
H6 Optional warning lamp
H7 Optional warning lamp
H8 Optional warning lamp
HA1 Horn
K01 Starter relay
K02 Preheating relay
K03 Fuel shut off relay
K4 Safety start relay
KT1 Fuel shut off timer
KT2 Preheating timer
M1 Starter motor
P1 RPM instrument
P2 Hour counter
P3 Fuel level indicator
P4 Water temperature instrument
R30 Heating start
R31 Fuel level sender
R32 Water temperature sender
S6 Starting switch
S21 Engine water high temperature switch
S22 Air filter blocked switch
S23 Engine oil low pressure switch
S24 Fuel gauge
Y0 Fuel shut off solenoid valve
CONNECTORS
X1 Front line (engine) 11 way connector
X4 Monitor 11 way connector
X8 Lateral dashboard 17 way connector
X10 Front line-engine line 13 way connector
X11 Power 3 way connector
X12 Front line-cross line 3 way connector
X13 Front line-engine line 2 way connector
X14 Front line-cross line 4 way connector
X15 Start key 4 way connector
X16 Conditioner clutch 2 way connector
X17 Lateral dashboard 21 way connector
X18 Power box 5 way connector
X19 Front dashboard 9 way connector
X21 Fuel level indicator 3 way connector
XA Generator 2 way connector
XAD Diode 2 way connector
XAM Fuel shut off valve 3 way connector
XS Multifunction instrument 16 way connector
XT1 Fuel shut off timer 4 way connector
XT2 Preheating timer 4 way connector
FUSES
F3A Safety start fuse 7.5A
F3B Switch + warning light + return to dig fuse 7.5A
F7A Monitor fuse 7.5A
F7C Fuel shut off fuse 7.5A
FUG1 General fuse 60A
FUG2 Preheating fuse 80A
FUG3 Fuel shut off power fise 30A
FUG4 Generator fuse 70A
10-86
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
ELECTRICAL CIRCUIT DIAGRAM (2/7)
10-87
WB97S-2
87a
30
R
0ohm
NON MONTATO
RELE' K7
A-R1
1.9
X29
1
X29
2
S10
X28
12
1 0
S1
15/1 30/3 L/6
49/4 30b/2 R/7
X9
13
X
1
9
6
R/N1
2.2
10
1.20
C-L1
3.1
M-N1
4.5
R/N1
3.12
G
-
V
1
X28
8
X28
10
X28
9
M
-
B
1
X28
4
X28
6
X28
5
X28
7
MANIPOLATORE
C
-
B
1
C
/B
1
M
-
N
1
X28
2
X28
1
V
/N
1
X28
3
D14
X5
7
X5
8
X5
3
X8
1
M
-
N
1
M-N1
V2.5
X9
1
X9
9
+15
L26
F5A
15A
R26
1/4W
L
1
7
R17
1/4W
K04
86 87
85 30
X28
11
17
4.18
33
4.19
X6
9
H
1
C
-
N
1
Y5
1
2
X27
4
R1
4.7
31
3.1
N
1
V
/N
1
EV4
X27
5
X27
1
L4
1.2
2
V
-
N
2
.5
C
/B
1
C
-
B
1
EV1
4 3
X20
1
X27
6 2
EV2
L4
X27
3
N
1
N
1
N
1
N
1
A1.5
V
-
B
1
N1
4.1
1
0
2
3
S4
2 3 4
+ 1
V
-
N
1 S
1
H11 H10 H9 H12
B
1
.5
R
1
.5
N
1
Z
-
B
1
X2
4
X9
10
X2
7
32
4.17
31
4.17
D4
18
3.1
L5
R5
1/4W
C
-
L
1
M
/N
1
X5
10
X5
5
X5
11
20
3.7
X9
16
D8
+15
F3C
7.5A
A
-
N
1
L
-
B
1
R/N1
2.19
R/N1
II
0 I
S2A
2 6 7 9
3 5 10
X
1
9
7 A
-
R
1
X9
8
L/B1
3.9
1
1.20
11
1.20
X8
4
X
1
8
3
L
1
4
+15
R14
1/4W
F4A
7.5A
L
2
7
R27
1/4W
X9
15
X8
13
Z-N1.5
X3
7
X
1
4
4
R
1
.5
R
1
R
1
.5
S20
B
-
R
1
.5
B
-
R
1
S19
X
1
4
3
B
-
R
1
G
-
N
1
A
-
G
1
X5
1
X3
4
12
1.20
S
-
N
1
X3
5
S15
X
2
3
2
X
2
3
1
OPTIONAL
N
1
p
S16
S18
S17
15
4.16
16
4.6
N
1
N
1
N
1B
-
R
1
B
/V
1
B/V1
1.15
L
-
B
1
X3
3
X
2
4
3
X24
1
X22
l
X22
-
M
M2
X
2
4
4
M
M3 53
53a
53b
31b
31
31
1.20
N
1
D22
D21
40
3.1
M
M4
Z
-
N
1
N
2
.5
X
2
0
2
X
2
5
1
V2.5
V
-
N
2
.5
1 0
S2
15/1 30/3 L/6
49/4 30b/2 R/7
K3
86 87a 87
85 30
X
2
0
X
2
0
X27
X43
2
X43
1
M
-
V
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RKZ04600
COMPONENTS
EV1 Opened grab solenoid valve
EV2 Closed grab solenoid valve
EV4 Rear 1^ boom unlock solenoid valve
H9 4WD warning lamp
H10 Engine water high temperature warning light
H11 Engine oil high temperature warning light
H12 Fuel reserve warning light
K04 Powered blower motor relay
K3 Insert double traction relay
M2 Washer pump
S1 Economy power switch
S2 Rear 1^ boom unlock switch
S4 Blower motor switch
S10 Hammer button
S15 Hand brake switch
S16 Brake oil low level switch
S17 Stop switch
S18 Stop switch
S19 Stop light switch
S20 Stop light switch
S2A Winshield wiper-washer switch
on front dashboard
Y5 Economy power solenoid valve
CONNECTORS
X2 Lights switch and gear shift line
9 way connector
X3 Front line 11 way connector
X5 Cabin command 11 way connector
X6 Solenoid valves line 9 way connector
X8 Lateral dashboard 17 way connector
X9 Front dashboard 17 way connector
X14 Front line-cross line 4 way connector
X18 Power box 5 way connector
X19 Front dashboard 9 way connector
X20 Blower motor 4 way connector
X22 Windshield washer pump 2 way connector
X23 Optional 2 way connector
X24 Windshield wiper 4 way connector
X25 Powered blower motor 2 way connector
X27 Valves line 6 way connector
X28 Joystick way connector
X29 Convert detachment button 2 way connector
X43 Pred. 2 way connector
FUSES
F3C Forward and reverse solenoid valve fuse 7.5A
F4A 4WD-windshield wiper/washer fuse 7.5A
F5A Blower motor switch fuse 15A
10-88
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
ELECTRICAL CIRCUIT DIAGRAM (3/7)
10-89
WB97S-2
NON MONTATO
RELE' K1
C1
22uF
G
-
R
1
H13 H14
A-R1
B-G1
R/N1
4.5
2
X33
1
X33
5
R-V1
A
-
N
1
G1.5
G
/N
1
HA2
R
/N
11 0
S3A
1 9
5 10
X33
3
X9
7
X33
6
L19
+15
R19
1/4W
+30
L11
R8
1/4W
L8 R11
1/4W
F2B
7.5A
F5C
15A
X
1
9
1
G-V1
X
1
9
2
G
/N
1
G
/N
1
X2
1
X17
19
R/N1
2.20
8
1.20
X9
12
R7
1/4W
L7
+30
L10
F2A
10A
R10
1/4W
F1C
3A
G-V1
4.8
F1B
3A
II
0 I
S2L
2 6 7 9
3 5 10
K05
86 87a 87
85 30
A-R1
A
/R
1
X33
4
B
-
G
1
B
-
G
1
A
-
R
1
A
-
N
1
A
/R
1
H21 H20
M
M8 53
53a
53b
31b
31
31
4.1
N
1
N
1
N
1
N
1
B
1
L
-
G
1
.5
N
0
.5
M
1
R-V1
X5
4
A
X39
B
X39
C
Y6
G1
4.1
X3
1 6
12
4.5
G-R1
4.7
X
3
1
1
X
3
1
2
N1
H18 H17
3
X31
4
2
H16
S27
N
1
.5
N
1
L. CABINA
N
1
L
.0
5
M
H19
L-G1.5
L/B1
L1.5
1 0
S1L
1 9
5 10
1 0
S5L
1 9
5 10
B-R1
L
/N
1
X17
10
X8
16
X2
9
7
1.16
L/B1
2.2
+15
F5B
15A
R1
1/4W
L1
D1
L
1
.5
X2
5
19
4.19
L2
R2
1/4W
D3
K2
86 87a 87
85 30
X8
14
X17
17
B
-
R
1
A
-
N
1
1 0
S3
15/1 30/3 L/6
49/4 30b/2 R/7
C-L1
2.20
R/N1
1.14
X17
16
X17
18
X8
15
S
-
G
1
+15
A
-
N
1
+15
3
J2
2 1
F6A
15A
R15
1/4W
F4B
10A
L15
40
2.9
18
2.8
R20
1/4W
L20
1 0
S4L
1 9
5 10
B-R1.5
G
1
X5
9 8 2 6 17
R
-
V
1
X1
H15 1
M
M5
X30
2
X30
1
R
-
N
1
.5
20
2.5
X6
1
P4
X6
7
X6
4
X6
5
3
1.20
X6
3
N
1
.5
N
1
.5
H
-
L
1
X5
2
HA4
Y7
HA3
31
2.20
N
1
N
1
N
1
1 0
S3L
1 9
5 10
L18
R18
1/4W
R
-
N
1
.5
G1
4.9
AUTORADIO
ALIM.
X6 X6 X6 X8 X5
X
3
2
X
3
2
X31
X
3
9
X33
1.14
R/N1
R
/N
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RKZ04610
COMPONENTS
H13 Dashboard light
H14 Dashboard light
H15 Cigarette lighter lamp
H16 Cabin lamp
H17 Front working lamp
H18 Front working lamp
H19 Beacon lamp
H20 Rear working light
H21 Rear working lamp
HA2 Buzzer
HA3 Rear horn
HA4 Buzzer
K05 Return to dig relay
K2 Reverse speed relay
M5 Fuel pump
M8 Windshield wiper motor
S1L Rear working light switch on lat. dashboard
S27 Npn sensor
S2L Windshield wiper-washer switch on lat. dashboard
S3A Front working light switch on front dashboard
S3L Beacon switch on lat. dashboard
S4L Horn switch on lat. dashboard
S5L Optional switch on lat. dashboard
Y6 Return to dig solenoid valve
Y7 Plate unlock solenoid valve
CONNECTORS
X1 Front line (engine) 11 way connector
X2 Lights switch and gear shift line 9 way connector
X3 Front line 11 way connector
X5 Cabin command 11 way connector
X6 Solenoid valves line 9 way connector
X8 Lateral dashboard 17 way connector
X9 Front dashboard 17 way connector
X17 Lateral dashboard 21 way connector
X19 Front dashboard 9 way connector
X30 Fuel pump 2 way connector
X31 Cabin 5 way connector
X32 Radio power 2 way connector
X33 Windshield wiper and beacon 7 way connector
X39 Proximity 3 way connector
FUSES
F1B Right traffic light fuse 3A
F1C Left traffic light 3A
F2A Beacon fuse 10A
F2B Radio and cabin lamp fuse 7.5A
F4B Forward-reverse speed fuse 10A
F5B Rear working light switch fuse 15A
F5C Front working light switch fuse 15A
F6A Windshield wiper-washer switch fuse 15A
10-90
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
ELECTRICAL CIRCUIT DIAGRAM (4/7)
10-91
WB97S-2
C
O
N
S
E
N
S
O
A
V
V
IA
M
E
N
T
O
O
U
T
B
L
O
C
C
A
G
G
IO
D
IF
F
.
B
A
C
K
U
P
A
L
A
R
M
K
IC
K
-
D
O
W
N
M
A
S
S
A
B
U
Z
Z
E
R
A
L
L
A
R
M
I
IN
P
E
D
A
L
E
F
R
E
N
O
+
1
5
E
G
M
D
E
C
L
U
T
C
H
8 6 7 4 2 3 5
19
3.5
4
1.20
17
2.16
33
2.16
2
1.12
D
1
5
9
G
-
V
1
8 6 7
C
1
A
/B
1
4 3 2
DEVIO LUCI
5 9
15
2.7
X9
14
13
1.12
X2
2
R
-
N
1
X2
6
L21
D9
K8
86 87a 87
85 30
L24
9
1.20
X7
1
32
2.9
31
2.9
13
31
A
-
B
1
A
-
G
1
R
-
G
1
L
1
11 9 10 7 5 6 8
+15 +15
3
N
1
N
1
X40
1
N
1
2 8
A
1
4
N
1
12
N
1
F7B
10A
R24
1/4W
R21
1/4W
N
1
G-V1
3.14
H22 H23 H24
M-N1
2.20
R/N1 R/N1
3.20
H25
2
X19
9 A
-
V
1
X9
11
1
X
1
9
8
X9
3
K9
C
+
R
X9
5
A
/V
1
X2
3
X9
17
X9
6
V
1
R
-
N
1
B
1
16
2.7
F4C
15A
R29
1/4W
D7
L22
R16
1/4W
+15
R22
1/4W
K6
86 87a 87
85 30
+30
X
1
8
2
A
/N
1
B
/R
1
A
/N
1
B
-
R
1
A-N1
N1
2.8
X9
4
+30
R
1
.5
X2
8
H
-
N
1
L12
+30
R12
1/4W
F2C
10A R28
1/4W
D6
F1A
15A
K5
86 87a 87
85 30
1 0
S4A
2 8 5 10
4 6 3 1 7
F6C
10A
A
1
R1
A
-
B
1
G1
3.10
X
2
6
4
X26
6
H31
7
X
2
6
3 1
X26
5
H30
5
7L
5
9
c
3
1
G-R1
A
1
A
-
B
1
12
3.12
G
-
R
1
M
1
10 2 9
X
3
5
4
X
3
5
6
X
3
5
3 2
X35
1
G-R1
3.12
R1
2.20
N
1
N
1
N
1
.5
P1
G1
X3
6
M
1
B
1
11
X3
8
4 6 3
X
3
4
2
X34
1
H26
5
6
a
5
6
bR
5
7
3
1
G1
3.13
31
3.20
N
1
.5
N
1
.5
H27
5
6
a
5
6
bL
5
7
3
1
B
1
L9
R9
1/4W
L28 L29
L16
H32
5
7R
5
9
c
3
1
F6B
7.5
XD1
1
2
XD1 XD1 XD1 XD1 XD1 XD1 XD1 XD1
X7 X7 X7 X7 X7 X7 X7 X7
X
1
8
X9
X3 X3 X3 X3
X
3
4
X
3
4
X
3
4
X
3
5
X
2
6
X
2
6
X
2
6
X
2
6
X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40
5.1
EGM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RKZ04620
COMPONENTS
H22 Indicators warning lamp
H23 Main beam warning lamp
H24 Low level brake oil warning lamp
H25 Differential lock warning lamp
H26 Right front lamp
H27 Left front lamp
H30 Left rear lamp
H31 Number plate lamp
H32 Right rear lamp
K5 Low beam relay
K6 Main beam relay
K8 Horn relay
K9 Flasher unit
S4A Warning switch on front dashboard
CONNECTORS
X2 Lights switch and gear shift line 9 way connector
X3 Front line 11 way connector
X7 Not connected 9 way connector
X9 Front dashboard 17 way connector
X18 Power box 5 way connector
X19 Front dashboard 9 way connector
X26 Rear line 8 way connector
X34 Right front light 6 way connector
X35 Left front light 6 way connector
X40 Flasher unit 13 way connector
XD1 Lights switch 9 way connector
FUSES
F1A Low beam fuse 15A
F2C Warning fuse 10A
F4C High beam fuse 15A
F6B Lights switch fuse 7.5A
F6C Warning power fuse 10A
F7B Horn fuse 10A
10-92
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
ELECTRICAL CIRCUIT DIAGRAM (5/7)
10-93
WB97S-2
14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13
13 12 11 10 9 8 7 6 5 4 3 2 1
N
0
.5
H35
N
0
.5
N
0
.5
H34
N
0
.5
N
0
.5
H33
N
0
.5
S9
N
0
.5
N
0
.5
S8
N
0
.5
N
0
.5
N
0
.5
S7
N
2
.5
X
E
7
X
E
6
X
E
5
X
E
4
X
E
3
X
E
2
X
E
1
M
-
B
1
L
-
G
1
A
-
R
1
S
-
G
1
M
-
N
1
L
-
B
1
S28
X
5
5
B
X
5
5
C
X
5
5
A
X
5
4
C
X
5
4
B
X
5
4
A
X
5
6
3
X
5
6
2
X
5
6
1
N
1
M
-
V
1
M
1
N
1
X
5
1
11
N
1
X
5
1
6
X
5
1
7
M
1
M
-
V
1
X
6
4
2
X
6
4
1
R
-
N
1
X
5
1
4
R
-
N
1
X
6
3
2
X
6
3
1
X
6
2
2
X
6
2
1
X
6
1
2
X
6
1
1
R
-
V
1
X
5
1
3
R
-
V
1
V
1
X
5
1
2
V
1
N
1
N
1
N
1
N
1
31
4.20
R
/N
1
X
5
1
1
R
/N
1
Y4 Y3 Y2 Y1
N
1
N
1
R
1
R
1
R
1
X
5
1
10
R
1
B
-
R
1
X
5
1
8
R
1
B
-
R
1
R1
1.20
R
1
R
1
X53
1
X
5
1
9
R
1
Z
-
B
1
X
5
1
5
Z
-
B
1
N
1
N
1
G
-
V
1
S
-
N
1
C
-
N
1
G
-
R
1
A
-
B
1
N1
1.20
N
1
S1
1.20
G1
1.20
Z-N1
1.20
H
-
R
1
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
X
5
2
S
1
G
1
Z
-
N
1
B-N1
1.20
A-V1
1.20
N1.5
1.20
R1.5
1.20
V-N1
1.20
A-G1
1.20
V-B1
1.20
B
-
N
1
A
-
V
1
N
1
.5
R
1
.5
V
-
N
1
A
-
G
1
V
-
B
1
X
M
1
E D M
POTENZIOMETRO
POSTERIORE
MONITOR
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
X
M
2
S29
RKZ04630
COMPONENTS
H33 2WS warning lamp
H34 Round steering warning lamp
H35 Crab steering warning lamp
S7 2WS steering button
S8 Round steering button
S9 Crab steering button
S28 Front axle alignment sensor
S29 Rear axle alignment sensor
Y1 4WS solenoid valve
Y2 2WS solenoid valve
Y3 Round steering solenoid valve
Y4 Crab steering solenoid valve
CONNECTORS
X51 Chassis cable 12 way connector
X52 Steering buttons 13 way connector
X53 Extension 1 way connector
X54 Front axle 3 way connector
X55 Rear axle 3 way connector
X56 Rear potentiometer 3 way connector
X61 4WS solenoid valve 2 way connector
X62 2WS solenoid valve 2 way connector
X63 Round steering solenoid valve 2 way connector
X64 Crab steering solenoid valve 2 way connector
XE EDM 7 way connector
XM1 Monitor 20 way connector
XM2 Monitor 18 way connector
10-94
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
ELECTRICAL CIRCUIT DIAGRAM (6/7)
10-95
WB97S-2
8 9 7 5 4 6 2 3
X
D
1
1
54D 49 54S 57/58
L 31 56b 56a 30
DEVIO LUCI
DX
SX
X
D
1
X
D
1
X
D
1
X
D
1
X
D
1
X
D
1
X
D
1
X
D
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RKZ03250
CONNECTORS
XD1 Lights switch 9 way connector
10-96
WB97S-2
PAGE INTENTIONALLY LEFT BLANK
ELECTRICAL CIRCUIT DIAGRAM (7/7)
10-97
WB97S-2
X1 X4 X6 X8
X2 X3 X5 C04 X9
F1A
F1B
F1C
F2A
F2B
F2C
F3A
F3B
F3C
F4A
F4B
F4C
F5A
F5B
F5C
F6A
F6B
F6C
F7A
F7B
F7C
K2 K4 K6 K8
K1 K3 K5 K7
K9
RKZ03140
COMPONENTS
K1 Forward speed relay
K2 Reverse speed relay
K3 Insert DT relay
K4 Safety start relay
K5 Low beam relay
K6 Main beam relay
K7 Lights switch relay
K8 Horn relay
K9 Flasher unit
FUSES
F1A Low beam fuse 15A
F1B Right traffic light fuse 3A
F1C Left traffic light 3A
F2A Beacon fuse 10A
F2B Radio and cabin lamp fuse 7.5A
F2C Warning fuse 10A
F3A Safety start fuse 7.5A
F3B Switch + warning light + return to dig fuse 7.5A
F3C Optional valve fuse 7.5A
F4A 4WD-windshield wiper/washer fuse 7.5A
F4B Forward-reverse speed fuse 10A
F4C High beam fuse 15A
F5A Blower motor switch fuse 15A
F5B Rear working light switch fuse 15A
F5C Front working light switch fuse 15A
F6A Windshield wiper-washer switch fuse 15A
F6B Lights switch fuse 7.5A
F6C Warning power fuse 10A
F7A Monitor fuse 7.5A
F7B Horn fuse 10A
F7C Fuel shut off fuse 7.5A
10-98
WB97S-2
Normal or standard technical data . . . . . . . . . . . . . . . . . . . 2
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Measuring compression pressure . . . . . . . . . . . . . . . . . . . 19
Testing and adjusting fuel injection timing . . . . . . . . . 20
Checking and tightening the fan - belt . . . . . . . . . . . . . . 22
Checking and tightening the compressor
fan - belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Measuring accelerator pedal operating travel
and accelerator lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Adjusting brake pedal travel, brake alignment,
microswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air bleeding - releasing residual pressure . . . . . . . . . . 27
Checking and setting pressure in the attachments
hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Testing and adjusting of load sensing signal
(LS valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Checking unloading valve functionality . . . . . . . . . . . . . 37
Testing pump delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Testing priority valve operation . . . . . . . . . . . . . . . . . . . . . . 40
Testing and setting steering
control system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Testing brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Control of the engine speed under load . . . . . . . . . . . . 44
Testing pressures in the power train group. . . . . . . . . 46
Testing the correct functioning of the
power train clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Adjusting the sensor for Return to Dig device. . . . . . 49
Analysis of causes hydraulic drift . . . . . . . . . . . . . . . . . . . . 50
Testing the air-conditioning unit . . . . . . . . . . . . . . . . . . . . . 55
TESTING AND ADJUSTMENTS
20-1
When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level
ground. Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine
is undergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed
while the liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
WB97S-2
Machine model WB97S-2
Engine S4D106-1FA
Check item Test conditions Unit
Standard
value
Permissible
value
Engine speed
High idling
Low idling
Set speed
rpm
rpm
rpm
2375w50
1050w50
2200
2375 2425
1000 1100