KOMATSU PW95-1 SHOP MANUAL
SHOP MANUAL
WEBMPW9500
PW95-1
HYDRAULIC EXCAVATOR
SERIAL NUMBER
0000007 and up
CONTENTS
No. of page
10 STRUCTURE AND FUNCTION ............................................. 10-1
20 TESTING AND ADJUSTING ................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ........................................... 30-1
40 MAINTENANCE STANDARD ............................................... 40-1
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00-2-2
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by FKI and describe in this manual are both effective
and safe methods of operation. Some of these operations require the use of tools specially designed by
FKI for the purpose.
To prevent injury to workers, the symbols
ual. The cautions accompanying these symbols should always be carefully followed. If any danger arises
or may possibly arise, first consider safety, and take necessary steps to face.
and are used to mark safety precautions in this man-
SAFETY
GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions written on the decals which
are suck on the machine.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
. Always wear safety glasses when hitting parts
with a hammer.
. Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on
the controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct 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 machine on hard, level ground, and block the wheels
to prevent the machine from moving.
8. Before starting work, lower ourigger, bucket or
any other work equipment to the ground. If this
is not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
to lock all the control levers and hang warning
sign on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before starting 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 hydraulic 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 circuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.
00-3
13. Before starting work, remove the leads from the
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 capacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
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.
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.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gasoline when washing electrical parts.
19. Be sure to assemble all parts again in their original places. Replace any damage parts with new
parts.
. When installing hoses and wires, be sure that
they will not be damaged by conctat with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.
00-4
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into
the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This sections explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs.
Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, dissassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your FKI distributor for the latest information.
00-5
HOW TO READ THE SHOP MANUAL
e
HOW TO READ THE SHOP MANUAL
VOLUMES
Shop manual are issued as a guide to carry out repairs. These various volumes are designed to avoid
duplicating the same information.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will
be sent to FKI 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
page number.
Example
10 - 3
Numero dell'articolo (10. Struttura
funzionamento)
Numero di pagina progressivo per
ogni articolo
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page number.
Fle as in the example.
Example:
10-4
10-4-1
10-4-2
] Added pages
10-5
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
Special safety precautions are necessary when performing the
work.
Safety
Caution
Weight
Tightening
torque
Coat
Oil, water
Drain
Extra special safety precautions
are necessary when performing
the work because it is under internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Weight of parts or systems.
Caution necessary when selecting
hoisting wire, or when working
posture is important, etc.
Parts that require special attention
for the tightening torque during assembly.
Parts to be coated with adhesives
and lubricants etc.
Places where oil, water or fuel
must be added, and their quantity.
Places where oil or water must be
drained, and quantity to be
drained.
REVISED EDITION MARK
(123....)
When a manual is revised, an edition mark is re-
corded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVISED PAGES between the title page and SAFETY
page.
00-6
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
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 below:
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
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
ing, and a serious accident can result.
Hooks have maximum strenght 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
rope, or slipping of the rope from its original
winding position on the load, which can
cause 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 allowable load (kg) when hoisting is made with two
ropes, 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 120ë 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 150ë.
30
40
50
60
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-
10.0
18.0
28.0
40.0
00-7
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
The following charts give the stardard tightening torques of bolts and nuts. Exceptions are given in sections of «Disassembly and Assembly».
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Thread diameter
of bolts
(mm)
6
8
10
12
14
16
18
20
22
24
27
Pitch of
bolts
(mm)
1
1.25
1.5
1.75
2
2
2.5
2.5
2.5
3
3
Width across flat
(mm)
10
13
17
19
22
24
27
30
32
36
41
5
6
8
10
12
14
14
17
17
19
19
kgm Nm kgm Nm
0.96w0.1
2.3w0.2
4.6w0.5
7.8w0.8
12.5w1
19.5w2
27w3
38w4
52w6
66w7
96w10
9.5w1
23w2
45w4.9
77w8
122w13
191w21
262w28
372w40
511w57
644w70
945w100
1.3w0.15
3.2w0.3
6.5w0.6
11w1
17.5w2
27w3
37w4
53w6
73w8
92w10
135w15
1329w140
13.5w1.5
32.2w3.5
63w6.5
108w11
172w18
268w29
366w36
524w57
719w80
905w98
30
33
36
39
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
3.5
3.5
4
4
46
50
55
60
22
24
27
Ð
131w14
177w20
230w25
295w33
1287w140
1740w200
2250w250
2900w330
184w20
250w27
320w35
410w45
1810w190
2455w270
3150w350
4050w450
00-8
STANDARD TIGHTENING TORQUE
2. TIGHTENING TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter
of nut part
(mm)
1/2" - 20
9/16" - 18
3/4" - 16
7/8" - 14
1
1.
/16"-12
5
1.
/16"-12
5/8"
1.
-12
22
33
Width across flats
of nut part
(mm)
17
17
22
27
32
38
50
27
41
TIGHTENING TORQUE
kgm Nm
2.6w0.5
4w0.5
6.7w2
8w2
9.7w3
17w3
20w5
8w2
20w5
COATING MATERIALS
The recommended coating materials prescribed in FKI Shop Manuals are listed below:
Nomenclature Code Applications
Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-mettalic parts when a fast, strong
seal is needed.
Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Used for high resistant of threaded parts that can be removed with normal tools.
Used for high resistant locking and for sealing threaded parts, bolts and stud
bolts.
Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
only after heating
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.
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.
Used by itself on mounting suface on the final drive and transmission cases.
(Thickness after tightening :0.07-0.08 mm).
Applied to bearings and taper shaft to facilitate press-fitting and to prevent sticking, burning or rusting.
Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Used for protecting battery electrode terminals from corrosion.
Adhesives
Gasket sealant
Antifriction compound
(Lubricant inclunding
Molybdenum disulfide)
Grease
(Lithium grease)
Vaseline
ASL800010
ASL800020
Loctite 222
Loctite 242
Loctite 262
Loctite 270
Loctite 542
Loctite 573
Loctite 601
Loctite 675
ASL800060
ASL800070
ASL800040
ASL800050
±
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
00-9
ELECTRIC WIRE CODE
ELECTRIC
ELECTRIC WIRE CODE
In the wiring diagrams. various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R -N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Nominal
number
0.35 11 0.20 0.35 1.55 3.5 Proximity sensor
0.5 16 0.20 0.50 2.40 6 Instrument
0.8 11 0.30 0.78 2.80 8 Instrument - transmitter
1 14 0.30 0.99 2.80 11 Lighting - signal etc.
1.5 21 0.30 1.48 3.35 14 Working light - solenoid valve etc.
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28 Alternator - preheating etc.
6 84 0.30 5.93 5.20 37 Starter motor fuses
50 399 0.40 50.11 14 160 Ground - starter motor
Number
strands
Copper wire
ù of strands
(mm)
Cross section
(mm
2
)
Cable O.D.
(mm)
Current rating
(A)
Applcable circuit
Control panel - Ignition switch etc.
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A-B A/B A-G A/G A-N A/N A-R A/R A-V A/V
Colour Light blue Light blue-White Light blue-Yellow Light blue-Black Light blue-Red Light blue-Green
Code B B-G B/G B-L B/L B-N B/N B-R B/R
Colour White White-Yellow White-Blue White-Black White-Red ÐÐ
Code C C-B C/B C-N C/N C-V C/V
Colour Orange Orange-White Orange-Black Orange-Green ÐÐ ÐÐ
Code G G-N G/N G-R G/R G-V G/V ÐÐ ÐÐ ÐÐ ÐÐ
Colour Yellow Yellow-Black Yellow-Red Yellow-Green ÐÐ ÐÐ
Code H H-G H/G H-N H/N H-R H/R ÐÐ ÐÐ ÐÐ ÐÐ
Colour Gray Gray-Yellow Gray-Black Gray-Red ÐÐ ÐÐ
Code L L-G L/G L-N L/N L-R L/R ÐÐ ÐÐ ÐÐ ÐÐ
Colour Blue Blue-Yellow Blue-Black Blue-Red ÐÐ ÐÐ
Code M M-B M/B M-N M/N ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Brown Brown-White Brown-Black ÐÐ ÐÐ ÐÐ
Code N ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Black ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Code R R-N R/N R-V R/V ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Red Red-Black Red-Green ÐÐ ÐÐ ÐÐ
Code S S-G S/G S-N S/N ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Pink Pink-Yellow Pink-Black ÐÐ ÐÐ ÐÐ
Code V V-B V/B V-N V/N V-R V/R ÐÐ ÐÐ ÐÐ ÐÐ
Colour Green Green-White Green-Black Green-Red ÐÐ ÐÐ
Code Z Z-B Z/B Z-G Z/G Z-N Z/N ÐÐ ÐÐ ÐÐ ÐÐ
Colour Violet Violet-White Violet-Yellow Violet-Black ÐÐ ÐÐ
ÐÐ ÐÐ ÐÐ ÐÐ
ÐÐ ÐÐ
COMPOSITION OF THE COLOURS
The coloration of two-colour wires is indicated by the composition of the symbols listed.
Example: G-V = Yellow-Green with longitudinal colouring.
G/V = Yellow-Green with transversal colouring.
00-10
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Machine model PW95-1
From serial no. 0000007
Engine assembly 492
Radiator - exchanger 41
Hydraulic tank (without hydraulic oil) 76
Fuel tank (without fuel) 104
Revolving frame 1092
Counter weight 1150
Swing circle 130
Swing machinery assembly 65
Main hydraulic pump 60
Auxiliary pump 16.5
Operator's cab 250
Operator's seat 32
Operator's seat support 9
Unit: kg
Platform 55
Control valve 60
Track frame assembly 860
Front axle 403
Rear axle 410
Transmission assembly 72
Wheel assembly 79
Center swivel joint 97
Axle locking cylinder cylinder 30.5
Swing bracket 36
Engine hood (movable) 60
Engine hood (fixed) 83
Control valve hood 16
Boom 358
st
1
boom 272
nd
2
boom 195
Arm (L=1850) 156
Arm (L=1600) 134
Outrigger 76
Bracket 29
Outrigger support 140
Blade 192
00-11
TABLE OF OIL AND COOLANT QUANTITIES
RESERVOIR
Lubricating oil
sump
Engine oil filter
Hydraulic system 148 82
Front axle:
.
differential
. planetary (each)
Rear axle:
.
differential
. planetary (each)
Transmission
Swing
machinery
Fuel
tank
KIND OF
FLUID
OIL
. API CD-SG
. MIL-L-2104 E
. CCMC D4-G4
OIL
. UTTO FLUID
OIL
. API GL5
. MIL-L-2105 D
DIESEL FUEL 140 ÐÐ
±20 ±10 0 10 20 30ëC
*
AMBIENT TEMPERATURE CAPACITY (
Specified Refill
SAE 10W
SAE 20W-20
SAE 30
SAE 40
SAE 10W
SAE 80W/90
ASTM D975 N. 2
11.5
1
7.8 7.8
0.9 0.9
7.8 7.8
0.9 0.9
1.9 1.9
44
11.5
< )
1
WATER+
ANTI-FREEZE
Cooling system
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
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
WATER 20 ÐÐ
PERMANENT
LIQUID
ASTM D975 N. 1
*
NOTE:
(1) When fuel sulphur content is less than 0.5%,
change oil in the oil pan ebery periodic maintenance hours described in operation and maintenance manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Fuel sulphur content
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
Oil change interval in engine oil
pan
(2) When starting the engine is weathers temperature
below 0ëC, be sure to use engine oil SAE 10W,
SAE 20W-20, even if weather temperature goes
up to 10ëC day time.
(3) Use classification CD as engine oil, if use classifi-
cation CC, reduce the engine oil change interval to
half.
(4) Use original products, which have characteristics
specifically formulated and approved for the engine, the hydraulic circuit of equipment and for reductions.
20 ÐÐ
20 ÐÐ
00-12
GROUP
10
STRUCTURE AND FUNCTION
P.T.O. .............................................. 10- 2
Power train ........................................ 10- 3
Transmission ...................................... 10- 4
Front axle - differential. .. ......................... 10- 6
Rear axle - differential .. .......................... 10- 7
Planetary........................................... 10- 8
Axles ............................................... 10- 9
Parking brake and cylinder. .. .................... 10-10
Steering system ................................... 10-12
Steering unit .. ..................................... 10-16
Swing circle........................................ 10-17
Swing machinery ... ............................... 10-18
Check valve and oil cooler safety by-pass . .. . .. 10-19
Hydraulic circuit diagram......................... 10-20
Main hydraulic pump ............................. 10-21
Pump drive ........................................ 10-22
Summation horsepower control.................. 10-23
3 circuit control valve ............................. 10-26
Mode-System ...................................... 10-28
Auxiliary pump .................................... 10-29
Priority valve. . ..................................... 10-30
Control valve (valve) .............................. 10-31
Control valve (ports) .............................. 10-32
Swing motor ... .................................... 10-34
Swing motor relief valve .......................... 10-35
Center swivel joint . ............................... 10-36
Travel motor .. ..................................... 10-37
Displacement automatic control high
pressure related ................................... 10-38
Travel motor brake valves........................ 10-39
Servocontrol feed unit ............................ 10-40
R.H. PPC valve.. .................................. 10-42
L.H. PPC valve .. .................................. 10-43
Accumulators ...................................... 10-44
Swing motor braking circuit selector valve...... 10-45
Travel PPC valve . ................................. 10-46
nd
2
boom PPC valve .. ............................ 10-47
Boom swing PPC valve ........................... 10-48
Outrigger and blade PPC valve. ................. 10-49
Outrigger and blade safety valve ................ 10-50
Brake pump . ....................................... 10-51
Axle locking valve ................................. 10-52
Solenoid valves. ................................... 10-53
Electrical circuit diagrams:
1 - Starting and engine line ...................... 10-59
2 - Beams, direction indicator horn and
fan line .. ....................................... 10-61
3 - Column steering switch, R.H. dashboard
switch, mechanical travel speed change
relay and rotary and cutting shovel switch
line ............................................. 10-63
4 - Mode System, relief servocontrol and L.H.
dashboard switch line . ....................... 10-65
5 - Steering emergency switch steering
selection switch and upper slip ring
collector line .. ................................. 10-67
6 - Track frame solenoid valve and steering
relay box line .................................. 10-69
7 - Main box and track frame relay box
disposition ..................................... 10-71
10-1
P.T.O.
3
1
4
2
A
5
15
14
13
12
11
A
Section A - A
6
7
8
9
10
D0400002
1. Connecting plate
2. Crown wheel
3. Flywheel housing
4. Centering ring
5. Screw
6. Screw
7. Screw
8. Hub
9. Pump plate
10-2
10. Screw
11. Flywheel
12. Washer
13. Screw
14. Nut
15. Loose piece
POWER TRAIN
REDUCTION RATIO
Transmission Differential Planetary Axle Total
High speed
Low speed
1.96
3.22 4.25 13.68
6.062 82.92
Front of machine
26.82
Z=12
Z=13
Z=39
Z=9
Z=51
Z=29
Z=49
8
Z=29
10
5
7
Z=29
6
4
Z=51
Z=25
3
2
7
1. Engine
2. Pump
3. Control valve
4. Swivel joint
5. Travel motor
6. Transmission
1
Z=9
Z=12
Z=13
9
Z=29
Z=39
11
D0400003
7. Propeller shaft
8. Front axle
9. Rear axle
10. Front wheel
11. Rear wheel
10-3
TRANSMISSION
6
7
9
A
1
a
3
2
b
A
4
5
8
1. Front coupling
2. Rear coupling
3. Oil drain plug
4. Refilling plug
5. Oil level
6. Safety switch
7. Neutral manual control
8. Speed surveyor
9. Vent plug
10-4
Section A - A
D0400004
a. A port (From EV3 - A2 port)
b. B port (From EV3 - A3 port)
214365 7 8910
11
12
13
14
15
16
17
18
272829
26
19
20
25
24
23
1. Neutral manual control shaft
2. Ball
3. Spring
4. Piston (slow drive control)
5. Piston
6. Piston (high drive control)
7. Input gear
8. Shifting fork
9. Shifting (dog) gear
10. Low speed driven gear
11. Gear (coupling internal gear)
12. Output drive gear
13. Bearing
14. Input shaft
15. Roller bearing
16. Ring gear
17. Output driven gear
18. Bearing
19. Output shaft
20. Rear coupling
21. Roller bearing
22. Protection
23. Low speed idle gear
24. Bearing
25. Front coupling
26. Bearing
27. Roller bearing
28. Flange
29. Coupling
Low speed
Reduction ratio: 1 : 6.0617
High speed
Reduction ratio: 1 : 1.96
Amount of oil: 1.9
22
21
D0400153
,
10-5
FRONT AXLE - DIFFERENTIAL
1
10
Front of machine
3
12
4
5
7
89
11
2
3
4
5
6
1. Central housing
2. Brake bleading screw
3. Service brake piston
4. Braking group
5. Drive shaft
6. Pin
7. Drain plug
8. Differential gear
9 Bevel gear
10. Grease nipple
11. Ring bevel gear
10-6
19
18
17
16
19
14
15
12. Union brake pump
13. Differential bearing
14. Pinion bearing
15. Coupling
16. Nut
17. Seal ring
18. Bevel pinion
19. Refilling plug
Amount of oil: 7.8
D0400006
,
REAR AXLE - DIFFERENTIAL
21
3
6
89
13
10
11
12
4
5
1415 16
24
10
11
7
Front of machine
1. Adjustment screw
2. Cylinder fulcrum lever
3. Parking brake cylinder
4. Differential brake
5. Bevel gear
6. Brake bleading screw
7. Right lever
8. Adjustment screw
9. Push rod
10. Braking group
11. Drive shaft
12. Drain plug
13. Union brake pump
23
22
18
19
2021
14. Central housing
15. Ring bevel gear
16. Service brake piston
17. Pin
18. Pinion bearing
19. Seal ring
20. Nut
21. Coupling
22. Bevel pinion
23. Refilling plug
24. Left lever
Amount of oil: 7.8
17
D0400007
,
10-7
PLANETARY
214365789
22
10
11
Section A - A
23
Section B - B
25
24
A
2
18192021
1617
A
12
13
14
15
1. Drive shaft
2. Bearing
3. Knuckle pin
4. Seal ring
5. Bearing
6. Wheel hub
7. Stud bolt
8. Nut
9. Bearing
10. Planetary carrier
11. Bevel gear
12. Bevel gear pin
13. Pinion
14. Plug
10-8
B
B
15. Ring gear
16. Ring gear support
17. Screw
18. Seal ring
19. Steering knuckle
20. Bushing
21. Bearing
22. Screw
23. Nut
24. Cotter pin
25. Ball-and-socket joint
Amount of oil: 0.9
D0400008
,
AXLES
Front of machine
28°
ba
Front axle
c d
28°
3
Rear axle
3
D0400009
28°
28°
1. Adjustment screw
2. Nut
3. Sensor
FRONT AXLE
a. A Port - From EV9-EV10 group (T Port)
b. B Port - From swivel joint (9a Port)
REAR AXLE
c. C Port - From EV9 - EV10 Port (A Port)
d. D Port - From EV9 - EV10 Port (B Port)
10-9
PARKING BRAKE AND CYLINDER
4365789
13
2
1
14
12
10
11
15
1. Screw
2. Nut
3. Cylinder fulcrum pin
4. Cylinder
5. Gasket
6. Spring
7. Piston
8. Filter
9. Piston fulcrum pin
10. Ball joint
11. Scraper ring
a
12. Bushing
13. Screw
14. Bracket
15. Cylinder fulcrum lever
16. Piston fulcrum lever
a. From EV1 - A Port
SPECIFICATIONS
. Minimum unlocking pressure: 20 bar
. Required oil volume: 47 cm
16
D0400010
3
10-10
110
16
18 19
417
20
D0400011
17. Lever
18. Push rod
19. Push disk
20. Brake disks
B
15
20
EV2
Servocontrol
feed unit
Brake
pump
SYSTEM DESCRIPTION
The parking brake is of the «negative» type, e.i. it provides full mechanical braking in the absence of pressure in the circuits that make the machine safe to
drive.
b
A
19
467
17
D
18
19
18
P3
Engine
C
20
D0400155
16
OPERATION
When the engine is started up the auxiliary pump (P3)
connected to it sends oil to the brake pump and the
servocontrol circuit and pressurizes the system to
which the solenoid valve EV2 is connected when the
machine is idle.
When push-button is pushed EV2 is energized and allows oil to flow into chamber b of the cylinder (4); when
the pressure exceeds the loading on the spring (6) it is
compressed and the piston (7) moves, thus lengthening side B-C of the parallelogram A-B-C-D formed by
the swing centers of the levers (15) and (16), the cylinder fulcrum B (4) and the fulcrum C of the lever (16)
connected to the piston (7).
The swing of levers (15) and (16), coupled directly to
lever (17), cancels out the action on the push rods
(18) joined to the push disks (19).
The limit of the swing and the distribution of the load
generated by the pressure in the cylinder (4) are governed by adjustable screws (1) that act directly on levers (15) and (16).
When the engine stops, EV2 is de-energized, and releases pressure in the circuit. As pressure drops the
spring (6) commences the thrusting action that rotates
the levers (15) and (16). The force of the spring is
transferred to the push rods of the push disks (19)
which act on the brake disks (20) on the rear axle.
10-11
STEERING SYSTEM
12
4
1
3
10
a
T
P
11
d
5
A
2
(P4)
6
B
b
LR
7
(EV9)
(EV10)
8
9
D
13
C
c
D0400013
1. Engine
2. Pump (P4)
3. Tank
4 Priority valve
5. Steering unit
6. Steering wheel
7. Swivel joint
8. Elettrovalvola EV9 esclusione sterzatura ponte
posteriore
9. Elettrovalvola EV10 inversione senso sterzatura
ponte posteriore
10. Cilindro di sterzatura ponte anteriore
11. Cilindro di sterzatura ponte posteriore
12. Pistone cilindro ponte anteriore
13. Pistone cilindro ponte posteriore
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 necessary quantity of oil to the steering system (5), even
when other oleodynamic components supplied by
the same circuit are in operation. The oil passes
from this group (5) into the swivel joint (7) and from
there into the steering cylinders (10) and (11).
Two solenoid valves (8) and (9) can switch the oil
flow to provide three types of steering:
1 - 2 wheels steering
Steering condition in which the rear axle is excluded.
2 - 2 wheels steering and 2 wheels countersteer-
ing. 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 (10) and (11) and transformed into mechanical steering power.
10-12
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