40-28 PC15R-8

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

PW110R-1
00-2 PW110R-1
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to table
below.
C Page to be newly Add

c Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

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

00-1 10-26 10-67 10-108 20-22

00-2 10-27 10-68 10-109 20-23
00-2-1 10-28 10-69 10-110 20-24
00-2-2 10-29 10-70 10-111 20-25
00-3 10-30 10-71 10-112 20-26
00-4 10-31 10-72 10-113 20-27
00-5 10-32 10-73 10-114 20-28
00-6 10-33 10-74 10-115 20-29
00-7 10-34 10-75 10-116 20-30
00-8 10-35 10-76 10-117 20-31
00-9 10-36 10-77 10-118 20-32
00-10 10-37 10-78 10-119 20-33
00-11 10-38 10-79 10-120 20-34
00-12 10-39 10-80 10-121 20-35
00-13 10-40 10-81 10-122 20-36
10-41 10-82 10-123 20-37
10-1 10-42 10-83 10-124 20-38
10-2 10-43 10-84 10-125 20-39
10-3 10-44 10-85 10-126 20-40
10-4 10-45 10-86 20-41
10-5 10-46 10-87 20-1 20-42
10-6 10-47 10-88 20-2 20-43
10-7 10-48 10-89 20-3 20-44
10-8 10-49 10-90 20-4 20-45
10-9 10-50 10-91 20-5 20-46
10-10 10-51 10-92 20-6 20-47
10-11 10-52 10-93 20-7 20-48
10-12 10-53 10-94 20-8 20-49
10-13 10-54 10-95 20-9 20-50
10-14 10-55 10-96 20-10 20-51
10-15 10-56 10-97 20-11 20-52
10-16 10-57 10-98 20-12 20-53
10-17 10-58 10-99 20-13 20-54
10-18 10-59 10-100 20-14 20-55
10-19 10-60 10-101 20-15 20-56
10-20 10-61 10-102 20-16 20-57
10-21 10-62 10-103 20-17 20-58
10-22 10-63 10-104 20-18 20-59
10-23 10-64 10-105 20-19 20-60
10-24 10-65 10-106 20-20 20-61
10-25 10-66 10-107 20-21 20-62

PW110R-1 00-2-1
 Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

20-63 30-43 30-100 30-157 30-214

20-64 30-44 30-101 30-158 30-215
20-65 30-45 30-102 30-159 30-216
20-66 30-46 30-103 30-160 30-217
20-67 30-47 30-104 30-161 30-218
20-68 30-48 30-105 30-162
20-69 30-49 30-106 30-163 40-1
20-70 30-50 30-107 30-164 40-2
20-71 30-51 30-108 30-165 40-3
20-72 30-52 30-109 30-166 40-4
20-73 30-53 30-110 30-167 40-5
20-74 30-54 30-111 30-168 40-6
20-75 30-55 30-112 30-169 40-7
20-76 30-56 30-113 30-170 40-8
30-57 30-114 30-171 40-9
30-1 30-58 30-115 30-172 40-10
30-2 30-59 30-116 30-173 40-11
30-3 30-60 30-117 30-174 40-12
30-4 30-61 30-118 30-175 40-13
30-5 30-62 30-119 30-176 40-14
30-6 30-63 30-120 30-177 40-15
30-7 30-64 30-121 30-178 40-16
30-8 30-65 30-122 30-179 40-17
30-9 30-66 30-123 30-180 40-18
30-10 30-67 30-124 30-181 40-19
30-11 30-68 30-125 30-182 40-20
30-12 30-69 30-126 30-183 40-21
30-13 30-70 30-127 30-184 40-22
30-14 30-71 30-128 30-185 40-23
30-15 30-72 30-129 30-186 40-24
30-16 30-73 30-130 30-187 40-25
30-17 30-74 30-131 30-188 40-26
30-18 30-75 30-132 30-189 40-27
30-19 30-76 30-133 30-190 40-28
30-20 30-77 30-134 30-191 40-29
30-21 30-78 30-135 30-192 40-30
30-22 30-79 30-136 30-193 40-31
30-23 30-80 30-137 30-194 40-32
30-24 30-81 30-138 30-195 40-33
30-25 30-82 30-139 30-196 40-34
30-26 30-83 30-140 30-197 40-35
30-27 30-84 30-141 30-198 40-36
30-28 30-85 30-142 30-199 40-37
30-29 30-86 30-143 30-200 40-38
30-30 30-87 30-144 30-201 40-39
30-31 30-88 30-145 30-202 40-40
30-32 30-89 30-146 30-203 40-41
30-33 30-90 30-147 30-204 40-42
30-34 30-91 30-148 30-205 40-43
30-35 30-92 30-149 30-206 40-44
30-36 30-93 30-150 30-207 40-45
30-37 30-94 30-151 30-208 40-46
30-38 30-95 30-152 30-209 40-47
30-39 30-96 30-153 30-210 40-48
30-40 30-97 30-154 30-211
30-41 30-98 30-155 30-212
30-42 30-99 30-156 30-213

00-2-2 PW110R-1
 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 man-
ual. The cautions accompanying these symbols should always be carefully followed. If any danger arises
or may possibly arise, first consider safety, and take necessary steps to face.

SAFETY
GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions written on the decals which
are suck on the machine.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
. Always wear safety glasses when hitting parts
with a hammer.
. Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on
the controls in the operator's compartment.
5. Keep all tools in good condition and learn the cor-
rect way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor.
Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chine on hard, level ground, and block the wheels
to prevent the machine from moving.
8. Before starting work, lower 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 start-
ing work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting
on or off the machine.
Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
cuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.

PW110R-1 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 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.
00-4
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.
PW110R-1
 FOREWORD

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

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

STRUCTURE AND FUNCTION

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

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

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

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

NOTE

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

PW110R-1 00-5
HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

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

Symbol Item Remarks

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

Example Weight of parts or systems.

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

REVISED EDITION MARK

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

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

00-6 PW110R-1
HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

ing, and a serious accident can result.

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

1. If a part cannot be smoothly removed from the

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

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

The allowable load value is estimated to be

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

2) Sling wire ropes from the middle portion of the

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

PW110R-1 00-7
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

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

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

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

6 1 10 5 0,96w0,1 9,5w1 1,3w0,15 13,5w1,5

8 1,25 13 6 2,3w0,2 23w2 3,2w0,3 32,2w3,5

10 1,5 17 8 4,6w0,5 45w4,9 6,5w0,6 63w6,5

12 1,75 19 10 7,8w0,8 77w8 11w1 108w11

14 2 22 12 12,5w1 122w13 17,5w2 172w18

16 2 24 14 19,5w2 191w21 27w3 268w29

18 2,5 27 14 27w3 262w28 37w4 366w36

20 2,5 30 17 38w4 372w40 53w6 524w57

22 2,5 32 17 52w6 511w57 73w8 719w80

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

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

30 3,5 46 22 131w14 1287w140 184w20 1810w190

33 3,5 50 24 177w20 1740w200 250w27 2455w270

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

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

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

00-8 PW110R-1
STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

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

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

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

Sealing
Superficie surface
di tenuta

Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm
9/16" - 18 17 2.3 ± 2.5 23 ± 25
11/16" - 16 22 3.4 ± 3.9 33 ± 38
13/16" - 16 24 5.2 ± 5.8 51 ± 57
1" - 14 30 8.2 ± 9.2 80 ± 90
1.3/16" - 12 36 12.2 ± 13.3 120 ± 130
1.7/16" - 12 41 15.3 ± 17.3 150 ± 170
1.11/16" - 12 50 18.4 ± 20.4 180 ± 200
2" - 12 57 20.4 ± 24.4 200 ± 240

PW110R-1 00-9
 COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:

Nomenclature Code Applications

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020 seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives
Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270 bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573 dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601 only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675 and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
ASL800060 tings in hydraulic circuits of less than 50 mm in diameter.
Used by itself on mounting flat surface
Gasket sealant Loctite 510 (Clearance between surfaces within 0.2 mm)
Used by itself on mounting flat surface
Loctite 518 (Clearance between surfaces within 0.5 mm)
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent stick-
(Lubricant including ASL800040 ing, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
(Lithium grease) ASL800050 facilitation of assembling work.
Vaseline ± Used for protecting battery electrode terminals from corrosion.

00-10 PW110R-1
ELECTRIC WIRE CODE

ELECTRIC WIRE CODE ELECTRIC

In 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
Copper wire
Nominal Cable O.D. Current rating
number Number ù of strands Cross section (mm) (A)
strands (mm) (mm2)
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
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-N A/N A-R ± A-V A/V A-G ± A-B ±
Colour Light blue Light blue-Black Light blue-Red Light blue-Green Light blue-Yellow Light blue-White
Code B B-G ± B-N B/N B-R B/R ± ± ± ±
Colour White White-Yellow White-Black White-Red ± ±
Code C C-V ± C-B C/B C-N C/N C-L ± ± ±
Colour Orange Orange-Green Orange-White Orange-Black Orange-Blue ±
Code G G-N ± G-R G/R G-V ± G-L ± ± ±
Colour Yellow Yellow-Black Yellow-Red Yellow-Green Yellow-Blue ±
Code H H-G ± H-N ± H-R H/R H-L ± ± ±
Colour Gray Gray-Yellow Gray-Black Gray-Red Gray-Blue ±
Code L L/G ± L-N ± L/R ± ± ± ± ±
Colour Blue Blue-Yellow Blue-Black Blue-Red ± ±
Code M M-B ± M-N ± M-V ± ± ± ± ±
Colour Brown Brown-White Brown-Black Brown-Green ± ±
Code N ± ± ± ± ± ± ± ± ± ±
Colour Black ± ± ± ± ±
Code R R-N R/N R-V ± R-G ± ± ± ± ±
Colour Red Red-Black Red-Green Red-Yellow ± ±
Code S S-G ± S-N ± ± ± ± ± ± ±
Colour Pink Pink-Yellow Pink-Black ± ± ±
Code V V-B V/B V-N ± ± ± ± ± ± ±
Colour Green Green-White Green-Black ± ± ±
Code Z Z-B Z/B 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.

PW110R-1 00-11
 WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model PW110R-1

From serial no. 2260000282
Engine assembly 350
Radiator - exchanger 37
Hydraulic tank (without hydraulic oil) 67
Fuel tank (without fuel) 47
Counterweight 1450
Swing circle 124
Revolving frame 1370
Swing machinery assembly 87
Main hydraulic pump ± Gear pump 97
Cabin 220
Seat 32
Seat support 14.5
Platform 51
Control valve 65
Track frame assembly 1380
Front axle 380
Rear axle + transmission 436
Travel motor 49
Wheel 9.00-20 94
Swivel joint 54
Axle locking cylinder 32x2
Swing bracket 230
Engine hood 36
Front hood 27
Boom 405
st
1 boom 314
nd
2 boom 278
Arm (L=1850) 178
Arm (L=2000) 200
Outrigger 100x2
Bracket 42x2
Blade - outrigger support 179
Blade 217
Work equipment (1-piece boom version)
1300
(Bucket L=900 - Arm L=2000)
Work equipment (2-piece boom version)
1650
(Bucket L=900 - Arm L=1850)

00-12 PW110R-1
 TABLE OF OIL AND COOLANT QUANTITIES
AMBIENT TEMPERATURE CAPACITY ( < )
KIND OF
RESERVOIR ±20 ±10 0 10 20 30ëC
FLUID Specified Refill

SAE 10W

SAE 20W-20
OIL
Crankcase sump 12.5 12.5
. API CD SAE 30

SAE 40

OIL
Hydraulic system SAE 10W 180 84
. API CD
Front axle: 9 9
. differential
. final drive (each) OIL 0.8 0.8
Rear axle . UTTO FLUID
. differential 9 9

. final drive (each) 0.8 0.8

OIL
Transmission SAE 80W/90 1.6 1.6
. API GL5

Swing OIL
SAE 80W/90 3.5 3.5
machinery . API GL5

]
Fuel tank GASOIL 150 ±
ASTM D975 N. 2

WATER+
18 ÐÐ
ANTI-FREEZE

Cooling system WATER 18 ÐÐ

PERMANENT
18 ±
LIQUID

] 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
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

NOTE: (2) When starting the engine is weathers temperature

(1) When fuel sulphur content is less than 0.5%,
change oil in the oil pan ebery periodic mainte-
nance hours described in operation and mainte-
nance manual. Change oil according to the follow-
ing table if fuel sulphur content is above 0.5%.
Fuel sulphur content Oil change interval in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
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 en-
gine, the hydraulic circuit of equipment and for re-
ductions.

PW110R-1 00-13
PW110R-1
GROUP 10
40-28 PC15R-8
 STRUCTURE AND FUNCTION
P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2
Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3
Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
Rear axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
Steering system . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15
Steering unit . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 20
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
Hydraulic circuit . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25
Hydraulic circuit (work equipment) . . . . .. . . . . .. . . . .. . 27
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 28
Main pump. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 29
LS valve. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 38
PC valve .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 46
Priority valve. . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 54
Control valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 56
Swing motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 84
Swing motor relief valve .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 85
Swivel joint . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 86
Travel motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 87
PW110R-1
Displacement automatic control high pressure
related . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 88
Travel motor brake valves . .. . . . .. . . . . .. . . . . .. . . . .. . . . 89
Cylinders . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 90
Axle locking cylinder . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 92
Servocontrol feed unit . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 94
Accumulators . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 99
PPC Valve . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 100
PPC Valve
(blade, boom swing, 2-piece boom) . .. . . . . .. . . . .. . 104
Travel PPC valve .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 107
Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 108
Boom and arm safety valve . . . . .. . . . . .. . . . . .. . . . .. . 109
2-piece boom safety valve . .. . . . .. . . . . .. . . . . .. . . . .. . 110
Blade or outrigger safety valve. .. . . . . .. . . . . .. . . . .. . 111
Over load sensor switch . . . .. . . . .. . . . . .. . . . . .. . . . .. . 112
Solenoid valve
Electrical diagram (1/4) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 119
Electrical diagram (2/4) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 121
Electrical diagram (3/4) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 123
Electrical diagram (4/4) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 125
10-1
P.T.O.

1 2 3

6 5 4 RKP05340

1. Damper
2. Disc
3. Flywheel
4. Dowel
5. Hub
6. Pump

10-2 PW110R-1
POWER TRAIN

REDUCTION RATIO
Transmission Differential Planetary Axle Total
High speed 1.31 29.71
3.78 6.00 22.68
Low speed 4.53 102.74

Fronte macchina
Front of machine 10

Z=34 8
Z=70

Z=14

Z=27

Z=9

7 2
5
3
4
Z=51
Z=39

Z=86
Z=19

6
Z=70

Z=14

Z=27

Z=9 Z=34
9
11
RKP05680

1. Engine 7. Propeller shaft

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

PW110R-1 10-3
FRONT AXLE

Differential
1 2 3 4 5

8 7 6

11 12
9 10

16 15 14 13
RKP05390

1. Ring nut 11. Pinion (Z=9)

2. Differential housing 12. Plug
3. Pin 13. Bearing
4. Ring bevel gear (Z=34) 14. Spacer
5. Bearing 15. Ring nut
6. Bevel gear 16. Flange
7. Differential gear
SPECIFICATIONS
8. Drive shaft
Amount of oil: 9,
9. Nut
Reduction ratio 9:34
10. Bearing

10-4 PW110R-1
Brakes

A
1 2 3 a

A
Section
SezioneAA±-AA

4 5 6 7

RKP05380

1. Pin a. From swivel joint (7a Port)

2. Pressure disk
3. Screw
4. Disk
5. Brake disk
6. Bushing
7. Screw
8. Spring

PW110R-1 10-5
Final reduction

4 5 6 7 8 9 10

11
1 2 3
12

13

14

16 15

23 22 21 20 19 18 17 RKP05370

1. Bearing 15. Bevel gear (Z=70)

2. Dowel 16. Ring gear carrier
3. Cardan shaft (Z=14) 17. Screw
4. Bushing 18. Seal
5. Pin 19. Seal
6. Seal 20. Bushing
7. Wheel hub 21. Housing
8. Bearing 22. Seal
9. Nut 23. Bush
10. Stud bolt
SPECIFICATIONS
11. Support
Amount of oil: 0.8 ,
12. Bevel gear (Z=27)
Reduction ratio: 1:6
13. Bushing
14. Plug

10-6 PW110R-1
Steering cylinder

A A
a 2 b

Section
Sezione B
B ±- B
B
3 4 Section AA-±AA
Sezione
RKP05320

1. Steering cylinder
2. Sensor
3. Nut
4. Pin cotter
a. Port b - From swivel joint (1a Port)
b. Port a - From ST4 solenoid valve group (T Port)

PW110R-1 10-7
TRANSMISSION

B
B

1 2 A 3

5
6
4

7
a b 10 9 8
Section BA-±BA
Sezione RKP05300

a. e Port - From swivel joint (14a Port) 8. Selector shaft

b. f Port - From swivel joint (5a Port) 9. Ball
10. Spring
1. Filler and level oil plug
2. Oil drain plug SPECIFICATIONS
3. Flange Amount of oil: 1.6 ,
4. Neutral manual control Reduction ratio:
5. Speed selector piston . Low speed: 1: 4.53
6. Selecting fork . High speed: 1: 1.31
7. Safety switch

10-8 PW110R-1
 1 2 3 4

5
6

19

18
17

16 15
9
14

13 12 11 10
RKP05270

1. Flange 11. Protection

2. Breather 12. High speed drive gear (Z=51)
3. High speed drive gear (Z=39) 13. Oil drain plug
4. Front housing 14. Cover
5. Low speed drive gear (Z=19) 15. Bearing
6. Bearing 16. Flange
7. Low speed driven gear (Z=86) 17. Output shaft
8. Roller bearing 18. Nut
9. Bearing 19. Bearing
10. Front housing

PW110R-1 10-9
REAR AXLE

Differential
1 2 3 4 5

8 7 6

11 12

9 10

16 15 14 13
RKP05290

1. Ring nut 13. Bearing

2. Differential gear 14. Spacer
3. Pin 15. Seal ring
4. Ring bevel gear (Z=34) 16. Ring nut
5. Bearing
SPECIFICATIONS
6. Bevel gear
Amount of oil: 9,
7. Differential gear
Reduction ratio: 9:34
8. Drive shaft
9. Bearing
10. Bearing
11. Pinion (Z=9)
12. Plug

10-10 PW110R-1
Final reduction

4 5 6 7 8 9 10

11
1 2 3
12

13

14

16 15

23 22 21 20 19 18 17 RKP05370

1. Bearing 15. Ring gear (Z=70)

2. Dowel 16. Ring gear carrier
3. Cardan shaft (Z=14) 17. Screw
4. Bushing 18. Seal
5. Joint 19. Seal
6. Seal 20. Bushing
7. Wheel hub 21. Housing
8. Bearing 22. Seal
9. Nut 23. Bushing
10. Stud bolt SPECIFICATIONS
11. Support Amount of oil: 0.8 ,
12. Bevel gear (Z=27) Reduction ratio: 1:6
13. Bushing
14. Plug

PW110R-1 10-11
Steering cylinder

A A
a 2 b
2

Section
Sezione B
B± B
-B
3 4 SectionAA- ±AA
Sezione
RKP05330

1. Steering cylinder
2. Sensor
3. Nut
4. Pin cotter

a. d Port - From ST4 solenoid valve (B port)

b. c Port - From ST4 solenoid valve (A port)

10-12 PW110R-1
Brakes and parking brake cylinder

1 2 3

Section
Sezione A
A ±- A
A

7 6 5

9 10 11

8 5

a b
13 12
RKP05250

1. Pin 10. Screw

2 Nut 11. Bushing
3. Dowel 12. Spring
4. Brake bleeding screw 13. Brake disk
5. Brake lever
a. From swivel joint (8a Port)
6. Push-rod
b. From swivel joint (4a Port)
7. Pressure disk
8. Brake lever
9. Disk

PW110R-1 10-13
 17 18 19 20

14 15 16

8
2 3

23 22 21
RKP05440

14. Tie-rod SYSTEM DESCRIPTION

15. Return lever The parking brake is of the «negative» type, e.i. it pro-
16. Piston vides full mechanical braking in the absence of pres-
sure in the circuits that make the machine safe to
17. Guide ring drive.
18. Spring
19. Gasket OPERATION
20. Cylinder fulcrum pin When the engine is started up the pump (P1) con-
21. Cylinder nected to the servocontrol circuit pressurizes the sys-
tem to which the solenoid valve Y11 is connected
22. Filter
when the machine is idle.
23. Fulcrum lever When push-button is pushed Y11 is energized and al-
lows oil to flow into chamber b of the cylinder (21);
when the pressure exceeds the loading on the spring
(18), it is compressed and the piston (16) moves, thus
lengthening side B-C of the parallelogram A-B-C-D
formed by the swing centers of the levers (8) and
(23), the cylinder fulcrum B (21) and the fulcrum C of
the lever (8) connected to the piston (16).
The swing of levers (8) and (23), coupled directly to le-
ver (5), cancels out the action on the push rods (6)
joined to the push disks (7).
The limit of the swing are governed by adjustable
screws (3) that act directly on levers (8) and (23).
When the engine stops, Y11 is de-energized, and re-
leases pressure in the circuit. As pressure drops the
spring (18) commences the thrusting action that ro-
tates the levers (8) and (23). The force of the spring
is transferred to the push rods of the push disks (7)
which act on the brake disks (13) on the rear axle.

10-14 PW110R-1
STEERING SYSTEM

4 1
3
10
9 T P
a d
5
A D
2 (P2)
11 6 12
B C

7 Y22 Y24 c
b
R L
1 1 P B

2 2 T A
Y21 Y23

RKP10410

DESCRIPTION
. The steering system is completely hydraulic. The
1. Engine oil required, supplied by the pump (2) driven by
2. Pump (P2) the motor (1), is sent to the priority valve (4) which
3. Tank functions by Load Sensing, and sends the neces-
sary quantity of oil to the steering system (5), even
4 Priority valve
when other oleodynamic components supplied by
5. Steering unit the same circuit are in operation. The oil passes
6. Steering wheel from this group (5) into the swivel joint (7) and from
7. Swivel joint there into the steering cylinders (9) and (10).
8. ST4 Solenoid valve group: The solenoid valve group (8) can switch the oil flow
to provide three types of steering:
± Y21: Rear steering cut out
1 - 2 wheels steering
± Y22: Front/rear steering
Steering condition in which the rear axle is ex-
± Y23: Phase coincidence steering cluded.
± Y24: Crab steering 2 - 2 wheels steering and 2 wheels counter-
9. Front axle steering cylinder steering. Steering condition in which rear
10. Rear axle steering cylinder steering is activated and the direction of the
11. Front axle cylinder piston rear wheels is contrary to that of the front
12. Rear axle cylinder piston 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 trans-
formed into mechanical steering power.

PW110R-1 10-15
OPERATION
1 - Steering with front wheels, only.

b 12 a 10 b 10 12 a

B A B A

e R T e R T
h h
5 3 5 3
g g
L P L P

4 4
f f
7 7
6 2 6 2
(P2) (P2)
Y21 Y22 Y21 Y22

Y23 Y24 Y23 Y24

RKP10420 RKP04390

STEERING TO THE RIGHT STEERING TO THE LEFT

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

10-16 PW110R-1
2 - Steering with 2 wheels steering and 2 wheels countersteering.

b 12 a 10 10 12
b a

B A
B A

h e R T h e R T
g 5 3 3
g 5
L P
L P
f 4 f 4
7
7
6 2 6 2
(P2)
(P2)
Y21 Y22
Y21 Y22

Y23 Y24
Y23 Y24
m
n m
n
C D
C D

c 13 11 d c d
11 13
RKP04410
RKP04420

STEERING TO THE RIGHT STEERING TO THE LEFT

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

PW110R-1 10-17
3 - Steering with 4 wheels steering in the same direction.

b 12 a 10 10 12 a
b

B A B A

h e R T h e R T

g 5 3 5 3
g
L P L P

f 4 f 4
7 7
6 2 6 2
(P2) (P2)
Y21 Y22 Y21 Y22

Y23 Y24 Y23 Y24

m m
n n
C D C D

c d
11 13 c 13 11 d

RKP04430
RKP04450

STEERING TO THE RIGHT STEERING TO THE LEFT

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

10-18 PW110R-1
STEERING UNIT

a e b

LS

L R

T P

c d RKP03740

a. L Port - To swivel joint (1A Port) SPECIFICATIONS

b. R Port - To swivel joint (9A Port) Steering unit type: OSPC200LS
c. T Port - To tank Rated discharge: 20 ,/min
d. P Port - From priority valve (CF Port)
e. LS Port - From priority valve (LS Port) OPERATION
. The steering unit consists of a control valve and a
rotating oil dispenser and functions hydrostatically.
. When the steering wheel is moved, the control
valve sends oil from pump P2 (through the rotating
oil dispenser) to one or other of the chambers of the
steering cylinder. The rotating oil dispenser en-
sures that the amount of oil supplied to the cylinder
is proportional to the rotation angle of the steering
wheel.
. If the steering unit pump malfunctions the oil dis-
penser functions automatically like a hand-pump
to ensure emergency steering.

PW110R-1 10-19
SWING CIRCLE

4 5

1
Section C -±CC
Sezione C

2 Section A -±AA
Sezione A
3
6
Section B -±BB
Sezione B
D
7

A
D

C
6
Section
Sezione D
D±- D
D
C

B
B

8
SezioneEE±- E
Section E
A
RKP04680

1. Swing circle outer race 7. Nut

2. Ball bearing 8. Grease nipple (No. 2)
3. Swing circle inner race
4. Pin SPECIFICATIONS
5. Screw Reduction ratio: 81/11=7.37
6. Screw

10-20 PW110R-1
 PAGE INTENTIONALLY
LEFT BLANK

PW110R-1 10-21
SWING MACHINERY

9
8

10
a
11
7
12

6 13

5 14
15
4
3

16

2
17

RKP04240

10-22 PW110R-1
 1. Swing pinion (Z=11) 14. Drive gear (Z=78)
2. Case 15. 2nd reduction central gear (Z=18)
3. 2nd planetary carrier 16. Bearing
4. 2nd reduction sun (Z=29) 17. Bearing
5. 1st planetary carrier
6. 1st reduction sun (Z=32) a. x Port - From ST2 solenoid valve (A1 port)
7. Joint
8. Spring
9. Plug
10. Piston
11. Brake disc
12. Motor support
13. 1st reduction central gear (Z=12)

PW110R-1 10-23
 PAGE INTENTIONALLY
LEFT BLANK

10-24 PW110R-1
HYDRAULIC CIRCUIT

Boom swing 2-Piece boom

PPC valve PPC valve

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

R.H. PPC valve Y8 Y9
T OP2 Solenoid
Travel valve group
P PPC valve B A
T
T Rear axle
P
ST2 Solenoid A P4 P3 P2 P1 P1 P2 P1 P2
valve group P
P4 P3 P1 P2
Y2 T P Y1

A1 ST3
Y5 ø 0.6 ø 0.6 ø 0.6 ø 0.6
d c
B A f

Y11 A e
ST4 Solenoid
T valve group Swing motor
P
Y21
Y22

TS PDB PA1 PA2 PA3 PA4 PA5 PA6 PA7 PA8 PA9 PA10 P T
ST1 Solenoid
valve group B A
T

2-Piece boom
Boom swing
300 kg/cm2

equipment
Additional
Y12 Y4 Y23

L.H. travel

Bucket
Boom
Travel
Y24

Arm
A2

A3
P1
Y10

330 kg/cm2
32 kg/cm2
B A
A1

R.H. swing

200 kg/cm2

200 kg/cm2
Y7 Front axle
a b
A

PLS
P T

220 kg/cm2

Axle locking
ø 0,6

cylinder
TC TB TSW PB1 B1 A1 P2 PB2 B2 A2 PB3 B3 A3 PB4 B4 A4 PB5 B5 A5 PB6 B6 A6 PB7 B7 A7 PB8 B8 A8 PB9 B9 A9 PB10 B10 A10
B B

R.H. swing
Oil cooler

L.H. swing
Forwards
Reverse

Lower

Close

Close
Raise

Close
Open

Open

Open
ø 0.5

2-Piece boom cylinder

Boom swing cylinder

R.H. side

L.H. side
2

(Ø100xØ60-900)
Bucket cylinder
(Ø110xØ70-770)
14 12 10 8 6 4

Boom cylinder
Swivel jonit

(Ø90xØ60-800)
13 11 9 7 5 3 1

(Ø100xØ60-650)
Arm cylinder

(Ø90xØ60-650)
70 艎
Delivery
filter 25␮
B S A
PST
PST

Hydraulic M3
tanck 220/170 bar
Filter: 10␮
Suction
MA
MB

filter 90␮

PLS PEN PD3 P2

39.4 kg/cm2
PEPC

Swing
ø 0.9

ø 0.3min F R2 R1
PC motor
X
Q max

ø 0.9

T'1
T1 P R
EPC

Q min

PR
PA
Ø1
ø 0.9

P
38 kg/cm2

50 kg/cm2

P1 T'2
B
T2

P CF
T L
PA3 PB PD1 PS PD2 T
EF LS
N
PGA
PGS

M2 Priority Brake pump Steering unit

valve LS

RKP07201

10-25
 PAGE INTENTIONALLY
LEFT BLANK

10-26
HYDRAULIC CIRCUIT (WORK EQUIPMENT)

REAR OUTRIGGER AND

FRONT BLADE VERSION 4 OUTRIGGER VERSION

LEFT RIGHT LEFT RIGHT

T P T P T P T P

P1 P2 P1 P2

P2 P1 P2 P1

P1 P2 P2 P1 P1 P2 P2 P1

REAR BLADE VERSION REAR OUTRIGGER VERSION

LEFT RIGHT
T P T P
T P
PA2 P B2 P A7 P B7 PA2 PB2 PA7 PB7
P2 P1 P2

P1 P2 P1

P1 P2 P2 P1
P1 P2

A2 A7 A2 B2 A7 B7 PA2 PB2
B2 B7
PA2 PB2 PA7 PB7

FRONT BLADE FRONT OUTRIGGER

Left Right Left Right

10 2 6 10 2 6

A2 B2
A2 B2 A7 B7

C2 C1 C2 C1 C2 C1 C2 C1
10 2 6

V2 V1 V2 V1 V2 V1 V2 V1 10 2 6

V2 V1 V2 V1
C2 C3 C2 C3

P1 P1 V2 V1 V2 V1
C2 C1 C2 C1
P2 P2

C2 C1 C2 C1

C4 C1 C4 C1

V2 V1 V2 V1 V2 V1 V2 V1 Left Right
REAR BLADE

Left Right
C2 C1 C2 C1 C2 C1 C2 C1
REAR OUTRIGGER

Left Right Left Right

REAR OUTRIGGER REAR OUTRIGGER

RKP07190

10-27
HYDRAULIC PUMP

1 2 3

c 4 b

d e f

l 6

Vista Y h g 5
RKP03410

a. PGS Port - From hydraulic tank 1. LS valve

b. PEPC Port - From servocontrol feed unit 2. PC valve
(PR Port) 3. Fixed throttle valve
c. PS Port - From hydraulic tank 4. Mode System solenoid valve (y6)
d. PA Port - To servocontrol feed unit (P1 Port) 5. Main pump
e. PB Port - From control valve (P1 port) 6. Gear pump
f. PD Port - To hydraulic tank
SPECIFICATIONS
g. PA3 Port - From gear pump (PGA port)
Main pump theorical displacement: 90 rev.
h. PLS Port - From control valve (PLS port)
Gear pump theorical displacement: 32 rev.
l. PGA Port - To hydraulic tank (P2 port)

10-28
MAIN PUMP

HPV95

a b

A A

B B

View
Vista X
x

X Y

ViewyY
Vista

View zZ
Vista RKP03400

a. PD Port - To hydraulic tank

b. PA Port - To servocontrol feed unit (P1 Port)
c. PS Port - From hydraulic tank

PW110R-1 10-29
 1 2 3 4 5 6 7 8 9

10 12 11
Section
SezioneA
A±- A
A Section
Sezione C
C±- C
C

D
C
C

D Section
Sezione D
D ±- D
D

Section B -±BB
Sezione B RKP03150

1. Shaft
2. Cradle
3. Case
4. Swash plate
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Cover
10. Spring
11. Servo piston
12. Lever

10-30 PW110R-1
FUNCTION
. The engine rotation and torque transmitted to the
pump shaft is converted into hydraulic energy,
and pressurized oil is discharged according to the
load.
. It is possible to change the delivery amount by
changing the swash plate angle.

1 2 3 4 5 A 6 7 8 9

B a 10
Section
Sezione A
A±- A
A RKP03120

STRUCTURE
. The cylinder block (7) is supported to the shaft (1)
by the spline a, and the shaft (1) is supported by
the front and rear bearings.
. Tip of the piston (6) is a concave ball, and shoe (5)
is caulked to it to form one unit. The piston (6) and
the shoe (5) form a spherical bearing.
. The rocker cam (4) has a flat surface A, and the
shoe (5) is always pressed against this surface
while sliding in a circular movement.
. The rocker cam (4) brings high pressure oil at the
cylindrical surface B with the cradle (2), which is se-
cured to the case, and forms a static pressure bear-
ing when it slides.
. The piston (6) carries out relative motion in the axial
direction inside each cylinder chamber of the cylin-
der block (7).
. The cylinder block (7) seals the pressure oil to the
valve plate (8), and carries out relative rotation.
This surface is so designed that the oil pressure
balance is maintained at a suitable level. And oil in-
side each cylinder of the cylinder block (7) is
sucked in and discharged through the valve plate
(8).

PW110R-1 10-31
OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the 1 4 5 A 7
shaft (1), and the shoe (5) slides on the flat sur-
face «A».
At this time, the rocker cam (4) moves along
the cylindrical surface «B», so the angle «a»
between the center line X of the rocker cam
(4) and the inclination of the cylinder block
(7) in the axial direction changes.
This angle «a» is called the swash plate angle. X
B RKP03560

2 - When the center line X of the rocker cam (4)

maintains the swash plate angle «a» in rela-
tion to the axial direction of the cylinder block 1 4 A 6 F
(7), the flat surface «A» acts as a cam for the
5
shoe (5).
By this, the piston (6) slides on the inside of
the cylinder block (7), creates a difference be-
tween capacities E and F, then suction and
discharge of oil for the amount of the differ-
ence (F±E) will be carried out.
In other words, oil is discharged as the capa-
city of the chamber E decreases when the cy- X
linder block (7) rotates.
In the mean time, the capacity of the chamber E
F increases, and the oil is sucked at this pro-
7 RKP03570

cess.
(The figure shows the state of the pump when
suction of the chamber F and discharge of the
chamber E have completed).

3 - When the center line X of the rocker cam (4)

becomes in line with the axial direction of the
cylinder block (7) (swash plate angle = 0),
the difference between capacities of E and F 4 F
inside the cylinder block (7) becomes 0, so
the pump does not carry out any suction or dis-
charge action of oil.
(In actual fact, the swash plate angle never be-
comes 0). X
4 - In other words, discharge amount of the pump
is directly proportional to the swash plate an-
gle «a».

7 E RKP03580

10-32 PW110R-1
2. Control of Discharge Amount 4
2
. As the swash plate angle «a» becomes larger,
difference between the capacities E and F be-
comes larger, so the discharge amount Q in-
creases.
The swash plate angle «a» is changed by the
servo piston (11).
. The servo piston (11) moves in a linear recipro-
cating motion ( × ) under the signal pressure of
TVC and LS valve.
This linear motion is transmitted with the lever
(12) to the rocker cam (4), which is supported
by the cylindrical surface of the cradle (2), and
the rocker cam slides in the semi-circular reci-
procating direction ( ).
. The upper and lower pressure receiving area of
the servo piston (11) are different from each
other, and to the pressure chamber of the smal- RKP03550
ler piston side (right), discharge pressure (self
pressure) PP of the main pump is always intro-
duced.
To the pressure chamber of the larger piston
side (left), output pressure PEN of the LS valve
is introduced. 11 12
Movement of the servo piston (11) is controlled
by the relationship between pressures PP and
PEN and the proportion of the pressure receiving
areas of the smaller and larger pistons (11).
PEN

PP

RKP03610

PW110R-1 10-33
LS VALVE

1 2 3 4 5 6 7 8

f
a
b c d e
RKP03420

a. PLS Port - Control valve LS pressure inlet port 1. Union

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

PC VALVE

1 2 3 4 5 6 7 8 9 10 11

a b c d e

RKP03430

a. Pa Port - Drain pressure outlet port 1. Piston

b. PPL Port - PC valve signal pressure outlet port 2. Spring
c. PA Port - Pump delivery pressure inlet port 3. Seat
d. PA3 Port - Swing sensing pressure port 4. Spring
e. PM Port - PC mode select pressure inlet port 5. Seat
6. Spool
7. Piston
8. Sleeve
9. Nut
10. Union
11. Nut

10-34 PW110R-1
FIXED THROTTLE VALVE
1 b c 2

RKP03380

a. Pa Port - Drain pressure outlet port 1. Plug

b. Pout Port - Control pressure outlet port 2. Plug
c. Pin Port - LS valve signal pressure inlet port

PW110R-1 10-35
FUNCTION
1. LS VALVE
. The LS valve detects the load and controls the dis-

Q (ᐍ / min)
charge amount.
This valve controls main pump discharge amount Q

Pump discharge amount Q

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

PC VALVE (Power Control)

FUNCTION
. The PC valve carries out an approximate equal
horse-power control so that the hydraulic horse-
power sucked by the pump does not exceed the en- Mode system P with
swing pump in operation
gine horse-power by limiting the discharge amount
Q to a specified about in relation with the discharge x=0.6A Mode system E
Pump discharge amount Q

pressure PP, even if the LS valve tries to increase

the pump discharge amount Q when the discharge x=0 Mode system P
pressure PP becomes high and opening area of the
control valve is large.
. In other words, when a load becomes large during
operation and the pump discharge pressure PP
rises, the PC valve reduces the pump discharge
amount Q, and when the pump discharge pressure
PP lowers, it increases the pump discharge amount
Q. Pump discharge pressure PP
RKP03441
. Relationship between the pump discharge pres-
sure PP and the pump discharge amount Q is as
shown in the chart.
Normally, it is set to the pump suction torque of the
standard mode, but when a signal from the PC-
EPC mode switching solenoid valve is inputted,
the pump suction horsepower lowers by approxi-
mately 20% as shown by the light-load mode curve.
. Since the swing pump is mounted directly on the
main pump, when the swing pump is in operation,
suction torque of the main pump is reduced by
the amount sucked by the swing pump so that the
sum of the main pump suction torque and the
swing pump suction torque becomes the total suc-
tion torque (100%).

10-36 PW110R-1
 PAGE INTENTIONALLY
LEFT BLANK

PW110R-1 10-37
LS VALVE

OPERATION
1. When the control valve is at «NEUTRAL» position

To the actuator

PLS

Control valve
PPLS

PT
Servocontrol
PC valve feed unit

PP

Gear pump
D
Main
pump C

Fixed throttle H 6 B 4
valve

A A

K J
Large
diameter end 11 Small diameter end

Direction of
RKP03461
min. discharge

10-38 PW110R-1
. The LS valve is a three-way selector valve, with
pressure PLS (LS pressure) from the inlet port of
the control valve brought to spring chamber B,
and main pump discharge pressure PPLS brought
to port H of sleeve (8).
The size of the force produced by this LS pressure
PLS+force Z of spring (4) and the main pump pres-
sure (self-pressure) PPLS determines the position
of spool (6).
. Before the engine is started, servo piston (11) is
pushed to the right (large diameter end). (See the 11
diagram on the right).
(The spring chamber B is open to the drain circuit
through the spool of the control valve).
. Therefore, the spool (6) is pushed to the right side
( ), a path is formed between the Ports C and
D, and then the pump pressure PP is led to the
chamber K at the large diameter side of the servo Section
Sezione A
A ±- A
A RKP03850
piston (11).
. Though the pump pressure PP is always intro-
duced to the chamber J of the small diameter side
of the servo piston (11), because the force to the
large diameter side is larger due to the difference
of the areas at two ends of the servo piston (11),
the servo piston (11) is moved to the minimum
swash plate angle side ( ).

PW110R-1 10-39
2. When the opening of the control valve is large (lever stroke large)

To the actuator

PLS
Control valve
PPLS

PT
Servocontrol
PC valve feed unit

PP

Gear pump E

Main
D
pump
C
B

Fixed throttle 6 4
valve

K J
Large
diameter end 11 Small diameter end

Direction of
RKP03491
min. discharge

10-40 PW110R-1
. When the control lever is moved to full-stroke, in
other words, as the opening area of the control
valve becomes large, the difference of the pump
pressure PPLS and the LS pressure PLS (LS differ-
ential pressure DPLS) becomes smaller.
. LS pressure PLS introduced to the spring chamber
B of the LS valve becomes more or less the same
as the pump pressure PPLS and the spool (6) is
pushed to the left side ( ) by the combined force
of the LS pressure and the spring (4), closing the
Port C and forming a path between the Ports D
and E.
. Therefore, the pressure oil functioning to the cham-
ber X at the large diameter side of the servo piston
(1) flows to the Port D from the Port E, and then to
the PC valve.
. At this time, since the Port E of the PC valve is open
to the drain inside the pump case through the in-
side of the piston, pressure in the chamber K of
the large diameter side of the servo piston also be-
comes to the drain pressure.
. By this, the servo piston (11) is moved to the max.
swash plate angle side ( ) by the pump pressure
PP functioning to the chamber J at the small dia-
meter side.

PW110R-1 10-41
3. When pump delivery reduces

To the actuator

PLS

Control valve
PPLS

PT
Servocontrol
PC valve feed unit

PP

Gear pump
D
Main
pump C

Fixed throttle 6 4
valve

K J
Large
diameter end 11 Small diameter end

Direction of
min. discharge RKP03501

10-42 PW110R-1
. The following explains the situation if servo piston
(11) moves to the left (the discharge amount be-
comes smaller). When LS differential pressure
DPLS becomes larger (for example, when the area
of opening of the control valve becomes smaller
and pump pressure PPLS rises), the force pro-
duced by pump pressure PPLS pushes spool (6)
to the ( ).
. When spool (6) moves, main pump pressure PP
flows from port C to port D, and it enters the large
diameter end of the piston (11) from port K.
. Main pump pressure PP also enters port J at the
smaller diameter end of the piston, but because
of the difference in area between the large dia-
meter end and the small diameter end of servo pis-
ton (11), servo piston (11) is pushed to the ( ).
As a result, the swash plate moves in the direction
to make angle smaller.

PW110R-1 10-43
4. When the pump flow is proper the demand of the control valve

To the actuator

PLS

Control valve
PPLS

PT
Servocontrol
PC valve feed unit

PP

E
Gear pump
D
Main
pump C

H 6 4
Fixed throttle
valve

PEN

A1 A2
Large
diameter end 11 Small diameter end
K J
RKP03481

10-44 PW110R-1
. Let us take the pressure receiving area at the large
diameter side of the servo piston (11) as A1, pres-
sure receiving area at the small diameter side as
A2, pressure functioning to the large diameter side
as PEN, and the pressure to the small diameter side
as PP.
. When the pump flow rate reaches the flow demand
of the control valve, the pump pressure PPLS func-
tioning to the Port H of the LS valve balances with
the combined force of the LS pressure PLS func-
tioning to the spring chamber B and the spring
(4), and the piston (6) stops at the intermediate po-
sition.
(It will stop at a position where the openings of the
throttle from port D to port E and from port C to port
D of spool (6) are approximately the same).
. At this time, because the relationship of the pres-
sure receiving areas on the servo piston (11) is
A2 : A1=1 : 1.75, the pressure functioning to
two ends of the servo piston (11) becomes
PP : PEN=2 : 1, so the forces to the two ends of
the servo piston (11) becomes 1 : 1, and the servo
piston (11) stops at the position, balancing the flow
demand of the control valve and the pump dis-
charge.
. Spring force is so adjusted that the piston (6) is -
balanced when
PPLS ± PLS=DPLS=22 bar (22.5 kg/cm2).

PW110R-1 10-45
PC VALVE

FUNCTION
1. When load on the actuator becomes small (pump discharge pressure lowers)

To the actuator

PLS
Control valve

PPLS

Servocontrol
feed unit
PP Swing
blade

PG
PT

Main pump
pressure Gear pump
C
Gear pump
pressure
4 6 Main pump

LS valve

Fixed
throttle
valve

2 3

Large
Small diameter end diameter end

Direction of Direction of
max discharge min. discharge

mode-system
PC-EPC selector
valve

Resistor

1 RKP03471

10-46 PW110R-1
a) Action of PC-EPC solenoid (1)
. The command current from resistor flows to PC-
EPC solenoid (1).
This command current acts on the PC-EPC valve
and outputs the signal pressure. When this signal
pressure is received, the force pushing piston (2)
is changed.
. On the opposite side to this force pushing piston (2)
is the spring set pressure of springs (4) and (6) and
pump pressure PP pushing spool (3). Spool (3)
stops at a position where the combined force push-
ing spool (3) is balanced, and the pressure (pres-
sure of port C) output from the CP valve.

PW110R-1 10-47
b) Function of the spring

To the actuator

PLS
Control valve

PPLS

Servocontrol
feed unit
PP Swing
blade

PG

B C
B
PT
Gear
C pump
A
D
Main pump

When port B and C 4 5 6 7

are connected E

LS valve

8
G
9 Fixed
throttle
valve

2 3

J
Large
Small diameter end diameter end

Direction of
max discharge

mode-system
PC-EPC selector
valve

Resistor

1 RKP03511

10-48 PW110R-1
. Port C of the PC valve is connected to port E of the
LS valve (see (1) LS valve).
Self-pressure PP enters port B, the small diameter
end of servo piston (9), and port A.
. The spring load of springs (4) and (6) in the PC
valve is determined by the swash plate position.
. When servo piston (9) moves, piston (7), which is
connected to slider (8), also moves to the right or
left.
. If piston (7) moves to the left, spring (6) is com-
pressed, and if it moves further to the left, spring
(6) contacts seat (5) and is fixed in position. From
this point, only spring (4) is actuated. In other
words, the spring load is changed by piston (7) ex-
tending or compressing springs (4) and (6).
. if the command current input to PC-EPC valve sole-
noid (1) changes further, the force pushing piston
(2),changes. The spring load of springs (4) and (6)
also changes according to the value of the PC-
EPC valve solenoid command current.
. When pump pressure PP is small, spool (3) is on
the left. At this point, port C and D are connected,
and the pressure entering the LS valve becomes
drain pressure PT. If port E and G of the LS valve
are connected (see (1) LS valve), the pressure en-
tering the large diameter end of the piston from port
J becomes drain pressure PT, and servo piston (9)
moves to the right. In this way, the pump discharge
amount moves in the direction of increase.
. As servo piston (9) moves further, piston (7) is
moved to the right by slider (8). Spring (4) and (6)
expand and the spring force becomes weaker.
When the spring force becomes weaker, spool (3)
moves to the right, so the connection between port
C and port D is cut, and the pump discharge pres-
sure ports B and C are connected. As a result, the
pressure at port C rises, and the pressure at the
large diameter end of the piston also rises, so the
movement of piston (9) to the right is topped.
In other words, the stop position for piston (9)
(=pump discharge amount) is decided at the point
where the force of springs (4) and (6) and the push-
ing force from the PC-EPC valve solenoid and the
pushing force created by pressure PC acting on
spool (3) are in balance.

PW110R-1 10-49
2. When load on the actuator is large (pump discharge pressure is high)

To the actuator

PLS
Control valve

PPLS

Servocontrol
feed unit
PP Swing
blade

PG

B PT
Gear
A C pump

D Main pump

2 3 4 6 7 E

LS valve

9 G
Fixed
throttle
valve

Large
Small diameter end diameter end

Direction of
min. discharge

mode-system
PC-EPC selector
valve

Resistor

1 RKP03521

10-50 PW110R-1
. When the load is large and pump discharge pres-
sure PP is high, the force pushing spool (3) to the
left becomes larger and spool (3) moves to the po-
sition shown in the diagram above.
When this happens, as shown in the diagram
above, part of the pressurized oil from port X
passes through the LS valve, flows out from port
C to port D, and the pressurized oil flowing from
port C to the LS valve becomes approximately 3/5
of main pump pressure PP.
. When port E and port G of the LS valve are con-
nected (see (1) LS valve), the pressure from port
J enters the large diameter end of servo piston
(9), and servo piston (9) stops.
. If main pump pressure PP increases further and
spool (3) moves further to the right, main pump
pressure PP flows to port B and port C and acts
to make the discharge amount the minimum. When
piston (9) moves to the left, piston (7) is moved to
the left. For this reason, springs (4) an(6) are com-
pressed and push back spool (3).
When spool (3) moves to the left, the opening of
port C and port D becomes larger. As a result,
the pressure at port C (=J) drops, and piston (9)
stops moving to the left. The position in which pis-
ton (9) stops when this happens is further to the left
than the position when pump pressure PP is low.
. The relation of pump pressure PP and the position
of servo piston (9) forms a bent line because of the
Pump amount discharge Q

double-spring effect of springs (6) and (4). The rela-

tionship between pump pressure PP and pump dis-
charge amount Q is shown in the figure on the
right.

Pump discharge pressure PP RKP04130

2 (x:Large)
. If command current X sent to solenoid (1) increases
Pump amount discharge Q

further, the relationship between pump pressure 1 (x:SMall)

PP and pump discharge amount Q is proportional
to the pushing force of the PC-EPC valve of output
pressure. In other words, if the pushing force of out-
put pressure is added to the force pushing to the
left because of the pump pressure applied to the
piston (2), the relationship between PP and Q
moves from 1 to 2 in accordance with the increase.
Pump discharge pressure PP RKP04121

PW110R-1 10-51
3. When the swing is operated

To the actuator

PLS
Control valve

PPLS

Servocontrol
feed unit
Swing
PP blade

PG

B C
B PT
Gear
A C pump

D Main pump

When port B and C

are connected

LS valve

9 Fixed
throttle
valve

2 3
J

Large
Small diameter end diameter end

Direction of
min. discharge

mode-system
PC-EPC selector
valve

Resistor

1 RKP03541

10-52 PW110R-1
. When the swing is not being used, in other words
when no load is applied o the swing pump, the
pump suction torque is same as the standard mode
or the light-load mode.
. Once the swing is activated, thus, a load is applied
on the swing pump, the signal pressure PG is
putted t the port A and the piston (3) is pushed to
the left ( ) side according to the volume of the
signal pressure.
. By this action, the springs (4) and (6) are contracted
and, because the spring load increases, the pump
suction torque lowers according to the volume of
load on the swing pump.

PW110R-1 10-53
PRIORITY VALVE

P
b

PP LS

EF CF

d c

RKP03680

a. P Port - From P2 pump (PGA Port) OPERATION

b. LS Port - To steering unit (LS Port)
. The oil from the pump is distributed through the
c. CF Port - To steering unit (P Port) priority valve to the steering unit (Port CF) and to
d. EF Port - To by-pass valve (C Port) the other hydraulic components (Port EF).
. Distribution is determined by the position of the
SPECIFICATIONS priority valve slider in function of:
Type: OLS/40 a - the Load Sensing signal coming from the
steering unit (Port LS);
b - the pump oil delivery;
c - the pressure in the steering system;
d - the pressure in the connected hydraulic circuit.
. The slider position is such as to ensure that deliv-
ery to the steering unit always corresponds to the
actual requirements.

10-54 PW110R-1
 PAGE INTENTIONALLY
LEFT BLANK

PW110R-1 10-55
CONTROL VALVE

A
C B
D A
aa
AA AA
Pt Ps
Pr O O
v N Pq
N x
Pp Po
t u
M M
Pn Pm
r s
L L
Pl Pk
p q
B K K
Pj n Pi
J J o
Ph Pg
l m
H H
Pf j Pe
G G
k
Pd h Pc
F F i
P Pb Pa
f g
E E xx
d e
BB BB
c
C D A
Pu
a b P B

ViewAA
Vista
y

w
Vista B
View B
RKP03161

10-56 PW110R-1
a. Tc Port - To exchanger
b. Tsw Port - To swing motor (S1 Port)
c. TB Port - To hydraulic tank
d. A1 Port - To swing motor (A Port)
e. B1 Port - To swing motor (B Port)
f. A2 Port - See hydraulic circuit
g. B2 Port - See hydraulic circuit
h. A3 Port - To swivel joint (13A Port)
i. B3 Port - To swivel joint (12A Port)
j. A4 Port - To boom cylinder (bottom side)
k. B4 Port - To boom cylinder (head side)
l. A5 Port - To arm cylinder (head side)
m. B5 Port - To arm cylinder (bottom side)
n. A6 Port - To bucket cylinder (head side)
o. B6 Port - To bucket cylinder (bottom side)
p. A7 Port - See hydraulic circuit
q. B7 Port - See hydraulic circuit
r. A8 Port - To boom swing cylinder (head side)
s. B8 Port - To boom swing cylinder (bottom side)
t. A9 Port - To 2-piece boom cylinder (head side)
u. B9 Port - To 2-piece boom cylinder (bottom side)
v. A10 Port - To attachment (L.H. side)
x. B10 Port - To attachment (R.H. side)
y. P2 Port - From priority valve (EF Port)
w. P1 Port - From servocontrol unit (P2 Port) and to pump (PB Port)
aa. PLS Port - To hydraulic pump (PLS Port)
xx. TS Port - To hydraulic tank
Pa. PA1 Port - From L.H. PPC valve (P3 Port)
Pb. PB1 Port - From L.H. PPC valve (P4 Port)
Pc. PA2 Port - See hydraulic circuit
Pd. PB2 Port - See hydraulic circuit
Pe. PA3 Port - From ST3 solenoid valve group (A Port)
Pf. PB3 Port - From ST3 solenoid valve group (B Port)
Pg. PA4 Port - From R.H. PPC valve (P2 Port)
Ph. PB4 Port - From R.H. PPC valve (P1 Port)
Pi. PA5 Port - From L.H. PPC valve (P1 Port)
Pj. PB5 Port - From L.H. PPC valve (P2 Port)
Pk. PA6 Port - From R.H. PPC valve (P4 Port)
Pl. PB6 Port - From R.H. PPC valve (P3 Port)
Pm.PA7 Port - See hydraulic circuit
Pn. PB7 Port - See hydraulic circuit
Po. PA8 Port - From boom swing PPC valve (P2 Port)
Pp. PB8 Port - From boom swing PPC valve (P1 Port)
Pq. PA9 Port - From 2-piece boom PPC valve (P2 Port)
Pr. PB9 Port - From 2-piece boom PPC valve (P1 Port)
Ps. PA10 Port - From OP2 solenoid valve group (B Port)
Pt. PB10 Port - From OP2 solenoid valve group (A Port)
Pu. PDB Port - From PA4 Port

PW110R-1 10-57
 17

15 16

13 14

11 12

9 10

7 8

5 6

3 4

1 2

18

Section
SezioneAA±- A
A RKP03170

1. L.H. travel suction valve (A3 port) 10. R.H. outrigger suction valve (B7 Port)
2. L.H. travel suction valve (B3 port) 11. Boom swing suction valve (Head side) (A8 port)
3. Boom suction valve (Bottom side) (A4 port) 12. Boom swing suction valve (Bottom side) (B8 port)
4. Boom suction valve (Head side) (B4 port) 13. 2-piece boom suction valve (A9 Port)
5. Arm suction valve (Head side) (A5 port) 14. 2-piece boom suction valve (B9 Port)
6. Arm suction valve (Bottom side) (B5 port) 15. Attachment safety valve (R.H. side) (A10 port)
7. Bucket suction valve (Head side) (A6 port) 14. Attachment safety valve (L.H. side) (B10 port)
8. Bucket suction valve (Bottom side) (B6 port) 17. Safety valve
9. R.H. outrigger suction valve (A7 Port) 18. Lift check valve

10-58 PW110R-1
 11

10

Section
SezioneB
B±- B
B
RKP03180

1. Main relief valve (P1 port) 7. Spool (bucket)

2. Spool (swing) 8. Spool (R.H. outrigger)
3. Spool (blade or outriggers) 9. Spool (boom swing)
4. Spool (travel) 10. Spool (2-piece boom)
5. Spool (boom) 11. Spool (attachment)
6. Spool (arm)

PW110R-1 10-59
 18

8 16

7 15

6 14

5 13

4 12

3 11

2 10

1 9

17

19

Section C±
Sezione C C
-C
RKP03190

Flow compensation valve: Reducing pressure compensation valve:

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

10-60 PW110R-1
 9

Section
Sezione D
D± D
-D RKP03200

1. Swing check valve 6. Outrigger check valve

2. Blade check valve 7. Boom swing check valve
3. Boom check valve 8. 2-piece boom check valve
4. Arm check valve 9. Attachment check valve
5. Bucket check valve

PW110R-1 10-61
 2

Section
SezioneBB
BB±- BB
BB RKP02820

5 3

4 Section
SezioneEE±- E
E RKP02810

1. Main relief valve (P1 port)

2. Lift check valve

SWING VALVE
3. Spool (swing)
4. Spool (boom raise at joining pump discharge)
5. Check valve (swing)

10-62 PW110R-1
 2

3
Section
SezioneAA
AA±- AA
AA
RKP02840

6
Section
Sezione FF ±- F
F RKP02830

1. Pump pressure detection plug

2. Pressure relief plug
3. LS bypass plug
4. Safety relief valve

BLADE VALVE
5. Spool (blade)
6. Main relief valve (P2 port)

PW110R-1 10-63
 1 2

5 4
Section
Sezione G
G ±- G
G RKP02850

6 7

10 9
Section
SezioneHH±- H
H
RKP02860

TRAVEL VALVE BOOM VALVE

1. Suction valve (A3 port) 6. Suction valve (Head side)
2. Suction valve (B3 port) 7. Suction valve (Bottom side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve

10-64 PW110R-1
 1 2

RKP02870

5 4
Section
Sezione JJ±- JJ

6 7

RKP02880
10 9
Section
SezioneKK±- K
K

ARM VALVE BUCKET VALVE

1. Suction valve (Head side) 6. Suction valve (Head side)
2. Suction valve (Bottom side) 7. Suction valve (Bottom side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve

PW110R-1 10-65
 1 2

5 4
RKP03210
Section
Sezione L ±L
L-L

6 7

10 9
RKP03220
Section
Sezione M ±M
M-M

OUTRIGGER VALVE BOOM SWING VALVE

1. Suction valve (A7 Port) 6. Suction valve (Head side)
2. Suction valve (B7 Port) 7. Suction valve (bottom side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve

10-66 PW110R-1
 1 2

5 4
RKP03230
Section N±N
Sezione N-N

6 7

10 9
RKP03240
Section
SezioneOO-O
±O

11

RKP03250
Section
SezionePP-P
±P

2-PIECE BOOM VALVE ATTACHMENT VALVE

1. Suction valve (A9 Port) 6. Safety valve (L.H. side)
2. Suction valve (B9 Port) 7. Safety valve (R.H. side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve
11. Unload valve

PW110R-1 10-67
 PAGE INTENTIONALLY
LEFT BLANK

10-68 PW110R-1
2. FUNCTION PRINCIPLE
1. Control of pump swash plate angle
. The pump swash plate angle (pump discharge amount) is so controlled that the LS differential pressure DPLS,
which is the difference between the pump discharge pressure PP and the LS pressure PLS at the outlet Port of
the control valve (actuator load pressure), is maintained at a constant level.
(LS differential pressure DPLS=Pump discharge pressure PP ± LS pressure PLS).
. If the LS differential pressure DPLS becomes lower than the setting pressure of the LS valve, the pump swash
plate angle becomes larger, and if it becomes higher, the pump swash plate angle becomes smaller.
H For the details of this action, refer to the descriptions of "HYDRAULIC PUMP".

Angolo piatto oscillante Q

Actuator Max.

Control valve Min.

0 Pressione
differenziale ∆PLS Punto di taratura
della valvola LS
PLS RKP02930
Pump passage
LS passage

Main pump
PP

Min. Max.

Servo piston

∆ PLS
LS valve

Differential
pressure high Differential
pressure
low
PC valve

Pump pressure Pump pressure

high low
RKP02921

PW110R-1 10-69
2. Pressure compensation control
. Valves (pressure compensation valves) are installed at the inlet Port side of the spools of the control valves to
balance the loads.
When the actuators are complex-operated, the pressure differences DP at the upstream (inlet) and down-
stream (outlet) are made equal by these valves.
In this way, the flow from the pump are distributed in proportion to the opening areas S1 and S2 of each
valve.

Load
Load
W W

Actuator Actuator

∆P ∆P
S1 S2

Pressure Pressure
compensation compensation
valve valve

LS valve RKP02941

10-70 PW110R-1
3. Operation for each function and valve

Hydraulic circuit diagram and names of valves

Ls
324 bar
1. Unload valve
5 Ls ø0,5
LS pressure+23 bar (25 kg/cm2)
9
2. Main relief valve (P1 port)
A10
B10
294 bar (300 kg/cm2)
Attachment 3. Pressure compensation valve
Pa10 Pb10
9 4. Suction valve
3 5. Safety valve
4
A9
324 bar (330 kg/cm2)
Pa9
B9 2-piece boom 6. Main relief valve (P2 port):
216 bar (220 kg/cm2)
Pb9
4
3 4 7. Lift check valve
A8 8. Cooler bypass valve
Boom swing
opening pressure: 8.1 bar (8.3 kg/cm2)
B8
Pa8 Pb8
4
9. Safety valve: 196 bar (200 kg/cm2)
3 4
A7

Pa7
B7 R.H. outrigger
Pb7
4
3 4
A6
B6
Pa6 Bucket
Pb6
4
3 4
A5

Pa5
B5 Arm
Pb5
4
3 4
A4

Pa4
B4
Boom
Pb4
4
3 4
A3
B3 Travel
Pa3 Pb3
4
3
A2
B2 Blade and/or
Pb2
Pa2
outrigger
P2
216bar 6
A1
B1 Swing
Pa1 Pb1

PDB
TS

2 294 bar 1 31 bar 8 TSW

7 TB
TC
P1
RKP03261

PW110R-1 10-71
1. Unload valve

FUNCTION
1. When the control valve is at «NEUTRAL», pump discharge amount Q for the minimum swash plate angle is re-
leased to the tank circuit.
At this time, the pump discharge pressure PP is set at 26 bar (27 kg/cm2) by the spring (2) inside the valve.
(LS pressure PLS=0 bar (0 kg/cm2)

PP PLS

T
1 2 3

RKP02960

OPERATION
When the control valve is at «NEUTRAL»
. In this way, the pump discharge pressure PP is set
. To two end surfaces of the spool (1), the pump dis-
to 26 bar (27 kg/cm2).
charge pressure PP is acting on the left and the LS
pressure PLS is acting on the right side.
. Since no LS pressure PLS is generated when the
control valve is at «NEUTRAL», only the pump dis-
charge pressure PP is acting, and PP is set only by
the load of the spring (2).
. As the pump discharge pressure PP rises and
reaches the spring load of the spring (2) (26 bar
(27 kg/cm2)), the spool (1) is shifted to the right
( ) side and the pump circuit PP becomes open
to the tank circuit T through the drill holes in the
sleeve (3).

10-72 PW110R-1
2. When the flow demand from the actuator is within the discharge amount for the pump minimum swash angle
plate during fine control of the control valve, the pump discharge pressure PP is set to the LS pressure PLS +23
bar (27 kg/cm2).
Since the unload valve opens when the differential pressure between the pump discharge pressure PP and the
LS pressure PLS reaches the spring load of the spring (2) (26 bar (27 kg/cm2)), the LS differential pressure DPLS
at this time becomes 26 bar (27 kg/cm2).

PP PLS

T
1 2

RKP02970

OPERATION
Fine control of the control valve
. Thus, the pump discharge pressure PP is set to the
. When the control valve is fine-controlled, the LS
combined pressure of the spring force (26 bar (27
pressure PLS is generated and acts on the right
kg/cm2)) and the LS pressure PLS, and the LS dif-
end of the spool (1).
ferential pressure DPLS becomes 26 bar (27 kg/
At this time, since the LS pressure PLS is small be-
cm2).
cause the opening area of the spool of the control
valve is small, there is big difference from the pump
discharge pressure PP.
. When the differential pressure between the pump
discharge pressure PP and LS pressure PLS
reaches the spring load of the spring (2) (26 bar
(27 kg/cm2)), the spool (1) moves to the right ( )
side and a path is formed between the pump circuit
PP and the tank circuit T.

PW110R-1 10-73
3. When the flow demand from the actuator becomes greater than the pump flow for the minimum swash plate
angle during operation of the control valve, the flow to the tank circuit T is cut off, and all the pump discharge
Q flows into the actuator circuit.

PP PLS

T
1 2

RKP02980

OPERATION
When the control valve is operated
. As the result, the path between the pump circuit PP
. When the control valve is operated to a bigger
and the tank circuit T is shut off, and whole pump
stroke, the LS pressure PLS is generated and acts
discharge Q flows to the actuator circuit.
on the right end surface of the spool (1).
At this time, since the opening area of the spool of
the control valve is large, the difference between
the LS pressure PLS and the pump discharge pres-
sure PP is small.
. For this reason, because the differential pressure
between the pump discharge pressure PP and the
LS pressure PLS noes not reach the spring load of
the spring (2) 26 bar (27 kg/cm2)), the spool (1) is
pushed to the left ( ) side by the spring (2).

10-74 PW110R-1
2. Introduction of LS pressure
FUNCTION
. The LS pressure denotes the actuator load pressure at the outlet Port of the control valve.
. Actually, in the control valves, the pump pressure PP is reduced to the same pressure of the actuator circuit
pressure A by the pressure reducing valve (3) in the pressure compensation valve before introducing into the
LS circuit PLS.
Furthermore, the orifice C is provided in the middle of the circuit from the pump circuit PP to the pressure
reducing valve (3) for damper function.
. In the travel valves, the actuator circuit pressure A is directly introduced into the LS circuit PLS.

A
b
1

a d

PP SA PA 3 PLS1 SLS
2

C 4 PLS
RKP02990

OPERATION
1. Control valves (boom, 2-piece boom, arm,
bucket, boom swing, attachment)
. When the spool (1) is operated, the pump pres-
sure PP starts to flow to the actuator circuit A
from the flow control valve (2) and the spool
notch a through the bridge path b.
. At the same time, the pressure reducing valve
(3) moves to the right ( ) side, so the pump
pressure PP introduced from the orifice c is de-
pressurized by the pressure loss at the notch d
and introduced to the LS circuit PLS, and then,
further introduced to the spring chamber PLS1.
. At this time, the LS circuit PLS is open to the
tank circuit T through the LS bypass plug (4) (re-
fer to the description of the LS bypass plug).
. Areas of the both ends of the pressure reducing
valve (3) are same (SA=SLS), and on the SA
side, the actuator circuit pressure PA (=A) is
acting, and on the opposite SLS side, the re-
duced pump pressure PP is acting.
. Therefore the pressure reducing valve (3) bal-
ances at the point where the actuator circuit
pressure PA and the spring chamber pressure
PLS1 are balanced, and the pump pressure PP
reduced by the notch d is introduced to the LS
circuit PLS as the actuator circuit pressure A.

PW110R-1 10-75
 A
b

a d

PP 2 PA 3

PLS
RKP03270

2. Travel valves
. When the spool (1) is operated, the pump pres-
sure PP starts to flow to the actuator circuit A
from the flow control valve (2) and the spool
notch a through the bridge path b.
. At the same time, the pressure reducing valve
(3) is moved to the right ( ) side by the actua-
tor circuit PA, and paths are made between the
notches c and d to the LS circuit PLS respec-
tively.
. By this, the actuator circuit pressure PA (=A) is
introduced to the LS circuit PLS from the notch c
through the notch d.
H In the travel circuits, unlike the work equipment circuits, the actuator circuit pressure PA is directly introduced
to the LS circuit PLS.

10-76 PW110R-1
3. LS bypass plug
DESCRIPTION
1 - The LS bypass plug releases the residual pressure of the LS pressure PLS.
2 - This makes the pressure-rising speed of the LS pressure PLS more gentle, and with this discarded throttled
flow, it creases a pressure loss in the throttled amount of the spool or shuttle valve and increases the stability
to lowering the effective LS differential pressure.

1 T

PLS

RKP03010

OPERATION

. The pressurized oil in the LS circuit PLS flows from

the clearance filter a, which is formed by the clear-
ance between the LS bypass plug (1) and the body,
to the tank circuit T through the orifice b.

PW110R-1 10-77
4. Pressure compensation valve

FUNCTION
1. During complex operation, if the load pressure at one side becomes lower than that of the other actuator and
the oil flow is about to increase, pressure compensation is carried out.
(In this case, the other actuator (right side) of the complex operation has higher load pressure than that of this
side (left side).

W W
A A
PA
PPA

a a

T
PLS1
PPA PA
2 1
PP

PLS PP
RKP03020

OPERATION

. During complex operation, when the load pressure
of the other actuator side (right side) becomes high-
er, the flow in the actuator circuit A at this (left) side
tends to increase.
. In this case, the LS pressure PLS at the other actua-
tor acts on the spring chamber PLS1, and pushes
the pressure reducing valve (1) and the flow control
valve (2) to the left ( )side.
. The flow control valve (2) throttles the opening area
between the pump circuit PP and the upstream side
of the spool PPA, and generates a pressure loss in
between PP and PPA.
. The flow control valve and the pressure reducing
valve (1) are balanced at the point where the differ-
ential pressure between PA and PLS, which act on
the both end surfaces of the pressure reducing
valve (1), becomes equal to the pressure loss in be-
tween PP and PPA before and after the flow control
valve (2).
. By this operation, the differential pressures be-
tween the upstream pressure PPA and the down
stream pressure PA of both spools in the complex
operation are made same, and the pump flow is
distributed in proportion to the opening areas of
notches a of each spool.

10-78 PW110R-1
5. Area ratio of pressure compensation valve

FUNCTION

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

S1 PPB PP 2 1 PA 3 S2

PLS
RKP03030

Area ratio (S1/S2) and compensation characteristics

. When the ratio is 1.00 : [Pump pressure PP - Upstream pressure of the spool notch PPB]6[LS circuit pressure PLS
- Actuator circuit pressure PA (=A)] Thus, the flow is distributed in proportion of opening areas of the spool.
. When the ratio is larger than 1.00 : PP ± PPB>PLS ± PA (=A)
Thus, the flow is divided less than the proportion of opening areas of the spool.
. When the ratio is smaller than 1.00 : PP ± PPB<PLS ± PA
Thus, the flow is divided more than the proportion of opening areas of the spool.

PW110R-1 10-79
6. Travel LS bypass circuit

FUNCTION
. When the travel and another actuator are operated at the same time, by increasing the LS throttle amount in the
LS circuit PLS which is discarded, and relaxing the pressure compensation precision in the travel circuit, drop in
the travel speed is minimized.
. The bypass circuit is closed when the travel or another actuator is operated individually.

A1 1 A2 PA

PLS
PLS1
a

PB 4
2 c

RKP03060

OPERATION
Normal operation
. When the boom spool (1) is operated, the pressure
in the LS circuit PLS becomes same as the boom
circuit pressure A1.
. At the same time, the LS circuit pressure PLS is also
introduced to the spring chamber PLS1 of the pres-
sure reducing valve (2) in the travel valve.
. Since the travel spool is not operated, the travel ac-
tuator circuit is closed, and the check valve (4) in
the reducing valve (2) is also closed.
. Thus, during individual operation of the boom, the
travel LS bypass circuit is closed.

10-80 PW110R-1
 A1 1 A2 PA

PLS
PLS1
a

PB 4
2 c

RKP03070

When the travel and another actuator are operated

together

. When the boom spool (1) is operated, the pressure

in the LS circuit PLS becomes same as the boom
circuit pressure A1.
. Since the pressure in the boom RAISE actuator cir-
cuit is normally higher than that of the travel actua-
tor (A1>A2), the pressure in the spring chamber
PLS1 in the reducing valve (2) at the travel side is
higher than the travel circuit pressure (PA).
. Therefore, the pressure reducing valve (2) moves to
the left ( ) side, and the LS pressure in the spring
chamber PLS1 from the orifice a pushes and opens
the check valve (4), and flows to the travel circuit PA
through the path b and the path c.
. Thus, the LS circuit pressure PLS, which has been
the same as the boom circuit pressure A1, flows
to the travel circuit A2 and lowers.

PW110R-1 10-81
7. Boom and arm regeneration circuit

FUNCTION (Explanation by boom)

1. When the boom is being lowered, if the bottom pressure A of the cylinder (1) is higher than the head pressure
B, and there is hydraulic drift, this sends the return flow at the bottom end to the head end to increase the cy-
linder speed by that amount.

1
B
A
4
2

T
3
a

PP PLS

RKP03080

OPERATION
. When there is hydraulic drift when lowering the
boom, the pressure A at the bottom end of the
boom cylinder (1) becomes higher than the pres-
sure B at the head end.
. At this time, a part of the return flow at the bottom
end passes the regeneration passage a of the
boom spool (2), pushes the check valve (3) open,
and flows to the head end.
. As the result, the boom lowering speed is in-
creased.

10-82 PW110R-1
 2. When lowering the boom, if the head pressure B of the cylinder (1) is greater than the bottom pressure A, and
the operation is in the load process, the check valve (3) closes to shut off the circuit between the head and the
bottom sides.

B
A
4
2

T
3
a

PLS
PP

RKP03090

OPERATION

. During a load process such as lowering the boom,

etc., the pressure B at the head side of the boom
cylinder (1) becomes higher than the pressure A
at the bottom side.
. At this time, the check valve (3) is closed by the
pressure B at the head side and the spring (4),
and the passage between the head circuit and
the bottom circuit is shut off.

PW110R-1 10-83
SWING MOTOR

1
f

X
c d

b
2 2

RKP03630

View Z
View X
e

1. Swing motor SPECIFICATIONS

2. Safety valve Motor capacity: 32 rev.
a. A Port - From control valve (A1 Port) Safety valve
b. B Port - From control valve (B1 Port) Max. pressure: 170 ± 220 bar at 50 ,/min
c. X Port - From L.H. PPC valve (P4 Port)
d. X1 Port - From L.H. PPC valve (P3 Port)
e. T Port - To hydraulic tank
f. S Port - To control valve (TSW Port)

10-84 PW110R-1
SWING MOTOR RELIEF VALVE

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

a. Pilot system port

(From control valve PA1 - PB1 port)
3

4 Measured at V=41 mm2/s and t=50°C

10
7
Pressure difference ⌬p (bar)
8
5
6
6
4

RKP03620 0
0 20 40 60 80 100
Amount Q (l / min)
FUNCTION AND OPERATION
RKP04051
The function of these valves is to protect the engine
from pressure peaks and extreme pressure drops
due to sudden interruptions in cabin rotation. Protec-
tion consists of transferring amongst the various lines
either the amount of oil that has caused a pressure
peak, or the amount of oil required to prevent the ca-
vitation phenomenon. 1

Function of the safety valve

. In normal conditions valves (4) and (5) are closed.
When the pressure of line b (higher than the cali-
brated value) is transferred to chamber d through
a nozzle (6), the pilot valve (4) opens to allow the
pressurized oil to flow through a hole c.
The pressure in line b acts on the main valve (5)
which opens to allow passage of the oil-flow in line
3
b to line d.
c
Function of the anti-cavitation valve
4
. When there is pressure in line d and a vacuum in
a
line b the pressure in line d acts on the main valve
(5) which is opened to allow communication be-
tween lines b and d. 5
d
. The pilot system pressure that acts on the control
valve shutting that governs cabin rotation is also
transmitted to the piston (1). When the piston 6
moves it increases the load on the spring (3) of b
the pilot valve in proportion to the pressure needed
for rotation. RKP03621

PW110R-1 10-85
SWIVEL JOINT

Front
Fronte of machine
macchina

Inlet axis
1 3A-7A-11A
Asse ingressi
3A-7A-11A
2
4a 7a
3 8a
13a
4
1a
11a
14A
6a
3a
13A
5
Inlet
Asseaxis
ingressi Inlet axis
Asse ingressi
4A-8A-12A
4A-8A-12A 2A-6A-10A-11A
1A-5A-9A-13A
11A 2a
14a
12A 10A
12a 9a
6 9A 5a 10a

8A 7A Inlet axis
Asse ingressi
2A-6A-10A-11A
2A-6A-10A-14A
6A
5A View
VistaZZ
4A 3A RKP03780

2A 1. 14 slip ring collector

1A 2. Collector support
7
10 3. Screw
4. Screw
5 9 5. Anti-friction ring
6. Seal
7. O-Ring seal
8
8. Body
Z 9. Guard ring
10. Rotor

1A. From steering unit (L Port) 1a. To front axle (b Port)

2A. See hydraulic circuit 2a. See hydraulic circuit
3A. To hydraulic tank 3a. From travel valve (T Port)
4A. From ST2 solenoid valve group (A Port) 4a. To brake cylinder
5A. From ST1 solenoid valve group (A2 Port) 5a. To transmission (f Port)
6A. See hydraulic circuit 6a3. See hydraulic circuit
7A. From brake pump (T1 Port) 7a. To front axle brake
8A. From brake pump (T2 Port) 8a. To rear axle brake
9A. From steering unit (R Port) 9a. From ST4 solenoid valve group (P Port)
10A. See hydraulic circuit 10a. See hydraulic circuit
11A. From ST1 solenoid valve group (A1 Port) 11a. To locking axle cylinder (B Port)
12A. From control valve (B3 Port) 12a. To travel motor (A Port)
13A. From control valve (B3 Port) 13a. To travel motor (B Port)
14A. From ST1 solenoid valve group (A3 Port) 14a. To transmission (e Port)

10-86 PW110R-1
TRAVEL MOTOR

5
c 1

2 4 a b 4

3
View XX
Vista

RKP04460

1. Motor SPECIFICATIONS
2. Brake valve Min. displacement: 35.5 cc/rev.
3. Displacement automatic control Max. displacement: 80 cc/rev.
4. Relief/anti-cavitation Check valve rated pressure: 350 bar
5. Travel speed increment solenoid valve (Y25)

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

b. B Port - To swivel joint (13a Port)
c. T Port - To swivel joint (3a Port)

PW110R-1 10-87
DISPLACEMENT AUTOMATIC CONTROL HIGH PRESSURE
RELATED
1 1
4
a
5
Detail X X
Particolare
FUNCTION
. This device automatically varies the displacement
in function of the working pressure.
A displacement increase leads to a reduction in the
engine shaft rpm and an increase in the torque.
OPERATION
. The pressurized oil coming from the control valve
arrives through the brake valve (1) on the smaller
surface of the positioning piston (2), thus pushing
it towards the minimum displacement limit stop.
The smaller surface is connected hydraulically to
the pilot system bushing (4), which contains a mea-
suring piston with two different surfaces. The avail-
able pressure therefore acts in a differential man-
ner and, with the spring (6), causes the piston (5)
to perform the function of governing the pressure
flows.
. When delivery line pressure increases the mea-
surement piston (5) moves, compresses the spring
(6), and allows oil to pass through line a into cham-
ber b of the larger surface of the positioning piston
(2).
10-88
3
b
6
5
4
7
RKP04470
. The pressure moves the positioning piston (2)
which, because it is connected mechanically to
the engine cylinder, causes this to move and in-
crease the displacement.
The movement of the positioning piston (2) con-
tinues until equilibrium has been reached between
the delivery pressure acting on the smaller surface
of the piston and the pressure acting on the larger
surface. Once equilibrium has been reached the
spring (6) returns the measuring piston (5) to its
neutral position.
Maximum displacement is determined by the me-
chanical limit stop (7).
. When delivery line pressure diminishes there is no
longer equilibrium between the forces acting on the
positioning piston; the measuring piston moves,
and opens passage c to release the existing pres-
sure in chamber b.
Under this new pressure the positioning piston (2)
gradually returns to the minimum displacement po-
sition. The movement stops when a new equili-
brium is reached between the forces acting on
the measurement piston (5) and the positioning pis-
ton (2).
PW110R-1
TRAVEL MOTOR BRAKE VALVES
8 9 10 11 f 11
5
6
7 c
b a
FUNCTION
. The brake valves control loading in order to prevent
the cavitation phenomenon which occurs when the
rotation speed of the hydraulic motor exceeds the
speed determined by pump delivery through the
control valve.
. The brake valves are not a substitute for the ma-
chine duty brakes.
OPERATION
. Pressurized oil from the control valve enters line a
causing valve (1) to open, and acts through the pilot
system channel c the ring chamber d and valve (2)
to feed the piston motor.
The pilot system oil acts on the surface of piston (3)
and causes it to move to compress the spring (4)
while the throttles (5) control the passages to obtain
slow and regular piston movement.
The piston movement (3) releases a progressive
throttling action (6) and allows the oil drained out
of the motor to return to the tank through the valve
opening (7).
PW110R-1
10 9 2
5
3
4
RKP04550
. When the pressure in line a drops due to loading
changes or due to the movement of the controls,
there is an immediate reduction of pressure in the
spring housing e; pressure from the spring (4)
and residual pressure from the drainage lines
cause the piston (3) to return, leading to a reduction
in the amount of oil draining through the throttle (6),
and thus provoking an automatic braking action.
. Valves (2) and (8) protect the engine against both
pressure peaks and the cavitation phenomenon.
. When the pressure in line f exceeds the calibration
value of the spring (9), the pilot valve (10) opens to
eliminate pressure inside the main valves (11). The
pressure in line d acts on the outside of the main
valves (11) which causes them to open and allow
communication between their lines of delivery a
and drainage b.
10-89
CYLINDERS

CYLINDERS

2 3 4 5 6 7 8 9 10

1 17 16 15 14 13 12 11
RKP04340

ARM

2 3 4 5 6 7 8 9 18 19 11
1

17 16 15 14 13 12 20
RKP04310

BUCKET, BOOM SWING, BLADE

(H The figure shows the blade cylinder)

2 3 4 5 6 8 9 10 11
1

17 16 15 14 12 13
RKP05700

10-90 PW110R-1
2-PIECE BOOM

2 3 4 5 6 8 9 18 11
1

17 16 15 14 13 12 RKP04330

1. Head bushing 8. Gasket 15. Cylinder head

2. Snap ring 9. Guide ring 16. Gasket
3. Gasket 10. Half flange (No. 2) 17. Clamping flange
4. Gasket 11. Bottom bushing 18. Nut
5. Guide ring 12. Bottom bushing 19. Bottom cushion plunger
6. Piston rod 13. Gasket 20. Ball (No. 12)
7. Head cushion plunger 14. Cylinder

Blade or
Cylinder Boom 2-piece-boom Arm Bucket Boom swing
outriggers
Piston rod size
70 50 60 60 60 60
diameter
Cylinder inside
120 90 100 90 100 120
diameter
Piston stroke 770 580 900 800 650 185
Max. cylinder
1990 1510 2230 1970 1650 710
length
Min. cylinder
1220 930 1330 1170 1000 525
length
Piston nut width
Ð 60 70 Ð Ð Ð
across flat

PW110R-1 10-91
AXLE LOCKING CYLINDER

B
2

3 4 5 6

Section
Sezione B
B± B
-B
Section
Sezione A
A ±- A
A
RKP03770

a. B Port - From swivel joint (11a Port)

1. Cylinder
2. Piston
3. Cover
4. Plunger
5. Valve seat
6. Screw
7. Oil seal
8. Gasket

10-92 PW110R-1
 PAGE INTENTIONALLY
LEFT BLANK

PW110R-1 10-93
SERVOCONTROL FEED UNIT

a b
B
A A

d
RKP03961

a. P2 Port - To control valve (P1 Port)

b. Pc Port - To brake pump (P Port)
c. PR Port - To ST1 solenoid valve group (P Port)
d. T Port - To hydraulic tank

10-94 PW110R-1
 2

11 6 5 4
Particolare Z
Detail Z
1

8 7 Z
Section
SezioneA
A±- A
A

10 9
Section
Sezione B
B ±- B
B RKP03970

1. Pump case
2. Valve
3. Spring
4. Screw
5. Poppet
6. Spring (reducing valve pilot)
7. Spring (reducing valve main)
8. Spool (reducing valve)
9. Spring (safety valve)
10. Ball

PW110R-1 10-95
OPERATION
1. When engine is stopped
PC
. Poppet (5) is pushed against the seat by spring
P1 P2
(6), and the passage from Port PR T is
closed.
. Valve (8) is pushed to the left by spring (7), and
the passage from Port P1 PR is open.
. Valve (2) is pushed to the left by spring (3), so
the passage between Port P1 P2 is closed.
(See Fig. 1)
T
PR
Hydraulic diagram
RKP03861

Control valve
P2
PC 2 3

P1

PR

8 7 5 6

PC valve PPC valve

LS valve

Fig. 1 RKP03871

10-96 PW110R-1
2. At neutral
Control valve
3. When load pressure P2 is low (when moving
down under own weight (boom LOWER or arm P2
IN) PC d 2 3
Note: When load pressure P2 is lower than output
pressure PR of the self-reducing pressure
valve.
. Valve (2) receives force in the direction to close P1
the passage from Port P1 P2 from spring (3)
and pressure PR (when the engine is stopped,
the pressure is 0 bar (0 kg/cm2)).
However, when hydraulic oil flows in from Port T
P1, the pressure is balanced so that pressure
P16 force of spring (7) + (area ùd x pressure
PR), and the opening from Port P1 P2 is ad-
justed so that pressure P1 is kept at a certain
value above pressure PR.
PR
. When pressure PR goes above the set pres- a
8 7 5
sure, poppet (5) opens, and the hydraulic oil
flows in the following circuit: Port PR hole
a inside spool (8) opening of poppet (5)
tank Port T.
As a result, a pressure difference is created on M
both sides of hole a inside spool (8), so spool (8)
moves in the direction to close the opening from PC valve PPC valve
Port P1 PR.
LS valve
Pressure P1 is reduced to a certain pressure
(set pressure) by the amount of opening at this RKP03881

point, and is supplied as pressure PR. Fig. 2

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

LS valve

Fig. 3 RKP03891

PW110R-1 10-97
5. When there is abnormal high pressure
When pressure PR of the self-reducing pressure
valve becomes abnormally high, ball (10) pushes
against the force of spring (9), separates from
the seat, and allows hydraulic oil to flow from out- M
put Port PR T, so pressure PR goes down.
This action protects the equipment at the destina-
PPC valve
tion for the hydraulic pressure supply (PPC valve,
electromagnetic valve, etc.) from abnormally high
pressure. (See Fig. 4) PR P1 T

10 9
RKP03901

Fig. 4

10-98 PW110R-1
ACCUMULATORS
TECHNICAL DATA
Servocontrol feed group:
Nominal volume: 0.35 ,
Pre-set pressure: 12 1 bar
Working pressure: 35 ± 45 bar
Braking system
Nominal volume: 0.70 ,
Pre-set pressure: 70 bar
Working pressure: 65 ± 150 bar
PW110R-1
RKP03910
FUNCTION
. A rubber bag (1) containing nitrogen gas is used in
the accumulator. Its function is to maintain oil pres-
sure in the circuit to which the accumulator is con-
nected.
OPERATION
. When the engine is running, the chamber A of the
rubber bag (1) (containing nitrogen) is compressed
by the pressurized oil from line B.
. If the oil pressure in line B falls below the maximum
calibration pressure (even after intensive use), the
rubber bag (1) will expand due to the pressure of
the nitrogen inside it.
10-99
PPC VALVE

WORK EQUIPMENT

a b

d c

E E
D D
e
B f

A C

C A RKP01070

L.H. PPC VALVE R.H. PPC VALVE

a. P2 Port - To control valve (PB5 Port) (arm close)
b. P4 Port - To control valve (PB1 Port) (R.H. swing)
c. P1 Port - To control valve (PA5 Port) (arm open)
d. P3 Port - To control valve (PA1 Port) (L.H. swing)
e. T Port - To hydraulic tank
f. P Port - From ST1 solenoid valve (A Port)
a. P2 Port - To control valve (PA4 Port) (boom raise)
b. P4 Port - To control valve (PA6 Port) (bucket open)
c. P1 Port - To control valve (PB4 Port) (boom lower)
d. P3 Port - To control valve (PB6 Port) (bucket close)
e. T Port - To hydraulic tank
f. P Port - From ST1 solenoid valve (A Port)

10-100 PW110R-1
 6

5 7
4
8

3
9

2 10

Section A -±AA
Sezione A Section
SezioneBB±- B
B

Section
SezioneDD±-DD

Section C -±CC
Sezione C

Section
Sezione E
E± E
-E

RKP01080

1. Spool 7. Joint
2. Adjusting spring (internal) 8. Cover
3. Return spring (external) 9. Pin
4. Plunger 10. Body
5. Disc
6. Nut

PW110R-1 10-101
FUNCTION
1. At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)

D
f T
P

1
P3 (P1) P4 (P2)

A Control valve
B

RKP01091

Fig. 1

2. During fine control (NEUTRAL fine control)

When piston (4) starts to be pushed by lever (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off 5
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber 4
PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes from 3
port P1 to port A.
When the pressure at port P1 becomes higher, 2
spool (1) is pushed back and fine control hole f D
is shut off from pump pressure chamber PP. f T
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1. P
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is balanced
with the pressure at port P1. The relationship in 1 PP
the position of spool (1) and body (8) (fine control 10
hole f is at a point midway between drain hole D P1 P2
and pump pressure chamber PP) does not change
until retainer (7) contacts spool (1).
Therefore, metering spring (2) is compressed pro-
A B
portionally to the amount of movement of the con- Control valve
trol lever, so the pressure at port P1 also rises in
proportion to the travel of the control lever. In this RKP01101
way, the control valve spool moves to a position Fig. 2
where the pressure in chamber A (the same as
pressure at port P1) and the force of the control
valve spool return spring are balanced. (Fig. 2).

10-102 PW110R-1
3. During fine control (when the lever is returned)
When control lever (5) starts to be returned, spool
(4) is pushed up by the force of centering spring (3)
and the pressure at Port P1.
When this happens, fine control hole f is con- 5
nected to drain chamber D and the pressure oil
at port A from port P1 is released. 4
If the pressure at port P1 drops too far, spool (1) is 9
pushed down by metering spring (2), and fine con-
trol hole f is shut off from drain chamber D. At al- 3
most the same time, it is connected to pump pres-
sure chamber PP, and the pump pressure is sup- 2 D
plied until the pressure at port P1 recovers to a f T
pressure that corresponds to the lever position. P
When the spool of the control valve returns, oil in f'
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working. 1 PP
The oil passes through port P2 and enters cham-
ber B to fill the chamber with oil. (Fig. 3). P1 P2

A Control valve
B

Fig. 3 RKP01113

4. At full stroke
When disc (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is
shut off from drain chamber D, and is connected
with pump pressure chamber PP. Therefore, the pi-
lot pressure from the control pump passes through 5
fine control hole f and flows to chamber A from port
P1, and pushes the control valve spool. 4
The oil returning from chamber B passes from port
P2 through fine control hole f' and flows to drain 9
chamber D. (Fig. 4)

D
f T
P
f'
1 PP
P1 P2

A Control valve
B

RKP01123
Fig. 4

PW110R-1 10-103
PPC VALVE
(Blade, boom swing, 2-piece boom)
(H Be careful about mounting direction)
A

5
4
c d 6

3 7

2
a. T Port - To hydraulic tank 8
b. P Port - From ST1 solenoid valve group
(A Port) 1
c. P1 Port - For boom swing: 9
to control valve (PB8 port) Section
SezioneAA±- A
A
For 2-piece boom: RKP00960
to control valve (PB9 Port)
For L.H. outrigger: 1. Spool
to control valve (PA7 Port) 2. Metering spring
For R.H. outrigger or blade:
3. Centering spring
to control valve (PB2 port)
For blade 4. Piston
to control valve (PA2 Port) 5. Lever
d. P2 Port - For boom swing: 6. Plate
to control valve (PA8 Port) 7. Retainer
For 2-piece boom: 8. Body
to control valve (PA9 Port)
9. Filter (100 mesh)
For blade or R.H. outrigger:
to control valve (PB7 Port)
For L.H. outrigger:
to control valve (PA2 Port)
For blade
to control valve (PB2 Port)

10-104 PW110R-1
FUNCTION
1. At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)

D
T

f P

1
P1 P2

A Control valve B

RKP00971

Fig. 1

2. During fine control (NEUTRAL fine control)

When piston (4) starts to be pushed by lever (5),
retainer (7) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
5
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber 4
PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes from
Port P1 to Port A.
When the pressure at Port P1 becomes higher,
spool (1) is pushed back and fine control hole f 7 D
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain T
chamber D to release the pressure at Port P1. 2
When this happens, spool (1) moves up or down 8
so that the force of metering spring (2) is ba-
lanced with the pressure at Port P1. The relation- f P
ship in the position of spool (1) and body (8) (fine
control hole f is at a point midway between drain
hole D and pump pressure chamber PP) does not 1 P1 P2
change until retainer (7) contacts spool (1).
Therefore, metering spring (2) is compressed pro- PP
portionally to the amount of movement of the con-
trol lever, so the pressure at Port P1 also rises in A B
proportion to the travel of the control lever. In this Control valve
way, the control valve spool moves to a position
where the pressure in chamber A (the same as RKP00981

pressure at Port P1) and the force of the control Fig. 2

valve spool return spring are balanced. (Fig. 2)

PW110R-1 10-105
3. During fine control
(when the lever is returned)
When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) 5
and the pressure at Port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil 4
at Port P1 is released.
If the pressure at Port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con-
trol hole f is shut off from drain chamber D. At al- 7 D
most the same time, it is connected to pump pres-
sure chamber PP, and the pump pressure is sup- 3 T
plied until the pressure at Port P1 recovers to a
pressure that corresponds to the lever position. 2
When the spool of the control valve returns, oil in P
drain chamber D flows in from fine control hole f' f
in the valve on the side that is not working. The oil f'
passes through Port P2 and enters chamber B to
fill the chamber with oil. (Fig. 3) 1 P1 P2 PP

A Control valve B

RKP00993

Fig. 3

4. At full stroke
When lever (5) pushes down piston (4), and retai-
ner (7) pushes down spool (1), fine control hole f is
shut off from drain chamber D, and is connected
with pump pressure chamber PP. Therefore, the 5
pilot pressure from the control pump passes
through fine control hole f and flows to chamber
A from Port P1, and pushes the control valve 4
spool.
The oil returning from chamber B passes from
Port P2 through fine control hole f' and flows to
drain chamber D. (Fig. 4)
7 D

P
f
f'
1 P1 P2 PP

A Control valve B

RKP01003

Fig. 4

10-106 PW110R-1
TRAVEL PPC VALVE

25
°
1
4
6 2 3
1

2
b
a 5
3

ViewZZ
Vista RKP03690

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

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

b. T Port - To tank
c. A Port - To ST3 solenoid valve group (P Port)

PW110R-1 10-107
BRAKE PUMP

1
2

c d
b

4
e g f a

i h

View A
Vista A
RKP11560

1. Parking brake pedal SPECIFICATIONS

2. Lever Brake pressure: 50w5 bar
3. Pump Unitary displacement: 70 cc
4. Brake pressure adjusting screw Recharge pressure: 90w10 bar
Max. pressure accelerator: 120w10 bar
a. P Port - From servocontrol feed unit (PC Port)
b. N Port - To hydraulic tank
c. T1 Port - Brake light pressure switch port
d. F Port - Accumulator pressure switch port
e. B Port - To pump (PLS Port)
f. R2 Port - To A1 accumulator
g. R1 Port - To A2 accumulator
h. T1 Port - To swivel joint (7A Port)
i. T2 Port - To swivel joint (8A Port)

10-108 PW110R-1
BOOM AND ARM SAFETY VALVE

a b

c d

1 2

3
4
5
e

RKP04170

1. Screw SPECIFICATIONS
2. Valve Pilot ratio: 22:1 bar
3. Rod
4. Nut
5. Nut 20
Differential pressure ⌬p (bar)

a. T Port - To hydraulic tank 16

b. P Port - For boom: From control valve

2
C
➔

12 V2
V2

(PB4 Port) ➔
C2
For arm: From control valve 8

(PB5 Port)
4
c. V2 Port - For boom: From control valve
(A4 Port) 0
0 25 50 75 100 125 150
For arm: From control valve Amount Q (ᐍ / min)
(A5 Port)
d. M Port - For boom: To the overload sensor switch RKP04161

e. C2 Port - For boom: To the cylinder (Bottom side)

For arm: To the cylinder (Head side)

PW110R-1 10-109
2-PIECE BOOM SAFETY VALVE

a b
A A

1 1

2 3 3 2
Section
SezioneAA±-AA

c d

RKP04070

1. Screw SPECIFICATIONS
2. Plug Start opening: 4.25:1 bar
3. Valve
24
a. C1 Port - To 2-piece boom (Head side)
Differential pressure ⌬p (bar)

20
b. C2 Port - To 2-piece boom (Bottom side)
V2

c. V1 Port - From control valve (A9 Port)

➔

16
C2

C2
d. V2 Port - From control valve (B9 Port) ➔
12 V2

0
0 12 24 36 48 60
Amount Q (ᐍ / min)

10-110 PW110R-1
BLADE OR OUTRIGGER SAFETY VALVE

a b

A A

Section
SezioneAA±- A
A
c d

RKP03760

a. V2 Port - See hydraulic circuit SPECIFICATIONS

b. V1 Port - See hydraulic circuit Start opening: 8 bar (8.1 kg/cm2)
c. C2 Port - To blade or outrigger (Bottom side)
d. C1 Port - To blade or outrigger (Head side)
16
Differential pressure ⌬p (bar)

14
12
10
8 C2
V2
6 V2
4 C2

2
0
0 6 12 18 24 30
Amount Q (ᐍ / min)

RKP04541

PW110R-1 10-111
OVER LOAD SENSOR SWITCH

3 4 5

3
1
2

RKP11580

a. From boom safety valve (M port) TECHNICAL DATA

Setting valve: 140 bar
1. Connector
2. Pressure sensor switch FUNCTION
3. Adjusting screw The overload sensor switch is connected through the
4. Protection boom safety valve to boom cylinder (bottom side).
When the pressure rises over the setting valve, the
5. Connection plate sensor close the electrical circuit and the actives the
horn.

10-112 PW110R-1
SOLENOID VALVE
Solenoid valve group ST1
Locking axle, speed change and servocontrol

1
3 4

b c

d e f
RKP11530

a. T Port - To hydraulic tank 1. Y4 High speed

b. P Port - From servocontrol feed unit (PR Port) 2. Y12 Low speed
c. A3 Port - To swivel joint (14A Port) 3. Y10 Locking axle
d. A2 Port - To swivel joint (5A Port) 4. Y7 Servocontrol
e. A1 Port - To swivel joint (11A Port)
f. A Port - To servocontrol feed unit

PW110R-1 10-113
Solenoid valve group ST2
Swing brake, parking brake

1 2

c d RKP11550

a. T Port - To hydraulic tank

b. P Port - From servocontrol feed unit (PR Port)
c. A1 Port - Swing machinery (X Port)
d. A Port - To swivel joint (4A Port)

1. Y5 Swing brake
2. Y11 Parking brake

10-114 PW110R-1
Solenoid valve group ST3 (EV0-EV1)
Travel direction

1 a b 2

d c

RKP04570

1. Y1 Reverse
Measured at V=41 mm2/s e t=50°C 1 2
2. Y2 Forward
10

a. Port P - From travel PPC valve (A Port)

Differential pressure ⌬p (bar)

8
b. Port B - To control valve (PB3 Port)
6
c. Port T - To hydraulic tank
d. Port A - To control valve (PA3 Port) 4

0
0 20 40 60 80
Amount Q (ᐍ / min)

RKP04491

PW110R-1 10-115
Solenoid valve group ST4 (Y21 - Y22 - Y23 - Y24)
For steering

2 3

a b

T A

P B

c 5 d

1 4
RKP03670

Measured at V=41 mm2/s e t=50°C

Measured at V=41 mm2/s e t=50°C
5 3
6 9
10
10
Differential pressure ⌬p (bar)

Differential pressure ⌬p (bar)

8
8

6
6

4
4

2
2

0
0 20 40 60 80 0
Amount Q (ᐍ / min) 0 20 40 60 80
Amount Q (ᐍ / min)
RKP04501 RKP04511

1. Y21: Rear steering cut out

2. Y22: Front/rear steering
3. Y23: Phase coincidence steering
4. Y24: Crab steering
5. Blocks connection

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

b. A Port - To rear steering cylinder (c Port)
c. P Port - From swivel joint (9a Port)
d. B Port - To rear steering cylinder (d Port)

10-116 PW110R-1
Solenoid valve group OP1 (Y26)
Front outriggers or blade and rear outrigger selection

c d

b e

10
Differential pressure ⌬p (bar)

4
C
P
a f 2

0
10 30 50 70 90
Amount Q (ᐍ / min)
RKP05460
RKP04521

a. P1 Port - From swivel joint (10a Port) e. C4 Port - To R.H. rear outrigger safety valve
b. C1 Port - To L.H. rear outrigger safety valve (V1 Port)
(V1 Port) f. P2 Port - From swivel joint (2a Port)
c. C2 Port - With 4 outriggers:
To L.H. front outrigger safety valve
(V1 Port)
- For front blade and rear outrigger:
Not used
d. C3 Port - With 4 outriggers:
To R.H. front outrigger safety valve
(V1 Port)
- For front blade and rear outrigger:
To blade cylinder safety valve
(V1 Port)

PW110R-1 10-117
Solenoid valve group OP2 (Y8 - Y9)
For breaker, rotating grab bucket control

a b
1 2

d c

RKP03940

1. Y8 L.H. optional equipments control

2. Y9 R.H. optional equipments control
a. T Port - To hydraulic tank
b. A Port - To control valve (PB10 Port)
c. P Port - From ST1 solenoid valve group
(A4 Port)
d. B Port - To control valve (PA10 Port)

10-118 PW110R-1
ELECTRICAL DIAGRAM (1/4)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
M-B1 M-B1
STRUMENTO MULTIFUNZIONALE 4.1

R-G1 R-G1
MULTIFUCTION INSTRUMENT 4.1
R1 ACC BR R2 C
OFF ACC H/R1 H/R1
R1 4.1
ST XS XS XS XS XS XS XS XS XS XS XS XS XS XS XS XS H-N1.5 H-N1.5
4.1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

G1

H-L1
M-N1

A-V1

G/R1
B M-N1
S6

V1
2.1

Z/B1
Z-B1

V/B1
H/R1

R-V1
HA5

A2.5

M-V1
MANIPOLATORE Z-B1

G4
4.14
PPC VALVE
K11 A-V1
XC 1 G1 S7 3.1

Z-B1

A-V1
H-N1
R4

16
12

13
5

9
R-N1
2.1

L/R1
2.1

5 16 7 19 20 4 9 5 11 4 8 2 12 4

X7 X7 X4 X9 X9 X7 X9 X3 X4 X3 X4 X11 X4 X4
3.15

X17

X17

X17

X17
X16
X17

X17

X17
X16 +30 +15 F1B F4B F2B +15
R4 X17 X17
1 3 1 2 7 4 7.5A 3A 3A
5 8 2 6
9
R4

Z-B1

Z-N1
B-R1

B-N1

M-V1

L/R1

V1

S1
H-N1
V-B1

H-G1.5
G4

R-V1
1
2 3 6 2 1 7 3.9
1 4 1 3 10 11 5 2 9
2

X14

X14
X15

X15

X15
X13
X15

X14
X14
X15
X14 3.4
X13 X14 X14 X15

V1
K8

L/R1
V-B1
86 87a 87 86 87a 87
l KT1 K4
X12
KT2

M-V1

R-V1
85 30 85 30
R4

R4

53M
G4

53S
Z-B1

Z-N1
B-R1

B-N1

15

31
+15

H-N1
53M
53S
XT1 K2 K3
XT1
XT1
K1 86 87a 87 86 87a 87

15
31
86 87a 87
X12 +30
F4C

XT2
XT2
XT2
XT2
- 1 4 2 3
F3B F6A
85 30 85 30 85 30
M10

R-N1.5
5A 7.5A 15A
G/N1

1 2 4 3
R4

B/N1

G1
M1
K01 K03 K02
FUG2 FUG4 FUG1 FUG3 86 87 86 87 86 87
Z/B1

50A 80A 30A 70A

85 30 85 30 85 30

X5 X5 X5 X5 X6 X6 X8 X6 X9 X8 X9 X8 X7
B1.5 10 5 11 3 3 6 9 4 3 3 13 13 14

H2.5

A-N1
A-N1

A-N1.5
4.6
R4
R10

G2.5

B1.5 A-N1.5
3.1

- + 1 2 X20 2
M10

H-R1

A-G1
B-N1
R50

A-N1.5

B-R1.5
H-G1.5

H-G1.5
1
XA
XA

XAM XAM XR
-
S24
M1 G2 XW K12
B1.5

86 87
R1.5

R3
S1
G1 30 50 R1 R2 HA2 R4 S21 HA4
D+ Y0 Y13 S16 S17 S20 Y2 Y1 X1

1
M 30
G W
85 30
12Vcc 3 t p p p
U
L/R1

2
N1.5

t
31 XW M2
S25 X20

B-G1
XAM XR +
M 1
S5
N50

3 2
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
N1.5

N1.5

N1.5

N1.5

N1.5
31 2.1

RKP07211

K12 - TRANSFER PUMP RELAY S24 - TRANSFER PUMP START BUTTON X11 - LATERAL DASHBOARD LINE 13 WAY CONNECTOR
COMPONENTS FUSES
KT1 - PREHEATING TIMER S25 - TRANSFER PUMP SWITCH X12 - DIODE 2 WAY CONNECTOR
G1 - BATTERY F1B - GEAR VALVE FUSE 7.5A
KT2 - FUEL SOLENOID VALVE TIMER Y0 - FUEL SHUT OFF SOLENOID VALVE X13 - POWER 3 WAY CONNECTOR
G2 - GENERATOR F2B - JOYSTICK - INSTRUMENT POWER FUSE 3A
M1 - STARTER MOTOR Y1 - REVERSE SPEED SOLENOID VALVE X14 - ENGINE LINE 7 WAY CONNECTOR
HA2 - REVERSE BUZZER F3B - SAFETY START - FUEL SHUT OFF FUSE 7.5A
M2 - TRANSFER PUMP Y2 - FORWARD SPEED SOLENOID VALVE X15 - ENGINE LINE 11 WAY CONNECTOR
HA4 - LOOM HORN F4B - RIGHT TRAFFIC LIGHT AND INSTRUMENT LIGHT FUSE 3A
R1 - HEATING START Y13 - WORKING MODE SOLENOID VALVE X16 - POWER 3 WAY CONNECTOR
HA5 - BUZZER F4C - GENERATOR AND TIMERS (STARTING MOTOR PREHEATING) 5A
R2 - RESISTOR X17 - LATERAL DASHBOARD 9 WAY CONNECTOR
K01 - STARTER RELAY F6A - PLIERS VALVE-HORN-CURRENT INTAKE FUSE 15A
K02 - FUEL SHUT OFF RELAY
R3 - WATER TEMPERATURE SENDER CONNECTOR X20 - TRANSFER PUMP 2 WAY CONNECTOR
FUG1 - FUEL SHUT OFF FUSE 30A
R4 - FUEL LEVEL SENDER X1 - INTERFACE LINE 5 WAY CONNECTOR XA - GENERATOR 2 WAY CONNECTOR
K03 - PREHEATING RELAY FUG2 - GENERAL FUSE 50A
S5 - TRANSFER PUMP SENSOR X3 - RIGHT LATERAL DASHBOARD LINE 18 WAY CONNECTOR XAM - FUEL SHUT OFF 3 WAY CONNECTOR
K1 - FORWARD SPEED VALVE RELAY FUG3 - GENERATOR FUSE 70A
S6 - STARTING SWITCH X4 - RIGHT LATERAL DASHBOARD LINE 12 WAY CONNECTOR XR - RESISTOR 2 WAY CONNECTOR
K2 - REVERSE SPEED SOLENOID VALVE RELAY FUG4 - PREHEATING FUSE 80A
S7 - JOYSTICK HORN BUTTON X5 - ENGINE LINE 11 WAY CONNECTOR XS - MULTIFUNCTION INSTRUMENT 16 WAY CONNECTOR
K3 - SPEED CONNECTION RELAY
S16 - HIGH WATER TEMPERATURE SWITCH X6 - LIGHTS SWITCH-GEAR SHIFT LINE 13 WAY CONNECTOR XT1 - PREHEATING 4 WAY CONNECTOR
K4 - KEY SAFETY START RELAY
S17 - AIR FILTER SWITCH X7 - STEERING INTERFACE LINE 21 WAY CONNECTOR XT2 - FUEL SHUT OFF 4 WAY CONNECTOR
K8 - HORN RELAY
S20 - ENGINE OIL LOW PRESSURE SWITCH X8 - LOOM LINE 21 WAY CONNECTOR XW - 2 WAY CONNECTOR
K11 - POWER MODE UNIT
S21 - BRAKES PRESSURE SWITCH X9 - LIGHTS SWITCH-GEAR SHIFT LINE 21 WAY CONNECTOR

10-119
 PAGE INTENTIONALLY
LEFT BLANK

10-120
ELECTRICAL DIAGRAM (2/4)

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

PULSANTIERA PRINCIPALE MANIPOLATORE PULSANTIERA PRINCIPALE PULSANTIERA SECONDARIA

PPC VALVE SECONDARY SWTCHES PANEL
MAIN SWITCHES PANEL MAIN SWITCHES PANEL

XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 XP1 S11 S10 XP2 XP2 XP2 XP2 XP2 XP2 XP2 XP2 XP2 XP2 XP2 XP2 X13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 1

A/V1

M-B1
G-V1

A-G1
V-B1

R-V1
G-N1

G-R1
V-N1
L/R1

Z-N1
R-N1

C-N1
M-N1

C-B1

S-N1

R/N1
R-G1
M-N1
1.20

R-N1
1.20

L/R1
1.20

C/N1

R1.5
3.16
R1.5

10 12 5 7 8 6 1 2 18 3 9 10 15 12 13 16 14 9 11 17

X4 X11 X3 X3 X3 X3 X3 X3 X3 X4 X3 X3 X3 X3 X3 X3 X3 X3 X3

14
4.10
11 12
4.8 4.1
13
4.10
10 4.8

9 4.8

+15 +15 +15 OP +15

8 4.5

F7A F2C F2A F3A

K9 86 87a 87
15A 7.5A 5A 7.5A

85 30

X6 X6 X5 X6 X6 X6 X8 X8 X8 X8 X8 X8 X9 X8
2 8 1 13 12 11 15 7 20 8 19 6 21 18

S1
R1

R1

M1
C-L1

G1.5

L/G1

M-V1
Z-N1

A-V1
R-N1

S-G1
M-N1

G-N1
8 S14

G/N1
X15
R1 R1
3.13

S13 S23 Y9 Y8 Y3 1 2 Y10 Y11 S15 Y7 S8 S9 S22

+ -
X19 X19 p p
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
1.20 3.1 RKP07221

COMPONENTS CONNECTORS FUSES

Y8 - HAMMER SOLENOID VALVE XP1 - SWITCHES PANEL 18 WAY CONNECTOR
K9 - STOP LIGHT RELAY X3 - RIGHT LATERAL DASHBOARD LINE 18 WAY CONNECTOR F2A - SERVOCONTROL VALVE FUSE 5A
Y9 - GRAB SOLENOID VALVE XP2 - SWITCHES PANEL 12 WAY CONNECTOR
S8 - HAMMER PEDAL BUTTON X4 - RIGHT LATERAL DASHBOARD LINE 12 WAY CONNECTOR F2C - BUTTONS RELAYS FUSE 7.5A
Y10 - AXLE LOCK SOLENOID VALVE
S9 - PLIERS BUTTON X5 - ENGINE LINE 11 WAY CONNECTOR F3A - BUTTONS RELAYS FUSE 7.5A
Y11 - PARKING BRAKE SOLENOID VALVE
S10 - HAMMER BUTTON X6 - LIGHTS SWITCH-GEAR SHIFT LINE 13 WAY CONNECTOR F7A - STOP LIGHT AND HEATER 15A
S11 - JOYSTICK GRAB BUTTON X7 - STEERING INTERFACE LINE 21 WAY CONNECTOR
S13 - BRAKE LIGHT SWITCH X8 - LOOM LINE 21 WAY CONNECTOR
S14 - ARM MICRO SWITCH X9 - LIGHTS SWITCH-GEAR SHIFT LINE 21 WAY CONNECTOR
S15 - ANTI OVERTURNING PRESSURE SWITCH X11 - LATERAL DASHBOARD LINE 13 WAY CONNECTOR
S22 - BRAKE PRESSURE SWITCH X13 - PARKING BRAKE LIGHT 1 WAY CONNECTOR
S23 - WORKING BRAKE SWITCH X15 - ENGINE LINE 11 WAY CONNECTOR
Y3 - WORKING BRAKE SOLENOID VALVE X19 - OPTIONAL PLIERS SOLENOID VALVE 2 WAY CONNECTOR
Y7 - SERVOCONTROL SOLENOID VALVE

10-121
 PAGE INTENTIONALLY
LEFT BLANK

10-122
ELECTRICAL DIAGRAM (3/4)

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

G1
SPIE DEVIO DEVIO LUCI
GEAR SHIFT LAMPS LIGHTS SWITCH 1
B C F
0 1
15/1 30/3 R/7
1
B C F
0 1
15/1 30/3 L/6
0 2 0 2

XD1 XD1 XD1 XD1 XD2 XD2 XD2 XD2 XD2 XD2 XD2 XD2 XD2 XD2 XD2 XD2 A E 49/4 49a/5 L/6 A E 49/4 30b/2 R/7
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12
S3 S1 S4 S2

A-B1
G-L1

A-N1
V1

A1

B1
L-N1
H1
H-L1
G-V1

A-N1.5
C-B1
R1.5
2.20

A-V1
1.20

A-N1.5
1.20

A1
R1
L1.5

B1.5
G1.5
A-B1

B/R1
H-R1

S-G1

A-N1

C-V1.5

A-R1.5
V1.5

H1.5

B-G1
8 11 6 16 15 10 10 5 3 14 18 2 9 7 6 17 6 12 1 3 8 11 13 2 4 1

X9 X9 X9 X9 X9 X9 X11 X11 X4 X9 X9 X9 X11 X11 X11 X9 X4 X9 X4 X11 X11 X11 X11 X4 X11 X11
2 +15 28
1.20 4.1

F5A F5C
3A 10A
+30
+15 +30 +15
K5 86 87a 87 K6 86 87a 87 K10
+15
F3C F5B F4A F7B F6C F6B +

7.5A 15A 15A 85 30 85 30 10A 10A 7.5A

25 C R F7C
4.10
10A

24
4.5

15 1
4.5 1.20
3
1.20

27 26 16
4.15 4.10 4.1

X8 X8 X8 X8 X8 X8 X8 X8 X8 X8 X6 X6 X9 X6 X5 X5 X5 X5 X6 X6 X10 X10
10 4 21 11 1 2 12 17 14 16 5 7 1 10 6 8 9 7 9 1 1 4

A-B1
G-R1

A1
G1
4 6

A1
G1
B1

R1

M1.5

M1.5
B1.5

B1.5
A-B1
5 7

G-R1
S1.5

G1.5

H1.5
A/N1

G-N1.5

C-V1.5

A-R1.5
X15 X15 X15 X15
1 3 2 1 4 6

A1
R1

R1
G1
A-B1
G-R1

X29
1 2 1 2 5 4 1 2 3 6 7 8 X29 X29 X24 X24 X24
X32 X32 X33 X33 X18 X18 X18 X18 X18 X18 X18 X18
H7
H2 H3 H4 H5
56a

56b

56a

56b
R

57

57
L
Y12 Y4 Y5 S18 S19

57

59c
57

59c
L
1 2
H1 H6 M3 H8
M
X31

X31

p p M

31

31
31

31

X32 X33
3 3 R1
2.20
N1

N1

N1

N1

N1

N1

N1.5

N1.5

N1.5

N1.5

N1.5
N1
2.20 4.1

RKP07230

COMPONENTS CONNECTORS FUSES

K10 - FLASHER UNIT X29 - HEATER 4 WAY CONNECTOR
H1 - WORKING LIGHT X4 - RIGHT LATERAL DASHBOARD LINE 12 WAY CONNECTOR F3C - RADIO AND CABIN POWER FUSE 7.5A
M3 - BLOWER MOTOR X31 - RADIO 2 WAY CONNECTOR
H2 - FRONT RIGHT LIGHT X5 - ENGINE LINE 11 WAY CONNECTOR F4A - MAIN BEAM FUSE 15A
S1 - WARNING/HAZARD X32 - RIGHT FRONT LIGHT 3 WAY CONNECTOR
H3 - FRONT LEFT LIGHT X6 - LIGHTS SWITCH-GEAR SHIFT LINE 13 WAY CONNECTOR F5A - LEFT TRAFFIC LIGHT FUSE 3A
S2 - ROTATING LAMP SWITCH X33 - LEFT FRONT LIGHT 3 WAY CONNECTOR
H4 - REAR LEFT LIGHT X8 - LOOM LINE 21 WAY CONNECTOR F5B - LOW BEAM FUSE 15A
S3 - WORKING LIGHT SWITCH XD1 - GEAR SHIFT WARNING LIGHT 4 WAY CONNECTOR
H5 - REAR RIGHT LIGHT X9 - LIGHTS SWITCH-GEAR SHIFT LINE 21 WAY CONNECTOR F5C - LIGHTS SWITCH POWER FUSE 10A
S4 - HEATER SWITCH XD2 - LIGHTS SWITCH 12 WAY CONNECTOR
H6 - NUMBER PLATE LAMP X10 - CABIN LINE 5 WAY CONNECTOR F6B - DIRECTION INDICATORS POWER FUSE 7.5A
S18 - 1st ROTATION PRESSURE SWITCH
H7 - BEACON LAMP X11 - LATERAL DASHBOARD LINE 13 WAY CONNECTOR F6C - HAZARD POWER FUSE 10A
S19 - 2nd ROTATION PRESSURE SWITCH
H8 - WORKING LIGHT X15 - ENGINE LINE 11 WAY CONNECTOR F7B - WORKING LIGHT FUSE 10A
Y4 - HIGH SPEED SOLENOID VALVE
K5 - MAIN BEAM RELAY X18 - REAR LINE 8 WAY CONNECTOR F7C - CABIN POWER (+15) AND BEACON FUSE 10A
Y5 - ROTATION SOLENOID VALVE
K6 - LOW BEAM RELAY X24 - CABIN 7 WAY CONNECTOR
Y12 - SLOW SPEED VALVE

10-123
 PAGE INTENTIONALLY
LEFT BLANK

10-124
ELECTRICAL DIAGRAM (4/4)

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

DEVIO GUIDA CENTRALINA CONTROLLO STERZATURA

GEAR SHIFT STEERING CONTROL UNIT

XD3 XD3 XD3 XD3 XD3 XD3 XD3 XD3 X21 X21 X21 X21 X21 X21 X21 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22 X23 X23 X23 X23 X23 X23 X23 X23 X23
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9

B-G1

C-L1
B1
S1.5

H1

R-G1

Z-B1

A/V1
M-V1

M-B1

N1.5
R1
B-G1

C-N1

G-V1

R-N1
V-B1
H/R1

S-N1

B-N1

S-N1

R/N1

R-V1

B-R1
C1

G-R1

V1
H-N1.5
H/R1
1.20

H-N1.5
1.20

R-G1 Z-B1
1.20 1.20

M-B1
1.20

2 7 7 4 5 15 5 4 21 9 2 13 3 8 1 1 3 10 20 6 12 19 17 18 11

X1 X9 X7 X9 X9 X7 X1 X1 X7 X7 X7 X7 X7 X7 X7 X1 X1 X7 X7 X7 X7 X7 X7 X7 X7

12 8 10 25
2.13 2.7 2.7 3.4 +15 +15
15 9 26
3.3 2.7 3.5

24 11 13
F1C F1A
3.3 2.7 2.15
3A 7.5A
14
2.16

27
3.4
16
3.6

28
3.19

X10 X10 A-N1

A1

S1
H1

G-R1

R1

R-N1
R/N1

R-V1
V-B1
1.20

V1
2 3
9 8 13 10 12 11 6 2 3 5 7 1 4 2 3 4

XG XG XG XG XG XG XG XG XG XG XG XG XG X26 X26 X26

B1
Z1

C/B1
GIUNTO
JOINT
B-R1

X25 X25 X26 X25 X25 X25 X25 X25 X25 X25 X25 X25 X25
C1

R1 X27 X27 X27 X27

9 8 1 10 12 11 6 2 3 5 7 1 4 3 1 2 4

V-B1

G-R1
3 2 5
A/V1
L1

S1

S1

V1
H1

X24 X24 X24 S12

R-N1
R/N1

R-V1
C B A C B A
X28 X28 X28 X30 X30 X30
H9
M4

L1

L1
N1

N1
M1

M1
Y24 Y23
1

M Y26 Y25 SENSORE DI Y21 Y22

MOVIMENTO SENSORE PONTE SENSORE PONTE
ANTERIORE POSTERIORE
MOVEMENT
SENSOR FRONT AXLE REAR AXLE
2

SENSOR SENSOR
N2.5
N1.5

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
3.20 /./ RKP07240

COMPONENTS CONNECTORS
XD3 - GEAR SHIFT 8 WAY CONNECTOR
H9 - CABIN LAMP X1 - INTERFACE LINE 5 WAY CONNECTOR XG - JOINT 17 WAY CONNECTOR
M4 - WASHER MOTOR X7 - STEERING INTERFACE LINE 21 WAY CONNECTOR
S12 - SPEED CONNECTION MICROSWITCH X9 - LIGHTS SWITCH-GEAR SHIFT LINE 21 WAY CONNECTOR FUSES
Y21 - FRONT STEERING SOLENOID VALVE X10 - CABIN LINE 5 WAY CONNECTOR
F1A - STEERING VALVE FUSE 7.5A
Y22 - DOUBLE STEERING SOLENOID VALVE X21 - STEERING UNIT 7 WAY CONNECTOR
F1C - PROXIMITY AND STEERING UNIT POWER FUSE 3A
Y23 - ROUND STEERING SOLENOID VALVE X22 - STEERING UNIT 13 WAY CONNECTOR
Y24 - CRAB STEERING SOLENOID VALVE X23 - CRAB STEERING SOLENOID VALVE
Y25 - ENGINE POWER CHANGE SOLENOID VALVE X24 - CONNECTOR MARK 7 VIE CABIN
Y26 - BRACKET SOLENOID VALVE X25 - ENGINE POWER CHANGE SOLENOID VALVE
X26 - BRACKET SOLENOID VALVE

10-125
10-126
GROUP 20
40-28 PC15R-8
 TESTING AND ADJUSTMENTS

Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2
Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19
Measuring the engine speed.. . . . . .. . . . .. . . . . .. . . . .. . 21
Adjusting valve clearance . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
Measuring compression pressure .. . . . .. . . . . .. . . . .. . 23
Testing and adjusting fuel injection timing . .. . . . .. . 24
Testing and adjusting fan belt tension .. . . . . .. . . . .. . 26
Adjusting the stroke of the accelerator lever . . . . .. . 27
Adjusting PPC valves clearance. . .. . . . .. . . . . .. . . . .. . 28
Adjusting the safety microswitch . .. . . . .. . . . . .. . . . .. . 29
Measuring the swing circle axial clearance. .. . . . .. . 30
Air bleeding from hydraulic circuits . . . .. . . . . .. . . . .. . 31
Releasing residual pressure .. . . . . .. . . . .. . . . . .. . . . .. . 34
Checking and regulating pressure in the
hydraulic circuits . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 35
Testing and setting of main valves . . . . .. . . . . .. . . . .. . 36
Adjusting PC valve.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 38
Measuring ls differential pressure
and adjusting LS valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 39
Checking and adjusting pressures in the
servocontrol feed unit. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 41
Measuring pumps delivery and flow
control starting point pump P1. . . . .. . . . .. . . . . .. . . . .. . 42
Checking that the priority valve is functioning
correctly . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 44
Checking and regulating the pressure of the
steering system. . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Checking leakages in the steering cylinders . . .. . . . 46
Checking the braking system . . .. . . . . .. . . . . .. . . . .. . . . 47
Checking wear in the brake disks . . . .. . . . . .. . . . .. . . . 52
Bleeding air from the brake lines . . . . .. . . . . .. . . . .. . . . 53
Adjusting the parking brake . . . . .. . . . . .. . . . . .. . . . .. . . . 54
Travel hydraulic equipment checking procedure . . . 55
Checking and adjusting the automatic
displacement control system of the travel motor . . . 56
Checking for leakages in the travel motor .. . . . .. . . . 57
Checking and adjusting the speed of the travel
propeller shaft . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 58
Adjustment of the speed surveyor . . . .. . . . . .. . . . .. . . . 59
Adjusting boom and arm safety valves. . . . .. . . . .. . . . 60
Adjusting 2nd boom safety valves. . . . .. . . . . .. . . . .. . . . 61
Measuring and setting of pressure switch signal
overload operation . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 62
Measurement of internal oil leakages
in the swing motor . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 63
Checking for leakages inside the swivel joint. . .. . . . 64
Analysis of the causes of hydraulic drifts . .. . . . .. . . . 67

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).

PW110R-1 20-1
NORMAL OR STANDARD TECHNICAL DATA
. FOR ENGINE
Machine model PW110R-1

Engine S4D106-1FB

Check item Test Conditions Unit Standard Permissible

value value

High idling rpm 2200w25 2200w50

Engine speed Low idling rpm 1100w25 1100w50
Set speed rpm 2000 ±

Sudden acceleration Index 0.9 Max. 1.5

Exhaust gas colour Bosch
At high idling speed 0.5 Max. 1.0

Intake valve (20ëC) mm 0.30w0.05 Max. 0.35

Valve clearance
Exhaust valve (20ëC) mm 0.30w0.05 Max. 0.35

Compression Oil temperature 69 ± 72ëC kg/cm2 35w1 28w1

pressure
(SAE30 oil) (Engine speed) rpm 250 250

Blow-by Water temperature in

operating range Ð Ð
pressure mm H2O
(SAE30 oil) Ð Ð
At high idling speed

Max. idling (in cold state) kg/cm2 Max. 6.0 Max. 6.0

Engine oil With water temperature in operating range

pressure High idling kg/cm2 4.0 ± 5.0 ±
At low idling kg/cm2 Min. 1.0 ±

Oil temperature Entire speed range ëC Max. 120 Max. 120

Fuel injection timing B.T.D.C. degrees 11 10 ± 12

Fan-belt tension Deflection when pressed mm Max. 10 10 ± 15

with finger force of approx. 10 kg

20-2 PW110R-1
. FOR MACHINE
All tests, if not otherwise specified, should be performed with WORKING MODE in position P

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible
cation value value

Engine speed with

pump P1 2100w50 2050 ± 2150
at max. pressure
. Hydraulic oil temp.: 45 ± 55ëC
Engine speed with . Engine oil pressure: in correct range
pump P1 and P2 . Cooling water temp.: in correct range 2075w50 2025 ± 2125
at max. pressure
Engine

. Swing lock pin inserted

. Max. pressure P1: with boom rpm
Engine speed with
pump P2 . Max. pressure P1-P2: with boom and 2150w50 2100 ± 2200
at max. pressure swing boom
. Max. pressure P2: with arm and
Engine speed when pumps swing boom
P1-P2 are at max. pressure 2140w50 2090 ± 2190
and the WORKING MODE
selector is in pos. E
Boom , a b , a b

Arm
Bucket ᐉ
a b
Swing
Spool travel

Blade-outriggers
mm
Boom swing 45 6.5w0.3 6.5w0.3 45 6.5w0.3 6.5w0.3
nd
2 boom
Travel RKP08070

Attachment
Boom double
speed

. At centre of Raise
Boom control lever Neutral Lower 80w8 70 ± 90
lever knob
. Reading at Extended
Arm control lever end of travel Neutral Retracted 80w8 70 ± 90
. Engine
stopped Open
Bucket control lever Neutral Curled 80w8 70 ± 90
. Equipment on
Travel of levers and pedals

the ground
Swing
Swing control lever Neutral right 80w8 70 ± 90
Swing left

Blade outriggers Neutral

Raise
100w10 80 ± 120
control lever Lower mm

Fuel control lever Min. Max. 130w15 110 ± 150

Swing
Boom swing pedal Neutral right 20w2 16 ± 24
Swing left

Open
2nd boom pedal Neutral Closed 30w3 25 ± 35

Travel control pedal Neutral Max. 60w6 50 ± 80

Brakes pedal Zero Max. 30w3 25 ± 35

PW110R-1 20-3
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible
cation value value

Raise boom . Engine speed: high idling 2.0w0.5 Max. 3.0

. Oil temperature: 45 ± 55ëC
Lower boom . Instrument coupling at centre 2.0w0.5 Max. 3.0
of control lever knob
Operating force for control of

Bucket curled-open 1.8w0.4 Max. 2.7

. Instrument coupling on outside
Arm open-close edge of pedal control 2.0w0.5 Max. 3.0
levers and pedals

Swing (R.H.-L.H.) 1.8w0.4 Max. 2.7

Blade control 1.7w0.3 Max. 2.0
and outriggers kg

Fuel control lever 5.0w1.0 Max. 7.0

Boom swing pedal 10w2.5 Max. 15
nd
2 boom pedal 10w2.5 Max. 15
Travel pedal 4.0w0.5 3.3 ± 4.7
. A 150 mm
from fulcrum
Brake pedal 50 5 40 ± 50

P1 pump (Safety) 294 ±0

+8
Main valve
pressure

. Engine speed: max.

P2 pump (Safety) . Oil temperature: 45 ± 55ëC bar 216 ±0
+8
. Check one circuit at a time
Servocontrols (Safety) 35 ±0
+3

Raise 294 ±0
+8
Boom
Lower 294 ±0
+8
Arm 294 ±0
. Engine speed: max. +8
. Oil temperature: 45 ± 55ëC
Bucket 294 ±0
. Check one circuit at a time +8
Swing 216/166 ±0
+8
Blade 216 ±0
+8
Outriggers (R.H. side) 216 ±0
+8
Hydraulic pressure

Outriggers (L.H. side) 216 ±0

+8
Boom swing 294 ±0
bar +8
2nd boom 294 ±0
+8
Travel 294 ±0
+8
Additional equipment 196 ±5
+5
Servocontrols 32 1 Max. 33
. Engine: . Levers at NEUTRAL ± ±
high idling
LS differential pressure
. Oil temperature: . Travel speed: Hi
14.2 w2
45 ± 55ëC . Wheels: raised
. Engine speed: low idling
Steering 170 5 ±
. Oil temperature: 45 ± 55ëC
. Engine speed: low idling
Braking 50w5 ±
. Oil temperature: 45 ± 55ëC

20-4 PW110R-1
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Work equipment at max. reach

Braking angle Degrees Max. 60ë Max. 80ë

RKP06000
(mm) (400) (540)
. Load in the bucket: 540 kg
. Engine speed: high idling.
. Oil temperature: 45 ± 55ëC
. Make centring marks on the outer swing
circle rings. Rotate the upper turret 360ë
and stop. Measure the difference between
the marks after stopping.

Working equipment at max. reach

90ë Ð Ð

Time taken to start swing sec

RKP06000

. Engine speed: high idling 180ë 5.5w0.5 Max. 6.5

. Oil temperature: 45 ± 55ëC
. Time taken also from starting posi-
Swing

tion at 90ë and 180ë.

Working equipment at max. reach

Time taken to swing sec 40w4 35 ± 45

RKP06000

. Engine speed: high idling

. Oil temperature: 45 ± 55ëC
. Make one turn to settle machine.
. Measure the time taken to make 5 full
swings.

15°

RKP06010

Hydraulic drift of swing Degrees 0 Ð

. Engine switched off (mm)
. Oil temperature: 45 ± 55ëC
. Brake disengaged (with specific tool)
. Park the machine on a 15ë slope and set
the boom at 90ë with respect to the ground
surface
. On the outer swing circle, mark the posi-
tion between turret and track frame.
. After 15 minutes measure the drift.

PW110R-1 20-5
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Engine speed: high idling

Swing

Internal leakage from swing . Oil temperature: 45 ± 55ëC

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

20-6 PW110R-1
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture

2nd speed
1150 + 50
± 100

Travel speed (1) rpm

(without load) RKP06020

. Engine speed: 2000 rpm

. Oil temperature: 45 ± 55ëC

4th speed
. Axle blocked + 100
. Rest the front work equipment on 3750 ± 200
the ground and push it down to rai-
se the machine
. Measure the speed of the propeller
shaft in 2nd fast gear.

Measuring posture

45° 2nd speed

20w2 17 ± 23

2nd speed sec

Travel

RKP06030
4th speed

. Engine speed: high idling 6.3w1 5 ± 7.5

. Oil temperature: 45 ± 55ëC
. On flat ground
. Travel for at least 20 metres and
then check on the time needed to
cover 50 metres.

Measuring posture

Hydraulic drift mm 0 0
of travel motor 15°

RKP06040

. Engine switched off

. Parking brake: disengaged
. Oil temperature: 45 ± 55ëC
. After 1 minute, mark the position; measure
drift for every 5 minutes and then check to-
tal drift in 15 minutes.

PW110R-1 20-7
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Engine speed: 2000 rpm

. Oil temperature: 45 ± 55ëC
Travel

Leakage from . Working brakes: engaged ,/min ± ±

travel motor . 2nd fast gear engaged
. After 30 seconds start to measure for full
minute

20-8 PW110R-1
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible
cation value value
Boom
Measuring posture A Max. 400 Max. 600
L=1850
Total work equipment
Boom
(Standard boom) B Max. 400 Max. 600
(Downward movement L=2000
bucket teeth tips) A
B Boom
C C Max. 400 Max. 600
L=2300
Boom
A Max. 10 Max. 20
RKP06051

L=1850
Boom
Boom cylinder . In this position, measure exten- B Max. 15 Max. 30
(Retraction) sion or retraction of each cylinder, L=2000
and any leakages occurring when mm
Boom
a load is applied to the tips of the
bucket teeth.
C Max. 20 Max. 40
L=2300
. Horizontal levelled ground
Boom
. Bucket: rated load 630 kg A Max. 55 Max. 100
. Levers: neutral L=1850
. Engine: switched off Boom
Arm cylinder B Max. 60 Max. 110
(Extension) . Oil temperature: 45 ± 55ëC
. Safety valve disengaged L=2000
. Take measurements as soon as Boom
the engine stops C Max. 65 Max. 120
L=2300
Hydraulic drift of working equipment

. Measure the variations every 5 mi-

Bucket cylinder nutes and check the total variation
after 15 mins. Max. 20 Max. 30
(Retraction)
Measuring posture Boom
A Max. 400 Max. 700
L=1850
Total work equipment
Boom
(Downward movement B Max. 400 Max. 700
of tips of bucket teeth) L=2000
(2-piece boom) A Boom
B
C C Max. 400 Max. 700
L=2300
RKP06061 Boom
A Max. 12 Max. 25
L=1850
Boom
Boom cylinder B Max. 16 Max. 35
(Retraction) . In this position, measure extension
L=2000
and retraction of each cylinder, and
any leakages when a load is ap- Boom
plied to the tips of the bucket teeth. C Max. 22 Max. 45
L=2300
. Horizontal levelled ground
. Bucket: rated load 540 kg Boom
A mm Max. 40 Max. 60
. Levers: neutral L=1850
. Engine: switched off
Boom
2nd boom cylinders . Oil temperature: 45 ± 55ëC B Max. 45 Max. 70
(Retraction) . Safety valve disengaged L=2000
. Take measurements as soon as Boom
the engine stops C Max. 50 Max. 75
. Measure the variations every 5 mi- L=2300
nutes and check the total variation Boom
after 15 mins. A Max. 55 Max. 100
L=1850
Boom
Arm cylinder B Max. 60 Max. 110
(Extension) L=2000
Boom
C Max. 65 Max. 120
L=2300

Bucket cylinder Max. 20 Max. 45

(Retraction)

PW110R-1 20-9
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible
cation value value
A Boom
B A Max. 10 Max. 15
C L=1850

Boom
Boom swing B Max. 12 Max. 18
(Standard boom) 15° L=2000

Boom
RKP06071
C Max. 14 Max. 21
L=2300
. Engine: switched off mm
. Oil temperature: 45 ± 55ëC Boom
. Bucket: rated load A Max. 12 Max. 18
L=1850
with standard boom: 630 kg
with 2-piece boom: 540 kg
Boom
Boom swing . In the same position as above, B Max. 14 Max. 21
(boom) park the machine on a 15ë slope L=2000
and bring the turret round to 90ë.
Hydraulic drift of working equipment

Measure the extension and retrac- Boom

tion of the cylinder after 15 mins. C Max. 16 Max. 24
L=2300

Outriggers RKP06080 mm 15w2 Max. 20

. Engine speed: high idling
. Oil temperature: 45 ± 55ëC
. Safety valve cut out
. Bring the outriggers to half stroke and
measure their height from the ground.
Measure the downward after 15 mins.

Blade
(measure the downward RKP06090
mm 15w2 Max. 20
movement of the edge of . Engine: switched off
the blade) . Oil temperature: 45 ± 55ëC
. Safety valve disengaged
. Raise the blade and measure the height of
the edge from the ground.
Measure the downward after 15 mins.
H Check one cylinder at a time.

Boom Max. 3.3 Max. 13.0

Internal cylinder leankage

nd
2 boom Max. 2.0 Max. 8.0
(2 cylinders) (each cylinder)
. Engine speed: high idling
Arm . Oil temperature: 45 ± 55ëC Max. 2.4 Max. 9.6
. Check leakages: on the cylinder on the si-
de opposite to the one under pressure
cc/
Bucket min Max. 2.0 Max. 8.0
H Check one cylinder at a time
Boom swing H For the 2-piece boom check the two cylin- Max. 2.4 Max. 9.6
ders individually but simultaneously.
Blade - outriggers Max. 3.3 Max. 13.0
(each cylinder)

Steering Max. 2.0 Max. 8.0

(each cylinder)

20-10 PW110R-1
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture

Raise
Boom
2.6w0.3 Max. 3.2
Bucket teeth on the ground

RKP06100

Lower
Cylinder completely 2.0w0.2 Max. 2.4
extended
. Engine speed: high idling
. Oil temperature: 45 ± 55ëC

Measuring posture
2nd boom

Closed
5.0w0.5 Max. 6.0
Cylinders completely
retracted

Inout
Cylinders completely
RKP06110 5.5w0.6 Max. 6.7
extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

Measuring posture
Arm
Closed

3.3w0.4 Max. 4.0

Work equipment

Cylinder completely
retracted
Speed

sec
Inout

Cylinders completely
RKP06120
2.5w0.3 Max. 3.1
extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

Measuring posture
Bucket
Curled

3.0w0.3 Max. 3.6

Cylinder completely
retracted
Dump

Cylinder completely
RKP06130 2.2w0.2 Max. 2.6
extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

Measuring posture
Boom swing
L.H.

5.5w0.8 Max. 6.2

Cylinder completely
retracted

RKP06140
R.H.

Cylinder completely 5.5w0.8 Max. 6.2

extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

PW110R-1 20-11
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture

Raise
Outriggers
2.5w0.3 Max. 3.1

Resting on ground

Lower
RKP06150
2.6w0.3 Max. 3.2
Work equipment

Fully raised
. Engine speed: high idling
Speed

. Oil temperature: 45 ± 55ëC

sec
Measuring posture

Raise
Blade
2.5w0.3 Max. 3.1
Blade on the ground

RKP06160
Lower
Blade raised to max. 2.6w0.3 Max. 3.2
height
. Engine speed: high idling
. Oil temperature: 45 ± 55ëC

20-12 PW110R-1
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Measuring posture

Boom Max. 2 Max. 3

(Standard)
RKP06170

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Retract fully the cylinders of the arm and
bucket.
Lower bucket to ground and measure time
taken for chassis to rise from ground.

Measuring posture
Work equipment

Boom Max. 2 Max. 3

Time lags

(2-piece boom)
sec
RKP06180

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Retract fully the cylinders of the arm and
bucket.
Extend the 2nd boom fully.
Lower bucket to ground and measure time
taken for chassis to rise from ground.

Measuring posture

2nd boom Max. 2 Max. 3

RKP06190

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Retract fully the cylinders of the arm and
bucket. Extend the 2nd boom fully. Bring
the boom into a vertical position. Close
completely the 2nd boom and measure
the time taken to increase the pressure.

PW110R-1 20-13
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture

Boom
A
B
A Max. 2.0 Max. 3.0
C L=1850

Boom
Arm RKP06201
B Max. 2.0 Max. 3.0
L=2000

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Bring the boom into a horizontal posi-
tion. Boom
Retract the cylinder of the arm com- C Max. 2.0 Max. 3.0
L=2300
pletely and then extend it.
Amount of time when arm stops for a
moment.

Measuring posture
Work equipment

Time lags

sec
Bucket Max. 2.0 Max. 3.0
RKP06210

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Bring the arm into a horizontal position.
Retract the bucket cylinder completely, then
extend it.
Measure the time that elapses between the
bucket stopping at dead centre and then
starting to move again

Measuring posture

Outriggers Max. 1.0 Max. 1.5

RKP06220

. Engine: low idling

. Oil temperature: 45 ± 55ëC
. Raise the outriggers to their max. height and
then lower them. Measure the time it takes
for the front of the machine to be lifted off
the ground, starting from the time the outrig-
gers contacts the ground.

20-14 PW110R-1
. FOR MACHINE

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture
Work equipment

Time lags

Blade RKP06230
sec Max. 1.0 Max. 1.5

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Raise the blade to its max. height, then lo-
wer it.
Measure the time it takes for the rear of the
machine to be lifted off the ground, starting
from the time the blade contacts the
ground.

Machine model PW110R-1

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Oil temperature: 45 ± 55ëC

Pump delivery

. Measure with engine at rated speed

Gear pump P2 . 58 Min. 52
Pumps

At relief valve set pressure

(29.4 bar (30 Kg/cm2)) ,/min
. Measure the deliveries for
WORKING MODE in position P
and with the 3 - circuit valve functioning.

Piston pumps P1 See following pages

PW110R-1 20-15
 Machine model PW110R-1

Classifi- . Delivery of individual piston pumps P1

cation . WORKING MODE selector: position P
. Pump speed: 2000 rpm.
. Oil temperature: 45 ± 55ëC.
Q (ᐍ/min)

200

Input shaft torque (kgm)

196 bar
182 ᐉ/min

182 Maximum delivery

178
35

220.3 bar
181.3 bar 159 ᐉ/min
166 ᐉ/min
150 30

294 bar
118 ᐉ/min

Minimum delivery 25

230.3 bar
117.5 ᐉ/min
Pump characteristics

100 20

294 bar
94 ᐉ/min
15

50 10

Gear pump pressure: 19.6 bar (20 kg/cm2)

0
49 98 147 196 245 294 P(bar)
(50) (100) (150) (200) (250) (300) (kg/cm2)

RKP10262

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

20-16 PW110R-1
 Machine model PW110R-1

Classifi- . Delivery of individual piston pumps P1

cation . WORKING MODE selector: position E
. Pump speed: 2000 rpm.
. Oil temperature: 45 ± 55ëC.
Q (ᐍ/min)

200

Input shaft torque (kgm)

52.9 bar
182 ᐉ/min
182
16.7 bar
178
176 ᐉ/min 25

66.7 bar
169 ᐉ/min

150 20

Maximum delivery

15

68.6 bar 173.5 bar

129 ᐉ/min 109 ᐉ/min
Pump characteristics

100 10

294 bar
68.3 ᐉ/min
Minimum delivery

50 0

294 bar
41.3 ᐉ/min

Gear pump pressure: 19.6 bar (20 kg/cm2)

0
49 98 147 196 245 294 P(bar)
(50) (100) (150) (200) (250) (300) (kg/cm2)

RKP10271

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

PW110R-1 20-17
 Machine model PW110R-1

Classifi- . Delivery of individual piston pumps P1

cation . WORKING MODE selector: position P
. Pump speed: 2000 rpm.
. Oil temperature: 45 ± 55ëC.

Input shaft torque (kgm)

Q (ᐍ/min)

200

85.2 bar
182 ᐉ/min
182
178
40

96.1 bar
169 ᐉ/min

45.6 bar
150 35
174 ᐉ/min

Maximum delivery

30

102 bar 203 bar

126 ᐉ/min 109 ᐉ/min
Pump characteristics

294 bar
100 25
80.4 ᐉ/min

Minimum delivery
20

50 15
294 bar
54.2 ᐉ/min

10

Gear pump pressure: 205.8 bar (210 kg/cm2)

0
49 98 147 196 245 294 P(bar)
(50) (100) (150) (200) (250) (300) (kg/cm2)

RKP10281

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

20-18 PW110R-1
SPECIAL TOOLS

Measurement check points Symbol Code Name Q.ty Remarks

Valve clearance - Adjusting A 1 Commercially Feeler gauge 1 Ð

parking brake available

1 ATR800090 Compression gauge 1 0-70 kg/cm2

Compression pressure B
2 ATR800130 Adapter 1 Ð

1 ATR800070 Multi-scale tachometer 1 20 - 4000 rpm

Engine speed C
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm

D 1 Commercially Digital temperature 1

Water and oil temperature available gauge ± 50 - 1200 ëC

1 ATR800170 Pressure gauge 2 Full scale 60 bar

2 ATR800150 Pressure gauge 1 Full scale 250 bar

3 ATR800140 Pressure gauge 1 Full scale 400 bar

E
4 ATR800010 Pressure gauge 1 Full scale 600 bar
Hydraulic pressures and
deliveries
Kit servocontrol
5 ATR800200 (differential pressure gau- 1 Ð
ge)

1 Flowmeter 1
F ATR800120 Ð
2 Tube union kit 1

Thickness of brake disks G 1 ATR500930 Feeler gauge 1 4.5/4.3 mm

1 ATR200380 Tool for checking 1 Ð

Brakes and swing motor drifts and brake line
H
drift test
2 ATR201310 Union kit 1 Ð

Hydraulic drift of boom L 1 21D-62-15530 Flange 1 Mount with O-Ring

and arm cylinders code 21D-09-69870

PW110R-1 20-19
 PAGE INTENTIONALLY
LEFT BLANK

20-20
TESTING AND ADJUSTMENTS MEASURING THE ENGINE SPEED

MEASURING THE ENGINE SPEED

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

not touch heated parts and take care not to become
entangled in rotating elements.

H Do not start to measure engine speed until the follo-

wing conditions have been met: C1
. Engine cooling water temperature: 68 ± 80ëC
. Hydraulic system oil temperature: 45 ± 55ëC
1 - Install and connect the tachometer C1.
H If a stroboscopic tachometer C2 is used, make a
distinct mark on the motor pulley to facilitate the
reading. RKPA5120

2 - Start the engine and check:

. Low idling without load (accelerator lever in «mini-
mum» position).
. High idling without load (accelerator lever in «ma-
ximum» position).
H Low idling: 1100w25 rpm
H High idling: 2200w25 rpm

H If the minimum and maximum engine speeds wi-

thout load do not fall within the correct range,
check the position stops of the accelerator lever
and the accelerator cable sheathing (See «ACCE-
LERATOR LEVER ADJUSTMENT») before per- RKPA5130

forming the stress tests.

. Engine rpm with the pumps working.

H Max. speed with the P1 pump working:
2100w50 rpm
H Max. speed with the P1 and P2 pumps working:
2075w50 rpm
H If the efficiency is not within the permissible limits,
call the Authorised Repair Shop to come and give
the engine a diagnostic check.

PW110R-1 20-21
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

H Adjust clearance between valves and rocker levers as

follows: 1
Unit: mm

Intake valve Exhaust valve

At cold
engine
0.20 0.20

H Ignition order 1-3-4-2-1.....

H Normal rotation sense: counterclockwise from flyw-
heel view.

. Adjusting procedure RKPB1370

1 - Remove the suction pipe (1).

2 - Rotate crankshaft in normal direction as long as
cylinder piston to be checked is at compression 3
Top Dead Center (TDC).
2
H In this position intake and exhaust valves are clo-
sed.
3 - Loose lock nut (2) and unscrew tappet (3) of about
1 turn.
4
H Check that valve insert (4) is laying flat on val-
ve stem and that it is not worn askew. YES NO
1 - If valve inserts (4) are damaged, replaced
them with new ones.
2 - Make sure that inserts feet and lay flat on RKP10811
4
valve stem.
4 - Connect A1 feeler gauge between insert and roc-
ker lever to adjust; rotate the tappet (3) until tou-
ching A1 feeler gauge. 3 2
Tight tappet (3) with lock nut (2).
H After tightening the lock nut, check the clea- A1
rance again.
5 - Adjust with same procedures second cylinder val-
ve and repeat same operation for the other cylin-
ders, according to the ignition order.

RKP10501

. Cover valves installation

1 - Check condition of cover valves (1), gasket (5), O- 1 7
Rings (6) and lock nuts (7); clean carefully contact
surface on cylinder head. 6
2 - Install valves cover (1), fit O-Rings (6) and lock
nuts (7).
Cover lock nut: 25w3 Nm

5
RKP10511

20-22 PW110R-1
TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

When measuring the compression pressure be care-

ful not to get caught in cooling fan, in the alternator 1
belt or in other rotating parts.
. Check all cylinders.
H Test condition: 2
. Engine: at operating temperature
. Hydraulic oil: 55 ± 60 ëC
. Battery: at full charge
. Valve clearance:
adjusted (see «ADJUSTING VALVE»)
1 - Disconnect high pressure pipe (1).
RKPA5140

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

checked.
3 - Disconnect connector (3) of fuel cut-off solenoid val-
ve.
4 - Crank engine with starting motor.

RKPB1380

5 - Install B2 adapter and connect B1 pressure gauge.

H Check that seal is installed in the adapter and that
it is not damaged.
6 - Crank engine with starting motor and measure com- B2
pression pressure.
H Compression value:
Normal: 35 ± 1 kg/cm2
Minimum permissible: 28w1 kg/cm2 at 250 rpm
H Difference between cylinders: 2 ± 3 kg/cm2 B1
7 - After measuring, install the nozzle holder assembly
(2), connect high pressure pipe, feedback pipe and
connector (3). RKPA5160

Nozzle holder collar bolts: 6.9 ± 8.8 Nm

High pressure union: 19.6 ± 24.5 Nm

40
Compression pressure

35

30

25

20
(kg/cm2)
200 250 300 350 400
Engine speed (rpm)
RKP10522

PW110R-1 20-23
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

H Check fuel injection timing of N.1 cylinder by means

of N.1 delivery valve of injection pump. Cylinder Nº 1
H Cylinders are numbered 1-2-3-4 starting from flywheel
side.
1 - Rotate crankshaft using engine pulley and put N. 1cy-
linder piston at top dead centre (TDC).
1

Flywheel
RKP11101

H Top dead centre (TDC) is shown by notch (4) on

pulley (1) positioned on «zero» of the scale (5) 4
and by closing of both cylinder N. 1 valves.
H If the notch (4) of pulley (1) is in «zero» position on
the scale (5) but cylinders N. 1 valves are not clo-
sed, rotate the crankshaft of 1 turn.
5
H After recognition of TDC, rotate the crankshaft in
counterclockwise direction (from pulley side view)
of about 20ë.

1
RKPB3840

2 - Disconnect cylinder N.1 high pressure pipe (2) from

injection pump.
3 - Rotate crankshaft slowly in clockwise direction from 2
pulley side view, checking fuel level into the N. 1 de-
livery of injection pump.

Nº1

RKPB3850

4 - Stop pulley (1) rotation as soon as fuel level starts to

increase. Level
N. 1 Union

RKP11111

20-24 PW110R-1
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

5 - Check notch (4) position on crankshaft pulley (1) com-

pared with scale (5); reading value corresponds to an- 5
gle of fuel injection timing.
H Standard fuel injection timing: 11ëw1ë
NOTE. Repeat checking more than once.
4

1
RKPB3860

6 - If injection timing is not on standard value, rotate in-

jection pump (6) toward external or toward engine af-
ter loosening pump nuts (7) (quantity 4) and pump 6
lock nuts (8) fixing the bracket (9) to injection pump.
. To RETARD injection, rotate the pump (6) toward 7
external.
. To ADVANCE injection, rotate the pump (6) to-
ward cylinders block. 8
8 - Tight the pump lock nuts (7) at cylinder block and the
nut (8) fixing injection pump to bracket (9). Pump side

Nuts: 34.2 ± 44.1 Nm

Bracket nut: 44.1 ± 53.9 Nm Carter side
9 Testing advance
injector
8 - Connect fuel delivery pipes (2) to pump. RKPB3871

Delivery pipe unions: 19.6 ± 24.5 Nm

PW110R-1 20-25
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION

1. Tension check
1 - Push fan belt (1) at midway point between alterna-
tor (2) and pulley operating water pump; check the
deflection.
With a pressure of 10 kg (98 N), deflection should 1 2
be of 10 ± 15 mm; if this value is not reached, ten-
sion fan belt.
H With new belt, deflection must be of 7 ± 9 mm.

RKPB1390

2. Fan belt tension

4
1 - Loosen mounting bolt (3) of the alternator (2) and
mounting bolt (4) of adjustment plate.
2 - Rotate the alternator (2) to give correct tension to
fan belt (1) and tighten mounting bolts (3) and (4).
3 - Check fan belt (1) tension.
H If belt has been replaced, check tension again af-
ter about 20 operating hours.
3
Mounting bolt (3): 44.1 ± 53.9 Nm
Mounting bolt (4): 22.5 ± 28.4 Nm RKPB1400

10kg (98 N)
Water pump
pulley

10--15mm

Alternator

Crankshaft
pulley
RKP10531

20-26 PW110R-1
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR LEVER

ADJUSTING THE STROKE OF THE ACCELERATOR LEVER

H Test conditions:
. Engine: Switched off, but at working temperature.
. Low idling: within correct range.
. Hydraulic oil: 45 ± 55ëC
. Accelerator lever at the mid-point of its stroke.
1 2
1 - Use the stretcher (2) to eliminate clearance in the jac-
ket (1).

RKPA5240

2 - Raise the right-hand cover in order to reach the

screws (3) and (4).
3 - Unscrew the nuts (5) and (6) and tighten the screws
(3) and (4) in the support.
4 - Move the accelerator lever (9) slowly towards low 9
idling position. Stop this movement when the lever 5 3 9 6 4
(7) on the cover of the injection pump comes into con-
tact with the low idling adjustment screw (8).
5 - Adjust the screw (3) until it is 0.1 mm from the lever
(9) and lock it in this position with the nut (5).
6 - Move the lever (9) towards the high idling position. RKPA5250
Stop this movement when the lever (7) on the cover
of the injection pump rests against the lead-sealed
high idling adjustment screw (10).
7 - Adjust the screw (4) to 0.1 mm from the lever (9) and 8 10
lock it in this position with the nut (6).
H After adjustment, replace the right-hand cover
and check that the aperture does not impede
the movement of the lever (9) towards its extreme
positions.

RKPA5260

PW110R-1 20-27
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE

ADJUSTING PPC VALVES CLEARANCE

The clearance of the PPC valve (hand and foot) levers is

adjusted as follows.

Lower the working equipment to the ground and stop

the engine.
2
Turn the ignition key to the «I» position and move the
command levers in all directions in order to release 1
all pressure in the hydraulic circuits. 3
Return the ignition key to the «O» (OFF) position and
remove it. 4
Push the lever of the safety device into the «LOC-
KED» position.
Slowly loosen the oil-tank refuelling cap to eliminate
residual pressure.

1. PPC valve (front equipment and boom swing)

1 - Remove cap (1).
2 - Loosen the nut (2) that retains the disc (3).
3 - Tighten the disc (3) until it makes light contact with
the 4 push-rods (4).
H During this adjustment, take care not to acti-
vate any of the push-rods (4) individually.
4 - Secure this position by tightening the retaining nut
(2) to the specific torque.
RKP06380
Retaining nut: 113w15 Nm

2. PPC valve (travel)

1 - Tighten the dowel (1) until eliminate clearance;
tighten a further quarter of a turn (90ë).
H While making this adjustment, take care not to
activate the plunger (2).
2 - Check that the pedal stroke is 25ë. To adjust this
stroke, act on the end-of-stroke screw (3), after ha-
25

ving loosened the nut (4).

°

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

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

3
1

RKP11020

20-28 PW110R-1
TESTING AND ADJUSTMENTS ADJUSTING THE SAFETY MICROSWITCH

ADJUSTING THE SAFETY MICROSWITCH

H Test conditions:
. Engine: switched off but at working temperature.
2
. Hydraulic oil: 45 ± 50ëC.
1 - Unscrew the nut (1) that secures the microswitch (2).
2 - Tighten or unscrew the microswitch (2) to the extent
indicated.
H Projection of microswitch: 16 1 mm
3 - Secure it in position with the nut (1). 1

RKPA5270

2
1

16 0+1

RKP07480

PW110R-1 20-29
TESTING AND ADJUSTMENTS MEASURING THE SWING CIRCLE AXIAL CLEARANCE

MEASURING THE SWING CIRCLE AXIAL CLEARANCE

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

RKP09250

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

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

2
RKPB0920

6 - Close the bucket, position the arm perpendicular

to the ground and rest the back of the bucket on
the ground. Worked zone

7 - Force the boom down until the front of the machi-

ne rises, in order to transfer the weight of the un-
der carriage onto the rear wheels.
8 - Check the movement of the comparator (1) in the-
se conditions. The value read corresponds to the
value of the swing circle axial clearance. 1
While the machine is raised, take care not to
place hands or feet beneath the wheels.
RKP09261
9 - Return the machine to phase 2 conditions and
check that the comparator returns to «zero». If it
does not, repeat the test, starting at phase 4.

150 ÷ 200 mm

RKP09270

20-30 PW110R-1
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS

AIR BLEEDING FROM HYDRAULIC CIRCUITS

Order for operations and procedure for bleeding air
Air bleeding procedure
Air bleeding item 1 2 3 4 5 6 7

Bleeding Bleeding Bleeding Bleeding

Bleeding Start air air from air from air from Start
Nature of work air from steering opera-
pump engine from swing travel unit LS tions
cylinder motors motor circuit

. Replace hydraulic oil

p p p p p p
. Clean strainer ,1 ,1
. Replace return filter element p p

. Replace, repair pump

p p p p
. Remove suction piping

. Replace, repair control valve p p p p

. Replace cylinder
p p p
. Remove cylinder piping

. Replace swing motor

p p p
. Remove swing motor piping

. Replace travel motor, swivel

p p p
. Remove travel motor, swivel piping

. Replace steering unit or priority

valve p p p
. Remove steering unit or priority
valve piping

,1: Bleed the air from the swing motors or travel motors only when the oil inside the motor case has been drained.

1. Bleeding air from pump P1

H When the hydraulic oil tank is drained, or when the
main pumps are removed for revision or replacement,
air must be bled from the intake circuit as follows: 1
1 - Loosen air bleed plug (1) from body pump (2).
2 - Fill the tank with oil up to the level of the hole in
the plug (1). 2
3 - Tighten plug (1).
Tighten plug:
17.2w2.5 Nm (1.75w0.25 kgm)
4 - Continue to fill the tank until the maximum level is
RKPB2620

reached.
5 - Starting the engine and run the engine at low
idling for 10 minutes.
(See «Bleeding air from hydraulic cylinders»)

PW110R-1 20-31
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS

2. Bleeding air from hydraulic cylinders

H Once the hydraulic cylinders or the tubes connected
to them have been removed, the air must be bleed
as follows:
1 - Start the engine and run at idling for approx. 5 mi-
nutes.
2 - Run the engine at low idling, then raise and lower
the boom 4-5 times in succession.
H Operate the piston rod to approx. 100 mm be-
fore the end of its stroke.
3 - Increase engine speed to high idling and repeat
the operations described at point 2. Reduce engi-
ne speed to low idling and take the piston through
its entire stroke until the hydraulic pump has rea-
ched maximum pressure.
4 - Repeat the operations (starting from point 2) for
the cylinders of the 2nd boom, the arm and the
bucket.

3. Bleeding air from swing motor

5
6 4
1 - Connect hoses (1), drain hose (2) and brake swing
release hose (3).
2 - Fill the swing motor case with hydraulic oil from 2
union (4)
3 - Connect hose (5). 1
4 - Start engine at low idling for approx. 10 minutes.
5 - Slowly swing in both direction few times. 3

RKPB2630

4. Bleeding air form the travel motor

1 - Connect motor feed pipes (1). 4
3
2 - Using the union (2) of the draining pipe, fill the ca-
sing with hydraulic oil (4) up to the bottom level of
hole.
3 - Connect the draining pipe (3).
1
4 - Start the engine and let it run for about 10 minutes
in order to heat the oil.
5 - Execute some slow travel actions in both ways. 2
RKPA7710

20-32 PW110R-1
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS

5. Bleeding air from the Load Sensing circuit

H When removing the priority valve or the steering unit
on starting up the machine, air must be bled from
the Load Sensing circuit. The procedure is as follows:
1 - Start the engine and leave it running at low idling
speed. 1
2 - Loosen the outgoing union (1) of the steering unit
(2).
3 - Start turning the steering wheel slowly, and conti-
nue until oil runs out of the union (1) without a tra-
2
ce of air.
4 - Stop turning the steering wheel and tighten the RKPA7720

union (1).
H After the bleeding operation and before star-
ting to travel, execute a complete steering ac-
tion with both axles.

PW110R-1 20-33
TESTING AND ADJUSTMENTS RELEASING RESIDUAL PRESSURE

RELEASING RESIDUAL PRESSURE

1. From the hydraulic circuits
1 - Rest the work equipment on the ground and stop the
engine. 0 1
2 - Put the ignition key at position «I» and move the con-
trol lever in all directions to relieve all pressure in the
main hydraulic circuits and the PPC valves.
3 - Turn the ignition key to position «O» (OFF) and remo- 0 1
ve it.
4 - Put the lever of the safety device into the «LOCKED»
position.
5 - Slowly loosen the oil-tank filler-cap to release any re-
RKP10570

sidual pressure.

2. From the brake line accumulators

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

20-34 PW110R-1
 CHECKING AND REGULATING PRESSURE IN THE
TESTING AND ADJUSTMENTS HYDRAULIC CIRCUITS

CHECKING AND REGULATING PRESSURE IN THE

HYDRAULIC CIRCUITS
INTRODUCTION
. The control valve is divided into two normally indepen-
dent sections, supplied by pumps P1 e P2 respective-
ly. 3
. Each section is protected against overpressures by a
main (or primary) relief valve with a regolable cartrid-
ge.
. Each section is protected by safety valve with pre-set-
ting cartridge.

1- Main relief valve (Section 1)

SECTION 1
2- Main relief valve (Section 2)
3- Safety valve

SECTION 2
P2

DIESEL P1 P2 2
TANK

P1

1
RKP10581

. The sections consist of the spools that govern:

Sec- Control Ports

tion

A3 - B3 9 9
Travel motor (Forward-Backward) A4 - B4
Boom (Raise-Lower) A5 - B5 10 10
Arm (Open-Close) A6 - B6 8 8
Bucket (Curl-Dump) A7 - B7
1
Blade and/or R.H. outriggers [ (Down-Up)
7 7
Boom swing (Left-Right) A8 - B8 6 6
2-piece boom (Down-Up) A9 - B9 5 5
H Attachment (L.H. side - R.H. side) A10 - B10
4 4
3 3
Swing (Left-Right) A1 - B1 2 2
2 A2 - B2
Blade and/or R.H. outriggers [ (Down-Up) 1 1

[ If expected
PORTS A B RKP10591
H Optional

PW110R-1 20-35
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES

TESTING AND SETTING OF MAIN VALVES

H Check condition:
. Engine: at working temperature
. Engine idling MIN. and MAX.: within standard
values
. Hydraulic oil: 45 ± 55ëC
. WORKING MODE selector: position P
. Swing lock pin: applied.

Release the remain pressure from circuits.

(See «REMAIN PRESSURE REMOVAL FROM CIR-
CUITS»).

1. Main valve Section 1

1 - Connect to pressure port M1 the gauge E3 (400 E3
bar). M1
2 - Start the engine and bring the accelerator on high
idling speed position.
3 - Acting on one of upper attachments (boom, arm,
bucket) bring the piston rod at the end of its stroke
and check that the pressure value reading on gau-
ge is 294w5 bar (300w5 kg/cm2).
H If the reading values on gauge are not the same
as shown, proceed to main valves setting.
RKPB2640

2. Main valve Section 2

1 - Connect to pressure port M1 the gauge E3 (400
bar).
2 - Start the engine and bring the accelerator on high
idling speed position.
3 - Raise the blade or L.H. outrigger up to the end of
stroke and check that the gauge connected to port
M2 shows a pressure of 216w5 bar (220w5 kg/
cm2). E3

4 - Put the blade on the ground and make the upper

structure swing on both directions; check that the M2
gauge connected to port M2 shows a pressure va-
lue of 216w5 bar (220w5 kg/cm2).

H If the pressure values are lower than the value

shown, check the safety valves of swing motor.

RKPB2650

20-36 PW110R-1
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES

3. Main valves setting

To make the valve setting, prepare the machine in
the same way as for pressure testing.
1st Section
1 - Loosen the locking nut (1).
2 - Adjust the pressure with screw (2).
2nd Section
. To INCREASE the pressure turn in CLOCKWISE
direction.
. To DECREASE the pressure turn in COUNTER-
CLOCKWISE direction.
3 - Lock the position with nut (1).
Locking nut: 49 ± 59 Nm (5 ± 6 kgm) RKPA5361

RKP10600

PW110R-1 20-37
TESTING AND ADJUSTMENTS ADJUSTING PC VALVE

ADJUSTING PC VALVE

H In case the engine speed lowers as a load becomes

larger, or in case the work equipment speed is slow
even though the engine speed, pump discharge pres- 1
sure and LS differential pressure are normal, adjust
the PC (1) valve according to the following procedure.
1 - Loosen the lock nut (2). For the cases of slow speed,
turn the sleeve (3) clockwise, and for the cases of lo-
wering of engine speed, turn the sleeve counterclock-
wise.
H Clockwise rotation of the sleeve «increases» the
suction torque of the pump, and counterclockwise
rotation «decreases» the absurption torque.
RKPB1490

H Rotation range of the sleeve (3) shall be within

180ë for both clockwise and counteclockwise.
2 - After adjustment finished, tighten the lock nut (2).
2

3
RKP10830

20-38 PW110R-1
 MEASURING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE

MEASURING LS DIFFERENTIAL PRESSURE

AND ADJUSTING LS VALVE
1. Measuring DPLS differential pressure
i) Disconnect pipe (1) and connect a Tee on the union
(2); screw an adapter (3) on the Tee.
Connect pipe (1). 2

RKPA5370

3 E5

RKPB1500

ii) Connect the pressure gauge E5 to adapter (3) on

control valve and to adapter M1 (delivery pump P1).
iii) Measure the DPLS differential pressure according to
the conditions shown in table 1.
Table 1 M1
Work Fuel Differential
mode lever Operation pressure

P Full Lever at NEUTRAL 32 1 bar

P Full Travel speed: Hi 21.5 3 bar

Travel idling (lever full)
RKPB2660
NOTE: Raised machine - Front axle locked.

PW110R-1 20-39
 MEASURING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE

2. Adjusting of the LS valve

If the values obtained during the measurement of the
differential pressure according to the foregoing condi-
tions are not in the standard value range, adjust the 4
LS valve (4) according to the following procedure.
1 - Loosen the lock nut (5) and turn the screw (6) to
adjust.
. Turn the screw:
CLOCKWISE to increase the differential pres-
sure;
COUNTERCLOCKWISE to decrease the diffe-
rential pressure.
RKPB1491

2 - After-the adjustment finished, tighten the locknut

(5).

NOTE: Make sure to adjust the LS valve with measu-

ring the differential pressure.
5

6 RKP10820

20-40 PW110R-1
 CHECKING AND ADJUSTING PRESSURES IN THE
TESTING AND ADJUSTMENTS SERVOCONTROL FEED UNIT

CHECKING AND ADJUSTING PRESSURES IN THE

SERVOCONTROL FEED UNIT
H Test conditions:
. Hydraulic oil: 45 ± 55ëC M3
Release any residual pressures from the circuits
(See «RELEASING RESIDUAL PRESSURES FROM
THE CIRCUITS»).
E1
1 - Connect the pressure gauge E1 to the adapter
M3.
2 - Start the engine and move the accelerator into its
maximum position.
3 - Put the lever of the safety device in its working po-
RKPB2670

sition, (UNLOCKED).
4 - Bring a servocontrol circuit up to pressure by ope-
rating the work equipment (i.e. bucket).
5 - Check the working pressure on the pressure gau-
ge E1.
H Working pressure: 32 1 bar (31.3 1 kg/cm2)
H If the working pressure is lower that the per-
missible value, check servocontrol feed unit
valve.

RKP10630

PW110R-1 20-41
 MEASURING PUMPS DELIVERY AND FLOW
TESTING AND ADJUSTMENTS CONTROL STARTING POINT PUMP P1

MEASURING PUMPS DELIVERY AND FLOW

CONTROL STARTING POINT PUMP P1
H Test conditions:
. Engine: at working temperature.
. Hydraulic oil: 45 ± 55ëC.
. WORKING MODE selector: position P.
. Work equipment on the ground and made safety.
. Swing lock pin inserted

1. Connecting the flowmeter

1 - Disconnect the delivery tube of the pump to be te-
sted.
2 - Connect the delivery outlet of the pump to the inlet
port of the flowmeter F1.
3 - Connect the discharge port of the flowmeter to the
tube disconnected in phase 1.
To control valve
4 - Mount a rev. counter (C1 or C2) to measure that
the delivery from the tested pump is within the to-
1
lerances allowed for the rated engine rpm.
H If an electronic pressure-transducer type rev.
counter is installed on a diesel supply tube
From pump
to the nozzle, make sure that it is mounted
at a distance from the hose-clamps.
H When measuring deliveries with the pumps
mounted on the machine, it is difficult to use
the accelerator to count the precise number F1
of revs needed for this test.
RKP10641

Make delivery measurements with the engine

running at a speed close to the test speed and
then make a proportional calculation.
Example:
MEASUREMENT
Engine speed: 1950 rpm
Delivery: 108.80 ,/min
PROPORTIONAL DELIVERY AT 2300 rpm
108.80 x 2000 = 111.6 ,/min
ÐÐÐÐ
1950

2. Measurement for pump P1

1 - Start the engine and bring it up to a speed of 2000
rpm.
2 - Adjust the delivery pressure with the flowmeter
knob (1) and measure the effective delivery of
the pump. 1
H Perform this test several times, varying the
pressure to cover the entire duty range
(max. 294 bar (300 kg/cm2)).
H Measure the flow values at each 9.8 bar
(10 kg/cm2) of pressure variation. F1

RKPB1540

20-42 PW110R-1
 MEASURING PUMPS DELIVERY AND FLOW
TESTING AND ADJUSTMENTS CONTROL STARTING POINT PUMP P1

3 - Check the flow ± pressure values against the va-

Q (ᐍ/min)
lues of «P MODE» diagram as shown on «TECHNI- 200
Point of initial
CAL SPECIFICATION» making if necessary, the regulation

proportional calculating to obtain the flow values 182

178
referred to 2000 rpm/min. necessary to make the
control. Maximum delivery

If the measured values are lower than those

permissible, it is necessary to overhaul or to 150

replace the pump.

NOTE: Making the flow readings each 9.8 bar Minimum delivery
(10 kg/cm2), also the initial pump regu-
lation is made, that, in the operating
mode «P», corresponds to a pressure
of 200w4 bar (196 kg/cm2). 100

4 - Turn the WORKING MODE selector on position E

and repeat the checks comparing the flow values
with «E MODE» curve.
5 - Raise the working attachments, turn the WOR-
KING MODE selector on position P and start the 50

upper structure rotation; keeping the lever to the

end of stroke, make the flow-pressure measure-
ments and compare the values with the «P MO-
DE» curve. Gear pump pressure: 19.6 bar (20 kg/cm2)

0
49 98 147 196 245 294 P(bar)
(50) (100) (150) (200) (250) (300) (kg/cm2)
RKP10263

3. Measurement of pump P2
1 - Start the engine and bring it at idling of 2000 rpm/
min. 1
2 - Adjust the delivery pressure with flowmeter knob
(1) at 29.4 bar (30 kg/cm2).
3 - Check the flow ± pressure values against the va-
lues shown on «TECHNICAL SPECIFICATION»
making if necessary, the proportional calculating F1
to obtain the flow values referred to 2000 rpm/
min necessary to make the control.
If the measured value is lower than that per-
missible, it is necessary to overhaul or to re-
RKPB1550

place the pump.

PW110R-1 20-43
 CHECKING THAT THE PRIORITY VALVE
TESTING AND ADJUSTMENTS IS FUNCTIONING CORRECTLY

CHECKING THAT THE PRIORITY VALVE IS FUNCTIONING

CORRECTLY
H Test conditions:
. Engine: at working temperature. E3
. Hydraulic oil: 45 ± 55ëC
. Working brakes: engaged.
M2
1. Checking the Load Sensing signal
1 - Connect pressure gauge E3 (400 bar) to the adap-
ter M2.
2 - Start the engine and put it into swing speed of
2000 rpm.
RKPB2650
3 - Use the pressure gauge E3 to check the pressure
value when the steering wheel is not moving.
4 - Start to turn the wheel very slightly and see whe-
ther the pressure increases.
5 - Complete the steering action and check that the
pressure increases up to the normal value
(170 5 bar) when force is applied to the steering 1
wheel.
H If the pressure as measured by the pressure
gauge shows no variation when the steering
wheel is turned, or if excessive effort is requi-
red on the steering wheel to execute the stee-
ring movement, check that the priority valve
(1) is functioning correctly.
RKPB2680

2. Checking that the priority valve is functioning

correctly
2 3
1 - Remove the priority valve (1).
(See «30. DISASSEMBLY AND ASSEMBLY»).
2 - Remove the cap (2) of the «PP» port and check (by
pushing with a rod) that the spool (3) moves freely
along the entire length of the stroke.
3 - Check that the nozzle (4) inside the spool is free of 4
obstructions.
4 - Re-assemble the priority valve (1). 1
5 - Start the engine and bleed the Load Sensing cir-
RKP09280
cuit. (See «BLEEDING AIR FROM THE LOAD
SENSING CIRCUIT»).
6 - Execute several steering operations and, if the dif-
ficulty persists, overhaul or replace the steering
unit.

20-44 PW110R-1
 CHECKING AND REGULATING THE PRESSURE
TESTING AND ADJUSTMENTS OF THE STEERING SYSTEM

CHECKING AND REGULATING THE PRESSURE OF THE

STEERING SYSTEM
H Test conditions:
. Engine: at working temperature E3
. Hydraulic oil: 45 ± 55ëC

Test
1 - Connect pressure gauge E3 (400 bar) to the adapter
M2
M2.
2 - Start the engine and put it into high idling and turn the
steering wheel as far as it will go.
3 - Apply extra force to the steering wheel in its fully tur-
ned position. RKPB1300

H Normal pressure: 170 5 bar

4 - Repeat this check while steering in the other direc-
tion. 3
5
Adjustment
4
If the pressure is not within permissible limits, it can be ad-
justed from the safety valve (1) of the steering unit (2).
1 - Remove the cap (3). 1
2 - Using a 4 mm screw wrench, adjust the maximum
pressure through the screw (4). 2
. To INCREASE pressure turn in a CLOCKWISE di- RKPB1360
rection.
. To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction.
3 - Stop the engine and replace the cap (3), making sure
that the washer (5) is properly seated.
Cap: 50w10 Nm

PW110R-1 20-45
TESTING AND ADJUSTMENTS CHECKING LEAKAGES IN THE STEERING CYLINDERS

CHECKING LEAKAGES IN THE STEERING CYLINDERS

H Test conditions:
. Engine: at working temperature.
1
. Hydraulic oil: 45 ± 55ëC
. Working brakes: engaged.
. Maximum steering pressure: within permissible li-
mits.
H First check the front axle cylinder and then the rear
3
axle cylinder.
2
1 - Start the engine and execute a full steering move-
ment in one of the two directions.
RKPB2690
2 - Stop the engine.
3 - Disconnect the supply hose (2) from the cylinder (1)
on the side of the fully extended piston rod (3). Seal
the hose securely.
4 - Connect a provisional hose to the cylinder (1) to col-
lect any leaking oil.
5 - Start the engine and put it into high idling.
6 - Apply maximum force to the steering wheel and hold
that position for 30 seconds; measure any oil leaka-
ges for another full minute.
7 - Release the steering wheel, bring the engine back to
low idling, then switch off.
8 - Check whether the amount of leakage is normal (See
«NORMAL OR STANDARD TECHNICAL DATA»).
H Check the cylinder for one side only, since just
one seal separates the two chambers.
9 - Re-assemble the hydraulic connections and execute
several full steering movements in both directions to
release air from the circuit.
10 - Use the same procedure to check the rear axle cylin-
der after having selected one of the two types of stee-
ring.

20-46 PW110R-1
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

CHECKING THE BRAKING SYSTEM

H Test conditions:
. Engine: at working temperature
1
. Hydraulic oil: 45 ± 55ëC

1. Checking accumulator recharging pressure

1 - Connect pressure gauge E3 (400 bar) to the adap-
ter M5 of the accumulator line (1).
M5
2 - Start the engine and put it into low idling.
3 - Depress the brake pedal completely to fully re- E3
charge the accumulators. Check that the maxi-
mum accumulator recharging pressure corre- RKPB2700

sponds to the normal value (120w10 bar).

4 - Using the push-button that engages the working
brakes, perform several braking actions to check
whether or not the accumulators start to recharge
when the normal minimum pressure is reached
(90w10 bar).

Adjustment
If the pressures are not within normal values, proceed
as follows:

Pressure at which to start recharging the accumu-

lators
This setting also causes variation in the maxi-
mum recharging pressure of the accumulators. 2
It will therefore also be necessary to perform
the adjustment described in the next paragraph.

1 - Loosen and remove the protective cap (2) and the

washer (3). 3
2 - Depress the brake pedal several times to reduce
pressure in the accumulators and then measure RKPB5740

the pressure at which the recharging operation

will start.
3 - Loosen the nut (4) and adjust the initial recharging
pressure using the adjustment screw (5).
H Initial recharging pressure: 90w10 bar.
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCKWI- 5
SE direction.
4 - Secure the adjustment screw (5) with the nut (4).
4

RKPB5750

PW110R-1 20-47
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

Maximum accumulator recharging pressure

1 - Loosen the nut (6) and adjust the pressure by
screwing or unscrewing the screw (7). 6
H Maximum pressure: 120w10 bar.
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCKWI-
SE direction.
2 - Secure the screw (7) with the nut (6). 7
3 - Re-assemble the washer (3) and the cap (2).
RKPA7761

2. Checking the braking pressure

1 - Connect the pressure gauge E2 (250 bar) to the
adapter of the brake line M6.
2 - Start the engine and put it into low idling.
E2
M6
3 - Recharge the accumulators.
4 - Completely depress the brake pedal and check
whether or not the pressure is normal (50w5 bar).

RKPA7770

Adjustment of braking pressure

If the pressure is not within normal values, proceed as
follows:
1 - Loosen the nut (8) locking adjusting screw (9).
2 - With the pedal fully depressed, adjust the braking
pressure using the adjusting screw (9).
H Braking pressure: 50 1 bar.
8
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCKWI-
SE direction. RKPB5910

3 - Secure the position of the screw (9) with the nut.

Lock nut: 45w4 Nm

9 8

RKPB5760

20-48 PW110R-1
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

3. Check the leaktightness of the hydraulic braking

circuit
1 - Connect the pressure gauge E2 (250 bar) to the
adapter of the braking line M6. E2
2 - Start the engine and put it into low idling.
M6

3 - Execute several braking actions to empty the ac-

cumulators and then recharge them completely
(120w10 bar).
4 - Stop the engine and return the ignition key to po-
sition «I» in order to supply voltage to the electric
circuits. RKPA7770

5 - Use the working brake engagement button to exe-

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

4. Checking the leaktightness of the brake groups

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

Identification of the defective axle

We shall describe here the procedure for the axles is
identical. 11
1 - Release all residual pressure in the accumulators. H1
12
2 - Disconnect the flexible hose (12), leading out of
the swivel joint (branch 7 for front axle, branch 8
for rear axle), from the rigid front axle supply tube
(11) (on the LH side of the lower frame).
E2 13
3 - Insert apparatus H1 between the two tubes, con-
necting it in such a way that the cut-off cock (13)
is connected to the flexible hose leading out of
the swivel joint. RKPA7800

PW110R-1 20-49
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

4 - Attach the pressure gauge E2 (250 bar) to the

adapter and open the cock (13) of apparatus H1.
5 - Start the engine and put it into low idling.
6 - Push the working brake engagement button to re-
charge the accumulators.
7 - Check that the braking pressure indicated by the
pressure gauge E2 is 50w5 bar.
8 - Close the cock (13) of apparatus H1 in order to
maintain pressure in the branch under examina-
tion, then stop the engine.
9 - Watch the pressure indicated by pressure gauge
E2 for 2 minutes.
. If the pressure value goes down, it means that
at least one piston in one of the two brake
groups under examination is defective. Test
the defective group, following the procedure
described in the next paragraph.
. If the pressure value remains constant, the
leakages are occurring in the rear axle.

Identification of the defective brake group

1 - Insert apparatus H1, complete with the pressure
gauge E2, into the supply line of the defective ax-
le.
2 - Disconnect the supply tube (15) of one of the two
brake groups from the Tee (14). Seal the free side
of the Tee (14) securely.
3 - Following the same procedure indicated for identi- 11
fication of the defective axle (from point 5 to point H1
8), pressurise the brake group that is still connec- 12
ted and close the cock (13).
4 - Watch the pressure indicated by the pressure
gauge E2 for two minutes.
. If the pressure value goes down, it means that E2 13
at least one brake piston is defective.
. If the pressure value remains constant, the
other brake group is defective.
RKPA7800

1 - Further confirmation of the leakage of one or

more brake pistons can also be found
through an increase in the level of oil in the
central body of the axle, or in the planetary.
2 - If such an oil increase, and hence mixing of
oils, are found as a result of brake piston lea- 15
kage, change all sealing rings between axle
sections and carry out a complete change of
the lubrication oil. 14

RKPB2710

20-50 PW110R-1
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

5. Checking the alarm pressure switch setting for

insufficient braking pressure
Before performing this test, first verify that there are 1
no leakages in the brake lines.
1 - Connect pressure gauge E3 (400 bar) to the adap-
ter M5 of the accumulator line (1).
2 - Start the engine and put it into low idling.
M5
3 - Execute several braking actions with the pedal un-
til the accumulators are completely recharged
(120w10 bar). E3
4 - Stop the engine and return the ignition key to po- RKPB2700

sition «I», in order to supply voltage to the electri-

cal circuits.
5 - Using the working brake engagement button, exe-
cute several braking actions (count them) while
keeping a check on both the warning light that in-
dicates insufficient braking pressure and the pres-
sure gauge E3.
The warning light should come on when the follo-
wing conditions have been reached:
. residual pressure: 80 2 bar.
. minimal number of braking actions: 15.

Adjustment
If the warning light comes on at values higher or lower
than 90 2 bar, adjust the intervention setting of the
pressure switch (16) that causes the warning lamp
to light up.
16
The setting is obtained by turning the screw (17).

. Switching pressure: 80 2 bar

. To INCREASE pressure turn in a CLOCKWISE di-
rection.
17
. To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction.
RKPB5770

PW110R-1 20-51
TESTING AND ADJUSTMENTS CHECKING WEAR IN THE BRAKE DISKS

CHECKING WEAR IN THE BRAKE DISKS

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

2 - Execute several braking actions with the working bra-
kes, until the braking system accumulators are com-
pletely recharged.
1
3 - Stop the engine.
4 - Return the ignition key to the «I» position and press
the button that engages the working brakes.
5 - Remove the filling cap (1) and use the tool G1 to
check the thickness «S».
H Minimum thickness «S»: 4.5 mm
RKPB2890

6 - Following the same procedure, check all the brake

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

S
RKPB2900

20-52 PW110R-1
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE BRAKE LINES

BLEEDING AIR FROM THE BRAKE LINES

H Bleed air from both axles.

1 - Start the engine and put it into low idling.
2 - Engage and release the working brakes several ti- 2
mes, until the accumulators of the brake line are com-
pletely recharged.
3 - Stop the engine.
4 - Return the ignition key to position «I» and press the 1
button that engages the working brakes.
5 - Attach a transparent flexible hose (1) to the bleeding
screws (2) in order to collect the oil. RKPA7870

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

one brake group until oil runs out of the screw without
any trace of air.
7 - Tighten the screw (2).
8 - Repeat the bleeding operation for the other brake 2
group.
1
H If the level in the accumulators drops during the
bleeding operation, and the warning light for low
brake oil pressure comes on, interrupt the blee-
ding operation and recharge the accumulators.
H Once the bleeding operation is concluded, repla-
ce the protective caps over the screws (2).
RKPA7880

PW110R-1 20-53
TESTING AND ADJUSTMENTS ADJUSTING THE PARKING BRAKE

ADJUSTING THE PARKING BRAKE

H Conditions for the adjustment:

. Engine at working temperature
. Hydraulic oil: 45 ± 55ëC
While carrying out this adjustment, the engine
must be running to maintain pressure in the par-
king brake line. Rest the work equipment, the
blade and, if necessary, the outriggers on the
ground.
Place safety wedges beneath the wheels.
5 4
1 - Adjust the clearance between the braking disks (For RKPB2880
details see «ADJUSTING BRAKING DISKS CLEA-
RANCE»).
2 - Start the engine and put it into low idling.
3 - Press the button that releases the parking brake in or-
der to bring the circuit up to pressure.
4 - Loose nut (4) and (5) completely, disconnect the cylin-
der (1) from the levers (2-3).
H Check the positions of the washer. 2

5 - Push the lever (2) towards the centre housing. Apply

8÷10 N
a force of approximately 1 kg until the inner part of the
lever rests on the brake disc.
6 - Turn the adjusting screw (6) until it reaches the lever 7 6
(2). RKPB2870

Tighten the lock nut (7) to block the adjusting screw

(6) in position.
Nut: 20 ± 25 Nm
7 - Follow the same adjustment procedure for the other
lever (3).
8 - Tighten the nut (5) until the levers (2) and (3) rest
against the adjusting screws.
9 - Tighten the nut (5) against the bracket (8).
Nut: 50 ± 60 Nm
10 - Stop the engine and check that when the parking bra- 3
2
ke is on, the stem (9) juts out 4 ± 5 mm from the head
of cylinder (1). 8 9 1 RKP11060

20-54 PW110R-1
TESTING AND ADJUSTMENTS TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE

TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE

H Check conditions:
. Engine: at working temperature
. Hydraulic oil: 45 ± 55 ëC
. Service brakes: on

This test id divided into two sections to facilitate identifica-

tion of the faulty member or part that is to be set.
1. Top portion of the equipment
Check that:
. Servocontrol pressure is normal (for details, see
«CHECKING AND ADJUSTING PRESSURES IN
THE SERVOCONTROL FEED UNIT»).
. That spools receive pressure from servocontrol.
. The distributor spool involved in travel executes
the whole travel (See «TECHNICAL DATA»).
. The valve in section 1 of the distributor is set. (For
details, see «TESTING AND SETTING OF MAIN
VALVES»).
. The pressure of differential unit DPLS of the LS is
normal (For details, see «MEASURING LS DIFFE-
RENTIAL PRESSURE AND ADJUSTING LS VAL-
VE»).
. There is no internal blow-by in the swing joint (for
details, see «CHECKING FOR LEAKAGES INSI-
DE THE SWIVEL JOINT»).
. The safety valves of the travel motor are set
(320w10 bar, bench controlled).

2. Bottom part of the equipment:

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

PW110R-1 20-55
 CHECKING AND ADJUSTING THE AUTOMATIC DISPLACEMENT
TESTING AND ADJUSTMENTS CONTROL SYSTEM OF THE TRAVEL MOTOR

CHECKING AND ADJUSTING THE AUTOMATIC DISPLACEMENT

CONTROL SYSTEM OF THE TRAVEL MOTOR
H Test conditions:
. Engine at working temperature E3
. Hydraulic oil: 45 ± 55ëC M1
. Working brakes: engaged

Test
1 - Connect the adapter M1 to the pressure gauge E3
(400 bar).
2 - Take off the cap and connect pressure gauge E4
(600 bar) to the automatic displacement control sy-
stem (1). RKPB2640

3 - Select the 2nd fast forward gear.

4 - Bring the engine up to a speed of 2000 rpm.
5 - Press lightly on the travel pedal and watch whether
the pressure gauge E4 connected to the control sy- 1
stem starts to move when the pressure gauge E3 con-
nected to the adapter M1 indicates a pressure of
200 10 bar.

E4

RKPA7900

Adjustment
1 - Take off the safety cap (2).
2 - Loosen the nut (3).
3 - Adjust the intervention point with the screw (4). 2
H Intervention point: 200 10 bar
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction
. To DECREASE pressure, turn in a CLOCKWISE
direction RKPA7910

4 - Secure the position of the screw (4) with the nut (3).
Lock nut: 10 Nm
5 - Replace the cap of the control system (1).
Cap: 30 Nm
6 - Replace the safety cap (2) to protect against unautho- 4
rised tampering.
3

RKP09320

20-56 PW110R-1
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR

CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR

Before carrying out this control, check the efficiency

of the working brakes.
H Test conditions:
. Engine at working temperature 1 3
. Hydraulic oil: 45 ± 55ëC
. Selector in WORKING MODE: position P
. Working brakes: engaged
2
1 - Disconnect the drainage tube (1) from the lower union
(2) of the motor (3) and plug it.
2 - Attach a provisional tube to collect the draining oil.
RKPB2720

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

4 - Select the 2nd fast forward gear and press the travel
pedal slowly to the end of its stroke.
5 - Hold the travel pedal in this position for 30 seconds
and then measure the oil drainage from the motor
for the next minute.
6 - Check whether the amounts of drainage oil are nor-
mal (see «NORMAL OR STANDARD TECHNICAL
DATA»).
7 - Stop the engine and re-assemble the hydraulic con-
nections.

PW110R-1 20-57
 CHECKING AND ADJUSTING THE SPEED OF
TESTING AND ADJUSTMENTS THE TRAVEL PROPELLER SHAFT

CHECKING AND ADJUSTING THE SPEED OF THE TRAVEL

PROPELLER SHAFT
H Test conditions:
. Engine at working temperature
. Hydraulic oil: 45 ± 55ëC
. Machine: completely raised
. Front axle: blocked BLOCK
BLOCK

Test
H Make a distinct mark (1) on the propeller shaft to faci-
litate the reading of the speed indicator C2.
1 - Position the machine with the arm vertical and the
back of the bucket resting on the ground. 10 cm
RKPB0821

2 - Push down the boom and the rear outriggers until the
machine is completely raised.
If the blade is mounted on the machine, rest it on
the ground after the machine has been raised.
1
3 - Place safety blocks, height 10 cm, beneath the centre
of the axles to prevent the machine from dropping ac-
cidentally.
After having lowered the axles gently onto the
blocks, check that the wheels are raised appro-
ximately 10 cm above the ground. C2

4 - Use blocks to stop the front axle from turning.

5 - Select the 2nd fast forward gear.
6 - Bring the engine up to high idling (2200w25 rpm) mea- RKPB2730

suring it with instrument C1.

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

w100
Normal speed: 3750 ± 200

Speed for TUV approval: TBG: 20 km/h 2550w100

25 km/h 3200w100 2

Adjustment
1 - Take off the safety cap (2). RKPB2130

2 - Loosen the nut (3).

3 - Regulate the speed with the minimum displacement
adjustment screw (4).
. To INCREASE the speed turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE the speed, turn in a CLOCKWISE
direction.
4 - Secure this position with the nut (3).
Lock nut: 69 Nm
5 - Apply a new safety cap (2) to protect against unautho-
rised tampering.
4 3
RKP10070

20-58 PW110R-1
TESTING AND ADJUSTMENTS ADJUSTMENT OF THE SPEED SURVEYOR

ADJUSTMENT OF THE SPEED SURVEYOR

When dismantling or substituting the speed surveyor, pro- 0

ceed as follows for the final positioning: 0,5 + 0,2
1 2 3
1 - Screw the sealing washer (2) onto the sensor (1) and 4
screw the sensor (1) into the casing of the transmis-
sion (3) by hand until it rests on the toothed wheel (4).
H Check the condition of the sealing washer (2) with
care.
2 - Unscrew the sensor (1) until a space of 0.5 0.2 mm is
obtained between the sensor and the toothed wheel
(4) (0.5 ± 0.6 turns).
5
3 - Secure the sensor with the nut (5). RKP09340
Lock nut: 22w2 Nm
4 - Connect the electric cabling and mount the protective
rubber sleeve (6).
Turn the protective sleeve (6) so that the cable 6
opening points towards the ground, in order to
prevent accumulations of water or condensates.

RKPB2740

PW110R-1 20-59
TESTING AND ADJUSTMENTS ADJUSTING BOOM AND ARM SAFETY VALVES

ADJUSTING BOOM AND ARM SAFETY VALVES

H Test conditions Boom

. Engine: at working temperature
. Hydraulic oil: 45 ± 55ëC
V2
. WORKING MODE selector: position P
. Main safety valves: set to 370w5 bar
2
. Valves in section 2 of the distributor: set at normal
value. (See «TESTING AND SETTING OF MAIN
VALVES») 1
1 - Rest the work equipment on the ground, stop the en-
gine and release any residual pressures (See «RE- C2
LEASING RESIDUAL PRESSURES FROM THE CIR-
CUITS»). RKPB1580

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

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

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

der head side slowly up to maximum pressure (320
bar), checking that no oil leaks out of the valve. 5
8 - Maintaining pressure, adjust the valve with the screw
6 10

(3), until a slight leakage of oil (just a few drops every Nm 70 Nm 4

minute) is seen coming from the flange V2.
3
140 Nm
. To INCREASE pressure, turn in a CLOCKWISE
Nm

direction. 7
. To DECREASE pressure, turn in an COUNTER-
CLOCKWISE direction.
H Every turn of the screw (3) changes the pressure V2
by 110 bar.
9 - Block the screw (3) in position with the nut (4).
Locknut: 70 Nm
10 - Screw the rod in (5) until it comes into contact with the C2
retaining element (7) and then turn it back for 5-6
turns. Secure it in position with the nut (6).
11 - Rest the equipment on the ground, stop the engine,
and release any residual pressures. T

12 - Re-assemble the valve connections.

RKP07440

20-60 PW110R-1
TESTING AND ADJUSTMENTS ADJUSTING 2nd BOOM SAFETY VALVES

ADJUSTING 2nd BOOM SAFETY VALVES

H Test conditions:
. Engine: at working temperature 4
. Hydraulic oil: 45 ± 55ëC 6
. WORKING MODE selector: position P 5
. Main safety valve of the 2nd section of the control 2
valve: set to 370w5 bar 3
. Secondary valves: set to normal values. 8
(See «2. Valves with a fixed setting»).
1
1 - Rest the work equipment on the ground, stop the en-
gine and release any residual pressures (See «RE- 7
LEASING RESIDUAL PRESSURES FROM THE CIR-
RKPA5460

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

11 9

RKP07430

PW110R-1 20-61
 MEASURING AND SETTING OF PRESSURE
TESTING AND ADJUSTMENTS SWITCH SIGNAL OVERLOAD OPERATION

MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL

OVERLOAD OPERATION
H NOTE: The illustration shows the pressure switch
without guard. E3
H Check condition: M1
. Engine: at working temperature
. Hydraulic oil: 45 ± 55ëC

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

2 - Start the engine and bring it at medium throttle.
3 - Apply the overload alarm.
4 - Raise boom until the lift end of stroke and increase RKPB2640

lowly the pressure; check the pressure value when

appear the overload signal.
H Standard operating pressure: 140 bar
(142.9 kg/cm2)

Setting
If the operating pressure in not within the standard limits,
make the pressure switch (1) setting as follows:
1 - Remove cover (2).
2 - Raise the boom checking on gauge E3 that hydraulic
cylinder approach the operating pressure.
3 - Loose the dowel (3) and turn the adjusting screw (4) 1
until to obtain the overload alarm signal. 2
. To INCREASE the operating pressure, turn the
screw in CLOCKWISE direction.
. To DECREASE the operating pressure, turn the RKPB5610

screw in COUNTERCLOCKWISE direction.

4 - Lock the position with dowel (3).
5 - Release the pressure and repeat several times the 4
measuring to check the setting stability.

RKPB5620

20-62 PW110R-1
 MEASUREMENT OF INTERNAL OIL LEAKAGES
TESTING AND ADJUSTMENTS IN THE SWING MOTOR

MEASUREMENT OF INTERNAL OIL LEAKAGES

IN THE SWING MOTOR
H Test conditions:
. Engine: at working temperature
2
. Hydraulic oil: 45 ± 55ëC
. WORKING MODE selector: position P
. Revolving frame: secured by the rotation-blocking
1
pin.
1 - Disconnect the drainage hose (1) of the motor (2).
2 - Attach a provisional hose to collect the drainage oil.
3 - Start the engine and bring it up to high idling speed.
4 - Push the swing control lever as far as it will go. RKPB2631

5 - Hold it in this position for 30 seconds and then mea-

sure the oil leakage for the next minute.
6 - Reduce motor speed to low idling, swing the revol-
ving frame 180ë and repeat the measurement.
7 - Check that the average between the two measure-
ments falls within the normal range. (See «TECHNI-
CAL DATA»).
8 - Re-assemble the hydraulic drainage circuit.

PW110R-1 20-63
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT

H Test conditions:
. Engine: at working temperature. 14 Slow gear insertion
. Hydraulic oil: 45 ± 55ëC. 13 Travel motor (Forward)
. WORKING MODE selector: position P.
12 Travel motor (Backward)
1. Functionality test 11 Axle locking

1 - When one of the lower-level tools (blade, travel
motors, speed increment, brakes) is found to be
defective, one of the causes of the failure may
be the swivel joint.
2 - To confirm the defect it is sufficient to by-pass the
joint by connecting (using an additional length of
tubing) the input and output hoses of the joint of
the branch to be checked.
If the defect disappears, it is certainly due to the
swivel joint.
If the defect remains, it can be due to other cau-
ses, but not to the swivel joint.
10 Blade-outrigger command (Descent) (R.H. side)
9 Blade-outrigger command (Descent) (L.H. side)
8 Rear axle braking
7 Front axle braking
6 Blade-outrigger command (Rise)
5 Fast gear insertion
4 Parking brake
3 Drainage (travel motor + EV OP2)
2 Front steering to the left
1 Front steering to the right

2. Identification of defective seal

These tests should be performed on those bran-
ches subjected to working pressures. Tests on
unstressed or unused branches are therefore
excluded.
The test method consists in pressurising the branch
under examination and measuring any leakage from
adjacent branches, as set out in the following table:

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

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

Blade-outrigger command (Descent) Axle locking 11

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

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

9
(L.H. side) Rear axle braking 8
Blade-outrigger command (Descent) (L.H. side) 9
8 Rear axle braking
Front axle braking 7
Rear axle braking 8
7 Front axle braking
Blade-outrigger command (Rise) 6
Front axle braking 7
6 Blade-outrigger command (Rise)
Fast gear insertion 5

20-64 PW110R-1
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

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

Blade-outrigger command (Rise) 6
5 Fast gear insertion
Parking brake 4
Fast gear insertion 5
4 Parking brake
Drainage (travel motor and EV OP2) 3
Parking brake 4
3 Drainage (travel motor and EV OP2)
Front steering to the left 2
Drainage (travel motor and EV OP2) 3
2 Front steering to the left
Front steering to the right 1
Front steering to the left 2
1 Front steering to the right
External leakage (Visible) ±

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

3. Preparation for testing:

. travel motors 1
. travel brakes
2
. speed increment
1 - Relieve all residual hydraulic pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR-
CUITS»). 3
2 - Identify the branch involved in the test (1).
3 - Disconnect the hoses (2) from the branches adjacent
to the part to be tested and cap them tightly.
Make sure that the detached tubes are securely
sealed, to prevent jets of high-pressure oil esca-
ping if circuits that are not undergoing tests RKP09350

should accidentally become pressurised.

H The tubes of the adjacent branches must be di-
sconnected from the upper parts of the swivel
joint.
4 - Provisional hoses (3) for collecting any oil leakages
3
should be connected to the inlets of the branches ad-
jacent to the one being tested.

4. Preparation for testing the blade

1 - Relieve all residual hydraulic pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR- 1
CUITS»).
2 - Identify the branch involved in the test.
3 - Disconnect the tube corresponding to the branch to
be tested from the safety valve input and cap it.
Make sure that the detached tubes are securely
sealed, to prevent the escape of jets of oil at high
pressure.
3
4 - Cap the valve to prevent entry of impurities.
5 - Disconnect from the swivel joint the hoses (2) of the
branches adjacent to the branch to be tested, and
cap them tightly. RKP09360

PW110R-1 20-65
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

Make sure that the detached hoses are securely

sealed, to prevent jets of high-pressure oil esca-
ping if the circuits that are not undergoing tests
should accidentally become pressurised.
H The tubes of adjacent branches must be discon-
nected from the upper parts of the swivel joint.
6 - Provisional hoses (3) to collect any leaking oil should
be connected to the inlets of the branches adjacent to
the one being tested.

5. Test
1 - Start the engine and bring it up to the test speed de-
scribed for each group or component.
2 - Pressurise the branch to be tested.
3 - After 30 seconds, watch for another minute if there
are any leakages.
H If oil leaks out of one of the two provisional hoses,
it means that there is a leakage in the intermedia-
te gasket between the branch connected to the
provisional hose and the pressurised branch.

20-66 PW110R-1
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

H If hydraulic drift occurs in the work equipment, a

check must be carried out to see if the cause is due
to a cylinder gasket or to the control valve.
H Conditions for all checks:
. Engine: at working temperature.
. Hydraulic oil: 45 ± 55ëC
. Removal and connection of tubes only after relief
of residual pressures. (See «RELEASING RESI-
DUAL PRESSURES FROM THE CIRCUITS»).

RKP09370

1. Boom test
1 - Position the machine with the arm vertical and the 3
bucket on the ground, resting on its back.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the hose (1) that feeds the cylinder on 4
the head side.
H Plug the hose to keep out impurity
4 - Disconnect the hose (2) and plug it to keep out im- 1
purity. 2
RKPB1041
5 - Remove safety valve (3) together with the pipe (4)
and plug the bottom side under port using flange
L1.
H Plug the pipe to keep out impurity.
6 - Start the engine and extend the arm completely.
7 - Stop the engine and check the position of the
boom for 5 minutes.
. If the boom drops, the drift is due to the cylin-
der gasket.
. If the boom does not drop, the drift is due to
the control valve.

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

RKP09380

PW110R-1 20-67
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

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

and plug them to keep out impurity.
2
Standard 3
4 - Plug the hose (1) feeding the cylinder on the head
side and connect a provisional hose on the bottom
side to collect any leaking of oil.
Safety valve version
5 - Remove the safety valve (3) from the cylinder and
plug it to keep out impurity. 1
6 - Plug the head side cylinder port using flange L1. RKPB1060

All version
7 - Start the engine and raise the boom.
8 - Stop the engine and check the position of the arm
for 5 minutes.
. If the arm drops, the drift is due to the cylinder
gasket.
. If the arm does not drop, the drift is due to the
control valve.

3. Testing the functionality of the boom and arm

safety valve.

H This test should be carried out after having chec-

ked that the drift is not due to the cylinder gaskets V2
(See «BOOM TEST» and «ARM TEST»), and after
having checked the valve settings (See «ADJU- 2
STING BOOM AND ARM SAFETY VALVES»).
1 - Depending upon which valve is to be checked, po- 1
sition the machine as for the «Boom test» or for the
«Arm test».
C2
2 - Disconnect the hose (1) that supplies the valve
(port V2). RKPB1580

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

RKPB1051

20-68 PW110R-1
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

4. 2nd boom test

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

RKP09390

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

RKPB1600

5 - Start the engine and raise the boom.

6 - Stop the engine and check the position of the 2nd
boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
cylinder gasket.
. If the 2nd boom does not close, the drift is due 50 cm
to the control valve.
To check one cylinder at a time, proceed as follows:
7 - Rest the bucket on the ground and release any re-
sidual hydraulic pressures.
8 - From one cylinder remove the cap mounted on the RKP09400
bottom side during phase 4.
9 - Start the engine, raise the boom and then stop the
engine.
10 - Check the position of the 2nd boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
gaskets of the cylinder that has been capped.
11 - Repeat the operation from phase 8 to phase 10 to
test the other cylinder.

PW110R-1 20-69
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

5. Testing the functionality of the 2nd boom safety

valves

H This test should be performed after having ascer- V2

tained that the drift is not due to the cylinders.
(See «2nd BOOM TEST») and after having checked
the adjustment of the safety valves (See «ADJU-
V1
STING 2nd BOOM SAFETY VALVES»).
1 - Position the machine with the arm and 2nd boom
fully extended. Rest the bucket teeth on the
ground.
2 - Stop the engine and relieve any residual hydraulic RKPA5530
pressures.
3 - Disconnect the connecting tubes of the safety val-
ves (two pipes of ports V1 and V2 for each valve).
4 - Start the engine and raise the boom.
5 - Stop the engine and check the position of the 2nd
boom for 5 minutes.
. If the 2nd boom tends to close, both safety val-
50 cm
ves are defective.

RKP09400

6. Bucket test
1 - Position the machine with the arm vertical and the
bucket horizontal and resting on the ground. Put a
weight in the bucket, or fill it with earth.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the pipes (1 and 2) of the bucket cylin-
der and cap them to prevent entry of impurities.
4 - Cap the hole in the bucket cylinder on the bottom
side and attach a provisional hose on the head si-
de to collect any oil leakages.
RKP09430

RKPA5520

20-70 PW110R-1
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

5 - Start the engine and raise the boom.

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

RKP09420

7. Boom swing test

1 - Position the machine with the boom, arm and buc-
ket raised and with the revolving frame turned 90ë
to the right.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the pipes (1 and 2) of the boom swing
cylinder and cap them. 15°
4 - Cap the hole in the boom swing cylinder on the
bottom side and attach a provisional hose to the
head side to collect any oil leakages. RKP09510

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

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

1 2

RKPA5490

8. Test for the outriggers

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

3 - Stop the engine and release all residual hydraulic

pressures.
RKP09450

PW110R-1 20-71
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

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

safety valves (1) to the cylinder (4). Plug the valves 2
to prevent entry of any impurities. 2
5 - Plug the tube (3) of the cylinder (4) on the head si-
de and attach a provisional tube on the base side 3
to collect any leakages. 3
6 - Start the engine, push down with the boom to rai-
se the machine and remove the supporting block 4
from beneath the outriggers. 4 1
7 - Lower the machine and stop the engine.
8 - Check the position of the outriggers for 5 minutes. RKPA7960

. If the outriggers drops, the drift is due to the

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

RKP09460

20-72 PW110R-1
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

9. Blade test
1 - Position the machine with the arm vertical and re-
sting on the ground, and with the bucket resting
on its back.
2 - Bring the blade to roughly half its potential stroke
and support it on a block, height 28 cm, placed in
the centre.
3 - Stop the engine and release any residual hydrau- 28 cm
lic pressure.
4 - Disconnect from both safety valves (1) union (2)
and pipe (3) that connect them to the cylinder RKP09470
(4). Plug the valves to prevent entry of any impuri-
ties.
5 - Plug the tube (3) on the head side of just one cy- 2 2
linder (4) and attach a provisional tube on the ba-
se side of the same cylinder to collect any leaka-
ges.
H The second cylinder should be left completely
free. 3
6 - Start the engine, push down with the boom to rai-
3 1
se the machine in order to remove the block on
which the blade is resting. 4

7 - Lower the machine and stop the engine. 4

8 - Check the position of the blade for 5 minutes. RKPA7970

. If the blade tends to sink, the drift is due to the

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

RKP09480

PW110R-1 20-73
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

10. Swing motor test

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

RKP09490

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

and cap them to prevent entry of impurities. At-
tach some provisional hoses to the motor to col- 1 2
lect any oil leakages.
4 - Disconnect brake swing hose (3) from motor.
5 - Connect equipment H1 between motor and hose
(3).
Check that cock is open and near the hose (3).

RKPB2632

6 - Connect gauge E1 to the equipment H1.

7 - Start engine and start swing. E1
H In this way the swing brake will be disenga-
ged.
8 - With the swing brake circuit under pressure (30
bar) close the cock of the equipment H1.
3

H1 RKP10841

9 - Let the machine travel onto a 15ë slope, and stop

the engine.
8 - Mark the position between revolving frame and
track frame on the swing circle. Check on any
swinging movement of the revolving frame for 5
minutes.
. If the revolving frame tends to swing, the drift
is due to the swing motor.
. If the revolving frame does not tend to swing,
15°
the drift is due to the control valve
H During this test, the pressure indicated on the
pressure gauge E1 should not drop below the
limit value of 18 bar. (*18 kg/cm2). RKP09440

20-74 PW110R-1
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

11. Checking the travel motor

1 - Position the machine with the arm vertical and the
back of the bucket resting on the ground. Stop the
engine.
2 - Disconnect the supply tube (2) from the parking
brake (1).
3 - Insert apparatus H1 between the brake (1) and the
tube (2). Attach the pressure gauge E1 (60 bar) to
the adapter of apparatus H1 to keep a check on
the parking brake release pressure throughout
the test.
RKP09520

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

the engine and engage and release the parking
brake several times.
5 - Raise the front work equipment and travel the ma-
2
H1
chine over a surface with a 15ë slope. 1
H The articulated axle should be facing towards
the lower part of the slope.
6 - Using the working brakes to hold the machine in 3
position, close the cock of apparatus H1 in order
to maintain pressure (35 3.5 bar) and thus to keep
the parking brake released. Stop the engine.
7 - After 5 minutes, mark the position of the machine.
E1
8 - Check whether or not the machine has moved RKPA7980

every 5 minutes for a total of 15 minutes.

H During this test the pressure indicated on the
pressure gauge E1 should not drop below a
minimum limit of 22 bar.

15°

RKP09530

PW110R-1 20-75
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

12. Test for the axle-locking valve

H Use the same method to check both cylinders.
1 - Start the engine and lock the axle.
2 - Fully extend the entire front work equipment and
lower it to approx. 70 cm above the ground.
3 - Swing the frame approx. 45ë to bring the work
equipment over the axle-locking cylinder (1-3) 70 cm
being tested.
4 - Stop the engine and check to see for 5 minutes,
whether the work equipment has dropped at all.
H If cylinder yields and there is no visible leaka- RKP09540

ge, drift comes from the check valve inside the

cylinder; check valve should be overhauled.

RKP09410

20-76 PW110R-1
GROUP 30
40-28 PC15R-8
 DISASSEMBLY AND ASSEMBLY
HOW TO READ THE MANUAL. . . .. . . . .. . . . . .. . . . .. . . 3
PRECAUTIONS TO BE TAKEN
WHEN WORKING .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
SPECIAL TOOLS . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5
STARTER MOTOR
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . . 9
ALTERNATOR
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 10
INJECTION PUMP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
NOZZLE HOLDER
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 15
THERMOSTAT
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 16
EXHAUST PIPE-MUFFLER
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 17
TURBOCOMPRESSOR
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 18
CYLINDER HEAD
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 23
SEAT
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 24
CABIN
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 25
ENGINE HOOD
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 26
FRONT HOOD
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 27
HEATING FAN
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 28
RADIATOR
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 29
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30
FUEL TANK
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 32
HYDRAULIC OIL TANK
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 33
PW110R-1
ENGINE-PUMP GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 37
PUMP GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
ENGINE-PUMP COUPLING JOINT
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 40
GEAR-PUMP
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 41
SWIVEL JOINT
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 42
SWING MOTOR
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 43
SWING MACHINERY
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 53
CONTROL VALVE
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 63
REVOLVING FRAME
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 64
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 65
COUNTERWEIGHT
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 66
SWING CIRCLE
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 67
TRANSMISSION - REVERSER, DIRECTION
INDICATOR AND HEADLIGHT DIPPER BEAM
CONTROL GROUP
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 68
R.H. PPC VALVE (BOOM - BUCKET)
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 69
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 70
L.H. PPC VALVE (ARM-SWING)
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 71
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 72
OUTRIGGER AND BLADE PPC VALVE
Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 73
30-1
BOOM SWING PPC VALVE
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . . 74
TRAVEL AND 2nd BOOM PPC VALVE
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . . 75
BRAKE PUMP
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . . 76
STEERING UNIT
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . . 77
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 78
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 84
PRIORITY VALVE
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . . 94
Disassembly and assembly . .. . . . .. . . . . .. . . . .. . . . 95
TRAVEL MOTOR
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 96
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 97
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 98
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 101
TRANSMISSION
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 106
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 107
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 114
AXLE LOCKING CYLINDERS
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 121
FRONT AXLE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 122
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 124
REAR AXLE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 125
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 127
AXLES
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 128
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 154
BOOM CYLINDER (For 1-piece boom)
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 190
BOOM CYLINDER (For 2-piece boom)
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 191
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 192
30-2
2nd BOOM CYLINDERS
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 193
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 194
ARM CYLINDER
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 195
BUCKET CYLINDER
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 196
BOOM SWING CYLINDER
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 197
CYLINDERS FOR OUTRIGGERS OR BLADE
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 198
WORK EQUIPMENT CYLINDERS
Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 199
Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 200
WORK EQUIPMENT (For 1-piece boom)
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 204
WORK EQUIPMENT (For 2-piece boom)
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 205
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 206
BUCKET
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 207
ARM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 208
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 210
2nd BOOM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 211
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 212
BOOM (1-piece boom)
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 213
BOOM (2-piece boom)
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 214
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 215
SWING BRACKET
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 216
BLADE AND OUTRIGGERS
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 217
BLADE AND OUTRIGGER ARMS
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 218
PW110R-1
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL

HOW TO READ THE MANUAL

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

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

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

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

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

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

3. List of special tools.

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

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

PW110R-1 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHEN WORKING

PRECAUTIONS TO BE TAKEN WHEN WORKING

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

1. Precautions for removal operations

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

30-4 PW110R-1
REMOVAL AND INSTALLATION SPECIAL TOOLS

SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

1 ATR201320 Coupling for brake 1 Ð

Removal/Installation and swing release
revolving frame
A 2 ATR200400 Rear raising equipment 1 Ð
Installation of swing
machinery for revolving frame
3 ATR200410 Front raising equipment 1 Ð

Removal/Installation of
counterweight
Removal of wheels B 1 ATR800230 Dynamometric wrench 1 Max. 700 kgm (700 dNm)
with multiplier
Disassembly/Assembly of
cylinder nut

1 ATR501290 Tool 1 Rotating unit assembly

2 ATR501300 Tool For central pin clearance

Assembly travel motor C checking

3 ATR501310 Tool Gasket, spacer, circlip

assembly

Removal/Installation of D 1 ATR200420 Swing circle raising 1 Ð

swing circle equipment

Removal of wheels E 1 ATR200650 Raising support 1 Ð

1 ATR200470 Pliers for mounting 1 All cylinders

gaskets

ATR200480 ù 50 calibrator 1

2 ATR200490 ù 60 calibrator 1 To calibrate piston rod

gaskets
ATR200500 ù 70 calibrator 1

ATR200510 ù 90 plunger 1

3 ATR200520 ù 100 plunger 1 To calibrate piston

gaskets
ATR200530 ù 120 plunger 1

ATR200540 ù 90 calibrator ring 1

To calibrate piston
4 ATR200550 ù 100 calibrator ring 1 gaskets
Disassembly/Assembly ATR200560 ù 120 calibrator ring 1
the cylinders F
ATR200570 ù 50 insertion bushing 1
for piston rod

5 ATR200580 ù 60 insertion bushing 1 To mount flange

for piston rod and head

ù 70 insertion bushing
ATR200590 for piston rod 1

6 ATR200600 Pliers for mounting 1 All cylinders

snap-ring

ATR800260 Socket wrench 1 Bucket cylinder

(6-point 60)
7
ATR800250 Socket wrench 1 Boom and arm cylinder
(6-point 70)

8 ATR200610 Tool for disassembly and 1 All cylinders

assembly cylinders

PW110R-1 30-5
REMOVAL AND INSTALLATION SPECIAL TOOLS

Type of work Symbol Code Description Q.ty Notes

1 ATR500860 Wrench 1 To remove and

mount lock-nut

2 ATR500870 Plunger 3 To remove inside ring

from pinion bearing

3 ATR500880 Plunger 1 To assemble inside

Disassembly/Assembly bearing ring
of swing machinery G
To mount outside
4 ATR500590 Plunger 1 bearing ring

5 ATR200380 Circuit sectioning tool 1 To test brake release

seal

6 ATR800140 Pressure gauge 1 Full scale 400 bar

Disassembly/Assembly H 1 ATR201370 Raising equipment 1 Ð

the swing bracket

1 ATR501620 Wrench 1 Ð
Removal/installation of
2 ATR501630 Tool 1 differential planetary
wheel pins
3 ATR501640 Bushing 1

4 ATR501650 Tool 1 Installation of differential

planetary wheel pins
ATR501660 Wrench 1
5 Flange locking
ATR501670 Wrench 1

6 ATR501680 Wrench 1 Flange ring nut locking

7 ATR501690 Wrench 1 Pinion locking

8 ATR501700 Block 1 Ð

9 ATR501710 Spacer 1 Ð

Disassembly/Assembly ATR501720 1
axles M
10 ATR501730 Bearing inner ring 1 Installation pinion bearing
installation kit
ATR501740 1

11 ATR501750 Tool 1 Pinion dimension

measuring

12 ATR501760 Bearing outer ring 1 Installation pinion bearing

installation kit

13 ATR501770 Wrench 1 Pinion torque measuring

14 ATR501780 Plunger 1

15 ATR501790 Plunger 1

16 ATR501800 Tool 1 Arm alignment

17 ATR501810 Bush 1

18 ATR501820 Extension 1

19 ATR501830 Plunger 1

30-6 PW110R-1
REMOVAL AND INSTALLATION SPECIAL TOOLS

Type of work Symbol Code Description Q.ty Notes

20 ATR501840 Plunger 1

21 ATR501850 Plunger 1

22 ATR501860 Plunger 1

23 ATR501870 Plunger 1
Disassembly/Assembly M
axles 24 ATR501880 Plunger 1

25 ATR501890 Bearing inner ring 1 Planetary bearing

installation kit installation

26 ATR501900 Plunger 1

27 ATR501910 Plunger 1

To remove the hydraulic

1 ATR200640 Special wrench 1 guide from the machine

Guide
Removal - Installation of 2 ATR501090 Plunger 1 Spool seal assembly
hydraulic guide Q
Assembly of steering unit
Plunger

3 ATR501100 Fork 1 Control shaft check

4 ATR501110 Plunger 1 Mounting guard

PW110R-1 30-7
REMOVAL AND INSTALLATION

PAGE INTENTIONALLY
LEFT BLANK

30-8 PW110R-1
REMOVAL AND INSTALLATION STARTER MOTOR

REMOVAL OF STARTER MOTOR

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

RKPB1630

INSTALLATION OF STARTER
MOTOR
. To install, reverse the removal procedure.

Screw: 78.4 ± 98 Nm

PW110R-1 30-9
REMOVAL AND INSTALLATION ALTERNATOR

REMOVAL OF ALTERNATOR
Disconnect the lead from the negative (±) battery
terminal.
1 2
1 - Remove upper cover (1) with exhaust pipe (2).

RKPB1640

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

RKPB0680

3 - Disconnect cable (4) and connector (5).

7
4 - Loosen bolts (6), (7) and (8) sufficiently to allow the al-
ternator (9) to be rotate.
4
5 - Free the pulley from the fan-belt (10) and remove al-
ternator (9).
5

RKPB1401

INSTALLATION OF ALTERNATOR
. To install, reverse the removal procedure. 10

9
H Check the union gasket of exhaust pipe.

H Adjust the tension of the fan-belt. (For details, see 8

«20. TESTING AND ADJUSTMENTS).

RKPB1391

30-10 PW110R-1
REMOVAL AND INSTALLATION INJECTION PUMP

REMOVAL OF INJECTION PUMP

Disconnect the cable from accumulator negative
terminal (±).
H Close the cock (1) of separator (2) to prevent fuel leak- 2
age. 1
H Plug removed or disconnected pipes to avoid impurity
entry.

RKPB1650

1 - Disconnect high pressure pipes (3) from injection

pump (4). 4

RKPB1660

2 - Disconnect from injection pump (3) fuel feeding pipes

(5) and return pipes (6). 6

3 - Disconnect pipes (8) and (9) from fuel feed-pump (7).).

4 - Disconnect the engine stop solenoid (10) from injec-
10
tion pump (3) and remove the complete unit. 5

9
8

7
RKPB1670
5 - Disconnect control cable (12) from accelerator lever
(11).

12 11

RKPB1381

PW110R-1 30-11
REMOVAL AND INSTALLATION INJECTION PUMP

6 - Remove the bolt (13) of injection pump lubricating

pipe (14). 14
7 - Remove injection pump lubricating pipe (14).

13

RKPB1690

8 - Remove coolant tank support (15).

9 - Remove fan guard (16).
16

15

RKPB5880

10 - Remove the inlet cover (17) to ignition gear system

and the filler oil plug (18).

18
16

17

RKPB1700

11 - Loosen and remove nut (19) and lock washer (20) of

pump driving gear (21).
H Be careful not to let lock washer drop in the hous- 21
ing.

20
19

RKPA5611

30-12 PW110R-1
REMOVAL AND INSTALLATION INJECTION PUMP

12 - Remove pump (3) driving gear (21).

H Before removing pump driving gear, mark posi- X2
tion compared to idling gear.
24
H For removal, use a puller (X1) and tighten its
screws (X2) directly in the gear (21). 22
H Be careful not to damage pump shaft thread.
H During removal be careful not to let key drop (22)
in the housing.
21 X1

X2
RKP07801

13 - Remove nuts (23) (No. 4) and injection pump (3) with

relative OR rings (24).
23
3

RKPB1691

PW110R-1 30-13
REMOVAL AND INSTALLATION INJECTION PUMP

INSTALLATION OF INJECTION PUMP

. To install, reverse the removal procedure.

Feed and return pipes:

24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)

High pressure pipes:

24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)

H Replace safety cotter pin.

Cover gasket: ASL800070

Timing gear system cover bolts:
18 Nm (1.84 kgm)

H Align marks among gears before to install pump Injection pump

and nut. drive gear
Gear lock nut: 83.3 ± 93.1 Nm (8.5 ± 9.5 kgm)

Pump lock nuts: 35.2 ± 43.1 Nm (3.5 ± 4.4 kgm)

Alignment reference
1 - Check fuel injection timing.
(For details, see «20. TESTING AND ADJUSTMENTS»).

Idling gear

RKP07811

30-14 PW110R-1
REMOVAL AND INSTALLATION NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER

1 - Remove suction pipe (1) with union (2).

3
2 - Remove collar (5) lock nut (4) and remove nozzle
holder (6), seat (7) and guard (8).

RKPB1371

6 8
7
INSTALLATION OF NOZZLE RKP07791

HOLDER
. To install, reverse the removal procedure.

High pressure pipe fittings:

24.5 ± 35.3 Nm (2.5 ± 3.5 kgm)
Collar screw: 9.8 ± 11.8 Nm (1 ± 1.2 kgm)

Collar lock nuts: 9.8 ± 11.8 Nm (1 ± 1.2 kgm)

PW110R-1 30-15
REMOVAL AND INSTALLATION THERMOSTAT

REMOVAL OF THE THERMOSTAT

Disconnect the cable from accumulator negative
terminal (±). 1
H Drain the engine cooling liquid. 3
Cooling liquid: 18 , 2
1 - Disconnect the radiator hose (1) from the thermostat
cover (2).
2 - Remove the thermostat cover screws (3).
3 - Remove the gasket (4), the thermostat (5) and the
ring seal (6).
Replace all gasket and seals. RKPB1710

3
2

RKP10850

INSTALLATION OF THE
THERMOSTAT
. To install, reverse the removal procedure.

1 - Refill the coolant liquid tank.

Coolant liquid: 18 ,
2 - Start the engine at low idling to circulate the coolant
liquid through all circuits.
3 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level
in the container.
H Check that there are no leaks.

Cover screws: 22 ± 27.8 Nm

30-16 PW110R-1
REMOVAL AND INSTALLATION EXHAUST PIPE-MUFFLER

REMOVAL OF THE EXHAUST PIPE-MUFFLER

Disconnect the cable from accumulator negative
terminal (±).
1 2
1 - Remove the cover (1) (No. 5 screws) together with the
exhaust pipe (2).

RKPB1640

2 - Loosen the clamps (3) and remove the protection (4).

Loose the nuts (5) (No. 4) that fasten the muffler (6) to 4 7 3
the turbocompressor (7).

RKPB1720

3 - Loosen the screws (8) from the muffler support brack-

et (9) and remove the muffler (6).

6
9

INSTALLATION OF THE
EXHAUST PIPE-MUFFLER
RKPB1402

. To install, reverse the removal procedure.

H Replace the sealing gasket.

PW110R-1 30-17
REMOVAL AND INSTALLATION TURBOCOMPRESSOR

REMOVAL OF THE TURBOCOMPRESSOR

Disconnect the cable from accumulator negative
terminal (±). 4 2
3
1 - Remove the muffler. (For details, see «REMOVAL OF
THE EXHAUST PIPE MUFFLER»).
2 - Disconnect the pre-heat cable (1).
3 - Disconnect the turbocompressor (3) coupling sleeve
(2) from the suction manifold (4). 1

RKPB1721

4 - Loosen the screws (5) that secure the lubrication oil 6

drainage tube. 3
5 - Loosen the union (6) that secures the lubrication oil
delivery tube.
6 - Loosen the nuts (7) that secure the turbocompressor
(3) and remove the turbocompressor. 7

RKPB1730

INSTALLATION OF THE
TURBOCOMPRESSOR
. To install, reverse the removal procedure.

Flange screws: 8 ± 9 Nm (0.8 ± 0.9 kgm)

30-18 PW110R-1
REMOVAL AND INSTALLATION CYLINDER HEAD

REMOVAL OF CYLINDER HEAD

Disconnect the cable from accumulator negative
terminal (±).
1 2
H Drain the cooling liquid.
Cooling liquid: 18 ,

1 - Remove the engine hood.

(For details see: «REMOVAL OF ENGINE HOOD»).
2 - Remove cover (1) (No. 5 screws) together with the ex-
haust pipe (2).
RKPB1640

3 - Remove the coolant tank (3).

5

RKPB5921

4 - Remove hose (4) from the radiator (5) and disconnect

the heater pipes (6). 6
5 - Loosen the clamp (7).
7

RKPB1750

6 - Disconnect the water temperature sensor cable (8)

and the water temperature alarm sensor cable (9).
7 - Disconnect the alternator (11) support bracket (10).
8 11

10

9
RKPB1711

PW110R-1 30-19
REMOVAL AND INSTALLATION CYLINDER HEAD

8 - Disconnect the pre-heater cable (12) and remove the

12 13
support (13).

RKPB1751

9 - Disconnect the coupling sleeve (14) from the turbo-

compressor (15). 14
Loosen the screws (16) and remove the suction mani- 15
fold (17).
17

16

RKPB1722

10 - Remove the fuel filter (18).

11 - Disconnect the fuel return hose (19) from the injec-
tors. 19

18

RKPB1760

30-20 PW110R-1
REMOVAL AND INSTALLATION CYLINDER HEAD

12 - Disconnect the oil supply and drainage tubes (20) 20

from the turbocompressor.

20

RKPB1731

13 - Disconnect the breather tubes (21), (22) and (23) from

21
the vapour chamber (24).
14 - Loosen the screw (25).

22

25
23
24
RKPB1770

15 - Remove the injectors (26).

(For details see: «REMOVAL OF THE NOZZLE IN-
JECTORS»)
16 - Loosen the nuts (27) and remove the tappet cover
(28).

27

26 28

RKPB1372

17 - Remove the valve rocker-arm (29).

H Loosen the nuts and unscrew the tappets by 2-3 29
turns. 32 31
18 - Take out the rocker arm control arms (30).

30

RKP10860

PW110R-1 30-21
REMOVAL AND INSTALLATION CYLINDER HEAD

19 - Remove the cylinder head screws (31) follow the indi-

BOLT LOOSENING ORDER
cated sequence to loosen the screws
H Sequence to be followed: see drawing.
Loosen the cylinder head retaining screws in two
stages. 7 16 14 6
1 9 18 12 4
Keep two positioning screws inserted and tigh-
tened 2-3 turns. 3 11 17 10 2
5 13 15 8

RKP07820

20 - Attach the cylinder head (32) to a hoist and apply ten-

sion to the hoisting cables.
Ensure that the cylinder head is detached from
the engine block and that all tubes and cables
are disconnected.
Attach the hoisting cables to the lifting logs and
the muffler.
Ensure that the cylinder head remains level
while hoisting.

21- Remove the complete cylinder head and place it on a

work-bench.
22 - Remove the turbocompressor.
(For details see: «REMOVAL OF THE TURBOCOM-
PRESSOR».

30-22 PW110R-1
REMOVAL AND INSTALLATION CYLINDER HEAD

INSTALLATION OF THE CYLINDER HEAD

. To install, reverse the removal procedure.

H Fill up the cooling circuit.

Coolant liquid: 18 ,
H Check carefully that there are no leaks.

Screws for intake line: Loctite 262

Screws for intake line:
45 ± 55 Nm (4.6 ± 5.6 kgm)

Flange screws: 8w9 Nm (0.8w0.9 kgm)

High-pressure pipe fittings:

24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)

Collar lock nuts: 9.8 ± 11.8 Nm (1 ± 1.2 kgm)

H Check the condition of the seals of the tappet cover and

the O-rings of the fastening nuts. Thoroughly clean the
contact surfaces on the cylinder heads.
Cover fastening nuts: 25w3 Nm (2.5w0.3 kgm)

H Check that the tappets are firmly engaged in their

rods and that the valve collars are correctly as-
sembled.
Rods - tappets: Engine oil
H Start tightening the rocker-arm shaft from the center
towards the outside.
Screws and nuts for the rocker-arm shaft:
22.5 ± 28.4 Nm (2.3 ± 2.9 kgm)
H Adjust the valve clearances (For details, see «20.
TESTING AND ADJUSTMENTS»).

H Install a new gasket.

Bolt and cylinder block threadings: Engine oil.
H Tighten the screws, manually at first, and then in two
stages, following the sequence indicated.
Cylinder head bolts.
First tightening: 88.3 ± 98.1 Nm (9 ± 10 kgm)
Final tightening: 181.4 ± 191.2 Nm
(18.5 ± 19.5 kgm) BOLT TIGHTENING ORDER

1 - Start the engine at low idling to circulate the coolant

liquid through all circuits.
2 - Accelerate gradually up to 1700 rpm. After about one 12 3 5 13
minute, stop the engine and check or top up the level 18 10 1 7 15

in the container. 16 8 2 9 17
14 6 4 11

RKP07830

PW110R-1 30-23
REMOVAL AND INSTALLATION SEAT

REMOVAL OF SEAT
Lower the work equipment until it is resting on the
ground, switch off the engine and remove the ignition
key.
1

1 - Raise the front window (1) completely.

2 - Remove the lower window (2) and place it in the sup-
ports provided at the back of the cabin.
3 - Remove the four screws (3) that secure the seat.
H Slide the seat forwards and backwards in order to
reach the screws.
4 - Remove the seat.
Seat: 32 kg

INSTALLATION OF SEAT 2

. To install, reverse the removal procedure.

RKPB1280

RKPB0940

30-24 PW110R-1
REMOVAL AND INSTALLATION CABIN

REMOVAL OF CABIN
Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Disconnect the connector (1) and hose (2) from the

1
windshield-washer tank and remove all the clamps
fixing them.
4
2 - Disconnect the heating hose (3) from the diffuser (4).
3 - Move the back of the operator's seat completely for-
2 3
ward and remove the panel (6) fixing screw (5).
4 - Raise the pane (6), disconnect the heating hose (7) RKPB1680

from the diffuser (8) and remove the panel (6).

5 - Remove the knob (9), remove the screws (10) (Në 3)
and remove the panel (11). 5
8
6 - Disconnect the connector (12). 6 6

7 - Remove the cable fixing screws (13) (në 7). 7

8 - Remove the upper protective caps and mount the
hoisting eyebolts (7).
9 - Attach the eyebolts (14) to the hoisting tackle and
move the cabin.
Cabin: 220 kg
RKPB1120

INSTALLATION OF CABIN
. To install, reverse the removal procedure. 14
14
H Make sure that the short screw (15) is placed on
the LH side.

10

12
15
9
13

11

RKPB1130 RKPB1100

PW110R-1 30-25
REMOVAL AND INSTALLATION ENGINE HOOD

REMOVAL OF ENGINE HOOD

Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Detach the gas cylinder (1) from the engine hood.

2 - While holding up the engine hood (2) remove the
1
screws (3) that attach the hood to the hinges (4).

H Mark the position of any shims.

Engine hood: 36 kg
2
RKPB1780

INSTALLATION OF ENGINE HOOD

3
. To install, reverse the removal procedure.

H Check the centering and adjustment of the clos-

ing hook (5).
H Position any shims.
Replace the cotter pins (6). 4

RKPB1790

6
5

RKPB0950

30-26 PW110R-1
REMOVAL AND INSTALLATION FRONT HOOD

REMOVAL OF FRONT HOOD

Lower the work equipment until it is resting on the
ground and switch off the engine.
2
1 - Detach the gas cylinder (2) from the support (1). 7

RKPB1800

2 - While holding up the hood (3) remove the screws (4)

that attach the hood (3) to the hinges (5). 4

H Mark the position of any shims.

Engine hood: 27 kg

3
5

RKPB1810

INSTALLATION OF FRONT HOOD

. To install, reverse the removal procedure.

H Check the centering and adjustment of the closing

hook (6).
H Position any shims.
Replace the cotter pins (7).
6

RKPA5680

PW110R-1 30-27
REMOVAL AND INSTALLATION HEATING FAN

REMOVAL OF HEATING FAN

Lower the work equipment until it is resting on the
ground and switch off the engine.

Disconnect the lead from the negative (±) battery

2
terminal. 3

Drain the coolant liquid to a level below that of the

connecting tubes (2-3) between the engine and the
1
heating fan.

Cooling liquid: approx. 5 ,

1 - Disconnect the hose clamp (1) and pipes (2) and (3) RKPA5631

from engine and lower the terminals to thoroughly

drain the liquid from the heating radiator.
5 7
Cooling liquid: approx. 1.5 ,
2 - Move the back of the operator's seat completely for- 5
ward and remove the panel (5) fixing screws (4). 6
3 - Raise the panel (5), disconnect the heating hose (6)
from the diffuser (7).

RKPB1121

4 - Remove the knob (8), remove screw (9) (në 3) and re-
move the panel (10).
5 - Move the seat forwards as far as it will go.
10
6 - Disconnect the pipes (11), remove the side screws
(12) that lock the fan unit (13) and disconnect the con-
nector (14).
9
7 - Extract the fan unit (9) backwards. 8

RKPB1140

INSTALLATION OF HEATING FAN

13
. To install, reverse the removal procedure.
1 - Make sure that the heating cock is fully open. 14
11
2 - Fill up with coolant liquid.

Quantity of coolant liquid: approx. 7.5 ,

3 - Start the engine to circulate the coolant liquid. 12

4 - Switch off the engine and top up the level.
RKPB1150

30-28 PW110R-1
REMOVAL AND INSTALLATION RADIATOR

REMOVAL OF RADIATOR
Lower the work equipment until it is resting on the
ground and switch off the engine.

Drain the engine coolant liquid. 1 2

Cooling liquid: 18 ,
3
Completely eliminate all residual pressures in all
circuits.
(For details see: «20. TESTING AND ADJUST-
MENTS»).

Drain the hydraulic oil.

RKPB1641

Hydraulic oil: 84 ,
1 - Remove the cover (1) (No. 5 screws) together with the
exhaust pipe (2). 6
2 - Remove the engine hood (3). 5
(For details see: «REMOVAL OF ENGINE HOOD»).
7
3 - Remove the coolant container (4) and the fan guard
(5).
4 - Disconnect the engine coolant circuit hoses (7) and 4
(8) from the radiator (6).
8

RKPB5920

5 - Disconnect the hydraulic oil supply pipe (9) and the

return pipe (10).
6 10
6 - Loosen the nut (11).

11 9

RKPB1820

7 - Loosen the radiator retaining screws (12) and remove

the radiator.
Radiator: 37 kg

12

RKPB1840

PW110R-1 30-29
REMOVAL AND INSTALLATION RADIATOR

INSTALLATION OF RADIATOR

. To install, reverse the removal procedure.

1 - Refill the coolant liquid circuit.

Coolant liquid: 18 ,

H Refill the hydraulic oil tank.

Hydraulic oil: 84 ,
2 - Start the engine at low idling to circulate all the fluids
and to fill up the oil coolers.
3 - Stop the engine and top up all levels.
4 - Bleed the hydraulic circuits.
(For details see: «20. TESTING AND ADJUST-
MENTS»).

30-30 PW110R-1
REMOVAL AND INSTALLATION FUEL TANK

REMOVAL OF FUEL TANK

Lower the work equipment until it is resting on the
ground and switch off the engine.

Disconnect the lead from the negative (±) battery

terminal.
H Turn the turret by 45ë towards the right.
1 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»).

2 - Remove the cap (1) of the fuel tank (2), open the tank
drainage cock (3), and drain the fuel.
4 - Disconnect the fuel suction pipe (4).
3

RKPB1651

4 - Disconnect the fuel return pipe (5) and the connector

(6) of the level gauge (7).
2
5
1
7

RKPB5890

5 - Disconnect the plate (8) that joins the tanks.

8
2

RKPB1860

PW110R-1 30-31
REMOVAL AND INSTALLATION FUEL TANK

6 - Hook the tank (2) to the hoisting equipment and

slightly put the rope under tension. 2

7 - Remove the bolts and the fuel tank.

Tank: 47 kg

RKPB1870

INSTALLATION OF FUEL TANK

. To install, reverse the removal procedure.
H Fill the fuel tank and start the engine.

30-32 PW110R-1
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK

REMOVAL OF HYDRAULIC OIL TANK

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de- 2

tails, see «20. TESTING AND ADJUSTMENTS»).

. Drain the hydraulic oil. 1

Quantity of oil: approx. 84 ,

1 - Remove the front hood (For details, see «REMOVAL

OF FRONT HOOD»).
2 - Remove the top cover (1) together with the exhaust
pipe (2).
RKPB5900

3 - Disconnect the top return pipe (3) from the exchan-

ger; also remove the connection(4). 3
4 - Disconnect the bottom pipe (5) and the connection (6)
from the exchanger.
5 - Remove the air suction pipe (7).
6 - Remove the vibration-damper (8).
3 5
7 - Remove the top fastener (9) of the radiator-exchan-
ger.
8 - Move the exchanger (10) and extract it upwards.
H To facilitate removal, screw the bottom connec- RKPB2601
tion (6) into the top hole.

Exchanger: 67 kg

INSTALLATION OF HYDRAULIC
OIL TANK
. To install, reverse the removal procedure.
1 - Fill the oil tank up to max. level.
During the filling operation, bleed the air from RKPB1830

the pump (For details, see «20. TESTING AND

ADJUSTMENTS»).

Hydraulic oil required: approx. 84 ,

2 - Start the engine to circulate the oil and check that 6
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.

RKPB0740

PW110R-1 30-33
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP

REMOVAL OF ENGINE-PUMP GROUP

Lower the work equipment until it is resting on the
ground and switch off the engine.

Disconnect the lead from the negative (±) battery 1

terminal.
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).

. Drain the hydraulic oil.

Quantity of oil: approx. 84 ,

. Drain the engine coolant liquid.
RKPB1652

Quantity of coolant liquid: 18 ,

. Close the feed cock of fuel tank (1).
1 - Remove the engine hood. (For details, see «RE-
MOVAL OF ENGINE HOOD»). 2
3
2 - Remove the top cover (3) complete with the exhaust
pipe (2).

RKPB1642

3 - Remove the rubber air filter elbow (4).

4
4 - Remove the rear lower protection.

RKPB1890

5 - Remove the electric board cover (5) and disconnect

the connector (6) and the earth cable (7).
6 - Remove the engine electric board. 6

RKPB1900

30-34 PW110R-1
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP

7 - Disconnect the pipe (9) coming from the separator

from the fuel pump (8). 8 11
8 - Disconnect the return tube (11) from the fuel filter 9 10
(10).

RKPB1692

9 - Disconnect the cable (12) and the sheathing (13) of

the accelerator as well as the earth plait (14) from
the engine.
10 - Remove the radiator.
(For detail see: «REMOVAL OF THE RADIATOR»). 13 12

14

RKPB1382

11 - Loosen the clamp (16) and disconnect the heating

pipes (15) from the engine.
15

16

RKPB1752

12 - Disconnect the flanges of the suction pipes and all

delivery pipes (17) from pumps.
H Mark the position of Load Sensing, Mode System 17
and servo-control feed pipes in order to avoid mix- 17
ing them up during installation.

RKPB1920

PW110R-1 30-35
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP

13 - Hook the engine (18) to the hoisting equipment using 18

the specific brackets and slightly put the chains under
tension.

RKPB1930

14 - Remove the screws (19) (No. 4) of the engine sup-

ports (20). 19 20
15 - Slowly lift the unit and remove the engine (18).

Engine - pumps: 550 kg

Ensure that the engine-pump group is not in any
way caught or fastened to the frame and that all
pipes and cables are disconnected.

RKP10710

30-36 PW110R-1
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP

INSTALLATION OF ENGINE-PUMP GROUP

. To install, reverse the removal procedure.

1 - Fill the hydraulic oil tank to maximum level.
While filling, bleed air from the main pump pis-
ton. (For details, see «20. TESTING AND AD-
JUSTMENTS»).

Hydraulic oil needed: approx. 84 ,

2 - Fill the cooling circuit.

Coolant liquid needed: approx. 18 ,

3 - Start the engine to circulate the oil and check that
there are no leakages.
4 - Switch off the engine, check the level and, if neces-
sary, top it up.

PW110R-1 30-37
REMOVAL AND INSTALLATION PUMP GROUP

REMOVAL OF PUMP GROUP

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
. Drain the hydraulic oil.
Quantity of oil: approx. 84 ,
1 - Remove the engine hood.
(For details, see «REMOVAL OF ENGINE HOOD»).
2 - Remove left and centre rear guards.
3 - Disconnect the suction flanges and all delivery pipes
from the pumps (1) and (2).
H Mark the position of Load Sensing, Mode System
and servo-control feed pipes in order to avoid mix-
ing them up during installation.

2
1

RKPB1921

6 - Attach the pump group to a hoist keeping the cables

under slight tension.
H Pass a harness under the gear pump to prevent
tilting of the unit.
3
7 - Pull out the screws (3) and remove the pump group;
disengage the group from the coupling joint shifting
it to one side.
Pump group: approx. 97 kg

RKPB1940

30-38 PW110R-1
REMOVAL AND INSTALLATION PUMP GROUP

INSTALLATION OF PUMP GROUP

. To install, reverse the removal procedure.

H Coat the coupling surfaces thinly:

Coupling surfaces: ASL800050

Pump check screws: Loctite 262
Pump check screws: 50w5 Nm (5.1w0.5 kgm)

1 - Fill the hydraulic oil tank to maximum level.

While filling tank, bleed air from pump. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
Hydraulic oil: 84 ,
2 - Start the engine to circulate the oil and check that
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.

PW110R-1 30-39
REMOVAL AND INSTALLATION ENGINE-PUMP COUPLING JOINT

REMOVAL OF ENGINE-PUMP COUPLING JOINT

Lower the work equipment until it is resting on the
ground and switch off the engine. 1
1 - Remove the pump group. (For details, see «RE-
MOVAL OF PUMP GROUP»).

Half joint on pump

2 - Loosen dowel pin (1) fixing half joint (2) in more
stages and alternatively.
H Heat dowel pins to 85 ± 100 ëC. 2
3 - Remove pump half joint (2).
RKPB1950

H If necessary, use a puller.

Half joint on flywheel

3
4 - Remove blots (5) and drive flange (6).

INSTALLATION OF ENGINE-PUMP RKPB1960

COUPLING JOINT
. To install, reverse the removal procedure.

Pump half joint mounting bolts: Loctite 262

Pump half joint mounting bolts: 50 Nm

Drive flange bolts: Loctite 262

Drive flange bolts: 50 Nm

1 - Fill up the tank until maximum level.

During the filling operation, bleed air from the
piston pump (For details, see «20. TESTING
AND ADJUSTMENTS»).

Hydraulic oil: 84 ,
2 - Start the engine to allow oil circulation in all systems
and check the seal.
3 - Stop the engine and, if necessary, restore oil level in
the tank.

30-40 PW110R-1
REMOVAL AND INSTALLATION GEAR-PUMP

REMOVAL OF GEAR-PUMP
Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de- 4

tails, see «20. TESTING AND ADJUSTMENTS»).
2 3
. Drain the hydraulic oil.
Quantity of oil: 84 ,
1 - Disconnect the suction flange (1) and the delivery
pipe (2) from the pump.
1
2 - Remove the bolts (3) and the pump (4), the joint (5)
and the gasket (6).
RKPB1970

6
4

INSTALLATION OF GEAR-PUMP 5
3 RKP10870
. To install, reverse the removal procedure.

H Before connecting the suction flange, check the con-

dition of the seal and keep it in its seat by applying
grease ASL800050.

Flange screws: 35w3.5 Nm (3.6w0.3 kgm)

Joint: ASL800050
Pump fastening screws:
98 ± 123 Nm (10 ± 12.5 kgm)
1 - Fill the hydraulic oil tank to maximum level.
While filling, bleed air from the main pump. (For
details, see «20. TESTING AND ADJUST-
MENTS»).

Hydraulic oil needed: 84 ,

2 - Start the engine to circulate the oil and check that
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.

PW110R-1 30-41
REMOVAL AND INSTALLATION SWIVEL JOINT

REMOVAL OF SWIVEL JOINT

Lower the work equipment until it is resting on the
ground and switch off the engine.
2
Release residual pressures from all circuits. (For de- 1
tails, see «20. TESTING AND ADJUSTMENTS»).
1
Disconnect the lead from the negative (±) battery
terminal.
3
1 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»).
2 - Remove the cabin (For details, see «REMOVAL OF 4
CABIN»).
RKPB2750
3 - Disconnect the tubes (1) on the lower side of the joint
(2) and plug them.
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling.
6 2
4 - Disconnect the stay bolt (3) from the joint (2) and
place it to one side.
5
5 - Disconnect the bottom connectors (4).
6 - Disconnect the tubes (5) on the top of the joint (2) and
plug them.
5
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling.
7
7 - Disconnect from the electric box the connectors (6) of
cables coming out on the top portion of joint. RKPB2760

8 - Unscrew and remove the four crews (7) of the swivel

joint.
9 - Hook the joint (2) to the hoisting equipment and re-
move it.
Swivel joint: 54 kg

INSTALLATION OF THE SWIVEL

JOINT
. To install, reverse the removal procedure.

H Before connecting the top pipes, introduce hydraulic

oil into the draining branch (branch 6).
1 - Start the engine and bleed air from the circuits by fol-
lowing the procedure given below:
a - Move the outriggers and blade (if mounted) sev-
eral times to the end of their stroke.
b - Perform several steering actions on both axles
and in both directions.
c - Bleed air from the brake line (For details, see «20.
TESTING AND ADJUSTMENTS»).

30-42 PW110R-1
REMOVAL AND INSTALLATION SWING MOTOR

REMOVAL OF SWING MOTOR

Lower the work equipment until it is resting on the
ground and switch off the engine.
4 2

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).

1 - Disconnect the feed pipes (1), exhaust pipe (2), the 3

break release pipe (3) and the drain line connection
(4).

2 - Remove the screws (5) (No. 14) that attach the motor
(6) to the swing machinery (7). 1
RKPB2010

INSTALLATION OF 6
SWING MOTOR 5

. To install, reverse the removal procedure.

H Fill the motor with hydraulic oil through the top drain
line connection.

Screw: 86 Nm (8.1 kgm)

RKPB2020

1 - Start the engine to allow oil circulation in all systems

and check the seals.
2 - Bleed the air from engine (For details, see «20. TEST-
ING AND ADJUSTMENTS»).

PW110R-1 30-43
REMOVAL AND INSTALLATION SWING MACHINERY

REMOVAL OF SWING MACHINERY

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»). 4
2
Drain the reduction gear hydraulic oil.
3
Quantity of oil: approx. 3.5 ,
1 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»). 1
2 - Disconnect the feed pipes (1), the exhaust pipe (2),
the brake release pipe (3) and the drain line connec- RKPB2011

tion (4).
3 - Remove the drain extension tube (5).
4 - Remove the check screws (6) (No. 12) of the reduction 6
gear (7). 7
5 - Fasten two screws into the holes opposite to each
other and remove the reduction gear (7).

6 - Sling the complete assembly and remove it.

H During removal, slowly lift the assembly and pay
particular attention not to damage the pipes or
other parts. 5
RKPB2030

Complete group: 87 kg

30-44 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

INSTALLATION OF THE SWING MACHINERY

. To install, reverse the removal procedure.

H In order to centre the holes of the pins and of the fas-
tening screws, connect tool A1 to the hydraulic motor A1
and slowly rotate the motor until the correct angle for
the positioning of the reduction gear has been ob-
tained.

H Fill with hydraulic oil through the breather (8).

8
Screws: 90 Nm (9.2 kgm)
RKPB2050

1 - Start the engine to allow oil circulation in all systems

and check the seals.
2 - Bleed the air from engine (For details, see «20. TEST-
ING AND ADJUSTMENTS»).

PW110R-1 30-45
REMOVAL AND INSTALLATION SWING MACHINERY

DISASSEMBLY OF SWING MACHINERY

H Before dismantling the swing machinery mark the po-

sition of the hydraulic motor (1) in relation to the brake
1
unit (2), the ring gear (3) and the reduction gear hous- 5
ing (4).
H Remove the oil filler plug (5). 2
3

RKP11030

1 - Take out the screws (6) and detach the hydraulic mo-
tor (1). 6 1

RKPB2420

2 - Detach the O-ring (7) from the motor (1).

1

7
RKPB2410

3 - Remove the adaptor ring (8) and loosen the screws

(9) (No. 15).
9

RKPB2430

30-46 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

4 - Detach the brake-flange group (2).

2

RKPB2440

5 - Detach the O-ring (10) from the brake unit (2).

10

RKPB2450

6 - Using a plunger and a pad, press on the spring retai-

ner (11) and remove the snap-ring (12). 12
11

RKPB2460

7 - Remove the spring retainer (11).

8 - Mark the position of the springs (13)
11 13

RKPB2470

PW110R-1 30-47
REMOVAL AND INSTALLATION SWING MACHINERY

9 - Remove the springs (13) from the piston seatings

(14). 13

14

RKPB2480

10 - Turn the brake unit (2) upside down and remove the
snap-ring (15). 2 15

RKPB2490

11 - Remove the ring (16) and brake discs (17). 17

16

RKPB2500

12 - Using a press tool, remove the piston (14) from the

brake unit (2). 14

RKPB2510

30-48 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

13 - Detach the O-rings (18) and (19) from the brake unit.
18 19

RKPB2520

14 - Extract the brake shaft (20).

20

RKPB2530

st
15 - Remove the pinion (21) from the 1 sun gear.

21

RKPB2140

16 - Remove the 1st sun gear group (22).

22

RKPB2150

PW110R-1 30-49
REMOVAL AND INSTALLATION SWING MACHINERY

17 - Remove the pinion (23) of the 2nd sun gear.

23

RKPB2160

18 - Take out the ring gear (3).

3

RKPB2170

19 - Remove the 2nd sun gear group (24).

24

RKPB2180

20 - Remove the O-ring (25) from the gearbox housing (4).

25

RKPB2190

30-50 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

21 - Lift the safety riveting of the lock-nut (26) that secures

the swing pinion (27).

27

26

RKPB2200

22 - Using the tool G1 remove the lock-nut (26).

G1

RKPB2210

23 - Lift off the spacer (28).

28

RKPB2220

24 - Using an extractor, lift the swing pinion out (27) of the

gearbox housing (4).

4 27
RKPB2230

PW110R-1 30-51
REMOVAL AND INSTALLATION SWING MACHINERY

25 - Using an extractor, remove the external bearing ring

(29) from the gearbox housing (4).

29

4
RKPB2240

26 - Turn the gearbox housing (4) upside down and re-

move the swing pinion sealing ring (30).

4
30

RKPB2250

27 - Using an internal extractor, remove the external bear-

ing ring (31) from the reduction unit (4).

31

RKPB2260

28 - Using the tool G2 and a press, remove the internal

bearing ring (31), the sealing ring (32) and the spacer
(33) from the swing pinion (27). G2

27

32

31 33
RKPB2270

30-52 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

ASSEMBLY OF SWING MACHINERY

1. IMPORTANT REMARKS
When installing the swing machinery, some fundamental
rules must be followed:
a - In the case of a damaged sun gear, the entire reduc-
tion unit must be substituted, not just the single sun
gear.
b - Always fit a new O-ring with the part to be replaced,
after thoroughly cleaning the installation seating and
after having spread a film of grease (ASL800050) over
the seatings and the seals to facilitate installation.

2. INSTALLATION
1 - Mount the spacer (33) on the swing pinion shaft (27).
H Check that the chamfered part rests on the pinion.

33

27

RKPB2280

2 - Mount the metal sealing ring (32).

32

RKPB2290

3 - Fill the metal sealing ring (32) with grease:

(ASL800050).

32

RKPB2300

PW110R-1 30-53
REMOVAL AND INSTALLATION SWING MACHINERY

4 - Apply a layer of grease over the inside bearing ring

(31).
Bearing: ASL800050

31

RKPB2310

5 - Using the tool G3 and a press, drive the inside bear-

ing ring (31) down over the spacer (32).
G3

31

32

RKPB2320

6 - Using the tool G4 and a press, drive the outside bear-

ing ring (31) down over the gearbox housing (4).

G4

RKPB2330

7 - Using the same method as above, mount the outside

ring of the other bearing (29) in the gearbox housing.

29

RKPB2340

30-54 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

8 - Mount the sealing ring (30) in the gearbox housing

(4).

30

RKPB2350

9 - Position the gearbox housing (4) over the swing pi-

nion (27).
4

27

RKPB2360

10 - Mount the inside bearing ring (29) on the swing pinion

(27).

29

27
RKPB2370

11 - Using the tool G3 and a press, assemble the pinion

(27) - gearbox housing (4) group.

G3
RKPB2341

PW110R-1 30-55
REMOVAL AND INSTALLATION SWING MACHINERY

12 - Mount the spacer (28) over the swing pinion shaft

(27).

28

27
RKPB2221

13 - Tighten the lock-nut (26).

H Use a new lock-nut.
Lock-nut: Loctite 242

26

RKPB2380

14 - Use the special wrench G1 and a dynamometric

wrench to tighten the lock-nut (26).
Lock-nut: 1000w50 Nm
H If new bearings (29) and (31), pinion (27), or gear- 4
box housing (4) have been fitted, check the rotat-
ing torque of the pinion (27).
Pinion rotation: 50 ± 60 Nm G1
H If the torque is higher, increase the thickness of
the spacer (28).
H If the torque is lower, reduce the thickness of the
spacer (28).
RKPB2390

15 - Block the position of the lock-nut (26) with 3 safety

caulkings, corresponding to the grooves in the pinion
shaft (27).

27

26

RKPB2400

30-56 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

16 - Lubricate the O-ring seating of the gearbox housing

(4) and mount the seal (25). 25
Seating: ASL800050
4

RKPB2190

17 - Install the 2nd sun gear groups (24).

24

RKPB2180

18 - Mount the toothed ring (3).

H Check the position against the marks made be-
3
fore dismantling.

RKPB2170

19 - Mount the pinion (23) of the 2nd sun gear.

23

RKPB2160

PW110R-1 30-57
REMOVAL AND INSTALLATION SWING MACHINERY

20 - Mount the 1st sun gear (22). 22

RKPB2150

21 - Mount the pinion (21) of the 1st sun gear.

21

RKPB2140

22 - Mount the brake shaft (20).

20

RKPB2530

23 - Mount the O-rings (18) and (19) in the brake body.

O-ring: ASL800050 18 19

RKPB2520

30-58 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

24 - Mount the brake piston (14) in the brake body (2).

H Take care not to damage the O-ring seals (18-19). 14

RKPB2540

25 - Insert the springs (13) into the seatings of the brake

piston (14).
H Insert the springs in their previous positions as 13
marked during disassembly.

14

RKPB2480

26 - Mount the springs retainer (11).

11

RKPB2550

27 - Using a press tool, press down on the springs retai-

ner (11) and mount the snap-ring (12) in the seating
11 12
of the brake body.

RKPB2460

PW110R-1 30-59
REMOVAL AND INSTALLATION SWING MACHINERY

28 - Mount a new stack of brake discs (17), starting with a

bronze disc (external toothing) and continuing with a
17
steel disc (internal toothing).
H Mount 6 bronze and 5 steel discs.

RKPB2560

29 - Mount the ring (16).

16

RKPB2570

30 - Mount the snap-ring (15) in the housing body (2).

2 15

RKPB2490

30-60 PW110R-1
REMOVAL AND INSTALLATION SWING MACHINERY

31 - Check the leak tightness of the seals of the brake-re-

lease group.
For this job, use the tool G5 and the 400 bar pressure
gauge, G6.
H Testing pressure: 150 bar
H Testing time: 3 min.
H Max. pressure drop: 0 bar
Gasket: ASL800050

G5 100
200
300

0 400

bar

G6

RKP11040

32 - Mount the O-ring (10) in the brake body (2).

10

RKPB2450

33 - Position the brake unit (2) on the ring gear (3).

H Check the position against the alignment marks 2
made before dismantling.

RKPB2441

PW110R-1 30-61
REMOVAL AND INSTALLATION SWING MACHINERY

34 - Tighten the screws (9) (No. 15) and mount the adap-
tor ring. 9
Screws and nut: 85 Nm

RKPB2580

35 - Mount the O-ring (7) in the seating of the hydraulic

motor (1).
1

7
RKPB2410

36 - Mount the hydraulic motor (1) over the gearbox and

fasten the screws (6). 1 6
H Check the position against the marks made be-
fore dismantling.
Screws: 86 Nm

RKPB2590

30-62 PW110R-1
REMOVAL AND INSTALLATION CONTROL VALVE

REMOVAL OF CONTROL VALVE

Lower the work equipment until it is resting on the
ground and switch off the engine. 1 4
1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
H Mark all pipes before removal.
1 - Disconnect pipes in the following sequence: servo
2
control pipes (1), feed pipes (2), return pipes (3), func- 3
tion pipes (4) and LS pipes (5).
H Plug all holes so as to keep out impurities.
2 - Fit the unit with two eyebolts (6). (M8x1.25) 5
RKPA5810

3 - Hook the unit (7) to the hoisting equipment and

slightly put the ropes under tension.
4 - Remove screws (8) (No. 3) and remove the control
6
valve.
Complete control valve: approx. 60 kg

INSTALLATION OF CONTROL
7
VALVE
. To install, reverse the removal procedure.

RKPB5830

Control valve check screws: 190 Nm (19.5 kgm)

Control valve check screws: Loctite 262

1 - Check the level of the tank; start the engine to allow

oil to circulate to all parts of the equipment. 8
Switch off the engine and top up the oil level.
2 - Bleed air from all parts of the equipment. (For details,
see «20. TESTING AND ADJUSTMENTS»).

RKPB5700

PW110R-1 30-63
REMOVAL AND INSTALLATION REVOLVING FRAME

REMOVAL OF REVOLVING FRAME

Disconnect the lead from the negative (±) battery
terminal.
1
1 - Remove the upper work equipment (For details, see
«REMOVING UPPER WORK EQUIPMENT»).
2
2 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»). 2
3 - Remove the cabin and the seat (For details, see «RE-
MOVAL OF CABIN AND REMOVAL OF SEAT»).
4 - Remove the boom cylinder. (For details, see «RE-
MOVAL OF BOOM CYLINDER»).
RKPB2751

5 - Disconnect all the lower tubes (2) from the swivel joint
(1) and plug them. Also plug the fittings left on the
joint.
6 - Remove the lower left-hand protective casing (3) of
the revolving frame (4) to gain access to the retaining 5
nuts of the LH area. 7

7 - Start the engine, swing the revolving frame (4) about

90ë to the left, until a screw (5) is accessible on the
under carriage (6) side. 6
8 - Remove the screw (5) and its nut.
9 - Leave the next screw in place and remove the other
thirty three screws. (No. 39). RKPB2770

Leave two screws in position for reasons of

safety, one at the front and one at the rear.

10 - Using the equipment A2 and A3 attach the revolving

frame to a hoisting tackle and apply slight tension to A3
the chains.

11 - Loosen and disengage the two screws, leaving them

A2
inserted in the bearing ring (7).
12 - Raise the revolving frame (4) slowly.

H While raising the revolving frame, take great care

not to damage the swivel joint. 4
RKPB0790

Revolving frame: approx. 4300 kg

3
4
RKP11050

30-64 PW110R-1
REMOVAL AND INSTALLATION REVOLVING FRAME

INSTALLATION OF REVOLVING FRAME

. To install, reverse the removal procedure.

H After connecting up all the hydraulic tubes, start

the engine and move all parts of the equipment
several times to bleed air from the circuits, while
checking for leakages.
8
H Switch off the engine and check level of the hy-
draulic oil.
7

H Align the two positions corresponding to the cen-

tering pins (9), then assemble. RKPA5850

Sealant and swing circle platform gaskets:

ASL800050
Internal swing circle grease: approx. 25 kg 9 11

Revolving frame attachment screws

(without nut): Loctite 262 12

10
Installation Procedure
In order to swing the revolving frame for centering
the reference pins (8), the pinion-swing circle cou-
pling and for mounting the screws (5): RKPB2012

1 - Disconnect the feed pipes (10), the drain line con-

nection (11) and the brake release tube (12) from
the swing motor (9).
H Plug connections to avoid impurity entry. A1
2 - Connect tool A1 and slowly rotate the turret until
correct centring is obtained.
3 - Insert the two screws left in the swing circle (7)
and secure them.
4 - Insert all the other screws (5).
5 - After having secured all the screws that join the 8
swing circle to the revolving frame, reconnect
the delivery tubes (10) of the swing motor (9), RKPB2050

the brake release tube (12) and union (11).

6 - Detach the hoisting tackle.

PW110R-1 30-65
REMOVAL AND INSTALLATION COUNTERWEIGHT

REMOVAL OF COUNTERWEIGHT
Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Remove the engine-hood.

(For details, see «REMOVAL OF ENGINE HOOD»). 1
2 - Remove the engine-hood hook support (1).
3 - Remove the protective caps and firmly tighten the
hoisting eyebolts (2).
4 - Attach the hoisting tackle and apply slight tension to
the cables.
5 - Using the tool B1, loosen the screws (3) and their RKPB0860

safety washers.
6 - Remove the counterweight (4).
Counterweight: 1450 kg

INSTALLATION OF 2 2
COUNTERWEIGHT
. To install, reverse the removal procedure.
4
RKPB0960

Counterweight screws: Loctite 262

H Carefully check that the vertical positioning mea-

surement (A) is 100w2 mm with respect to the re-
volving frame.
A
3

RKPB0880

30-66 PW110R-1
REMOVAL AND INSTALLATION SWING CIRCLE

REMOVAL OF SWING CIRCLE

1 - Remove the upper revolving frame. (For details, see

«REMOVAL OF UPPER REVOLVING FRAME»). S
3
2 - Completely remove all contaminated grease.
3 - Remove the screws (1) that secure the swing circle
(2).
4 - Remove the swing circle (2) using the tool D1.

Swing circle: 124 kg 1

2
RKPB0340

INSTALLATION OF
SWING CIRCLE
H Before installing the swing circle, check the condition D1
of the central gasket (3).
For reasons of safety, when installing the swing cir-
cle, insert two screws into the front and back holes 2 S
in the frame.
. To install, reverse the removal procedure.

Before attaching the swing circle, check that the area

marked with an «S» is positioned on the right-hand RKPB0350

side of the chassis.

Attachment screws: Loctite 242
Attachment screws: 314 Nm
Lubricating grease: approx. 25 kg

PW110R-1 30-67
 TRANSMISSION - REVERSER, DIRECTION INDICATOR
REMOVAL AND INSTALLATION AND HEADLIGHT DIPPER BEAM CONTROL GROUP

REMOVAL OF THE TRANSMISSION - REVERSER, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Lower the work equipment until it rests on the ground
and stop the engine. 1
Disconnect the lead from the negative (±) battery
terminal. 2
1 - Take out check screws (1) (No. 2) and remove the
front guard (2) of the steering column.
2 - Free cables from clamps and disconnect the connec-
tors (3).
3 - Remove the two connecting screws (4) of the switch-
ing groups (5-6).
RKPB5780

4 - Remove the RH half-clamp (7).

5 - Remove the LH half-clamp (8).

6 - Remove the switching group (5 and 6) complete with

wiring assemblies.

3
INSTALLATION
. To install, reverse the removal procedure.

H Check that the reference pin (9) can be fully inserted

into the steering column (10) and that the R.H. half- RKPB5790

clamp (7) adheres perfectly.

4
6

4
5
RKPB0380

9 7

10
RKPB0400 RKPB0390

30-68 PW110R-1
REMOVAL AND INSTALLATION R.H. PPC VALVE (BOOM - BUCKET)

REMOVAL OF R.H. PPC VALVE (BOOM - BUCKET)

Lower the work equipment until it is resting on the
ground and switch off the engine and remove the
starting key. 1 3
Release residual pressures from all circuits. (For de- 2
tails, see «20. TESTING AND ADJUSTMENTS»).
Disconnect the lead from the negative (±) battery 1
terminal.
5
1 - Remove screws (1) and remove cover (2).
2 - Disconnect connectors (3), remove screws (4) and re-
move the dashboard (5). 4
RKPB1190

3 - Take out cover (6) and disconnect connector (7).

6 7

RKPB1340

4 - Remove screws (8) and armrest (9).

5 - Remove retaining screws (10) (në 3) of R.H. dash- 9
board (11).
H To remove the inside screw, lower the seat and 11
push it right back.
10

8
RKPB1201

6 - Disconnect the catch (12) from the R.H. dashboard

(11).
12
7 - Move backward the R.H. dashboard. Disconnect 15
hoses (13) (në 6) from the PPC valve (12) and plug
them to prevent entry of impurities.
14
H Mark the position to avoid errors during assembly.
8 - Remove screws (15) and remove the PPC valve (14).
13
If there is a slack on the control lever, adjust the
unit (See «20: TESTING AND ADJUSTMENTS -
Adjustment of manual control slacks»).
RKPB1211

PW110R-1 30-69
REMOVAL AND INSTALLATION R.H. PPC VALVE (BOOM - BUCKET)

INSTALLATION OF R.H. PPC VALVE

. To install, reverse the removal procedure.

T
H Check the positions carefully when reconnecting
the tubes

P - Pressure P P2
T - Unload
P1 - Boom descent
P4
P4 - Bucket opening
P2 - Boom rising
P3 P1
P3 - Bucket closing RKPA3120

1 - Start the engine to allow oil circulation in all systems

and check the seals

30-70 PW110R-1
REMOVAL AND INSTALLATION L.H. PPC VALVE (ARM-SWING)

REMOVAL OF L.H. PPC VALVE (ARM-SWING)

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the knob (1) and loosen the heating control

fixing nut (2)
2 - Disconnect the catch (3) from the L.H. dashboard (4). 3

2
4 1

RKPB1220

3 - Remove the arm rest (6) fixing screws (5).

4 - Remove screws (7) and L.H. dashboard (4).
H To remove the inside screw, lower the seat and 5
6
push it right back.

4
7

RKPB1230

5 - Disconnect the six tubes (8) from the PPC valve (9)
and plug them to prevent entry of impurities.
10 9
H Mark the positions to avoid errors during assem-
bly.

6 - Remove screws (10) and remove PPC valve (9).

If there is a slack on the control lever, adjust the
unit (See «20: TESTING AND ADJUSTMENTS -
Adjustment of manual control slacks»)

8
RKPB1240

PW110R-1 30-71
REMOVAL AND INSTALLATION L.H. PPC VALVE (ARM-SWING)

INSTALLATION OF L.H. PPC VALVE

. To install, reverse the removal procedure.

T
H Check the positions carefully when reconnecting
the tubes

P - Pressure
P P2
T - Unload
P1 - Boom descent P4
P4 - Bucket opening
P2 - Boom rising P3 P1
P3 - Bucket closing RKPB1290

1 - Start the engine to circulate the oil and check the

seals.

30-72 PW110R-1
REMOVAL AND INSTALLATION OUTRIGGER AND BLADE PPC VALVE

REMOVAL OF OUTRIGGER AND BLADE PPC VALVE

Lower the work equipment until it is resting on the
ground and switch off the engine.
1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
4

1 - Remove the cabin (For details, see «REMOVAL OF 4

CABIN»). 5

2 - Remove the casing (1) from right-hand PPC valve

support.
2 3
1. Blade version
RKPA7090

1 - Disconnect tubes (2) and (3) and plug them.

H Place an identifying mark on each tube to prevent
mixing them up during installation.
2 - Take out screws (4) and remove PPC valve (5). 10
11
2. Blade - stabiliser version
9 10
1 - Disconnect feed and exhaust pipes (6) and (7).
H Place an identifying mark on each tube to prevent
mixing them up during installation. 7
6 8
2 - Remove pipes (8) and (9).
3 - Take out the screws (10) and remove the PPC valve
(11) for reconditioning or replacement.. RKPB0410

INSTALLATION OF OUTRIGGER
AND BLADE PPC VALVE
. To install, reverse the removal procedure.
1 - Start the engine to allow oil circulation in all systems .
2 - Bleed the air from the cylinders (For details, see «20.
TESTING AND ADJUSTMENTS»).

PW110R-1 30-73
REMOVAL AND INSTALLATION BOOM SWING PPC VALVE

REMOVAL OF BOOM SWING PPC VALVE

. Rotate the turret by 90ë to the left.

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the bottom left cover (1). 1
2 - Disconnect the pipes (2) (No. 4 tubes) from the PPC
valve.
H Place an identifying mark on the pipes to avoid
mixing them up during installation. RKP07970

3 - Remove the connections (3) from the PPC valve.

4 - Pull out the screws (4) and remove the PPC valve (5)
with the operation pedal (6). 3

INSTALLATION OF BOOM SWING

PPC VALVE
. To install, reverse the removal procedure.
2
1 - Start the engine to allow oil circulation in all systems .
2 - Bleed the air from boom swing cylinder (For details,
see «20. TESTING AND ADJUSTMENTS»). RKPA7140

5
4

RKPA7150

30-74 PW110R-1
REMOVAL AND INSTALLATION TRAVEL AND 2nd BOOM PPC VALVE

REMOVAL OF TRAVEL AND 2nd BOOM PPC VALVE

. Rotate the turret by 90ë to the left.

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the bottom left cover (1). 1
2 - Disconnect the pipes (2) (No. 4 tubes) from the PPC
valve concerned.
H Place an identifying mark on the pipes to avoid
mixing them up during installation. RKP07970

3 - Remove the connections (3) from the PPC valve.

2nd BOOM
4 - Pull out the screws (4) and remove the PPC valve (5)
or (6) with the operation pedal (6).
2

INSTALLATION OF TRAVEL AND

2nd BOOM PPC VALVE
. To install, reverse the removal procedure.
3
1 - Start the engine to allow oil circulation in all systems .
2 - Bleed the air from boom swing cylinder (For details, 2
see «20. TESTING AND ADJUSTMENTS»).
RKPB0420

2nd BOOM

4
RKPB5800

TRAVEL

4
RKPB0440

PW110R-1 30-75
REMOVAL AND INSTALLATION BRAKE PUMP

REMOVAL OF BRAKE PUMP

Lower the work equipment completely until it rests it
on the ground and stop the engine. 1

Release all residual pressures from all circuits, and

in particular from the brake line (See «20. TESTING
AND ADJUSTMENTS»).
1 - Disconnect the seven hoses (1) from the brake pump
and plug them. 3
2 1
H Make an identifying mark on the hoses to avoid
mixing them up during installation.
2 - Disconnect the terminals of pressure switches (2) and
(3). RKPB5810

H Make an identifying mark on the cables to avoid

mixing them up during installation.
4 - Remove the screws (4) locking support sensor (5) and
move away it.
5 - Remove the brake pump (6) and loosen three screws
(6).
5
7
INSTALLATION OF THE
BRAKE PUMP
. To install, reverse the removal procedure. 4 6
RKPB5820

Start the engine and bleed air from the brake lines
(See «20. TESTING AND ADJUSTMENTS»).

After re-connection, make sure that the protective

sleeves are positioned correctly and firmly.

30-76 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

REMOVAL OF THE STEERING UNIT

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the LH guard (1) of the revolving frame.

RKP07970

2 - Disconnect the tubes (3) from the steering unit (2).

H Make some identifying marks on the tubes before
disconnecting them, to avoid mixing up the posi- 4
tions when reconnecting.

2
RKPA8290

3 - Using the special wrench Q1, remove the screws that

fasten the steering unit group (2) to the steering col-
umn (4).
H In order to remove the front screws, attach the
5
special wrench Q1 to the steering unit (2) and
move it with a normal wrench inserted in the lower
Q1
provided between the cabin (5) and the revolving
frame (6).
2

6 RKP09570

INSTALLATION OF THE
STEERING UNIT
. To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing
circuit (See «20. TESTING AND ADJUSTMENTS»).

RKPB0470

PW110R-1 30-77
REMOVAL AND INSTALLATION STEERING UNIT

DISASSEMBLY THE STEERING UNIT

Disassembly the body of the steering unit
1 - Loosen and remove the screws (1-3) that hold the 3
cover (2) in place (six screws plus one special screw). 1

RKPA7990

2 - Remove the cover (2) by sliding it sideways.

RKPA8000

3 - Raise the rotating gear (4) complete with the O-rings

(34). Also remove the spacer (5).
4

5
34

RKPA8010

4 - Remove the drive shaft (6).

RKPA8020

30-78 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

5 - Remove the control lens (7).

RKPA8030

6 - Remove the threaded bush (8) of the safety valve.

RKPA8040

7 - Remove the O-ring (9).

RKPA8050

8 - Lift out the ball (10) of the check valve, and the pins
(11) and balls (12) of the anticavitation valves.

11

10

12

RKPA8060

PW110R-1 30-79
REMOVAL AND INSTALLATION STEERING UNIT

9 - While watching through the central hole of the spool,

position the spool-bushing connecting pin horizon-
tally. 13
Push the entire group (13) and the entire bearing until
they can be extracted from the body of the steering
unit (14).

14

RKPA8070

10 - Remove the outside ring (15), the inside ring (16), and
the roller bearing (17) from the spool. Also remove the
ring (33).
H The inside ring (16) sometimes gets left in the
body of the steering unit. Make sure that it has 33
been removed.
16

15 17

RKPA8080

11 - Lift out the cross pin (18), the bushing (19) and the
spool (20).
H Use the special cover-fastening screw (3) for total 19
extraction.
3

18

20

RKPA8090

12 - Slowly slide the spool (20) out of the bushing (19).

20

19

RKPA8100

30-80 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

13 - Push the neutral position springs (21) and extract

them from the spool (20).
21

20

RKPA8110

14 - Remove the dust-guard washer (22) and the compo-

site leaktight seal (23) (O-ring + washer).
23
22

RKPA8120

15 - Remove the caps (24) from the safety valves.

24

RKPA8130

16 - Remove the cup springs (25).

25

RKPA8140

PW110R-1 30-81
REMOVAL AND INSTALLATION STEERING UNIT

17 - Remove the adjustment screws (26) (6 mm screw

wrench).

26

RKPA8150

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

H The valve seatings are fixed in the body of the
steering unit and cannot be removed.

27

RKPA8160

19 - Check that the dismantled pieces resemble those in-

dicated in the figure. 26
25
27

28 24

27 25
26
RKPA8170

Removal of the safety valve

20 - Remove the cap (29) and its gasket (30) (8 mm screw
wrench).

29

30

RKPA8180

30-82 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

Disassembly the safety valve

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

NOTE
Cleaning
H Clean all the components with an aliphatic solvent
(white spirits or similar).

Inspections and substitutions

RKPA8190
H Change all the cup springs and seals.
H Inspect all the pieces and change those in a doubtful
state of wear.

PW110R-1 30-83
REMOVAL AND INSTALLATION STEERING UNIT

H Before assembly, lubricate all the components

with hydraulic oil.
1 - There is only one possible and correct way to assem-
a
ble of the spool (20) and bushing (19).
Assemble with the three holes (a) of the bushing (19) 20
opposite the slots (b) in the spool (20). 19
Check that the holes in the bushing are at least par-
tially visible through the slots (b) in the spool.
b

RKPA8200

2 - Insert the two flat springs (21a) in the seating and

centre them with respect to the diameter of the spool
(20). Insert the four curved springs (21b) between the
two flat springs (21a) , arranged in pairs, and push
them completely home.

21a
20
21b

RKPA8210

3 - Align the springs (21).

21

RKPA8220

4 - Insert the spool (20) into the bushing (19).

H Make sure that the position between bushing and
spool is as described in phase 1 of the assembly 20
instructions.

21 19

RKPA8230

30-84 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

5 - Push the springs (21) and the spool (20) down to-
gether until the springs are engaged in the seating
of the bushing (19).
21

20

19

RKPA8240

6 - Align the springs (21) with each other and centre

them with respect to the diameter of the bushing (19).
21

19

RKPA8250

7 - Install the ring (33) in the seating of the bushing (19).

H The ring (33) should be free to rotate without inter-
fering with the springs (21).

19

33

RKPA8260

8 - Insert the cross pin (18).

18

RKPA8270

PW110R-1 30-85
REMOVAL AND INSTALLATION STEERING UNIT

9 - Assemble the thrust bearing according to the se-

quence indicated at point 10.

16

17

15

RKPA8280

10 - Sequence for assembly the bearing.

15 - Outside ring 16
16 - Inside ring
17 - Needle bearing 17
19 - Bushing
15
20 - Spool

20

19
RKP09580

11 - Place the body of the steering unit (14) with the hole
horizontal.
Insert the guide of tool Q2 into the hole of the spool/
14
bushing group.

Q2

RKPA8300

12 - Lubricate the seal ring (23a) and the O-ring (23b) and
mount them on the push-rod of tool Q2.

23a Q2
23b

RKPA8310

30-86 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

13 - Mount the tool Q2 and insert it in the guide already

inserted in the hole of the steering unit.

23
Q2

RKPA8320

14 - Push the gasket (23) into the seating of the body of

the steering unit (14), assisting the movement with
slight rotatory movements.

14

RKPA8330

15 - Extract the guide from the body of the steering unit

(14) using the tool Q2, and leaving in position the
push-rod carrying the gaskets.

14

RKPA8340

16 - Insert the bushing/spool group (13) into the hole of

the steering unit (14).
Assist the insertion with slight rotatory movements.
H Insert the group while keeping the cross pin hori-
zontal. 13

14

RKPA8350

PW110R-1 30-87
REMOVAL AND INSTALLATION STEERING UNIT

17 - Push the group (13) as far as it will go in order to push

out the push rod that was left in position during phase
15.
14

13

RKPA8360

18 - Rotate the body of the steering unit (14) until the cen-
tral hole is vertical.
Insert the ball (10) of the safety valve into the hole in-
dicated by the arrow.
10

14

RKPA8370

19 - Screw the valve threaded bush (8) into the hole in the
safety valve.
H The upper part of the threaded bush should be
lower than the surface of the body of the steering
unit (14). 8

14

RKPA8380

Assembly of the anticavitation valve

20 - Insert the balls (12) into the two holes indicated by the
arrows.
12

RKPA8390

30-88 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

21 - Insert the pins (11) into the same holes.

11

RKPA8400

22 - Lubricate the O-ring (9) and mount it in the seating.

Mineral oil: viscosity approx. 500 cSt at 20ëC
9

RKPA8410

23 - Position the control lens (7) so that the holes corre-

spond to those in the body of the steering unit (14).
7

14

RKPA8420

24 - Insert the drive shaft (6) in the hole and engage the
cross pin; check that the pin engagement is parallel
to the connection flange between the steering unit
6
and the steering column.

RKPA8430

PW110R-1 30-89
REMOVAL AND INSTALLATION STEERING UNIT

25 - Place the drive shaft in a vertical position and hold it

steady with the tool Q3.

Q3

RKPA8440

26 - Lubricate the two O-rings (34) and mount them in the

two seatings of the ring bevel gear of the gear rim (4).
Mount the gear rim (4) on the drive shaft (6).
Mineral oil: viscosity approx. 500 cSt at 20ëC 4 34

RKPA8450

Positioning the motor

27 - Install the motor (4a) on the drive shaft (6) in such a
way that the bottom of a motor tooth corresponds to
the tooth base on the drive shaft.
Then rotate the external ring bevel gear (4b) in order 6
to align the attachment holes.

4a

RKPA8460

28 - Install the spacer (5).

4b

RKPA8470

30-90 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

29 - Mount the cover (2).

RKPA8480

30 - Insert the special screw (3) complete with washer in

the hole indicated in the figure.

RKPA8490

31 - Insert the six screws (1) complete with their cup

springs.
Tighten the screws (1) crosswise with a torque of
30w6 Nm.

RKPA8500

32 - Position the dust-guard seal (22) in the body of the

steering unit (14).

22

14

RKPA8510

PW110R-1 30-91
REMOVAL AND INSTALLATION STEERING UNIT

33 - Press the dust-guard seal (22) into the body of the

steering unit, using the tool Q4 and a plastic hammer.
Q4

22

RKPA8520

34 - Close the holes of the hydraulic couplings with plastic

caps to prevent the entry of impurities.
H Push the caps on by hand, without using the ham-
mer.

RKPA8530

Assembly of the main valve

35 - Mount the seal (32) on the main valve (31) and screw
the cartridge into the body of the steering unit (14)
using a 12 mm screw wrench.
31
Cartridge: 50w1 Nm
14

32

RKPA8540

36 - Screw the cap (29) complete with washer (30), using

an 8 mm. Screw wrench.
Cap: 50w1 Nm

29

30

RKPA8550

30-92 PW110R-1
REMOVAL AND INSTALLATION STEERING UNIT

Assembly of the safety valve

37 - Insert the balls (28) of the safety valves into the holes 28
indicated by the arrows.

RKPA8560

38 - Insert the springs (27) of the safety valves into the

holes.
27

RKPA8570

39 - Screw the pressure adjustment screws (26) into the

holes.
26

RKPA8580

40 - Mount the sealing cup springs (25) on the caps (24)

and screw the entire group into the two holes of the
safety valves. 24
Use a 6 mm screw wrench.
Caps: 30 Nm
25

RKPA8590

PW110R-1 30-93
REMOVAL AND INSTALLATION PRIORITY VALVE

REMOVAL OF THE PRIORITY VALVE

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTMENTS»).
1 - Disconnect the four tubes (2) and the priority valve 1
(1).
2 - Remove screw (3) and washer.
Remove the priority valve (1).

RKPB2680

2 RKP11070

INSTALLATION OF THE
PRIORITY VALVE
. To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing
circuit. (See «20. TESTING AND ADJUSTMENTS»).

30-94 PW110R-1
REMOVAL AND INSTALLATION PRIORITY VALVE

DISASSEMBLY OF THE PRIORITY VALVE

Unscrew the cap (1) (PP port) and take it off together with
its aluminium washer.
2 - Loosen the cap (2) (LS port).
3 - Lift off the cap (2) complete with the aluminium
2
washer and the spring (3).
4 - Using a nylon plunger, extract the spool (4).
3

ASSEMBLY OF THE
PRIORITY VALVE
H Before assembly:
1 - Wash the pieces thoroughly in kerosene or similar
product.
2 - Make sure that the spool throttle is clean.
3 - Lubricate the pieces before assembly.
4 - Change the aluminium washers.
1 - Insert the spool (4) using the nylon plunger to keep it
centred.
1 4
2 - Screw the cap (1) complete with its aluminium
washer, into the PP port.
3 - Screw the cap (2), complete with its aluminium RKP10200
washer and the spring (3) into the LS port.
4 - Tighten caps (2) and (1) firmly, and in that sequence.
Caps (1) and (2): 50w10 Nm

PW110R-1 30-95
REMOVAL AND INSTALLATION TRAVEL MOTOR

REMOVAL OF TRAVEL MOTOR

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits. (For
details, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the steps leading to the cabin (1).

RKPA8610

2 - Disconnect the front drive shaft (2) from the transmis-

sion (3).

3 2

RKPB2780

3 - Disconnect the supply tubes (4), the motor drainage

tubes (5) and the drainage tube. Plug the tubes and
the motor to prevent entry of impurities.

4 - Disconnect the connector (6).

5 - Loosen the four screws (8) that hold the motor (7).
6 - Place a hydraulic jack underneath the motor to sup-
port it.
6
RKPB2790

7 - Remove the screws (8). 7 4

8 - With the help of levers and a soft-headed mallet, 5
move the motor (7) and slide the shaft off the trans-
mission coupling.
H Take great care not to damage the coupling sur-
faces.

RKPB2721

30-96 PW110R-1
REMOVAL AND INSTALLATION TRAVEL MOTOR

INSTALLATION OF THE TRAVEL MOTOR

. To install, reverse the removal procedure.

Screw: 34 ± 41 Nm

H Before connecting the drainage tube (5), fill the

motor casing with hydraulic oil.

H Carefully check the O-ring seal between motor

and transmission. If there are any doubts as to
its condition, change it.
Sealant: ASL800050
1 - Start the motor and travel both forwards and back-
wards at low speed to bleed the system and to check
the leaktightness of the tubing.
9
2 - Stop the motor and check the level of oil in the tank.
7
If the travel motor is to be dismantled for any form of
inspection or overhaul, before using the machine
again check:

1 - The setting of the automatic displacement control

system.
2 - The speed of the travel propeller shaft.
H For test and adjustment procedures, see «20. RKP09590
TESTING AND ADJUSTMENTS».

PW110R-1 30-97
REMOVAL AND INSTALLATION TRAVEL MOTOR

DISASSEMBLY OF THE TRAVEL MOTOR

1 - Remove circlip (1) and spacer (2).

1

RKP09640

2 - Install two screws in gasket (3) holes and extract it

using pliers.

RKP09880

3 - Remove oil exchange valve (4).

RKP09600

4 - Remove recognition of travel direction device and

automatic displacement device (5), guide pin (6),
spring (7), bushing (8) and spring (9).
Remove brake valve (35).
Remove safety valve (36) (në 2).

9
8 36 35
7
5 6

RKP09610

30-98 PW110R-1
REMOVAL AND INSTALLATION TRAVEL MOTOR

5 - Set the motor on a work bench, mark measure «A» of

minimum displacement adjusting screw (34) and re-
move it. A

34

RKP09750

6 - Push positioning piston (10) until to bring the cylinder

barrel to position zero. 10
H Mark the measure «B» of maximum displacement
adjusting screw.

RKP09760

7 - Mark position between motor case (11) and displace-

ment adjusting case (12), and after removed bolts 12
(13) (No. 8) remove the adjusting case. 13

11

RKP09620

8 - Remove screw (14) and piston (15) complete with

gaskets. 15 16
Loosen locking screw (16) and positioning pin (17).
H For an easy removal, make a pin (17) and screw
(16) heating at about 120 ëC.

14
17
RKP09780

PW110R-1 30-99
REMOVAL AND INSTALLATION TRAVEL MOTOR

9 - Stop with threaded pin (18) a washer (19) and a nut

(20) the cylinder barrel in zero position. 20
Remove maximum displacement adjusting screw 19
(21).
18
H Threaded pin: M5x71

21

RKP09890

10 - Using a puller, remove the complete swing unit (22).

22

RKP09900

11 - Tighten the complete swing unit into a vice and re-

move nut (20), washer (19) and threaded pin (18). 20
Remove cylinder barrel (23).
H Use a vice provided with soft jaws.
19
18

23

RKP09910

12 - Loosen mounting bolts (24) of valve plate (25).

24

25

RKP09920

30-100 PW110R-1
REMOVAL AND INSTALLATION TRAVEL MOTOR

ASSEMBLY OF THE TRAVEL MOTOR

1 - Tighten the swing unit (26) in a vice and install pis-

tons (27), valve plate (25) and screws (24).

24

27

26 25

RKP09930

2 - Install cylinder block (23).

H Check that all components are oriented correctly
and in the right position.

RKP09790

3 - Block cylinder block (23) in vertical position using the

threaded pin (18), and washer (19) and nut (20).
H Threaded pin: M5X71 20
19
18

23

RKP09940

4 - Install tool C1 on swing unit (22).

22
C1

RKP09800

PW110R-1 30-101
REMOVAL AND INSTALLATION TRAVEL MOTOR

5 - Heat the motor case (11) at 80 ëC and insert complete

swing unit.

11

RKP09810

6 - Lock cylinder barrel in zero position using maximum

displacement adjusting screw (21).
Loosen nut (20) used to lock cylinder barrel and re-
move washer (19) and threaded pin (18).
Install O-ring gasket (28).
28
21

RKP09950

7 - Set valve plate (29) on cylinder barrel (23) and dowel

it with dowel pin of tool C2.

29

23
8 - Prepare tool C2 assembling the travel motor compo-
nents as shown in the illustration. RKP099

452010 452269
083105
Posizioni
utili per
particolari C2
452271
083010
452269
452271
452021
RKP10920 452014
RKP09970

30-102 PW110R-1
REMOVAL AND INSTALLATION TRAVEL MOTOR

9 - Assemble and set tool C2 on motor case (11).

Check and bring to zero dial gauge when knob has
been rotated in counterclockwise direction till end of C2
stroke.

11

RKP09980

10 - Rotate the knob for 4 turns in clockwise direction and

make sure with a caliper that the dial gauge has a
clearance of 2 mm and that pointer is in zero position.
H This is the starting zero for checking.

RKP10030

11 - Rotate the knob in clockwise direction till end of

stroke and check the central pin (30) clearance value
that corresponds to dial gauge indicated value.
H Pin clearance: 0.2w0.05 mm C2
H If central pin clearance is not within the tolerance,
replace springs guide plate (31).
30 31
11

RKP10080

12 - Remove tool C2.

PW110R-1 30-103
REMOVAL AND INSTALLATION TRAVEL MOTOR

13 - Assemble positioning piston (32) into the displace-

ment adjusting case (12). 32 16
Assemble the positioning pin (17) and locking bolt
(16).
H Use a new locking bolt.
H Tighten the bolt to recommended tightening tor-
que.

17
RKP09820

14 - Assemble rings (33) into the piston (15).

Assemble complete piston on positioning piston (32)
and tighten the bolt (14).
33
H Assemble rings (33) with opposed notch. 15
14

RKP09990

15 - Assemble displacement adjusting case (12) on pump

case (11) and tighten mounting bolts (13) (No. 8). 12
Restore the measures «A» and «B» of maximum (21) 13
and minimum (34) displacement adjusting bolts.
H Align marks made on pump case and on displace-
ment adjusting case before the disassembly.
11

RKP09620

16 - Assemble the spring (9), bushing (8), spring (7), guide

pin (6) and the recognition travel direction device (5).
Assemble the safety valve (36) (në 2).
Assemble the brake valve (35).

9
8 36 35
7
5 6

RKP09610

30-104 PW110R-1
REMOVAL AND INSTALLATION TRAVEL MOTOR

17 - Assemble the oil exchange valve (4).

RKP09600

18 - Using tool C3, fit the gasket (3), spacer (2) and circlip
(1). C3

1 2
3

RKP09831

PW110R-1 30-105
REMOVAL AND INSTALLATION TRANSMISSION

REMOVAL OF THE TRANSMISSION

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTMENTS»).
. Drain the transmission oil.
Transmission oil: approx. 1.6 ,
1 - Remove the travel motor (See «REMOVAL OF TRA-
VEL MOTOR»).
2 - Disconnect the rear drive shaft (2) from the transmis- 1 2
sion (1).
RKPB2781

3 - Disconnect the movement sensor (3) and the micro-

switch (4). 6
4 - Disconnect the gear-change tubes (4-5) and plug
them.
H Make some identifying marks on the tubes, to
avoid mixing up the position when reconnecting.
5 - Place a supporting jack underneath the transmission
(1).
5
6 - Loosen the screw (7) (No. 8) and remove complete 3
4
group.
H Take great care not to damage the sensor (3) and RKPB2742

the microswitch (4).

1
INSTALLATION OF THE
TRANSMISSION
. To install, reverse the removal procedure.

H Adjust the position of the transmission sensor.

(For details, see «20. TESTING AND ADJUST-
MENTS»).
7
H Position the protective sleeve with the cable outlet
pointing towards the ground to prevent accumula-
8
tions of water or condensates. RKPB2840

Screw: Loctite 242

Screw: 49 ± 51 Nm
Surface: Loctite 510

H Fill the transmission with lubricating oil.

Transmission oil: 1.6 <
1 - Start the engine to circulate the oil and, with the ma-
chine stationary, put it into gear several times to
bleed air from the circuit.

30-106 PW110R-1
REMOVAL AND INSTALLATION TRANSMISSION

DISASSEMBLY OF THE TRANSMISSION

3
2 1 View of gear
cylinder control
4
5 6 8 29
16 44 31
23
22 7
21 24
35 30
18
17 36 32
19
20
13
12 26
14
34
11
10
38
9 28
37
27
33 39 25

38
41

40

RKP09631

1 - Unscrew and take out the gear control shaft (6).

RKPA8670

PW110R-1 30-107
REMOVAL AND INSTALLATION TRANSMISSION

2 - Remove the gear control cylinder assembly (7) and

guard plate (8).

7
8
RKPA8680

3 - Disassemble the gear control cylinder (7).

7
H Check carefully the O-rings position.
H Arrange the components in reassembly order.

RKPA8690

4 - Remove the breather (3) and mount the eyebolt (A).

Apply a slight tension to the chain an remove the A
screws fixing the gear box (B) to the axle (C).
B
C

RKPA8700

5 - Using a plastic hammer, remove the gear box (B).

RKPA8710

30-108 PW110R-1
REMOVAL AND INSTALLATION TRANSMISSION

6 - Remove the gear position microswitch (9), washer

(10) and O-ring (11).

10
11
RKPA8720

7 - Remove the screw (12), spring (13) and ball (14) for
neutral position.

14 13
12

RKPA8730

8 - Remove the flange (1) with oil seal (4) and spacer (5).
H Note the spacers thickness.

RKPA8740

9 - Remove the nut (16).

H To remove the nut (16) heat it at about 120 ëC.
H Make unit cold before continuing in disassembly.

16 17

RKPA8750

PW110R-1 30-109
REMOVAL AND INSTALLATION TRANSMISSION

10 - Remove the ring (18) and the flange (17).

16 18

17

RKPA8760

11 - Remove the cover (19) complete with seal (20) and

thrust ring (22). X
H Note that notch «X» must be turned upwards.

20
22
19

RKPA8770

12 - Remove the bolts (23) and lightly the cover (24).

23 24

RKPA8790

13 - Using some levers, force the cover (24) to divide it

from housing (25).
H Prise the cover by the locating dowels.
H Take great care not to ruin surfaces. 24

25
RKPA8800

30-110 PW110R-1
REMOVAL AND INSTALLATION TRANSMISSION

14 - Pull out gear (39), needle bearings (38) and distance

piece (40) from the cover (25). 39

40 25

38
RKPA8810

15 - Take out bearing (36).

H Do not take out the bearing (36) if does not need
replacement.

36

RKPA8820

16 - Remove the oil shield plate (41).

H Operation to be carried on only if necessary.

41

RKPA8830

17 - Remove the bolts of cut flow housings (26) and (27)

27

RKPA8840

PW110R-1 30-111
REMOVAL AND INSTALLATION TRANSMISSION

18 - Remove the cut flow housing (27) and, in one time,

the hub (28) and the fork (29) complete with pads
(30) and transmission shaft (31).
29
27

31 28

RKPA8850

19 - Check sliding block (30), pin (32) and sliding coupling

(28) wear; replace if worn.

30

32
28
RKPA8860

20 - Using a plastic hammer, remove the output shaft (37)

with needle bearings (38), gear (33) and cut flow
housing (26). 38
37

26
33
RKPA8870

21 - Remove the output shaft (37), gear (33), needle bear-

ing (38), distance piece (34) and bearing (21).
H Replace worn or damaged components.

37 21
34

38
RKPA8880

30-112 PW110R-1
REMOVAL AND INSTALLATION TRANSMISSION

22 - Remove input shaft (35) from the cover (24).

35

24
RKPA8890

23 - Remove bearing (44) from carter (24).

24

44

RKPA8900

24 - Remove all the oil seal and clean and dry with accu-
racy all the components before reassembling.

PW110R-1 30-113
REMOVAL AND INSTALLATION TRANSMISSION

ASSEMBLY OF THE TRANSMISSION

Removed gaskets and O-rings cannot be used
again.
H Check carefully that contact surfaces are not damaged.
H Remove from contact surfaces each sealing residual.
H Lubricate the coupling surfaces of bearings and
seals.
Surfaces: ASL800050

1 - Install the bearing (44) into the casing (24) and fit seal
(4) and spacer (5) into the flange (1).
H Lock the spacers into position using grease.
Spacers: ASL800050

4
44
24 1

RKPA8910

2 - Install the flange (1) onto the casing (24) and bolt it.
Flange surface: Loctite 510
Flange screws: 49 ± 51 Nm

24

RKPA8920

3 - Lubricate the threaded portion of seal and fit the com-

plete shaft (35).
Seal: ASL800050
35

RKPA8930

30-114 PW110R-1
REMOVAL AND INSTALLATION TRANSMISSION

4 - Assemble the complete outlet shaft (37) and the flow

regulator casing (26) at the same time.
H Stop assembly at approx. 5mm from the final po-
sition.
37

26
RKPA8940

5 - Provisionally fit cover (19) and screw it down.

H Hold niche «X» turned to the top side of reduction
gear.

X
19

RKPA8950

6 - Install coupling (28), the complete fork (29) and the

flow regulator casing (27) all at the same time.

29
27

28

RKPA8851

7 - Bolt the assembly with screws.

Screws: Loctite 270
Screws: 25 ± 26 Nm

RKPA8970

PW110R-1 30-115
REMOVAL AND INSTALLATION TRANSMISSION

8 - Install the needle bearings (38), the gear (39) and the
distance piece (34). 34

39 38

RKPA8960

9 - Coat the outer rim of the flow regulator plate (41).

Flow-regulator: Loctite 510

41

RKPA8980

10 - Fit the flow regulator plate (41) into the reduction gear
housing (25) turning the oil inlet (Y) upwards.
Place it 5 ± 5.5 mm from the surface of the body.

41
Y
25

5ⴜ5,5mm
RKPA8990

11 - Fit the bearing (36) into the housing (25).

25

36

RKPA9000

30-116 PW110R-1
REMOVAL AND INSTALLATION TRANSMISSION

12 - Fit the housing (25) onto the casing (24) making sure
to centre the pins. 24
H Apply sealant to the surface of cover.
H Use a plastic hammer to mate.
Cover: Loctite 510

25

RKPA9010

13 - Bolt casing (24) and housing (25) with screws (23).

Screws: 48 ± 62 Nm

24
23

25
RKPA9020

14 - Lubricate the ball (14), spring (13) and the screw (12)
and install the neutral position assembly.
Ball and spring: ASL800050
Screw: 80 ± 100 Nm 13
14 12

RKPA8730

15 - Fit the in-gear-position microswitch (9), the O-ring (11)

and washer (10).
Microswitch: Max. 54.2 Nm
9

10
11
RKPA8720

PW110R-1 30-117
REMOVAL AND INSTALLATION TRANSMISSION

16 - Hook transmission (B) to the hoisting equipment and

fit it onto axle (C ). B
Coat supporting surfaces.
Bolt units with the relative screws. C
Surfaces: Loctite 510
Screws: Loctite 270
Screws: 52 ± 63 Nm

RKPA9030

17 - Pull out screws and remove the provisionally fitted

cover (19).

19

RKPA9040

18 - Push the bearing (21) to end of travel.

21

RKPA9050

19 - Using a depth gauge, measure jut «A» of bearing (21)

on flange surface.
21

RKPA9060

30-118 PW110R-1
REMOVAL AND INSTALLATION TRANSMISSION

20 - Measure dimension «B» between the surface of the

cover (19) and the edge of the seat of bearing. B
Calculate the required dimension of distance washers
so as to leave a slack of 0.2 ± 0.3 mm, i.e.: B ± 19
(A+0.2 ± 0.3)= dimension of distance washer.

19

RKPA9070

21 - Insert the required distance washers (22) in the cover,

greasing them to keep them in position.
Distance washers: ASL800050

X 19

22

RKPA9080

22 - Coat the supporting surfaces and fit the flange.

H Keep niche «X» upwards.
Surfaces: Loctite 510
Screws: Loctite 270
Screws: 48 ± 62 Nm

RKPA9090

23 - Fit the flange (17), the O-ring (18) and bolt them with
the nut (16).
Nut: Loctite 270
16
Nut: 260 ± 300 Nm

17

RKPA9100

PW110R-1 30-119
REMOVAL AND INSTALLATION TRANSMISSION

24 - Assemble the gear control cylinder (7).

7
H Carefully check position of O-rings.

RKPA8690

25 - Fit the protection plate (8) onto the transmission (B)

after coating the surface touching the transmission.
Plate: Loctite 510

8
B
RKPA9110

26 - Install the gear control cylinder (7) complete with O-

ring and bolt it with the relative screws.
Screws: 94 ± 51 Nm

RKPA8681

27 - Run the gear control rod (6) and tighten.

Rod: Loctite 242
Rod: 24 ± 26 Nm

RKPA8670

30-120 PW110R-1
REMOVAL AND INSTALLATION AXLE LOCKING CYLINDERS

REMOVAL OF AXLE LOCKING CYLINDERS

Lower the bucket (1) until level ground and make it
lean on the back.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTMENTS»). 1
1 - Bring the ignition key to the «I» position and operate
the axle release push-button; move the key to the 2
«O» (off) position and remove it.
3
2 - Disconnect the pipe (2) from the cylinder (1) and plug
it.
3 - Loosen the screws (3).
RKPB2800

4 - Sling the cylinder (1) and remove the screws (3).

Cylinder: 32 kg

INSTALLATION OF AXLE
LOCKING CYLINDERS
. To install, reverse the removal procedure.
1 - Start the engine, then lock and release the axle sev-
eral times to restore the circuit and check it is leak
tight.

PW110R-1 30-121
REMOVAL AND INSTALLATION COMPLETE FRONT AXLE

REMOVAL OF COMPLETE FRONT AXLE

1 - Remove the cabin access steps (1) from both sides of

the machine.

RKPA8610

2 - Disconnect the drive shaft (32) from the axle (3).

RKPB2691

3 - Start the engine and raise the front of the machine by

pushing down vertically with the boom, until the
wheels are about 20 cm above the ground.

20 cm

RKP09850

4 - Place a trestle (A) underneath the machine and some

blocks (B).
5 - Lower the machine slowly onto the blocks (B) and that
the wheels remain raised above the ground.
Lower the lower work equipment until it rests on the
ground and stop the engine.
Completely release all residual pressures from all B
circuits, and in particular from the brake line. (For
details, see « 20. TESTING AND ADJUSTMENTS»). A

RKPA9130

30-122 PW110R-1
REMOVAL AND INSTALLATION COMPLETE FRONT AXLE

6 - Mount the tool E1 on the wheel group (5) and apply a

slight tension to the hoisting cables. Using the dyna-
mometric wrench B1, take off the nuts and remove
E1
the entire wheel group.
Wheel group: 190 kg 4

RKPA9140

7 - Disconnect the tubes (5) from the steering cylinder

and plug both the tubes and the cylinder.
7
8 - Disconnect the brake-group tubes (6) and plug both
the tubes and the axle couplings.
9 - Remove the guard (7) the steering sensor.
H Protect both the sensor and the connector with vi- 6
nyl bags and insulating tape.
5

RKPB2810

10 - Place a lifting platform (C) and some blocks (D) be-

neath the axle. Raise this until the blocks are being
forced up against the arms of the axle (13).
H The lifting platform should be capable of an excur-
sion of about 15 cm in descent.

8
D

C
RKPA9171

11 - Remove the axle (10) fixing screws (9).

12 - Lower the lifting platform (C) until the axle is free of
the chassis.
13 - Extract the axle (10).

Front axle: 380 kg

9

10
RKPB2692

PW110R-1 30-123
REMOVAL AND INSTALLATION COMPLETE FRONT AXLE

INSTALLATION OF FRONT AXLE

. To install, reverse the removal procedure.

1 - Refill the axle with lubricating oil and check tightness.
2 - Start the engine to circulate the oil, recharge the ac-
cumulators of the brake line, and check the leaktight-
ness.
3 - Execute several complete steering manoeuvres.
4 - Bleed air from the front brake line.
(See «20. TESTING AND ADJUSTMENTS»).
5 - Stop the engine and check the level of the oil in the
tank.

30-124 PW110R-1
REMOVAL AND INSTALLATION COMPLETE REAR AXLE

REMOVAL OF COMPLETE REAR AXLE

1 - Remove the cabin access steps (1) from both sides of

the machine.

RKPA8610

2 - Disconnect the drive shaft (3) from the axle (2).

3 2

RKPB2780

3 - Start the engine and raise the front of the machine by

pushing down vertically with the boom, until the
wheels are about 20 cm above the ground.

20 cm

RKP09840

4 - Place a trestle (A) underneath the machine and some

blocks (B), roughly 15 cm high, at points correspond-
ing to the chassis.
5 - Lower the machine slowly onto the blocks, making
sure that the wheels remain raised above the ground.

Lower the lower work equipment until it rests on the

ground and stop the engine.
Release all residual pressures from all circuits in
particular from brake circuit. (For details, see « 20. A
TESTING AND ADJUSTMENTS»).
RKPA9190

PW110R-1 30-125
REMOVAL AND INSTALLATION COMPLETE REAR AXLE

Mount the tool E1 on the wheel group (4) and apply a

slight tension to the hoisting cables.
E1
Using the dynamometric wrench B1, take off the nuts
and remove the entire wheel group.

Wheels group: 190 kg

7 - Remove the travel motor (for details, see «REMOVAL
OF TRAVEL MOTOR»).

RKPA9200

8 - Disconnect the tubes (5) of the braking units and plug

both pipes and cylinder. 5 6
8
9 - Disconnect the brake group tubes (6) and plug both 5
the tubes and the axle couplings.
10 - Disconnect sensor (8).
H Protect both sensor (8) and connector (9) with vi-
nyl bags and tape.
9
11 - Disconnect the steering cylinder tubes (5) and plug
7
both the tubes and the cylinder.
12 - Disconnect pipes (10) and (11) from transmission and RKPB2820

plug them.
H Place an identifying mark on each tube to prevent
mixing them up during installation.
Disconnect the position sensor (12) and the mi- 11
croswitch (13).

10
12
13

RKPB2741

13 - Sling the axle (14) with ropes and hook it to a piece of

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

15
RKPB2830

30-126 PW110R-1
REMOVAL AND INSTALLATION REAR AXLE

INSTALLATION OF REAR AXLE

. To install, reverse the removal procedure.

1 - Refill the axle with lubricating oil and check tightness.
2 - Start the engine to circulate the oil, recharge the ac-
cumulators of the brake line, and check the leaktight-
ness.
3 - Execute a few full steering manoeuvres.
4 - Bleed air from the rear brake line.
(See «20. TESTING AND ADJUSTMENTS»).
5 - Stop the engine and check the level of the oil in the
tank.

PW110R-1 30-127
REMOVAL AND INSTALLATION AXLES

DISASSEMBLY OF AXLES
1. Planetary reduction
1
1 - Remove the securing screws (1) from the planetary
carrier cover (2).

1
RKPB2910

2 - Disjoint the planetary carrier cover (2) from the steer-

ing case (3) by alternatively forcing a screwdriver into 3
the appropriate slots.

RKPB2920

3 - Remove the complete planetary carrier cover (2).

2

RKPB2930

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

crown flange (5).
5

4
RKPB2940

30-128 PW110R-1
REMOVAL AND INSTALLATION AXLES

5 - Remove the safety flange (6).

RKPB2950

6 - Using a puller, remove the complete crown flange (5)

by acting on the stud bolts.
5

RKPB2960

7 - Partially extract the hub (7) using a plastic hammer.

H Alternately hammer on several equidistant points.
7

RKPB2970

8 - Remove the external bearing (8).

8

RKPB2980

PW110R-1 30-129
REMOVAL AND INSTALLATION AXLES

9 - By hand remove the complete hub (7).

7

RKPB2990

10 - Remove the pins and remove the steering case (3).

(For details, see «2. Remove the complete steering
case»).
3

RKPB3000

11 - Remove the snap rings (9).

RKPB3010

12 - With the help of a puller, remove the planet wheel

gears (10).
H Note down the assembly side of planet wheels. 10

RKPB3020

30-130 PW110R-1
REMOVAL AND INSTALLATION AXLES

13 - Remove the snap ring (12) from the crown (13).

12
13

RKPB3030

14 - Remove the crown flange (5).

RKPB3040

15 - Remove the sealing ring (14) from the hub (7).

14

RKPB3050

16 - Remove the internal bearing (15).

15

RKPB3060

PW110R-1 30-131
REMOVAL AND INSTALLATION AXLES

17 - Remove the external thrust blocks from the bearings

(8) and (15) forcing a pin-driver into the appropriate
slots on the hub (7).
H Hammer in an alternate way so as to avoid crawl-
ing or deformation of the thrust blocks.

RKPB3070

18 - Use a puller to remove the centring ring (16), the seal-

ing ring (17) and the bearing (18) from the steering
16
case (3).
H Note down the orientation of both centring ring 17
(16) and sealing ring (17).
16 17 18
18

RKPB3080

2. Steering case 1
1 - Remove the guard (1) and disconnect the articulation
pin (2) (See «5. Steering cylinder»).

RKPB3090

2 - Sling the entire unit (7) and connect it to the hoist,

putting the rod under light tension.
7

RKPB3100

30-132 PW110R-1
REMOVAL AND INSTALLATION AXLES

3 - Unloose and remove the fitting screws (3) from the

bottom articulation pin (4).
H Screws cannot be re-used.

3
RKPB3110

4 - Remove the bottom articulation pin (4) complete with

front sealing ring (5). 5

4
RKPB3120

5 - Unloose and remove the fittin screws (3) from the top
articulation pin (6).

RKPB3130

6 - Using two levers, remove the top articulation pin (6)

complete with front seal (5).
Pay attention not to damage the surfaces.

6
5

RKPB3140

PW110R-1 30-133
REMOVAL AND INSTALLATION AXLES

7 - Remove the complete steering case (7).

RKPB3150

8 - Using a puller for inner parts, remove the top bush (8)
and the bottom ball-bush (9).

RKPB3160

9 - Remove the articulation pins (4) and (6) and the front
sealing rings (5).
5
H Note down the side for assembly.

4 6

RKPB3170

10 - If the ball cover (11) needs replacing, remove it from

the bottom articulation pin (4).

11

RKPB3180

30-134 PW110R-1
REMOVAL AND INSTALLATION AXLES

3. Cardan shaft
1 - Remove the steering case. (For details, see «2. Steer-
ing case»).
H For front axle: introduce compressed air (approx.
3
7 bar) in the braking circuit.
2
2 - Unloose and remove the top and bottom check nuts
(2) from the dowels (3).

RKPB3190

3 - Remove top and bottom check dowels (3).

RKPB3200

4 - Remove the u-joint (4).

H To remove the u-joint use, if necessary, a plastic
hammer or a lever.

RKPB3210

5 - Remove the snap ring (5) from the bushing unit (6).

RKPB3220

PW110R-1 30-135
REMOVAL AND INSTALLATION AXLES

6 - Position the entire u-joint (4) under a press and re-

move the complete bush (6).
4

RKPB3230

7 - Remove the snap ring (7) from the bearing (8).

8 - Use a puller to remove the bearing (8), the sealing
ring (9) and the O-ring (10).
H Note down the assembly side of the ring (9).

7
8
8 9
10

RKPB3240

30-136 PW110R-1
REMOVAL AND INSTALLATION AXLES

4. Brakes
1 - Remove the swinging support (1) on the side opposite
the drive.
H If the bushing (2) is worn and needs replacing, 2 1
note down the assembly side of the connection
notch "A".

RKPB3250

2 - Disconnect the pins of the steering bars from the

steering case (See «5. Steering cylinder»).
Only for rear axle
3
3 - Disconnect the negative brake cylinder.
4 - Sling the arm (3) to be removed and put the rod under
slight tension.

RKPB3260

5 - Unloose and remove the screws (4) and the washers

(5) that fix the arm (3) to the central body (6). 4 5 6

3
RKPB3270

6 - Remove the arm (3) together with the pack of the

braking disks (7).
Place the arm on a bench.
7

3
RKPB3280

PW110R-1 30-137
REMOVAL AND INSTALLATION AXLES

7 - Remove the braking disks (7) and note down their or-
der of assembly.
H If the disks do not need replacing, avoid switching
their position.
8 - Extract the u-joint (17).
(For details, see «3. Cardan shaft»).

17
7
RKPB3290

9 - Remove the reversal springs (8) from the piston (9).

H If the springs (8) are weak or deformed they must 8
be replaced. 9

8
RKPB3300

10 - Remove the pin screws (10) guiding the piston (9).

If the screws are to be replaced, note down the 9
different colours for the different brake gap.
(See «3. Brake»)

10
RKPB3310

11 - Slowly introduce compressed air through the connec-

tion of the braking circuit in order to extract the entire
piston.
Hold on to the piston as it may be suddenly
ejected and damaged.

9
RKPB3320

30-138 PW110R-1
REMOVAL AND INSTALLATION AXLES

5. Removal of steering cylinder

1 - Remove the centring sensor (1) of the steering piston
(2), if supplied. 1
2

RKPB3330

2 - Remove the safety cotter pins (3) from the articulation

pins (4) of the steering bars (5).
Dispose of used cotter pins.

6
3

RKPB3340

3 - Remove the castellated nuts (6) that lock the articula-

tion pins (4).
4

RKPB3350

4 - Disconnect the tapered pins of the articulation (4)

from the steering case (7) by means of a puller.

4 5
7

RKPB3360

PW110R-1 30-139
REMOVAL AND INSTALLATION AXLES

5 - If the connection of the steering bars includes a

safety collar (13), raise the border. 13

RKPB3370

6 - Disconnect left and right steering bars (5) from the

piston (2).
2

RKPB3380

7 - Remove the securing screws (8) from the steering cy-

linder (9). 9

RKPB3390

8 - Extract the cylinder (9) using a plastic hammer.

RKPB3400

30-140 PW110R-1
REMOVAL AND INSTALLATION AXLES

6. Disassembly of steering cylinder

1 - Remove the snap ring (1) from the cylinder head (2). 2

RKPB3410

2 - With the help of a plastic hammer, push the head (2)

inside the cylinder (3).
H The head should line up with the edge of the cy- 3
linder.

RKPB3420

3 - With the help of a drift, apply pressure to the stop ring

(4) that is placed inside the cylinder (3) and extract
the ring using a screwdriver. 3

RKPB3430

4 - Hammer the piston (5) on the rear of the head (2)

using a plastic hammer.
Continue hammering until the head (2) is ejected from
the cylinder (3).

5
3
2
RKPB3440

PW110R-1 30-141
REMOVAL AND INSTALLATION AXLES

5 - Disassemble the cylinder unit (3) by extracting first

the head (2), then the piston (5). 5
Note down the assembly side of the piston (5).
The bevelled part "A" of the piston is oriented to-
wards the head (2).

A RKPB3450

6 - Remove all seals, anti-extrusion rings and scraper

rings from head (2), cylinder (3) and piston (5).
H All seals must be replaced every time the unit is
disassembled.
H Particular attention must be paid not to damage
the seats of both seals and piston slide.

7. Hydraulic negative brake cylinder

1 - Insert pressure into cylinder (4) in order to release the
brakes.
H If the machine hydraulic system cannot be used, 4
use an external manual pump.

RKPB3460

2 - Loosen and remove the external nut (7).

30-142 PW110R-1
REMOVAL AND INSTALLATION AXLES

3 - Release the pressure in the cylinder and disconnect

the pressure delivery tube.
3
Remove the fulcrum pin (3) from the cylinder (4).

RKPB3480

4 - Remove the snap ring (1) that checks the support (8)
and remove the distance piece (2).
8

1
RKPB3490

5 - Remove the cylinder assembly (4) complete with rod

(5), internal nut (6) and support (8). 4

6 5

RKPB3500

6 - Place cylinder (4) into a vice with the spring seat side
D
(10) engaged in it and, using a bar "D", loosen and re-
move the cylinder unit (9) complete with piston (13)
and spring (12). 9

4 13

12
10

RKPB3510

PW110R-1 30-143
REMOVAL AND INSTALLATION AXLES

7 - Gently introduce the union piece of the cylinder unit

(9) so as to eject the piston (13).
Hold the piston as it may be forced out rapidly
and be damaged.
13 9

RKPB3520

8 - Remove seals (14) and guide ring (15) from the piston 15 14
(13).
H Note down seals direction of assembly.
15 14
14

13
RKPB3530

9 - Only if necessary
Remove the guide ring (11) from the spring seat (10).
If the guide ring (11) is removed, it must be replaced. 10

11

RKPB3540

8 - Differential
1 - Remove the complete arms.

RKPB3261

30-144 PW110R-1
REMOVAL AND INSTALLATION AXLES

2 - Mark the position of the ring nuts (1). Remove the fit-
tin screws (3) from the ring nuts (1).
3

1
RKPB3470

3 - Uniformly heat the ring nuts (1) up to a temperature of

80ë C.
1

RKPB3550

4 - Apply tool M11 and remove the ring nuts.

H Accurately clean the threaded portions on ring
nuts of body and cover. M1

RKPB3560

5 - Remove the fittin screws (4) from the middle cover (5).
4 5

4
RKPB3570

PW110R-1 30-145
REMOVAL AND INSTALLATION AXLES

6 - Insert a screw-driver in the opposing slots then force 6

and remove the middle cover (5) and the complete dif- 5
ferential unit (6).
H Support the pieces using a rod.

RKPB3580

7 - If the bearings need replacing, extract the external

2 8
thrust blocks of the bearings (7) and (8) from middle
cover (5) and central body (2).
H Accurately check the O-ring (9).

7
5 9

RKPB3590

8 - Remove the top plug (10).

10
H Top plug cannot be re-used.

RKPB3600

9 - Remove the fittin screws (11) from the crown (12).

11

12

RKPB3610

30-146 PW110R-1
REMOVAL AND INSTALLATION AXLES

10 - If the bearing need replacing, extract the bearing (7)

and remove the crown (12). 7

12

RKPB3620

11 - Remove the shim washer (13) and the planetary gear

(14). 13

14

RKPB3630

12 - If the bearing need replacing, extract the bearing (8)

from the differential carrier (15).

15

RKPB3640

13 - Remove the snap rings (16) from the two pins (17) of
the planet wheel gears (18).

16 17

RKPB3650

PW110R-1 30-147
REMOVAL AND INSTALLATION AXLES

14 - Insert tool M2 between the planet wheel gears (18).

M2

18 18

RKPB3660

15 - Force tool M2 in-between the planet wheel gears (18)

using two pin-drivers.
Make sure that tool M2 is perfectly lined up with the
pins (17) when locked.

15

17
RKPB3670

16 - Place the differential carrier (15) under a press, posi-

M4A
tion bush M3 and insert gudgeon M4A. Press M4A M3
pin to limit position.
M4A

17

15

RKPB3680

17 - Remove gudgeon M4A and bush M3.

H In this condition the tool M2 contains pin (17). M4A
M3

RKPB3690

30-148 PW110R-1
REMOVAL AND INSTALLATION AXLES

18 - Remove tool M2 together with the pin (17) of the pla-

net wheel.

15

17
RKPB3670

19 - Leave the released planetary gear in position and

again lock tool M2. M2
20 - Repeat the operations for the extraction of the pin of
the 2nd planet wheel (17).
21 - Repeat the operations for all other pins.
18 18

RKPB3660

22 - Remove tool M2 and remove the last two planet

wheel gears (18), the 2nd differential unit gear (14)
and the relative shim washer (13) from the differential 14
carrier.
13

15

RKPB3700

9. Bevel pinion
1 - Remove the complete arms and the differential unit.
(For details, see «4. Brake» and «8. Differential»).

PW110R-1 30-149
REMOVAL AND INSTALLATION AXLES

2 - Only front axle

If disassembly is awkward, heat the check nut (1) of 2
the flange (2) at 80ëC.
H Heating is meant to unloose the setting of Loctite
1
on the nut (1).

RKPB3710

3 - Position tool M5A (or M5B), so as to avoid pinion ro-

tation.
Unloose and remove the nut (1); also remove the O- M5A
ring (3).

RKPB3720

4 - Remove the flange (2) complete with guard (4) by

means of a puller.

RKPB3730

5 - Remove the swinging support (5).

5

RKPB3740

30-150 PW110R-1
REMOVAL AND INSTALLATION AXLES

6 - Remove the sealing ring (6).

RKPB3750

7 - Only for rear axle

Remove bearing (7) and ring (8).
8

7
RKP11080

8 - For all axle

Position wrench M6 onto the ring nut (9) and apply
bar hold M7 to the pinion (10).
Stop wrench M6 and rotate the pinion so as to release
and remove the ring nut (9).
9
H If disassembly proves awkward, weld the ring nut
M7
at approx. 80ëC.

M6
RKPB3760

9 - Apply blocks M8 and, with the help of a puller, extract

the pinion (10) complete with the internal bearing 14
(11), the distance piece (12) and shims (13). M8
H The thrust blocks of the bearings remain in the
central body (14).
10

RKPB3770

PW110R-1 30-151
REMOVAL AND INSTALLATION AXLES

10 - Remove the pinion (10), shims (13) and distance

14
piece (12). 12
10

13

RKPB3780

11 - Using a puller and a press, remove the inner bearing

(11) from the pinion (10).

10

11

RKPB3790

12 - Remove the thrust block of the external bearing (15).

15

RKPB3800

13 - Insert a drift in the appropriate holes and remove the

thrust block of the internal bearing (11) as well as the
shim washers (16).

16

11
RKPB3810

30-152 PW110R-1
REMOVAL AND INSTALLATION AXLES

14 - Only for rear axle

Remove seal ring (17).

17
RKP11090

PW110R-1 30-153
REMOVAL AND INSTALLATION AXLES

ASSEMBLY OF AXLE
1. Bevel pinion
1 - Only for rear axle
Mount seal ring (17).

17
RKP11090

2 - For all axle

Using a surface plate, reset a centesimal comparator
and place it on the measurement ring M9 (with a
thickness of 30.2 mm).
Preset the comparator to approx. 2 mm.

M9

RKPB3880

3 - Bring the internal bearing (11), complete with its

thrust block, under the comparator.
Determine overall thickness "D" of the bearing check-
ing the discrepancy between this size and the size of
the measurement ring.
Press the thrust block in the centre and take sev-
eral measurements while rotating the thrust
block.
11

RKPB3890

4 - Partially insert the thrust block of the external bearing

(15).
14

15
M10C

M10A
RKPB3900

30-154 PW110R-1
REMOVAL AND INSTALLATION AXLES

5 - Install tension rod M10C, measurement ring M9 and

front guide tool M10A on the thrust block of the exter-
nal bearing (15).
M10B M9 M10C M10A

15
RKPB3910

6 - Connect the tension rod to the press and move the

thrust block of the external bearing (15) into its seat.
Disconnect the press and remove the tension rod.
H Before starting the next stage, make sure that the
thrust block has been completely inserted into its
seat.

RKPB3920

7 - Insert tool M11B complete with external bearing (15),

measurement ring M9 and gauged ring nut M11C.
Manually tighten.

M11C M9 M11B
15

RKPB3930

8 - Fit a centesimal comparator with long stem into bar

M11A; when the bar rests on two size- blocks of 57
mm, reset the comparator.
M11A
9 - Preset the comparator to approx. 2 mm and reset.

RKPB3940

PW110R-1 30-155
REMOVAL AND INSTALLATION AXLES

10 - Lay bar M11A on gauged nut M11C and take the size
"A" at about 57 mm corresponding to the maximum
diameter of arms centring. M11C

M11A A
RKPB3950

11 - Calculate size "B" which will be the first useful value

for calculating the size of the shims (16) that are to be M9
M11C
inserted under the thrust block of the internal bearing
(11).

R115
M11B

A
30.2 61
(61-A)+115+30.2=B B RKP11120

12 - Check the nominal size (X) marked on the pinion and

add or subtract the indicated variation (Y) so as to ob-
tain size "Z". 10
e.g.: Z= 118 + 0.1 = 118.1 X
Z= 118 ± 0.2 = 117.8

RKPB3960

13 - Calculate size "C" which represents the second value

for calculating the size of the shims "S" that are to be
placed under the thrust block of the internal bearing
(11).

(16) S
D Z
C=Z+D C RKP11130

30-156 PW110R-1
REMOVAL AND INSTALLATION AXLES

14 - Calculate the difference between sizes "B" and "C" B-C=S

so as to obtain the size "S" of the shim (16) that will 16 S
go under the thrust block of the internal bearing (11).

RKPB3970

15 - Insert shim "S" (16) and the thrust block of the inter-
nal bearing (11) in the central body.
H To hold shim "S" (16) in position, apply grease.

16
11
RKPB3980

16 - Position tool M10A and tension rod M10C.

Connect the tension rod to the press, fasten the thrust
block and then remove the tools.
H Before going on to the next stage, make sure that
the thrust block has been completely inserted.

M10C M10A
RKPB3990

17 - Position tools M11C and M11B complete with tapered

bearings (11) and (15); manually tighten until a rolling
torque has been obtained.
M11C 11 15
M11B

RKPB4000

PW110R-1 30-157
REMOVAL AND INSTALLATION AXLES

18 - Insert the stem of a depth comparator in either side

hole of tool M11C; reset the comparator with a preset- M11C
ting of approx. 3 mm.

RKPB4010

19 - Remove the comparator and release tools and bear-

ings from the central body.
20 - Re-install all and insert the distance piece (12) be- M11C
11
tween bearings (11) and (15); manually tighten the 12 15
whole pack. M11B

RKPB4020

21 - Insert depth comparator into tool M11B-M11C and

measure variation "H" in relation to the zero setting H
performed back at point 18.

11 M11C

15
M11B

RKPB4030

22 - The variation is to be added to a set value of 0.12± H+0,12÷ 0,13=S1

0.13 mm, so as to obtain the size of shim "S1" (13)
which will be inserted between the external bearing 13 S1
(15) and the distance piece (12) and subsequently,
to determine the preload for the bearings.

RKPB3971

30-158 PW110R-1
REMOVAL AND INSTALLATION AXLES

23 - Position the internal bearing (11) and the pinion (10)

under a press; force the bearing onto the pinion.

10

11

RKPB4040

24 - Fit the pinion (10), shim "S1" (13) and distance piece
(12) in the main body (14). 14
12
H The finer shims must be placed in- between the
10
thicker ones.

13

RKPB3780

25 - Insert the external bearing (15) in the central body in

order to complete the pack arranged as in the figure.
11 13 12 15

RKPB4050

26 - Connect the pinion (10) to the tie rod M12A and

M12B; connect the tie rod M12C to the press and
block.
10

RKPB4060

PW110R-1 30-159
REMOVAL AND INSTALLATION AXLES

27 - Apply Loctite 242 to the thread of the ring nut (9) and
screw the nut onto the pinion (10).

10
9

RKPB4070

28 - Apply special wrench M6 to the ring nut (9) and bar-

hold M7 to the pinion (10).
29 - Lock the wrench M6 and rotate the pinion using a dy-
namometric wrench, up to a minimum required tor- M7
que setting of 500 Nm.

M6
RKPB4080

30 - Apply onto the pinion (10) the bar-hold "M13" and

with the help of a torque metre, check the torque of
the pinion (8).
Torque: 120±170 Ncm M13
If torque exceeds the maximum value, then the
size of shim "S1" (13) between the bearing (15)
and the distance piece (12) needs to be in-
creased.
If torque does not reach the set value, increase
the torque setting of the ring nut (9) in different
stages to obtain a maximum value of 570 Nm.
If torque does not reach the minimum value,
then the size of shim "S1" (13) needs to be re- RKPB4090

duced.
When calculating the increase or decrease in
size of shim "S1", bear in mind that a variation
of shim (13) of 0.01 mm corresponds to a varia-
tion of 60 Ncm in the torque of the pinion (10).

30-160 PW110R-1
REMOVAL AND INSTALLATION AXLES

31 - Remove blocks M8 (used for extracting the pinion)

and re-install the arms.
(For details, see Disassembly «9. Bevel pinion»).

M8

RKPB4130

32 - Only for front axle

Lubricate the outer surface of the new sealing ring (6) 5
and fit it onto the central body (14) using tool M14.
33 - Install the swinging support (5).
H Check that it is properly oriented.

RKPB3740

34 - Fit the flange (2) complete with the guard (4) and fas-
ten it.
For keying the flange (2), use a plastic hammer if ne-
cessary.
H Make sure that the guard (4) is securely fastened
onto the flange and that it is not deformed.

2 4
RKPB4110

35 - Apply Loctite 242 to the threaded part of the pinion

(10).
Position tool M5A (or M5B) and fasten it in order to
avoid rotation.
Insert O-ring (3) the nut (1) and tighten it using a dy-
namometric wrench.
Torque wrench setting: 280±310 Nm
36 - Mount ring (8) and bearing (7).
M5A

RKPB4120

PW110R-1 30-161
REMOVAL AND INSTALLATION AXLES

2. Differential
1 - Insert the shim washer (13) and the planetary gear
(14) in the differential carrier (15). 14

13

15

RKPB3700

2 - Position the shim washer (19) and the first planet

wheel gear (18). 18
Hold them in position using bar M4C.

19

M4C

RKPB4140

3 - With the help of gudgeon M4A, position the second

planet wheel gear (18) and the relative shim washer 18
(19).
M4A

19 15

M4C

RKPB4150

4 - Insert tool M2 between the two planetary gears (18).

Line up the entire unit by pushing bar M4C all the M2
way down until gudgeon M4A is ejected.

M4C

RKPB4160

30-162 PW110R-1
REMOVAL AND INSTALLATION AXLES

5 - Lock tool M2 behind the planet wheel gears (18).

After locking, remove bar M4C. M2

18 18

RKPB3660

6 - Fit the snap rings (20) onto the pins (17).

20 17

RKPB4170

7 - Place the differential carrier (15) under the press, po-

sition bush M3 and insert the planet wheel pin (17).
17 M3

RKPB4180

8 - Put gudgeon M4B on top of the planet wheel pin (17).

M4B
17

M3
M4B

17

RKPB4190

PW110R-1 30-163
REMOVAL AND INSTALLATION AXLES

9 - Press M4B pin all the way down.

M4B M3

M4B
17

15

RKPB4830

10 - Remove gudgeon M4B, bush M3 and fit the snap ring

(16) on the pin (17).
Make sure that the snap ring centres the seat
and that it rests on the surface of the differential
carrier. 16
Repeat the operations on the other planet wheel
pin or planet wheel axle.
17

RKPB4200

11 - Position the second planetary gear (14) in the differ-

ential carrier (15).
13

14

RKPB3630

12 - Position the shim washer (13) on the crown (12).

H In order to hold the shim washer (13) in position,
apply grease to it. 13

12

RKPB4220

30-164 PW110R-1
REMOVAL AND INSTALLATION AXLES

13 - Position the crown (12) on the differential carrier (15)

and lock it with screws (11) applied with Loctite 242.
Torque wrench setting for screws: 128±142 Nm
H Secure the screws using the cross-tightening 11 12
method.

15

RKPB4230

14 - Install the bearings (7) and (8) using tool M15.

M15 8
M15 7

RKPB4240

15 - If the bearings are replaced, insert the external thrust 2

blocks in the middle cover (5) and in the central body
(2).

RKPB4250

16 - Position the differential unit (6) in the central body (2)

6
with the help of a bar and fit the middle cover (5). 5
H Thoroughly check the state of the O-ring (9) and
make sure that the cover is fitted with the oil dis-
charge in the lower position.

RKPB3580

PW110R-1 30-165
REMOVAL AND INSTALLATION AXLES

17 - Lock the middle cover (5) with screws (4).

4
Torque wrench setting for screw: 23.8±26.2 Nm
H If the ring nuts (1) are removed, spread them with
5
Loctite 242.

4
4

RKPB4260

18 - Tighten ring nuts on the crown side until clearance

between pinion and crown is zero, then lock the
crown; go back 1/4 ± 1/2 turn.
M1

RKPB4270

19 - Pre-set the bearings by means of the ring nut situated

on the opposite side of the crown, so as to increase
pinion torque up to 140 ± 210 Ncm.
If bearings are not new, check the static torque; if M13
bearings are new, check the continuous torque.

RKPB4090

20 - Introduce a comparator with rotary key "A" through

the top plug hole (10). Position the comparator on
the centre of one of the teeth of the crown (12), pre- 12 A
set it to 1mm and reset it.

RKPB4290

30-166 PW110R-1
REMOVAL AND INSTALLATION AXLES

21 - Manually move the crown (12) in both directions in or-

der to check the existing backlash between the pinion A
and the crown.

RKPB4300

22 - Adjust the backlash between the pinion and the

crown by unloosing one of the ring nuts (1) and tigh-
tening the opposite to compensate.
H Normal backlash: 0.18 ± 0.23 M1
H Difference between MIN. and Max. clearance for
whole circumference should not exceed 0.09 mm.

RKPB4270

23 - Apply Loctite 242 to the screws (3), fit them into one
of the two holes and tighten. 10
Torque wrench setting: 23.8±26.2 Nm
24 - Fit the top plug (10) after applying repositionable 3
jointing compound for seals to the rims.

RKPB4310

25 - Re-install the complete arms.

For details, see Assembly «3. BRAKE».

RKPB3261

PW110R-1 30-167
REMOVAL AND INSTALLATION AXLES

3. Brake
14
1 - Accurately clean the piston (9) and the seats of slide
and seal.
12
11
2 - Replace the O-rings (11) and (12) and the anti-extru-
sion rings (13) and (14); make sure that the assembly 13
side is correct.
Accurately check the positioning of the anti-ex-
trusion rings (13) and (14).

3
9
RKPB4320

3 - Insert the stroke automatic regulation springs (15);

place them in line with the piston (9).

15

15 9
RKPB4330

4 - Lubricate the seals (11) and (12) and fit the piston (9)
into the arm (3).
Make sure that the piston seat fits into the stop A
pin (A) inside the arm.

RKPB4340

5 - Assist the insertion of the piston (9) by lightly ham-

mering around the edge with a plastic hammer.

RKPB4350

30-168 PW110R-1
REMOVAL AND INSTALLATION AXLES

6 - Fit the pin screws (10) making sure that they are all of
the same colour. 9
White: 1 mm gap
Yellow: 0.75 mm gap
Blue: 0.5 mm gap
7 - Apply Loctite 270 to the thread.
Torque wrench setting: 5±7 Nm.

10
RKPB3310

8 - Fit the reversal springs (8) on the piston (9).

8
9

8
RKPB3300

9 - Slightly lubricate the braking disks (7) and fit them in

the arm following the correct sequence; orient them
so that the oil circulation holes and the marks "B"
are perfectly lined up.
B
H When installing the steel discs, the slot corre-
sponding to the oil level cap should always be
kept free.

7
RKPB4360

10 - Check that the positioning of the sealing ring (16) on

the arm is intact; install the complete arm. Lock it into
position using two facing screws (4) and washers (5).

16
RKPB3281

PW110R-1 30-169
REMOVAL AND INSTALLATION AXLES

11 - Check the flatness of the arms using tool M16 and fi-
M16
nally lock the arms with the screws (4) and the washer
(5) using the cross-tightening method.
Torque wrench setting: 298 Nm

RKPB4370

30-170 PW110R-1
REMOVAL AND INSTALLATION AXLES

4. Hydraulic negative brake cylinder

15 14
1 - Install guide ring (15) and seals (14) onto the piston
(13).
Carefully check seals assembly direction.
15 14
14

13
RKPB3530

2 - Lubricate the seals (14) and the inside of the cylinder

(9); introduce the whole piston (13) and move it to end
of stroke. 13 9

RKPB4380

3 - If guide ring has been removed, insert a new one (11)

into the seat of the spring.
10
Lubricate the guide ring.

11

RKPB3540

4 - Position the spring seat (10) in a vice and insert

spring (12).
Lubricate the thread. Assemble the whole cylinder 9
12
(9).

10

RKPB4390

PW110R-1 30-171
REMOVAL AND INSTALLATION AXLES

5 - Screw the cylinder (9) into the spring seat (10) and
lock it using a bar "D". D

10

RKPB4400

6 - Apply Loctite 270 to the rod (5) and screw it in the pis-
ton (13) as far as it will go.

RKPB4410

7 - Insert the pin of support (10) into the right-hand brak-

ing lever. Fit the second distance piece (2) and snap
ring (1). 8

1
RKPB3490

8 - Install cylinder (4) complete with rod (5) and internal

nut (6) and external nut (7).

4
5
6
7

RKPB3461

30-172 PW110R-1
REMOVAL AND INSTALLATION AXLES

9 - Centre the hole of fulcrum pin (3).

Apply Loctite 242 to the pin thread, screw and tighten
pin with a dynamometric wrench set at 25 ± 30 Nm.

RKPB4420

PW110R-1 30-173
REMOVAL AND INSTALLATION AXLES

5. Assembly of steering cylinder

1 - After applying grease, install the sealing ring (6) of
the shaft, the anti-extrusion ring (7) and the scraper 3 6 7 8
ring (8) inside the cylinder (3).
Thoroughly check that positioning of the anti-ex-
trusion ring (7) is correct.

RKP11140

2 - After applying grease, install the sealing ring (6) of

the shaft, the anti-extrusion ring (7) and the scraper
ring (8) in the head (2). 8 7 6 2
Thoroughly check that positioning of the anti-ex-
trusion (7) ring is correct.

RKP11150

3 - Fit the seal (9) onto the outside of the head (2).
1 - In order to facilitate assembly, apply grease
to the outer surface of the piston. 2 9
2 - Do not roll the seal (9) up.

RKP11160

4 - Prepare the piston (5) by fitting it with the guide ring

(10), the magnetic ring (11), the O-ring (12) and the
seal (13). 11
13 10
1 - In order to facilitate assembly, apply grease.
2 - If a centring sensor is not fitted, then the
magnetic ring (11) should be replaced by an-
other guide ring (10). 12 5

RKP11170

30-174 PW110R-1
REMOVAL AND INSTALLATION AXLES

5 - Apply tool M17 to the shaft on the opposite side of the

head (2) and centre it on the cylinder (3) so that it fits M17
into the piston (5).
H Apply a little grease to seals and cylinder. 5

RKPB4430

6 - Push the piston (5) into the cylinder for 100 mm using
a plastic hammer.
5

3
RKPB4440

7 - Remove tool M17 and apply it to the opposite side of

the piston (5).
M17

5
2
RKPB4450

8 - Apply grease to head (2) seals, fit the head onto the
piston (5) and push it into the cylinder (3) using a plas- 3
tic hammer. 2
H Insert the head as to line it up with the edge of the M17
cylinder.

5
RKPB4460

PW110R-1 30-175
REMOVAL AND INSTALLATION AXLES

9 - Insert the stop ring (4) ensuring that it fits into the seat
of the cylinder (3). 4

3
RKPB4470

10 - Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring (4).

RKPB4480

11 - Fit the snap ring (1) on the head (2).

Make sure that the snap ring (1) is securely fas- 2
tened in its seat.
If necessary, force it into its seat using a drift and
a hammer.

RKPB3410

30-176 PW110R-1
REMOVAL AND INSTALLATION AXLES

6. Install of steering cylinder

1 - Check that the O-rings (15) of the axle unit are in 9
good condition; lubricate the seats of the seals (15)
and fit the steering cylinder (9) into its seat.

RKPB4490

2 - Lock the cylinder by cross- tightening the screws (8).

9 8
Torque wrench setting: 116±128 Nm

RKPB4500

3 - Apply Loctite 242 to the thread and connect the steer-

ing bars by screwing the terminals onto the piston 13
stem.
Torque wrench setting: 240±270 Nm
H Versions with coupling require that the rim of the
articulation (13) is riveted onto the surfaces of the
piston stem.

RKPB4510

4 - Insert the pins (4) in the steering case (7) and lock into
position using a torque wrench setting of 260±290 4
Nm.
7
Find the position of the notching in relation to the hole
of the cotter pins and tighten the nut (6) further.
Check that rubber guards (A) are intact.

RKPB4520

PW110R-1 30-177
REMOVAL AND INSTALLATION AXLES

5 - Insert the cotter pins (3) and bend the safety stems.
Use new cotter pins.

6 3

RKPB4530

6 - Install the proximity (1) for checking piston (2) cen-

tring - if applicable - and tighten the screws (10).
Torque wrench setting: 5±6 Nm 1
2

10

RKPB3331

Eliminate the action of the negative brake, if fitted.

Apply tools M18 to the hubs and lock them. M18
Using a level "B", check that tools are perfectly flat
and parallel to each other.
M18

7 - Connect the sensor (1) to the inspection device ac- RKPB4540

cording to diagram.

I max=0,80 A
1
NERO
BLACK

CONNETTORE
CONNECTOR

2 BLU
1 3
BLUE
--
4

BATTERIA
BATTERY

MARRONE
BROWN
+
2A
RKP11180 RKPB4550

30-178 PW110R-1
REMOVAL AND INSTALLATION AXLES

8 - Centre the piston by slowly moving it first in one direc-

= =
tion then in the other and position it half way on the
stroke, which is determined by the switching on and
off of the signal lamp of the inspection device in the
reversal stage.

RKPB4560

9 - Inspect jut "C" on one side of the piston and note

down the size for checking later adjustments.
H If cylinders come without a sensor, the centring of C
the piston must be carried out on the basis of the
maximum stroke.

RKPB4570

10 - Without moving the piston, check front and rear size

at the edge of tools M18.
Max. difference: 0.6±0.7 mm
H In order to check the rear size, rotate the bevel pi-
nion and check that tools M18 are flat.

M18

RKPB4580

11 - If necessary, adjust convergency without moving the

centring of the piston and adjust the length of the
steering bars (5) or (14). 5 14
H With a half turn of screw, the front size is reduced
by about 3 mm, whereas the rear one is increased
by about 3 mm.

RKPB4590

PW110R-1 30-179
REMOVAL AND INSTALLATION AXLES

7. Convergency adjustment
1 - Unloose the nuts (11) and screw them onto the ball-
and-socket joints (15). 15
11

RKPB4600

2 - Hold the articulations still and rotate the ball-and-

socket joints (15).
15
Once the convergency has been adjusted, lock the
11
nuts (11).
Torque wrench setting for nuts: 298±328 Nm

RKPB4610

8. Cardan shaft
1 - Using tools M19 and M20, insert the sealing ring (9)
and the bearing (8) in the bush (6).
H Carefully check the assembly side of the seal (9).
M19 M20

9 8

6 6
RKPB4620

2 - Fit the snap ring (8) on the bearing (8).

7
11

RKPB4630

30-180 PW110R-1
REMOVAL AND INSTALLATION AXLES

3 - Heat the bearing in oil at an approx. temperature of

100ëC and fit the entire bush (6) on the u-joint (4).

RKPB4640

4 - Fit the check ring (5) on the bushing unit (6); also put
the O-ring (10) into position.
10
6

RKPB3221

5 - Insert the u-joint and tighten the top and bottom dow-
els (3).
Torque wrench setting: Max. 15 Nm.
H For u-joint coming with a bush, centre the point of 3
the check dowels in the slot.

RKPB4650

6 - Apply Loctite 242 to the jutting parts of the dowels (3).

RKPB4660

PW110R-1 30-181
REMOVAL AND INSTALLATION AXLES

7 - Screw the check nuts (2) of the dowels (3) and lock
them using a dynamometric wrench.
Torque wrench setting: 122 Nm 2

RKPB4670

9. Steering case
1 - If the bottom articulation pin (4) has been extracted,
position the pin under a press and fit the ball cover
(11).
11

RKPB4680

2 - Fit the front sealing rings (5) onto the articulation pins
(4) and (6).
H Carefully check that the rings are properly or-
5
iented (5).

4 6

RKPB3170

3 - Lubricate the top bush (8) or the bottom ball bush (9)
and fit them into the fulcrum holes of the arm.
Use tools M21 and M22.
M21

8 M22

RKPB4690

30-182 PW110R-1
REMOVAL AND INSTALLATION AXLES

4 - Lubricate the terminal of the u-joint (10) and install the

steering case (7).
Pay due attention not to damage the dust cover rings
and the sealing rings. 7

RKPB3150

5 - Fit a new seal (5) onto the top articulation pin (6). Lu-
bricate and install the unit in the steering case. Posi-
tion the screws (3) and lightly tighten.
6 - Check the correct assembly side of the seal (5).
6
5

RKPB3140

7 - Fit a new seal (5) onto the bottom articulation pin (4). 5
Lubricate and fit the unit in the steering case. Position
the screws (3) and lightly tighten.
8 - Check for the correct assembly side of the seal (5).

4
RKPB3120

9 - Tighten the new fittin screws (3) of top and bottom ar-
ticulation pins in sequence using the cross tightening 3
method.
Torque wrench setting: 128±142 Nm

3
RKPB4700

PW110R-1 30-183
REMOVAL AND INSTALLATION AXLES

10 - Connect the articulation pin (2) (See «Assembly of

1
steering cylinder»).
11 - Lubricate articulations with Molikote and fit the dust
cover (1).

RKPB3090

10. Planetary reduction

M23
1 - Lubricate the bushing (18) and the seat of the steer- 3
ing case (3).
2 - Install the bushing (18), using tool M23.

18
RKPB4710

3 - Lubricate the outer surface of the sealing ring (17)

and centring ring (16); fit them into their seat using
tool M24.

16 17 M24

RKPB4720

4 - Position the lower part of tool M25A and the thrust

block of the external bearing (8) under the press.

M25A

RKPB4730

30-184 PW110R-1
REMOVAL AND INSTALLATION AXLES

5 - Lubricate the seats of the bearings and position the

hub (7) on tool M25A; position the thrust block of
the internal bearing (15).
H Check that the thrust block is correctly oriented.
15

M25A

RKPB4740

6 - Position the upper part of tool M25B and press the

thrust blocks into the hub (7) all the way down.

M25B

RKPB4750

7 - Fit the bearing (15) into the internal thrust block.

15

RKPB4760

8 - Apply a repositionable jointing compound for seals to

the outer surface of the sealing ring (14).
9 - Position the sealing ring (14) in the hub (7).
14
H Check that the ring (14) is correctly oriented.
7

RKPB4770

PW110R-1 30-185
REMOVAL AND INSTALLATION AXLES

10 - Position tool M16 and press the sealing ring (14) into
its seat.
M26

14

RKPB4780

11 - Insert the flange (5) in the crown (13).

13

RKPB3041

12 - Insert the snap ring (12) in order to fix the flange (5) in
the crown (13).
H Carefully check that ring (12) is properly inserted
in the slot of the crown (13).
12
13

RKPB4790

13 - With the help of tool M27, insert the planet wheel

gears (10) into the cover (2). M27
Accurately check the orientation.

10
RKPB4800

30-186 PW110R-1
REMOVAL AND INSTALLATION AXLES

14 - Lock the gears (10) into position by fitting the snap

rings (9).
9

RKPB3010

15 - Fit the steering case (3) onto the U-joint (19) and in-
stall the articulation pins. For pin assembly details,
see Assembly «9. Steering case». 3

RKPB3000

16 - Connect the steering bars.

(For details, see «6. Assembly of steering cylinder»).

RKPB3091

17 - Install the hub (7).

7

RKPB2990

PW110R-1 30-187
REMOVAL AND INSTALLATION AXLES

18 - Install the external bearing (8).

8
H Using a plastic hammer, drive the bearing to the
limit stop by lightly hammering around the edge.

RKPB2980

19 - Fit the complete crown flange (5).

5
H In order to fasten the flange (5), use a plastic ham-
mer and alternately hammer on several equidi-
stant points.

RKPB4810

20 - Apply Tecnolube Seal 101 grease to the surface of

the safety flange (6) which touches the crown flange
(5). 6

21 - Fit the safety flange (6).

RKPB2950

22 - Apply Loctite 242 to the studs and fit in the nuts (4).

RKPB4820

30-188 PW110R-1
REMOVAL AND INSTALLATION AXLES

23 - Cross tighten the nuts (4) in two stages.

4
Initial torque wrench setting: 120 Nm
Final torque wrench setting: 255±285 Nm

RKPB4210

24 - Fit the planetary carrier cover (2) onto the hub (3).
2
Check that the O-ring (20) is in good condition
and in position.

RKPB2930

25 - Lock the planetary carrier cover (2) by tightening the

screws (1).
Torque wrench setting for screws: 40±50 Nm 1

RKPB4280

PW110R-1 30-189
REMOVAL AND INSTALLATION BOOM CYLINDER (For 1-piece boom)

REMOVAL OF BOOM CYLINDER (For 1-piece boom)

Extend the arm fully and open the bucket comple-

tely. Lower the work equipment until it is resting on 2
the ground

1 - Put a sling around the cylinder (1).

2 - Switch off the engine, release pressure in the cylinder
by moving the RH PPC valve lever several times.
3
3 - Remove the screw (2) and draw out the pin (3).
4
4 - Start the engine to retract the piston (4). 1
5 - Lower the cylinder (1) until it rests on a stand «A». RKPA7160

H To hold the piston rod in its fully retracted position

tie it with wire.
6 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
1
7 - Disconnect the tubes (5-6) and plug them. Also plug
the holes in the safety valve to avoid entry of impuri-
ties.
8 - Remove pipe (7) and plug the cylinder port and the
pipe to keep out impurities.
A
9 - Remove the screw (8) and safety valve (9).
RKPA7170

10 - Remove screw (10) and draw out the pin (11).

11 - Remove cylinder (1).

10
INSTALLATION OF BOOM
CYLINDER (For 1-piece boom)
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder rod) until a 11
clearance of 1 ± 2 mm is obtained.
RKPA7180

When aligning the positions between hole and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.
8
Inside bushings : ASL800050 9

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a 7
clearance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed air from the cylinder. (For 5
details, see «20. TESTING AND ADJUSTMENTS»). 6
H After bleeding the air, check the oil level in the
tank. RKPB1582

30-190 PW110R-1
REMOVAL AND INSTALLATION BOOM CYLINDER (For 2-piece boom)

REMOVAL OF BOOM CYLINDER (For 2-piece boom)

1 - Fully extend the front work equipment, raise the

boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A

RKPB0100

3 - Put a sling round the RH cylinder (1) of the 2-piece

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment to a given clearance (4).

4
4
2

5
5 3
RKPA7210

4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6

H To secure the piston rod in this position, tie it with

wire and switch off the engine.
1
6 - Disconnect the tubes (6) from the RH cylinder (1) and
plug them.
7 - Slide out the pin (7) until the cylinder (1) is free and 7
remove it. RKPA7220

8 - Put the boom cylinder in a sling.

9 - Slide the pin (7) out until the boom cylinder piston rod
(8) is disconnected.
H To hold the piston rod it its fully retracted position,
tie it with wire and switch off the engine.
8
10 - Start the engine and retract the piston.
11 - Lower the cylinder (8) and rest it on a stand (B). 7

B
RKPA7230

PW110R-1 30-191
REMOVAL AND INSTALLATION BOOM CYLINDER (For 2-piece boom)

12 - Disconnect the tubes (9) and (10) and plug them. Also
plug hole in the safety valve (11) to prevent impurities
from entering.
11 13
13 - Remove pipe (12) and plug the cylinder port and the
pipe (12) to keep out impurities.
14 - Remove the screw (13) and take out safety valve (11) 12
15 - Remove the screws (14) and take out the pin (15).
9

10
16 - Remove the cylinder.
RKPB1583

8 14
INSTALLATION OF THE BOOM
CYLINDER (For 2-piece boom)
. To install, reverse the removal procedure.

15
Self-locking nut: 118 Nm.
RKPA7240

Inside bushings: ASL800050.

When aligning the positions between hole and

pin, run the engine at minimum idling.
Do not insert fingers in the holes to check the
alignment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 0.5 ± 1 mm is obtained.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed the air from the cylinders
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the level of the oil
tank.

30-192 PW110R-1
REMOVAL AND INSTALLATION 2nd BOOM CYLINDERS

REMOVAL OF 2nd BOOM CYLINDERS

1 - Fully extend the front work equipment, raise the

boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A

RKPB0100

3 - Put a sling round the RH cylinder (1) of the 2-piece

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment to a given clearance (4).

4
4
2

5
5 3
RKPA7210

4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6
H To hold the rod in its fully retracted position, tie it
with wire and switch off the engine.
6 - Disconnect the tubes (6) from the RH cylinder (1) and 1
plug them.
7 - Slide out the pin (7) to free the cylinder (1) and re-
move it. 7
RKPA7220
8 - Put the boom cylinder in a sling.
9 - Slide the pin (7) out to disconnect the boom cylinder
piston rod (8).
10 - Start the engine and retract the piston.
H To hold the rod in its fully retracted position, tie it
with wire and switch off the engine.
11 - Lower the cylinder and rest it on a stand (B). 8

B
RKPA7230

PW110R-1 30-193
REMOVAL AND INSTALLATION 2nd BOOM CYLINDERS

12 - Repeat the procedure from points 3-7 to remove the

LH cylinder of the 2-piece boom.
6

7
9

RKPA7250

INSTALLATION OF 2nd BOOM

CYLINDERS
. To install, reverse the removal procedure.

Self-locking nut: 118 Nm.

Inside bushings: ASL800050.

When aligning the positions between hole and pin,

run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides) until a clearance of
0.5 ± 1 mm is obtained for each cylinder.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed the air from the cylinders
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the level of the oil
tank.

30-194 PW110R-1
REMOVAL AND INSTALLATION ARM CYLINDER

REMOVAL OF ARM CYLINDER

Open the front work equipment completely, then
raise it and place a supporting stand between the
boom and the 2-piece boom.
H The stand should be 1.60 m high.
1 - Manoeuvre the bucket until its teeth are resting on
the ground, together with the arm.
2 - Put a sling around the cylinder (1).
A
3 - Switch off the engine, release pressure in the cylinder
by moving the LH PPC valve lever several times.
4 - Remove the screw (2) and draw out the pin (3). RKPA7260

5 - Start the engine to retract the piston (4).

H To hold the piston in its fully retracted position, tie 5
the rod with wire.
6 - Switch off the engine and release any residual hy-
1
draulic pressures. (For details, see «20. TESTING 4
AND ADJUSTMENTS»). 3
7 - Disconnect the tubes (5) and plug them.
If a safety valve has been installed, disconnect
the tubes (6-7) from the valve.
2
8 - Remove the screw (8) and draw out the pin (9).
RKPA7050

9 - Lift out the cylinder (1).

INSTALLATION OF
ARM CYLINDER
. To install, reverse the removal procedure.
7
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the piston rod) until a
clearance of 1 ± 2 mm is obtained. 6

When aligning the positions between hole and RKPA5452

pin, let the engine run at minimum idling.

Do not insert fingers into the hole to check the
alignment.

Inside bushings: ASL800050

9 8
1
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.
RKPA7010

PW110R-1 30-195
REMOVAL AND INSTALLATION BUCKET CYLINDER

REMOVAL OF BUCKET CYLINDER

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 4
the ground

1 - Switch off the engine and release pressure in the cy-

2
linder by moving the RH PPC valve lever several
times.
2 - Remove the ring nut (2) and draw out the pin (3).

3 - Switch off the engine and retract the piston rod (4).
H To hold the piston rod in its fully retracted posi- 3
tion, tie it with wire. RKPA7690

4 - Switch off the engine and release any residual hy-

draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
6
5 - Disconnect the hoses (5) and plug them. Also plug
7
the holes of the rigid tubes to avoid entry of impuri-
ties. 1

6 - Put a sling around the cylinder (1).

7 - Remove the screw (6) and draw out the pin (7).

8 - Lift out the cylinder (1).

5
RKPA7270

INSTALLATION OF BUCKET 5
CYLINDER
. To install, reverse the removal procedure. 6
7
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the piston rod) until a
clearance of 1 ± 2 mm is obtained.

When aligning the positions between hole and

pin, do not insert fingers into the hole to check RKPA7280

the alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.

30-196 PW110R-1
REMOVAL AND INSTALLATION BOOM SWING CYLINDER

REMOVAL OF BOOM SWING CYLINDER

1 - Swing the boom to the right to extend the cylinder

fully.
2 - Swing the revolving frame 45ë and rest the work
equipment on the ground.
3 - Switch off the engine and move the PPC valve sev-
eral times to release all residual pressures.
1
4 - Remove the RH front guard (1) from the revolving
frame (2). 2
5 - Disconnect the tubes (3) from the cylinder and plug RKP11053
them. Also plug the flanges (4) of the cylinder (5).
6 - Disconnect the lubricator tube (6).
7 - Place a block beneath the cylinder head to prevent
the edge of the frame making dents in the piston
5
rod. Also place a support beneath the cylinder. 4 4
8 - Remove the screw (7), draw out the pin (8) and detach
the piston rod from its support (9).
9 - Remove the screws (10) and draw out the stop (11)
and the pin (12).
3
10 - Slide the cylinder out partially from the front and, as
soon as possible, put it in a sling and lift it off.
H During this operation take great care not to dent RKPA5491
the piston rod.

INSTALLATION OF BOOM SWING

CYLINDER 7
8
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston) until a clear-
ance of 1 ± 2 mm is obtained.
9
When aligning the positions between hole and RKPB0990

pin, let the engine run at minimum idling.

Do not insert fingers into the hole to check the
alignment.
10
12
Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis- 11

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained. 6

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.
RKPA7290

PW110R-1 30-197
REMOVAL AND INSTALLATION CYLINDERS FOR OUTRIGGERS OR BLADE

REMOVAL OF CYLINDERS FOR OUTRIGGERS OR BLADE

1 - Bring the arm into a vertical position and rest the back
of the bucket on the ground.
2 - Rest the blade and/or the outriggers on the ground.
3 - Stop the engine and release all residual pressures
from the blade and/or outriggers.
4 - Take away the screw (1), remove the dowel (2), and
disengage the piston rod from the blade or from the
outrigger.

5 - Start the engine and retract the piston rod (3). RKP10050

H Secure the totally retracted position by binding

both sides of the piston rod with wire.

6 - Stop the engine and release all residual pressures. 10

7 - Disconnect the tubes (4) and (5) and plug them. Also
plug the safety valve (6) couplings. 9
8 - Put a sling around the cylinder (7).
H Take care not to distort the valve tube (8).
3
9 - Take out the screw (9) and remove the dowel (10). 2

1
10 - Take out the cylinder complete with valve.
RKPB2850

INSTALLATION OF CYLINDERS 5
FOR OUTRIGGERS OR BLADE
. To install, reverse the removal procedure. 8
4
H Insert the shims on both sides of the rod.

6
When aligning the positions between hole and
pin, let the engine run at low idling.
Do not insert fingers into the holes to check on
alignment. RKPB2860

Internal bushings: ASL800050

H Insert the shims on both sides of the piston rod. 7

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the level of oil in the
tank.

RKPB0140

30-198 PW110R-1
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS

DISASSEMBLY OF WORK EQUIPMENT CYLINDERS

1. All cylinders
1 - Place the cylinder on the tool F8 and partially extract 3
the piston. F8 5
2 - Loosen the retaining screws of the flange (1) that se-
cures the head (2) and take it away. Move the flange
(1) towards the piston rod.
3 - Push the head (2) into the cylinder (3) and remove the
snap ring (4).
H Take great care not to damage the inside of the
cylinder.
RKPA7310
4 - Slide the piston rod (5) out of the cylinder (3), com-
plete with the flange (1), the snap ring (4), the head
(2) and the piston (6).

1
2. Boom, bucket, boom swing and blade cylinder 2 4

5 - Remove the screws (7) and remove the two half- 8

flanges (8).

4 6 7
RKPA7320

3. Arm and 2nd boom cylinder

1 - Heat the end nut (10) to a temperature of 140 ± 150 ëC. 10
9
2 - Only for the arm cylinder: loosen and remove the
safety screw (9).
3 - Loosen and remove the end nut (10). Use the key F7
and the dynamometric key B1.
H Before continuing with the dismantling opera-
tions, allow the piston rod to cool down.

RKPA7330

4. All cylinders
1 - Take the group to pieces.
For the arm cylinder, first take away the twelve
brake pin (12) retaining balls (11).
12
2 - Remove the seals from the piston rod.

11
RKPA7340

PW110R-1 30-199
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS

ASSEMBLY OF WORK EQUIPMENT CYLINDERS

H Take care not to damage the seals or the sliding sur-

faces.
H Prepare each individual component before final as- 3
2
sembly.
1 2

1. Assembly of the head-retaining flange.

1
1 - Mount the scraper (1) in the external seating of the
flange (2), making sure that it is positioned correctly.
Drive home the scraper using the press.
2 - Mount the O-ring seal (3). RKP07300 RKPA7350

H Use grease to hold the washer in place.

Sealant: ASL800050

6 5
7 1
2. Head assembly
1 - Mount the internal central retaining ring, positioning 4 2
first the O-ring (1) and then the sealing ring (2).
H Make sure that the lowering of the retaining ring is
turned towards the inside of the cylinder.
3 4
2 - Use the tool F1, mount the lip seal (3).
H Check that the lips are facing towards the inside RKP08000

of the cylinder.
3 - Mount the guide rings (4).
6 5 1 6 5 6
4 - Mount the O-rings (5) and relative anti-extrusion rings 7
(6) on the outside of the head (7).
H Check the position of the anti-extrusion rings (6).

4
3 2 4 RKP08010

1 2 F1

7 2

RKPA7360 RKPA7370

30-200 PW110R-1
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS

5 - Gauge the diameter of the internal seals, mounting

the group underneath the press and using the speci-
fic gauging knuckle pin F2 for the diameter of the pis-
ton rod.

F2

RKPA7380

3. Piston assembly
1 - Using the tool F3, mount the piston seal. Mount in the
correct sequence the rubber ring (1), the external seal
(2), and the rings wear (3).
2 - Mount the guide rings (4).
1 2 F3
3 - Only for arm and 2nd boom piston: Mount the O-ring
(5) and the rings wear (6) for the sealing between pis-
ton rod and piston.

RKPA7390

4 3 2 3 4

6 5 6
RKP08020

4 - Gauge the diameter of the seal (2) of the piston (7),

mounting the group under the press and using the
specific gauging ring F4 for the piston diameter.
7

F4

RKPA7400

PW110R-1 30-201
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS

4. Piston rod group assembly

1 - Mount on the end of the piston rod (1) the bushing F5
of the correct diameter. 2
1 4
2 - Slide the head-retaining flange (2), the snap ring (3)
and the head (4) onto the piston rod.
H Check carefully the positioning of the head-retain-
ing flange.
3 - Remove the bushing F5 from the end of the piston.
F5 3
RKPA7410

4 - Mount the O-ring (5) and the rings wear (6) in the end-
seating, for the sealing between the piston ring and 5
piston.
H For arm and 2nd boom the seal is housed in the
7 8
piston itself. 6
5 - Mount in the correct sequence the brake bushing (7)
(for the boom and arm cylinders only) and the piston
(8).

RKPA7420

6 - For the arm piston only: mount the brake pin (9) and
slide the twelve retaining balls (11) into the hole (10).
7 - Mount the half-flanges (12) that hold the piston (8) in
8 12
place, and secure them with the screws (1). 10
Flange retaining screws:
5w0.5 kgm (49w5 Nm)

Only for arm and 2nd boom piston: 13

1 - Mount the nut (14) that holds the piston (8) in 11 9
place, and tighten with the socket wrench F7 RKPA7430

and the dynamometric tool with multiplier G1.

Piston retaining nut: Loctite 262
Piston retaining nut:
2nd boom: 350w29 kgm (343w28.4 daNm) 8
Arm cylinder: 300w20 kgm (294w19.5 daNm) 14

Only for arm cylinder: 15

2 - Mount the safety screw (15).
Safety screws: Loctite 262
Safety screws: 9w0.9 kgm (88w8.8 Nm)

RKPA7331

30-202 PW110R-1
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS

5. Cylinder assembly
1 - Place the cylinder (1) and the piston rod group (2) on 1 3
the equipment F8 and align their axes. 4
2
2 - Lubricate the external seals and insert the piston (3)
in the cylinder (1).
Piston sealants: Grease ASL800050
H Before inserting the piston, check that the seals
are not damaged and that they fit perfectly in their
seatings.
3 - Lubricate the external seals of the head (4) and insert 5
it completely into the cylinder (1). F8 RKPA7311

Head sealants: Grease ASL800050

H Before inserting the head, check that the seals
are not damaged and that they fit perfectly in their
seatings.
4 - Using the tool F6, position the snap ring (5) that holds
8
the head (4) in the cylinder seating. 6
H Check that the snap ring is completely inserted in
the seating.
5 - Position the flange (6) that holds the head in place,
and secure it with the screws (7). F6
H Before positioning the flange, check that the O-
ring flange seal (8) is in its seating.
Flange blocking screws: 5w0.5 kgm (49w5 Nm)
RKPA7460

7
RKPA7470

PW110R-1 30-203
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 1-piece boom)

REMOVAL OF WORK EQUIPMENT

(For 1-piece boom)
Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 2
the ground
1 - Put a sling around the cylinder (1) of the boom. 7
2 - Switch off the engine, release pressure in the cylinder
by moving the PPC valve lever several times.
3 - Remove the screw (2) and draw out the pin (3). 3
6
4
4 - Start the engine to retract the piston (4).
1
H To hold the piston in its fully retracted position, tie
it with wire.
RKPA7161

5 - Lower the cylinder (1) until it comes to rest on blocks

(A).
6 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»). 1
7 - Disconnect the hoses (5) and plug them. Also plug
the rigid tubes.
8 - Put the equipment in a sling and apply slight tension
to the cables.
9 - Remove the screw (6) and the pin (7). Lift off the work A
equipment (8).
RKPA7170
Work equipment: 1300 kg

INSTALLATION OF WORK
EQUIPMENT (For 1-piece boom)
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis- 5 5

tributed on both sides of the piston) until a clear-
ance of 1 ± 2 mm is obtained.

When aligning the positions between holes and RKPA7480

pin, let the engine run at minimum idling.

Do not insert fingers into the hole to check the
alignment.

Inside bushings: ASL800050.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the arm) until a clearance
of 0.5 ± 1 mm is obtained.
. Start the engine to circulate the oil, and bleed air from
the cylinder.
H After bleeding the air, switch off the engine and 8
check oil level in the tank. RKPB0150

30-204 PW110R-1
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 2-piece boom)

REMOVAL OF WORK EQUIPMENT

(For 2-piece boom )
Fully extend the arm and the 2-piece boom and com-
pletely curl up the bucket. Position a stand (A)
(height 1.60 m.) between the boom and the 2-piece
boom, and rest the back of the bucket on the ground.
Stabilise the machine by resting the blade and/or the
stabilisers on the ground.
Completely eliminate residual pressures from all the A
circuits. (For details, see «20. TESTING AND AD-
JUSTMENTS»).

RKPA7500

1 - Disconnect the boom cylinder (1) from the 2-piece

boom and rest it on a stand (B).
H In order to disconnect the boom cylinder, it is ne-
cessary to remove the RH cylinder of the 2-piece
boom. (See «REMOVAL OF 2-PIECE BOOM CY- 2
LINDERS up to point 11).
A 1
After having disconnected the boom cylinder, re-
assemble the RH cylinder of the 2-piece boom
with the pin (2) and fasten it with its own screws.

B
RKPA7530

2 - Disconnect the eight hoses (3) that control the front

work equipment cylinders, and plug them. Also plug
the union fittings of the hoses (4).
3

RKPA7520

3 - Put the boom (5) in a sling and apply slight tension to

the cables.
H Pass the cables through the rigid tubes to avoid 5
distortion.
7
4 - Remove the screws (6) and take out the pin (7).

5 - Raise the boom (5) until it is disengaged from the swi- 6

vel support (8) and take away the stand (A).

Work equipment: 1650 kg 8

A
RKPA7510

PW110R-1 30-205
REMOVAL AND INSTALLATION WORK EQUIPMENT (For 2-piece boom)

6 - Swing the group to the side of the machine and rest

the boom on a stand (C).
5

RKP08030

INSTALLATION OF WORK
EQUIPMENT (For 2-piece boom)
. To install, reverse the removal procedure.

H Insert the shims (distributed on both sides of the

top of the cylinder) until a clearance of 1 ± 2 mm
is obtained.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.

Inside bushings: ASL800050

H Insert the shims (distributed on both sides of the

top of the piston rod) until a clearance of 1 ± 2
mm is obtained.

. Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
H After bleeding the air, switch off engine and check
oil level in the tank.

30-206 PW110R-1
REMOVAL AND INSTALLATION BUCKET

REMOVAL OF BUCKET
Lower the bucket to the ground, resting with its back
on a flat surface. 7
4
1 - Take out the safety pin (1) and the connecting pin (2)
between bucket (3) and tie-rod (4).
6
2
5
2 - Take out the safety pin (5) and the pin (6) that con-
nects the bucket to the arm (7).
1 3

INSTALLATION OF BUCKET RKPA7540

. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance be-

tween bucket (3) and tie-rod (4).

When lining up the hole and the pin, let the en-
gine turn at low idling speed.
Do not insert fingers into the holes to check
alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (on

both sides) between the bucket (3) and the arm
(7), until a play of 0.5 ± 1 mm is obtained.

PW110R-1 30-207
REMOVAL AND INSTALLATION ARM

REMOVAL OF ARM

1 - Remove the bucket (For details, see «REMOVAL OF

BUCKET»).
2 - Remove the bucket cylinder. (For details, see «RE- 1
MOVAL OF BUCKET CYLINDER»).
3 - If the machine is designed for the application of op-
tional front equipment, disconnect the boom (or the 2-
piece boom), the tubes (1) and remove the supports (2).

2
RKPA7550

4 - Loosen the ring nut (3) and pin (4) and remove the
thrust lever (5).
3

4
RKPA7560

5 - Raise the boom and bring the arm (6) into a vertical
position and then lower it to the ground.
6

RKP09740

6 - Switch off the engine and release residual pressures.

10 7
7 - Put the arm cylinder (7) in a sling, remove the screw 9
(8) and take out the pin (9).
8 - Start the engine and fully retract the piston (10).

H To hold the piston rod in its fully retracted posi-

tion, tie it with wire.
8

RKPA7570

30-208 PW110R-1
REMOVAL AND INSTALLATION ARM

9 - Rest the cylinder (7) on a block (A).

10 - Switch off the engine. 7

A
RKPA7580

11 - Connect the arm (6) to the hoisting tackle and apply

slight tension to the cable.
12 - Remove the cotter-pin (11) and the nut (12).

12
11

RKPA7590

13 - Take out the screw (13) and pull out the pin (14).
14 - Lift off the arm (6). 6
Arm L=1850: 178 kg
Arm L=2000: 200 kg

14

13
RKPA7600

15 - Start the engine and, for reasons of safety, lower the

boom or 2-piece boom until it rests on the ground.

RKPB1260

PW110R-1 30-209
REMOVAL AND INSTALLATION ARM

INSTALLATION OF ARM

. To install, reverse the removal procedure.

Inside bushings: ASL800050

H Insert shim

When aligning the positions between holes and

pin, do not insert fingers into the hole to check
the alignment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston) until a clear-
ance of 1 ± 2 mm is obtained.
When aligning the positions between holes and
pin, let the engine run at minimum idling.
Do not insert fingers into the holes to check the
alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis-
tributed on both sides) until a clearance of 0.5 ±
1 mm is obtained.
When aligning the positions between hole and
pin, do not insert fingers into the holes to check
the alignment.

30-210 PW110R-1
REMOVAL AND INSTALLATION 2nd BOOM

REMOVAL OF 2nd BOOM

1 - Remove the bucket, the bucket cylinder, the arm cy-

linder and the arm. For details see:
. REMOVAL OF BUCKET
1
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
2 - Start the engine and bring the 2-piece boom (1) into a
vertical position. Lower it until it rests on the ground
and switch off the engine.
RKPB0891

3 - Put a sling round the RH cylinder (2) of the 2-piece

boom and remove the nut (3), the screw (4) and the 2 2
shim (5).
4 - Slide out the pin (6) that connects the RH cylinder (2)
to the 2-piece boom (1) until the piston rod is comple- 5
tely disconnected. 5
3

6 4
RKPA7211

5 - Start the engine and completely retract the piston rod

of the RH cylinder.
H To hold the piston rod in a fully retracted position,
tie it with wire and switch off the engine.
6 - Lower the cylinder until it is in a vertical position, leav-
ing the boom tied up.
7 - Repeat these operations from point 3 to point 6 in or-
der to disconnect the LH cylinder (7).

RKPA7221

8 - Hook the 2-piece boom to the hoisting tackle.

9 - Remove the screws and take out the pin (8).

10 - Take off the 2-piece boom. 8

nd
2 boom: 278 kg

7
RKPA7610

PW110R-1 30-211
REMOVAL AND INSTALLATION 2nd BOOM

INSTALLATION OF 2nd BOOM

. To install, reverse the removal procedure.

Self-locking nut: 118 Nm.

Inside bushings: ASL800050.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.

. Insert the shims (distributed on both sides of the

boom) until a clearance of 0.5 ± 1 mm is obtained.
. Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
H After bleeding the air, switch off the engine and
check the oil level in the tank.

30-212 PW110R-1
REMOVAL AND INSTALLATION BOOM (1-piece boom)

INSTALLATION OF BOOM (1-piece boom)

1 - Remove the arm (For details, see «REMOVAL OF 2

ARM»).
2 - Remove the arm cylinder. (For details, see «RE-
MOVAL OF ARM CYLINDER»).
3 - Start the engine and lower the boom to the ground.
4 - Switch off the engine and move the PPC valve sev-
eral times to release pressures in the cylinder. 3
5 - Put the boom cylinder in a sling (1).
6 - Take out the screw (2) and pull out the pin (3). 4

1
7 - Start the engine and fully retract the piston (4). RKPA7162

H To hold the piston rod in its fully retracted posi-

tion, tie it with wire.
8 - Switch off the engine and release all pressures. (For 9
details, see «20. TESTING AND ADJUSTMENTS»).
9 - Lower the piston until it is resting on blocks (A).
10 - Remove the overload sensor. (For details, see «RE- 1
MOVAL OF OVERLOAD SENSOR»).
8
11 - Put the boom (5) in a sling, using the attachment hole
in the arm cylinder. Apply slight tension to the cable.
12 - Disconnect the front equipment hoses (6) and plug
them. Also plug the rigid tubes (7).
13 - Take out the screw (8) and pull out the pin (9). A
14 - Lift off the boom (5).
RKPA7171

Boom: 405 kg

INSTALLATION OF BOOM 5
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 1 ± 2 mm is obtained.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment. RKPB1350

Inside bushings: ASL800050

7 7
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the boom) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine to circulate the oil and bleed air from
the cylinders.
6 6
H After bleeding the air, switch off the engine and
check the oil level in the tank.

RKPA7481

PW110R-1 30-213
REMOVAL AND INSTALLATION BOOM (2-piece boom)

INSTALLATION OF BOOM (2-piece boom)

1 - Remove the bucket, the bucket cylinder, the arm cy-

linder, the arm, and the 2-piece boom. For details
see:
. REMOVAL OF BUCKET
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
. REMOVAL OF 2-PIECE BOOM

2 - Replace the fulcrum pin (1) of the 2-piece boom and

secure it with the proper screws.
2 1
3 - Manoeuvre the boom (2) until the fulcrum pin is rest-
ing on a stand (A), 1.60 m high.
A
4 - Switch off the engine and release any residual pres-
sures in the boom cylinder.
5 - Remove the 2-piece boom cylinders (3) and let the
3
boom cylinder (4) rest on a stand. (For details, see
«REMOVAL OF 2-PIECE BOOM CYLINDER»).
4
RKPB0180

6 - Remove the overload sensor. (For details, see «RE-

MOVAL OF OVERLOAD SENSOR»).
7
7 - Disconnect the six connecting hoses of the front work 6
5
equipment cylinders (5) and the two tubes (6) of the
optional equipment.
H Plug the hoses and rigid tubes to prevent entry of im-
purities.

RKPA7521

8 - Take out the four screws (7) and lift away the com-
plete rack of tubes. 7

RKPA7440

30-214 PW110R-1
REMOVAL AND INSTALLATION BOOM (2-piece boom)

9 - Screw four M10 UNI 2947 eyebolts (8) as far as they

will go into the holes of the rack of tubes.
8 10
10 - Attach the hoisting tackle to the eyebolts and apply
slight tension to the cables.
11 - Take out the screws (9) and remove the pin (10).
12 - Lift away the entire boom (2).
Boom: 314 kg.
2
9
RKPB0900

INSTALLATION OF BOOM
(2-piece boom)
. To install, reverse the removal procedure.

Inside bushings: ASL800050

Do not insert fingers in the holes in order to

check the alignment.

H Insert shims on both sides of the boom, until a

clearance of 0.5 ± 1 mm is obtained.
. Start the engine to let the oil circulate and bleed air
from the cylinders.
H After bleeding the air, switch off the engine and
check the level in the oil tank.

PW110R-1 30-215
REMOVAL AND INSTALLATION SWING BRACKET

REMOVAL OF SWING BRACKET

Extend the work equipment fully and rest it on the
ground.
1 - Remove the boom cylinder (For details, see «RE-
MOVAL OF BOOM CYLINDER»). 1
2 - Remove the front work equipment. (For details see H1
«REMOVAL OF WORK EQUIPMENT»).
3 - Disconnect boom swing cylinder.
4 - Attach the swing bracket to the hoisting tackle (1) and
apply slight tension to the cable.
5 - Place a jack (3) beneath the lower pin (2).
6 - Take out the retaining screws and pull out the pin (2). RKPB2110

7 - Take out the retaining screws and, with the help of a

lever, pull out the upper pin (4).
8 - Lift out the swing bracket (1).
Swing bracket: 230 kg

INSTALLATION OF SWING 3
BRACKET
RKPA7650

. To install, reverse the removal procedure.

Lower pin: ASL800050

Screw: Loctite 262

Upper pin: ASL800050

Screw: Loctite 262
4

H Insert the adjustments to a given clearance be-

tween the chassis and the support.
Unit: mm

Pos. Code No. Thick- Quantity RKPA7660

ness
1 21D-09-39140 5 2
2 21D-09-39130 0.5 2
2
Supporting surfaces and adjustments to a
given clearance: ASL800050

H Insert the shims (spread over two sides of the pis-

ton) until a clearance of 1 ± 2 mm is obtained.
2
When aligning hole and pin, engine should be idle.
Do not introduce fingers into the holes to check align-
ment.
1
RKP07490

30-216 PW110R-1
REMOVAL AND INSTALLATION BLADE AND OUTRIGGERS

REMOVAL OF BLADE AND OUTRIGGERS

1 - Raise the blade (1) or the outriggers (2) and place 1

blocks (A) under the arms (3); Lower the equipment
until the arms rest lightly on the blocks.

A
RKPB0210

2 - Attach the blade (1) or the outriggers (2) to the lifting

equipment and apply slight tension to the cables.
3
3 - Take out the screws and remove the pins (4).

4 - Remove the blade (1) or the outriggers (2).

4

Blade: 217 kg
Outrigger: 42 kg
A

2
RKPB0220

INSTALLATION OF BLADE
AND OUTRIGGERS
. To install, reverse the removal procedure.

Internal bushings: ASL800050

Do not insert fingers into the holes to check on

alignment.

H Insert the shims on both sides of the arm, in order

to obtain a clearance of 0.5 ± 1 mm.

PW110R-1 30-217
REMOVAL AND INSTALLATION BLADE AND OUTRIGGER ARMS

REMOVAL OF BLADE AND OUTRIGGER ARMS

1 - Remove the blade or the outriggers.

(For details, see «REMOVAL OF BLADE AND OUT-
RIGGERS»).
2 - Take out the screw (1) and remove the dowel (2).

3 - Start the engine and retract the piston (3). Stop the
engine. 2
3

1
RKPB0230

4 - Attach the arm (4) to the hoisting equipment and ap-

ply slight tension to the cables. 5
5 - Take out the screw (5) and remove the dowel (6).
6
6 - Remove the arm (4).

Arm: 100 kg
4

INSTALLATION OF BLADE RKPB0240

AND OUTRIGGERS ARMS

. To install, reverse the removal procedure.

Internal bushings: ASL800050

Do not insert fingers into the holes to check on

alignment.

H Insert the shims on both sides of the arm, in order

to obtain a clearance of 0.5 ± 1 mm.

30-218 PW110R-1
GROUP 40
40-28 PC15R-8
 MAINTENANCE STANDARD
P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2
Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3
Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
Rear axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 20
Control valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
Swing motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 33
Swivel joint . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 34
PW110R-1
Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 35
Travel motor brake valves . .. . . . .. . . . . .. . . . . .. . . . .. . . . 36
Servocontrol feed unit . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 37
Travel PPC valve .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
PPC valve . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
Blade safety valve. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Cylinders . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 42
Work equipment (1-piece boom) . . . . . .. . . . . .. . . . .. . . . 44
Work equipment (2-piece boom) . . . . . .. . . . . .. . . . .. . . . 46
40-1
P.T.O.

44 ± 54 Nm

85 Nm

70 Nm

44 ± 54 Nm
RKP05341

40-2 PW110R-1
FRONT AXLE

Differential
24 ± 26 Nm 128 ± 142 Nm
with Loctite 242 A with Loctite 242

Loctite 242

24 ± 26 Nm
A 1 2

500 ± 570 Nm 1
with Loctite 242
Sezione B - B

280 ± 210 Nm
with Loctite 270 B
35 ± 50 Nm

35 ± 50 Nm

3
Section
Sezione A
A -±AA RKP05560

Unit: mm

No . Check item Criteria Remedy

Backlash of crown wheel Standard clearance Clearance limit

1 Adjust
and pinion 0.18 ± 0.23 Ð

Tightening torque of slew

2 120 ± 170 Ncm
differential
Adjust
Tightening torque of slew
3 20 ± 40 Ncm
pinion (w/o seal)

PW110R-1 40-3
Brakes

A
3

A
Section
Sezione A
A±- AA

283 ± 312 Nm

35 ± 50 Nm

2 5 ± 7 Nm
with Loctite 270

RKP05580

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit
Free Installated Installated Free Installated
1 Returning spring
length length load length load
Ð Ð Ð Ð Ð
Standard thickness Min. thickness
2 Disk thickness Replace
Ð Ð
Standard clearance Max. clearance
3 Disk clearance Adjust
0.75 Ð

40-4 PW110R-1
Final drive

128 ± 142 Nm
1
1st tightening: 120 Nm
60 ± 70 Nm 2nd tightening: 255 ± 285 Nm
with Loctite 242 with Loctite 242

Tecnolupe seal 101

40 ± 50 Nm

128 ± 142 Nm
RKP05590

Unit: mm

No . Check item Criteria Remedy

Hub torque
1 5 ± 25 Nm Adjust
(with sealing ring)

PW110R-1 40-5
Steering cylinder

240 ± 270 Nm
with Loctite 242

116 ± 128 Nm
RKP05670

Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between shaft size clearance limit
1 Shaft Hole Replace
and bushing
45 Ð Ð Ð Ð

40-6 PW110R-1
Steering and convergency angle

28° 28°

A A

47,2

Detail B B
Particolare
260 ± 290 Nm
Section
SezioneAA±- A
A

1920±1
1000
1000

87,7 87,7

1920±1

RKP05660

PW110R-1 40-7
TRANSMISSION

25 Nm
A
49 ± 51 Nm
with Loctite 510

B
B

35 ± 50 Nm

49 ± 51 Nm
A 49 ± 51 Nm
35 ± 50 Nm

24 ± 26 Nm

Loctite 510 30 Nm
80 ± 100 Nm

Section
Sezione A
B±- BA RKP05610

40-8 PW110R-1
 Loctite 510

Loctite 510

280 ± 310 Nm
with Loctite 310 2

49 ± 51 Nm
with Loctite 242
Loctite 510
Loctite 510

25 ± 26 Nm RKP05620

Unit: mm

N-
Check item Criteria Remedy
o.

Standard clearance Clearance limit

1 Bearing clearance
0.25 ± 0.35 Ð Adjust

2 Bearing clearance 0.20 ± 0.30 Ð

PW110R-1 40-9
REAR AXLE
Differential

24 ± 26 Nm 128 ± 142 Nm
with Loctite 242 A with Loctite 242
Loctite 242

24 ± 26 Nm

A 1 2

1
SezioneBB±- B
Section B

B
35 ± 50 Nm

35 ± 50 Nm

900 ± 1000 Nm
3 with Loctite 270 RKP05570
Section
SezioneAA±- A
A

Unit: mm

N-
Check item Criteria Remedy
o.

Backlash of crow wheel Standard clearance Clearance limit

1 Adjust
and pinion 0.18 ± 0.23

Tightening torque of slew

2 120 ± 170 Ncm
differential
Adjust
Tightening torque of slew
3 20 ± 40 Ncm
pinion (w/o seal)

40-10 PW110R-1
 A
Brakes 3

A
Section
SezioneAA±- A
A

283 ± 312 Nm

35 ± 50 Nm Section
SezioneBB±- B
B

2 5 ± 7 Nm
with Loctite 270

B A B

1
35 ± 50 Nm RKP05600
with Loctite 270
Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit
Free Installated Installated Free Installated
1 Returning spring
length length load length load
Ð Ð Ð Ð Ð
Standard thickness Min. thickness
2 Disk thickness Replace
Ð 4.5
Standard clearance Max. clearance
3 Disk clearance Adjust
0.75 Ð

PW110R-1 40-11
Parking brake and cylinder

25 ± 30 Nm
with Loctite 242

24 ± 26 Nm

20 ± 25 Nm

2
20 ± 25 Nm

3 a
50 ± 60 Nm
RKP05630

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit
Replace if
Free Installated Installated Free Installated
1 Returning spring damage or
length length load length load
deformed
Ð Ð Ð Ð Ð
2 Clearance with 10 kg force 0 Ð Set
Check
brake
3 Piston jut 4±5
thickness
and adjust

40-12 PW110R-1
Final drive

128 ± 142 Nm
1
1st tightening: 120 Nm
60 ± 70 Nm 2nd tightening: 255 ± 285 Nm
with Loctite 242 with Loctite 242

Tecnolupe seal 101

40 ± 50 Nm

128 ± 142 Nm
RKP05590

Unit: mm

No . Check item Criteria Remedy

Hub torque
1 5 ± 25 Nm Adjust
(with seal)

PW110R-1 40-13
Steering cylinder

240 ± 270 Nm
with Loctite 242

116 ± 128 Nm
RKP05640

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between shaft size clearance limit
1 Shaft Hole Replace
and bushing
45 Ð Ð Ð Ð

40-14 PW110R-1
Steering and convergency angle

28° 28°

A A

47,2

Detail B B
Particolare

260 ± 290 Nm
Section
SezioneAA±- A
A

1920±1
1000
1000

87,7 87,7

1920±1
RKP05650

PW110R-1 40-15
SWING CIRCLE

290 Nm

Section
SezioneCC ±- C
C

Section
SezioneAA±- A
A
1
290 Nm
Section
Sezione B
B -±BB
D

290 Nm
A
D

C
Section
SezioneDD±- D
D

B
B

Section
SezioneEE±- E
E
A
RKP04690

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Axial bearing clearance Replace
0.3 ± 1.2 3

40-16 PW110R-1
 PAGE INTENTIONALLY
LEFT BLANK

PW110R-1 40-17
SWING MACHINERY

86 Nm

30 ± 40 Nm

85 Nm

3
2
4
950 ± 1050 Nm
with Loctite 243
1
90 Nm
6

ASL800050

RKP04260

40-18 PW110R-1
 Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

Backlash between No. 2
1
planetary gear and housing
0.18 0.38

Backlash between No. 1

2 0.18 0.38
planetary gear and housing

Backlash between
3 No. 1 sun gear and 0.12 0.33
No. 1 planetary gear

Backlash between
4 No. 2 sun gear and 0.12 0.33
No. 2 planetary gear
Replace
Backlash between swing
5 0.3 ± 0.5 1
pinion and swing circle gear

Standard size Size limit

Wear of swing pinion shaft
6 surface contacting with oil
seal + 0.012
é 70 ± 0.007 é 70 ± 0.25

Standard size Repair limit

Free length Installed Installed Free length Installed

7 Brake spring
x O.D. length load x O.D. load

32x10 23.5 33 kg 29x10 30 kg

PW110R-1 40-19
HYDRAULIC PUMP

66.2w7.4 Nm 11.25w1.45 Nm

68.6w9.8 Nm 30.5w3.5 Nm

66.2w7.4 Nm 17.2w2.5 Nm

110.3w12.3 Nm

View Y
Vista Y
13.25w1.45 Nm 144.55w12.25 Nm 100.45w12.25 Nm

RKP03730

40-20 PW110R-1
 PAGE INTENTIONALLY
LEFT BLANK

PW110R-1 40-21
CONTROL VALVE

A
C B
D A

AA AA
O O
N N

M M
L L

K K
J J

H H

G G

F F
P
E E xx

BB BB

C D A
Pu
P B

9.8 ± 12.7 Nm 29.4 ± 39.2 Nm

1 3

4 2

1st tightening: 19.6 ± 29.4 Nm View

Vista A
A
(2 ± 3 kgm) Tightening following
2nd tightening: 39.2 ± 49 Nm 1-2-3-4 order
(4 ± 5 kgm) in 3 times
3rd tightening: 58.8 ± 73.5 Nm
(6 ± 7.5 kgm)

Vista B
View B RKP03280

40-22 PW110R-1
 39 ± 49 Nm 39 ± 49 Nm

39 ± 49 Nm 39 ± 49 Nm

39 ± 49 Nm
39 ± 49 Nm

107.8 ± 147 Nm
RKP03290
Section
SezioneA
A±- AA

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free
Installed Installed Installed
Cooler by-pass length Free length
1 length load load Replace
valve spring x ée

231.4 N
Ð 33 Ð Ð
(23.6 kg)

PW110R-1 40-23
 1 1

1 1

1 1

1 1

1 1

1 2

1 3

1 1

1 1

3 3

Section
SezioneBB±- B
B RKP03370

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Spool return spring
Free
(Work equipment, swing, Installed Installed Free length Installed
length
1 boom, arm, bucket, length load x O.D. load
x O.D.
boom swing, blade,
travel, equipment)
34.7 N
Ð 40.5 Ð Ð Replace
(3.5 kg)

Spool return spring 54.6 N

2 Ð 40.5 Ð Ð
(Arm) (5.6 kg)

Spool return spring 4.9 N

3 Ð 40.5 Ð Ð
(Boom, swing) (5 kg)

40-24 PW110R-1
 118 ± 162 Nm
1

1
4
2

RKP03300
Section
SezioneCC ±- C
C

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Installed

Pressure compensation Free length
1 x O.D. length load load
valve spring
13.72 N
Ð 14.5 Ð Ð
(1.4 kg)
Replace
Pressure compensation 55.9w3 N
2 Ð 21.5 Ð Ð
valve spring (boom) (5.7w0.34 kg)

Spool (boom raise at joining 49 N

3 Ð 36 Ð Ð
pump discharge) (5 kg)

Flow compensation valve 27.6 N

4 Ð 20 Ð Ð
spring (boom) (2.82 kg)

PW110R-1 40-25
 24.5 ± 34.3 Nm

58.8 ± 78.5 Nm

Section
SezioneDD±- D
D RKP03310

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

Free length
1 Check valve spring length length load load
Replace
3.92 N
Ð 22 Ð Ð
(0.4 kg)

Check valve spring 13.7 N

2 Ð 11.5 Ð Ð
(Swing) (1.4 kg)

40-26 PW110R-1
 107.8 ± 147 Nm

1
49 ± 59 Nm

Section
SezioneBB
BB ±- BB
BB
RKP02821

19.6 ± 27.4 Nm 65.7 ± 85.3 Nm

with Loctite 638
Section E -±EE
Sezione E RKP02811

Unit: mm

No . Check item Criteria Remedy

Free length Installed Installed Installed

Free length
x O.D. length load load
1 Lift check valve spring Replace
138 N
Ð 46.4 Ð Ð
14.1 kg

PW110R-1 40-27
 34 ± 44 Nm

88.3 ± 107.9 Nm

34 ± 44 Nm

19.6 ± 27.5 Nm

34 ± 44 Nm

RKP02841
Section
SezioneAA
AA ±- AA
AA

39 ± 49 Nm

49 ± 59 Nm

Section
SezioneFF±- F
F RKP02831

40-28 PW110R-1
 RKP02851

Section
SezioneGG±- G
G

14.7 ± 19.6 Nm 14.7 ± 19.6 Nm

with Loctite 638 with Loctite 638

Section
Sezione H
H±- HH RKP02861

PW110R-1 40-29
 14.7 ± 19.6 Nm 14.7 ± 19.6 Nm
with Loctite 638 with Loctite 638

RKP02871
Section
SezioneJ J±- JJ

14.7 ± 19.6 Nm
with Loctite 638

Section
SezioneKK±- K
K RKP02881

40-30 PW110R-1
 14.7 ± 19.6 Nm
with Loctite 638

Section
SezioneL L-L
±L RKP03320

14.7 ± 19.6 Nm
with Loctite 638

Section M M-M
Sezione ±M RKP03330

PW110R-1 40-31
 14.7 ± 19.6 Nm
with Loctite 638

Section
SezioneNN-N
±N RKP03340

14.7 ± 19.6 Nm
with Loctite 638

30 ± 25 Nm

RKP03350
Section
SezioneOO-O
±O

147 ± 186 Nm

RKP03360
Section
Sezione P ±P
P-P

40-32 PW110R-1
SWING MOTOR

10w1 Nm

10w1 Nm

40w4 Nm
1

90w10 Nm

RKP03640

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free
Installed Installed Installed
1 Check valve spring length Free length
length load load
x ée
Replace
Ð Ð Ð Ð Ð

Check valve spring

2 Ð Ð Ð Ð Ð
(Swing)

PW110R-1 40-33
SWIVEL JOINT

RKP03790

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Backlash between rotor size Shaft Hole clearance limit
1 Replace
and stator
± 0.02 +0.10 0.12±
Ð 0.25
± 0.05 +0.15 0.20

40-34 PW110R-1
TRAVEL MOTOR

A
.......... Nm

2 .......... Nm

1
3

.......... Nm
.......... Nm
A .......... Nm
.......... Nm
.......... Nm

Section
SezioneAA±- A
A

RKP11200

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Free
Installed Installed Free Installed
1 Valve guide retain spring length
length load length load

Ð Ð Ð Ð Ð

2 Measure piston spring Ð Ð Ð Ð Ð

3 Centre spring of cylinder unit Ð Ð Ð Ð Ð

PW110R-1 40-35
TRAVEL MOTOR BRAKE VALVES

1 2 200 Nm
20 Nm 100 Nm

20 Nm

600 Nm

200 Nm
650 Nm

10 Nm 4

RKP04560

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

1 Pilot valve spring Free length Replace
length length load load

Ð Ð Ð Ð Ð

2 Main valve spring Ð Ð Ð Ð Ð Replace

3 Piston return spring Ð Ð Ð Ð Ð Replace

4 Single-acting valve spring Ð Ð Ð Ð Ð Replace

5 Check valve spring Ð Ð Ð Ð Ð Replace

40-36 PW110R-1
SERVOCONTROL FEED UNIT

3 22.0w4.9 Nm 29.4w4.9 Nm

9.8w2 Nm

1 2 9.8w2 Nm 4
66.2w7.3 Nm

Section
SezioneAA±- A
A Section
SezioneBB±- B
B
RKP04090

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

Free length
1 Pilot valve spring length length load load

19.6 N 17.7 N
19.2x7.2 16.1 Ð
(2 kg) (1.8 kg)
Replace
Reduction box pilot 20.6 N 18.6 N
2 16.5x7.2 12.7 Ð
valve spring (2.1 kg) (1.9 kg)

199.8 N 186.2 N
3 Spring 71x18 59 Ð
(20.4 kg) (19 kg)

61.7 N 58.8 N
4 Relief valve spring 16.1x7.8 13.4 Ð
(6.3 kg) (6 kg)

PW110R-1 40-37
TRAVEL PPC VALVE

1.8 Nm

1 2

RKP03720

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

1 Metering spring Free length Replace
length length load load

Ð Ð Ð Ð Ð

2 Centering spring Ð Ð Ð Ð Ð Replace

40-38 PW110R-1
PPC VALVE

BOOM, ARM, BUCKET, SWING

112.8w14.7 Nm

13.2w1.5 Nm

1
44.1w4.9 Nm

Section
Sezione A
A -±AA Section
SezioneBB±- B
B

8.3w2.5 Nm

2
Section
SezioneDD±- D
D

3
6.4w2.5 Nm

Section
SezioneCC±- C
C

Section
SezioneEE±- E
E RKP01331

Unit: mm

No Check item Criteria Remedy

Standard size Repair limit
Free length Installed Installed Free length Installed
Metering spring
1 x O.D. length load x O.D. load
(For P3 and P4 port)
Replace if
9.8 N 7.8 N
38.7x15.5 34 Ð damaged
(1.0 kg) (0.8 kg)
or
Centering spring 17.6 N 13.7 N deformed
2 42.5x15.5 34 Ð
(For P1 and P2 port) (1.8 kg) (1.4 kg)
15.2 N 11.8 N
3 Metering spring 26.1x8.2 24.7 Ð
(1.55 kg) (1.2 kg)

PW110R-1 40-39
BLADE, OUTRIGGER, BOOM SWING, 2nd BOOM

RKP04110

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Installed

Free length
1 Centering spring x O.D. length load load
Replace
124.5 N 100.0 N
33.9x15.3 28.4 Ð
(12.7 kg) (10.2 kg)

16.7 N 13.7 N
2 Metering spring 22.7x8.1 22.0 Ð
(1.7 kg) (1.4 kg)

40-40 PW110R-1
BLADE SAFETY VALVE

83 Nm

33 Nm

RKP04580

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Installed

1 Check valve spring Free length Replace
x O.D. length load load

16.5 11.12 2.464 kg 13.5 1.1 kg

PW110R-1 40-41
CYLINDERS

BOOM BUCKET, BOOM SWING, OUTRIGGERS OR BLADE

49 Nm
49 Nm
RKP04370

ARM

88 Nm
1 with Loctite 262

49 Nm 2940w196 Nm
with Loctite 262
RKP04360

2nd BOOM

3430w284 Nm
1 with Loctite 262

49 Nm
with Loctite 262
RKP04350

40-42 PW110R-1
 Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Shaft Hole

± 0.030 0 0.030
Bucket 60 0.326
± 0.060 + 0.166 0.226

± 0.05 0 0.025
2nd boom 50 0.316
± 0.025 + 0.166 0.216
Clearance
between
1 ± 0.030 0 0.030
piston rod Boom swing 60 0.326
and head ± 0.060 + 0.166 0.226

Outrigger and ± 0.030 0 0.030

60 0.326
blade ± 0.060 + 0.166 0.226

± 0.030 0 0.030
Boom 70 0.326
± 0.060 + 0.166 0.226

± 0.030 0 0.030
Arm 60 0.326
± 0.060 + 0.166 0.226

± 0.05 + 0.119 + 0.13

Bucket 50 1.0
± 0.089 + 0.08 + 0.208

± 0.05 + 0.119 + 0.13

2nd boom 50 1.0
± 0.089 + 0.08 + 0.208

± 0.05 + 0.119 + 0.13

Clearance Boom swing 50 1.0
± 0.089 + 0.08 + 0.208
between cylinder
2
head bushing
and pin Outrigger and ± 0.05 + 0.119 + 0.13
50 1.0
blade ± 0.089 + 0.08 + 0.208

± 0.06 + 0.146 + 0.16

Boom 60 1.0
± 0.106 + 0.1 + 0.252

± 0.05 + 0.119 + 0.13

Arm 50 1.0
± 0.089 + 0.08 + 0.208

± 0.05 + 0.119 + 0.13

Bucket 50 1.0
± 0.089 + 0.08 + 0.208

± 0.06 + 0.146 + 0.16

2nd boom 60 1.0
± 0.106 + 0.1 + 0.252

± 0.05 + 0.119 + 0.13

Clearance Boom swing 50 1.0
± 0.089 + 0.08 + 0.208
between cylinder
3
bottom bushing
and pin Outrigger and ± 0.05 + 0.119 + 0.13
50 1.0
blade ± 0.089 + 0.08 + 0.208

± 0.06 + 0.146 + 0.16

Boom 60 1.0
± 0.106 + 0.1 + 0.252

± 0.05 + 0.119 + 0.13

Arm 50 1.0
± 0.089 + 0.08 + 0.208

PW110R-1 40-43
WORK EQUIPMENT

(1-piece boom)

D
G
A B

7 6 4 5 3

Section
Sezione A
A -±AA Section
SezioneBB±-BB Section
SezioneCC±- C
C

Section
SezioneDD±- D
D Section
SezioneEE±- E
E Section
SezioneFF ±- FF

RKP05730

40-44 PW110R-1
 9

Section
SezioneG
G ±- G
G
RKP05740

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between swing size clearance limit
Shaft Hole
1 bracket-to-revolving
frame mounting and pin bushing ±0.072 +0.145 0.116±
100 0.8
±0.0126 +0.044 0.271
Clearance between boom-to-swing ±0.060 +0.047 0.107±
2 60 0.8
bracket mounting pin and bushing ±0.106 +0.127 0.233
Clearance between boom-to-arm ±0.060 +0.047 0.107±
3 60 0.8
mounting pin and bushing ±0.106 +0.127 0.233
Clearance between bucket
±0.050 +0.095 0.066±
4 cylinder-to-link mounting pin 50 1
±0.089 +0.016 0.184
and link bushing Replace
Clearance between arm-to-link ±0.050 +0.095 0.066±
5 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-arm ±0.050 +0.095 0.066±
6 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-link ±0.050 +0.095 0.066±
7 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bushing and ±0.050 +0.095 0.066±
8 50 1
connecting pin of outrigger ±0.089 +0.016 0.184
Clearance between bushing and ±0.050 +0.095 0.066±
9 50 1
bracket pin ±0.089 +0.016 0.184

PW110R-1 40-45
WORK EQUIPMENT

(2-piece boom)
D

F H
F

A B

7 6 4 5 3

Section
SezioneAA±- A
A Section
SezioneBB ±- B
B Section
SezioneC C± -CC

8 2

Section
SezioneD
D±- DD Section
SezioneEE±- EE Sezione F
Section F -±FF

RKP05760

40-46 PW110R-1
 9 10

Section G -±GG
Sezione G Section
SezioneHH±- H
H
RKP05750

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between swing size clearance limit
Shaft Hole
1 bracket-to-revolving
frame mounting and pin bushing ±0.072 +0.145 0.116±
100 0.8
±0.126 +0.044 0.271
Clearance between boom-to-swing ±0.060 +0.047 0.107±
2 60 0.8
bracket mounting pin and bushing ±0.106 +0.127 0.233
Clearance between boom-to-arm ±0.060 +0.047 0.107±
3 60 0.8
mounting pin and bushing ±0.106 +0.127 0.233
Clearance between bucket
±0.050 +0.095 0.066±
4 cylinder-to-link mounting pin 50 1
±0.089 +0.016 0.184
and link bushing
Clearance between arm-to-link ±0.050 +0.095 0.066± Replace
5 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-arm ±0.050 +0.095 0.066±
6 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-link ±0.050 +0.095 0.066±
7 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bushing and ±0.060 +0.047 0.107±
8 60 0.8
connecting pin of 2nd boom ±0.106 +0.127 0.233
Clearance between bushing and ±0.050 +0.095 0.066±
9 50 1
connecting pin of outrigger ±0.089 +0.016 0.184
Clearance between bushing and ±0.060 +0.047 0.066±
10 60 1
bracket pin ±0.106 +0.127 0.184

PW110R-1 40-47
40-48 PW110R-1