Retroexcavadora WB146

CEBM016503
Shop
Manual
WB146-5
BACKHOE LOADER
SERIAL NUMBERS WB146-5 A23001 and up
ENGINE 4D102LE-2
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2010 Komatsu

Printed in U.S.A.
Komatsu America Corp.
March 2010
FOREWORD CONTENTS
12
CONTENTS 00
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
90 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 D WB146-5
FOREWORD
The affected pages are indicated by using the following marks. It Mark Indication Action
is requested that necessary actions be taken to these pages accord-
ing to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 d ● 01-1 d ● 10-17 d ● 10-46 d
● 00-2 d ● 01-2 d ● 10-18 d ● 10-47 d
● 00-2-1 d ● 01-3 d ● 10-19 d ● 10-48 d
● 00-2-2 d ● 01-4 d ● 10-20 d ● 10-49 d
● 00-2-3 d ● 01-5 d ● 10-21 d ● 10-50 d
● 00-2-4 d ● 01-6 d ● 10-22 d ● 10-51 d
● 00-2-5 d ❍ 01-7 d ● 10-23 d ● 10-52 d
● 00-2-6 d ❍ 01-8 d ● 10-24 d ● 10-53 d
00-3 ❍ 01-9 d ● 10-25 d ● 10-54 d
00-4 ❍ 01-10 d ● 10-26 d ● 10-55 d
00-5 ❍ 01-11 d ● 10-27 d ● 10-56 d
00-6 ❍ 01-12 d ● 10-28 d ● 10-57 d
00-7 ● 10-29 d ● 10-58 d
00-8 ● 10-1 d ● 10-30 d ● 10-59 d
00-9 ● 10-2 d ● 10-31 d ● 10-60 d
00-10 ● 10-3 d ● 10-32 d ● 10-61 d
00-11 ● 10-4 d ● 10-33 d ● 10-62 d
00-12 ● 10-5 d ● 10-34 d ● 10-63 d
00-13 ● 10-6 d ● 10-35 d ● 10-64 d
00-14 ● 10-7 d ● 10-36 d ● 10-65 d
00-15 ● 10-8 d ● 10-37 d ● 10-66 d
00-16 ● 10-9 d ● 10-38 d ● 10-67 d
00-17 ● 10-10 d ● 10-39 d ● 10-68 d
00-18 ● 10-11 d ● 10-40 d ● 10-69 d
00-19 ● 10-12 d ● 10-41 d ● 10-70 d
00-20 ● 10-13 d ● 10-42 d ● 10-71 d
00-21 ● 10-14 d ● 10-43 d ● 10-72 d
00-22 ● 10-15 d ● 10-44 d ● 10-73 d
● 10-16 d ● 10-45 d ● 10-74 d
WB146-5 WB146-5 00-2-1 3

FOREWORD
● 10-75 d ● 20-11 d ● 20-44 d ● 30-6 d
● 10-76 d ● 20-12 d ● 20-45 d ● 30-7 d
● 10-77 d ● 20-13 d ● 20-46 d ● 30-8 d
● 10-78 d ● 20-14 d ● 20-47 d ● 30-9 d
● 10-79 d ● 20-15 d ● 20-48 d ● 30-10 d
● 10-80 d ● 20-16 d ● 20-49 d ● 30-11 d
● 10-81 d ● 20-17 d ● 20-50 d ● 30-12 d
● 10-82 d ● 20-18 d ● 20-51 d ● 30-13 d
● 10-83 d ● 20-19 d ● 20-52 d ● 30-14 d
● 10-84 d ● 20-20 d ● 20-53 d ● 30-15 d
❍ 10-85 d ● 20-21 d ● 20-54 d ● 30-16 d
❍ 10-86 d ● 20-22 d ● 20-55 d ● 30-17 d
❍ 10-87 d ● 20-23 d ● 20-56 d ● 30-18 d
❍ 10-88 d ● 20-24 d ● 20-57 d ● 30-19 d
❍ 10-89 d ● 20-25 d ● 20-58 d ● 30-20 d
❍ 10-90 d ● 20-26 d ● 20-59 d ● 30-21 d
❍ 10-91 d ● 20-27 d ● 20-60 d ● 30-22 d
❍ 10-92 d ● 20-28 d ❍ 20-61 d ● 30-23 d
❍ 10-93 d ● 20-29 d ❍ 20-62 d ● 30-24 d
❍ 10-94 d ● 20-30 d ❍ 20-63 d ● 30-25 d
❍ 10-95 d ● 20-31 d ❍ 20-64 d ● 30-26 d
❍ 10-96 d ● 20-32 d ❍ 20-65 d ● 30-27 d
● 20-33 d ❍ 20-66 d ● 30-28 d
● 20-1 d ● 20-34 d ❍ 20-67 d ● 30-29 d
● 20-2 d ● 20-35 d ❍ 20-68 d ● 30-30 d
● 20-3 d ● 20-36 d ❍ 20-69 d ● 30-31 d
● 20-4 d ● 20-37 d ❍ 20-70 d ● 30-32 d
● 20-5 d ● 20-38 d ● 30-33 d
● 20-6 d ● 20-39 d ● 30-1 d ● 30-34 d
● 20-7 d ● 20-40 d ● 30-2 d ● 30-35 d
● 20-8 d ● 20-41 d ● 30-3 d ● 30-36 d
● 20-9 d ● 20-42 d ● 30-4 d ● 30-37 d
● 20-10 d ● 20-43 d ● 30-5 d ● 30-38 d
00-2-2 3 WB146-5
FOREWORD
● 30-39 d ● 30-72 d ● 30-105 d ● 30-138 d
● 30-40 d ● 30-73 d ● 30-106 d ● 30-139 d
● 30-41 d ● 30-74 d ● 30-107 d ● 30-140 d
● 30-42 d ● 30-75 d ● 30-108 d ● 30-141 d
● 30-43 d ● 30-76 d ● 30-109 d ● 30-142 d
● 30-44 d ● 30-77 d ● 30-110 d ● 30-143 d
● 30-45 d ● 30-78 d ● 30-111 d ● 30-144 d
● 30-46 d ● 30-79 d ● 30-112 d ● 30-145 d
● 30-47 d ● 30-80 d ● 30-113 d ● 30-146 d
● 30-48 d ● 30-81 d ● 30-114 d ● 30-147 d
● 30-49 d ● 30-82 d ● 30-115 d ● 30-148 d
● 30-50 d ● 30-83 d ● 30-116 d ● 30-149 d
● 30-51 d ● 30-84 d ● 30-117 d ● 30-150 d
● 30-52 d ● 30-85 d ● 30-118 d ● 30-151 d
● 30-53 d ● 30-86 d ● 30-119 d ● 30-152 d
● 30-54 d ● 30-87 d ● 30-120 d ● 30-153 d
● 30-55 d ● 30-88 d ● 30-121 d ● 30-154 d
● 30-56 d ● 30-89 d ● 30-122 d ● 30-155 d
● 30-57 d ● 30-90 d ● 30-123 d ● 30-156 d
● 30-58 d ● 30-91 d ● 30-124 d ● 30-157 d
● 30-59 d ● 30-92 d ● 30-125 d ● 30-158 d
● 30-60 d ● 30-93 d ● 30-126 d ● 30-159 d
● 30-61 d ● 30-94 d ● 30-127 d ● 30-160 d
● 30-62 d ● 30-95 d ● 30-128 d ● 30-161 d
● 30-63 d ● 30-96 d ● 30-129 d ● 30-162 d
● 30-64 d ● 30-97 d ● 30-130 d ● 30-163 d
● 30-65 d ● 30-98 d ● 30-131 d ● 30-164 d
● 30-66 d ● 30-99 d ● 30-132 d ● 30-165 d
● 30-67 d ● 30-100 d ● 30-133 d ● 30-166 d
● 30-68 d ● 30-101 d ● 30-134 d ● 30-167 d
● 30-69 d ● 30-102 d ● 30-135 d ● 30-168 d
● 30-70 d ● 30-103 d ● 30-136 d ● 30-169 d
● 30-71 d ● 30-104 d ● 30-137 d ● 30-170 d
WB146-5 00-2-3 3
FOREWORD
● 30-171 d ● 30-204 d ● 30-237 d ● 30-270 d
● 30-172 d ● 30-205 d ● 30-238 d ● 30-271 d
● 30-173 d ● 30-206 d ● 30-239 d ● 30-272 d
● 30-174 d ● 30-207 d ● 30-240 d ● 30-273 d
● 30-175 d ● 30-208 d ● 30-241 d ● 30-274 d
● 30-176 d ● 30-209 d ● 30-242 d ● 30-275 d
● 30-177 d ● 30-210 d ● 30-243 d ● 30-276 d
● 30-178 d ● 30-211 d ● 30-244 d ● 30-277 d
● 30-179 d ● 30-212 d ● 30-245 d ● 30-278 d
● 30-180 d ● 30-213 d ● 30-246 d ● 30-279 d
● 30-181 d ● 30-214 d ● 30-247 d ● 30-280 d
● 30-182 d ● 30-215 d ● 30-248 d ● 30-281 d
● 30-183 d ● 30-216 d ● 30-249 d ● 30-282 d
● 30-184 d ● 30-217 d ● 30-250 d ● 30-283 d
● 30-185 d ● 30-218 d ● 30-251 d ● 30-284 d
● 30-186 d ● 30-219 d ● 30-252 d ● 30-285 d
● 30-187 d ● 30-220 d ● 30-253 d ● 30-286 d
● 30-188 d ● 30-221 d ● 30-254 d ● 30-287 d
● 30-189 d ● 30-222 d ● 30-255 d ● 30-288 d
● 30-190 d ● 30-223 d ● 30-256 d ● 30-289 d
● 30-191 d ● 30-224 d ● 30-257 d ● 30-290 d
● 30-192 d ● 30-225 d ● 30-258 d ● 30-291 d
● 30-193 d ● 30-226 d ● 30-259 d ● 30-292 d
● 30-194 d ● 30-227 d ● 30-260 d ● 30-293 d
● 30-195 d ● 30-228 d ● 30-261 d ● 30-294 d
● 30-196 d ● 30-229 d ● 30-262 d ● 30-295 d
● 30-197 d ● 30-230 d ● 30-263 d ● 30-296 d
● 30-198 d ● 30-231 d ● 30-264 d ● 30-297 d
● 30-199 d ● 30-232 d ● 30-265 d ● 30-298 d
● 30-200 d ● 30-233 d ● 30-266 d ● 30-299 d
● 30-201 d ● 30-234 d ● 30-267 d ● 30-300 d
● 30-202 d ● 30-235 d ● 30-268 d ● 30-301 d
● 30-203 d ● 30-236 d ● 30-269 d ● 30-302 d
00-2-4 3 WB146-5
FOREWORD
● 30-303 d ● 30-336 d 90-14
● 30-304 d ● 30-337 d 90-15
● 30-305 d ● 30-338 d 90-16
● 30-306 d ● 30-339 d 90-17
● 30-307 d ● 30-340 d 90-18
● 30-308 d ● 30-341 d 90-19
● 30-309 d ● 30-342 d 90-20
● 30-310 d ● 30-343 d 90-21
● 30-311 d ● 30-344 d 90-22
● 30-312 d ❍ 30-345 d 90-23
● 30-313 d ❍ 30-346 d 90-24
● 30-314 d ❍ 30-347 d 90-25
● 30-315 d ❍ 30-348 d 90-26
● 30-316 d ❍ 30-349 d ( ) 90-27 d
● 30-317 d ❍ 30-350 d ( ) 90-28 d
● 30-318 d ❍ 30-351 d
● 30-319 d ❍ 30-352 d
● 30-320 d ❍ 30-353 d
● 30-321 d ❍ 30-354 d
● 30-322 d
● 30-323 d ● 90-1 d
● 30-324 d 90-2
● 30-325 d 90-3
● 30-326 d 90-4
● 30-327 d 90-5
● 30-328 d 90-6
● 30-329 d 90-7
● 30-330 d 90-8
● 30-331 d 90-9
● 30-332 d 90-10
● 30-333 d 90-11
● 30-334 d 90-12
● 30-335 d 90-13
WB146-5 00-2-5 3
FOREWORD
00-2-6 3 WB146-5
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying
this symbol should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety,
and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
Mistakes in operation are extremely dangerous. Read the only in the areas provided for smoking. Never smoke
OPERATION & MAINTENANCE MANUAL carefully while working.
BEFORE operating the machine.
PREPARATIONS FOR WORK 00
1. Before carrying out any greasing or repairs, read all the

precautions given on the decals which are fixed to the 1. Before adding oil or making repairs, park the machine
machine. on hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or 2. Before starting work, lower blade, ripper, bucket or any
clothes with buttons missing. other work equipment to the ground. If this is not
● Always wear safety glasses when hitting parts with a possible, insert the safety pin or use blocks to prevent
hammer. the work equipment from falling. In addition, be sure to
● Always wear safety glasses when grinding parts with a lock all the control levers and hang warning signs on
grinder, etc. them.
3. When disassembling or assembling, support the

3. If welding repairs are needed, always have a trained,
machine with blocks, jacks or stands before starting
experienced welder carry out the work. When carrying
work.
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work..
4. Remove all mud and oil from the steps or other places
WARNING! Never modify, weld, cut, or drill used to get on and off the machine. Always use the
on any part of a ROPS handrails, ladders or steps when getting on or off the
structure. Doing so may machine. Never jump on or off the machine. If it is
weaken the structure which impossible to use the handrails, ladders or steps, use a
could lead to possible failure in stand to provide safe footing.
a rollover situation
PRECAUTIONS DURING WORK 00
1. When removing the oil filler cap, drain plug or

4. When carrying out any operation with two or more
hydraulic pressure measuring plugs, loosen them slowly
workers, always agree on the operating procedure
to prevent the oil from spurting out. Before
before starting. Always inform your fellow workers
disconnecting or removing components of the oil, water
before starting any step of the operation. Before starting
or air circuits, first remove the pressure completely from
work, hang UNDER REPAIR signs on the controls in
the circuit.
the operator's compartment.
2. The water and oil in the circuits are hot when the engine
5. Keep all tools in good condition and learn the correct
is stopped, so be careful not to get burned. Wait for the
way to use them.
oil and water to cool before carrying out any work on
the oil or water circuits.
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
WB146-5 00-3
FOREWORD SAFETY
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. 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.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. 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.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part 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.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.
00-4 WB146-5
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
STANDARD VALUE TABLE

This section explains the standard values for new machine and judgement criteria for testing, adjusting and
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.
TESTING AND ADJUSTING
This section 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
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.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
WB146-5 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00 REVISIONS 00
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Chassis volume: Issued for every machine model SYMBOLS 00
Engine volume: Issued for each engine series

So that the shop manual can be of ample practical use,
Electrical volume: Each issued as one to cover all models important places for safety and quality are marked with the
Attachment volume: Each issued as one to cover all models following symbols.
These various volumes are designed to avoid duplication of

information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment Special safety precautions are
be available. Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00
Special technical precautions or

other precautions for preserving
Any additions, amendments or other changes will be sent to ★ Caution
standards are necessary when per-
your distributors. Get the most up-to-date information before
forming the work.
you start any work.
Weight of parts or systems.
FILING METHOD 00
Weight
Caution necessary when selecting
hoisting wire or when working
1. See the page number on the bottom of the page. File the posture is important, etc.
pages in correct order. Places that require special
2. Following examples show how to read the page number: Tightening
attention for tightening torque
Example: torque
during assembly.
10 - 3 Places to be coated with adhesives

Coat
and lubricants etc.
Item number (10. Structure and Function)
Places where oil, water or fuel
Oil, water
Consecutive page number for each item must be added, and the capacity.
Places where oil or water must be
3. Additional pages: Additional pages are indicated by a Drain drained, and quantity to be
hyphen (-) and numbered after the page number. File as drained.
in the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK 00
When a manual is revised, an edition mark (bcd…) is

recorded on the bottom outside corner of the pages.
00-6 WB146-5
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol.
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load dur-
ing hoisting, untwisting of the
WIRE ROPES 00
rope, or slipping of the rope

from its original winding posi-
1. Use adequate ropes depending on the weight of parts to tion on the load, which can
be hoisted, referring to the table below: result in a dangerous accident
Wire ropes
4. Do not sling a heavy load with ropes forming a wide
(Standard “Z” or “S” twist ropes without galvanizing) hanging angle from the hook. When hoisting a load with
Rope diameter Allowable load two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
mm kN tons shows the variation of allowable load (kg) when hoist-
ing is made with two ropes, each of which is allowed to
10 9.8 1.0 sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of
11.2 13.7 1.4 total weight can be suspended. This weight becomes
1000 kg when two ropes make a 120° hanging angle. On
12.5 15.7 1.6 the other hand, two ropes are subject to an excessive
14 21.6 2.2 force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
WB146-5 00-7
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual pres-
sure from hydraulic tank.
WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected. Accord-
ingly, prepare an oil receiving container.
TYPE 1 00
DISCONNECTION 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold
the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-8 WB146-5
TYPE 2 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the right -
clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
WB146-5 00-9
12
TYPE 3 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3) contacts
surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-10 WB146-5
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers,
plastics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket ● Used as sealant for flange surfaces and bolts
sealant at high temperature locations; used to
LG-3 790-129-9070 1 kg Can prevent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
WB146-5 00-11
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
● Used as sealant for mating surfaces of final
drive case, transmission case.
● Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket ● Features: Silicon based, resistant to heat,
sealant cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case,
etc.
● Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube
● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
● Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
● Used as lubricant for sliding parts (to
LM-G 09940-00051 60 g Can
Molybdenum
prevent squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water or
Grease SYG2-160CA
steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
00-12 WB146-5
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52
WB146-5 00-13
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm kgm
10 14 59 - 74 43.51 - 54.57
12 17 98 - 123 72.28 - 90.72
16 22 235 - 285 173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 49 216.9 ± 36.1
00-14 WB146-5
12
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf ft})
Norminal No.
mm mm Range Target
02 14 35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
Varies depending on
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
type of connector.
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 1010 {550.22 - 744.93} 883 {651.26}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf lb})
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42}
10 10 17 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31}
12 12 19 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01}
14 14 22 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62}
16 16 24 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68}
18 18 27 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91}
20 20 30 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14}
24 24 32 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59}
30 30 32 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50}
33 33 _ 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE
SEAL TYPE) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {lbf ft}) Face seal type
type
Nominal Width
Nominal thread
size of hose across flats Thread size Root diameter (mm)
Range Target size - Threads per
(mm) (Reference)
inch, Thread series
34 - 54 {25.0 - 39.8} 44 {32.4} - 9/16 - 18UN 14.3
02 19
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
22 54 - 93 {39.8 - 68.5} 74 {54.5} - 11/16 -16UN 17.5
03
24 59 - 98 {43.5 - 72.2} 78 57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
(12) 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
(14) 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -
WB146-5 00-15
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue & Yel-
Color — Black & Red
Blue Yellow Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 WB146-5
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
METHOD OF USING THE CONVERSION TABLE 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
WB146-5 00-17
12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 WB146-5
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WB146-5 00-19
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 WB146-5
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
WB146-5 00-21
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

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

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-22 WB146-5
01 GENERAL
12
SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
MACHINE DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
BACKHOE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WITH STANDARD ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WITH EXTENDABLE ARM (RETRACTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
WITH EXTENDABLE ARM (EXTENDED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
SERVICE REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
TOTAL MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 01-9
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
FUEL REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
WB146-5 01-1 3
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
SPECIFICATIONS
MACHINE DIMENSIONS AND WEIGHTS
A Maximum height 4230mm (13’11”) Maximum digging height 5319mm (17’5”)

O
B Hinge pin height 3367mm (11’1”) -with extendable arm 5885mm (19’4")
C Overall height, ROPS Cab 2935mm (9’8”) Digging depth (2’ level bottom) 4370mm (14’4”)
P
D Maximum dumping height 2622mm (8’7”) -with extendable arm 5479mm (18’0")
Reach at maximum height Reach at maximum height 2828mm (9’3”)
E 750mm (2’5”) Q
and 45° dump angle -with extendable arm 3877mm (12’9")
F Dumping angle 45° Maximum reach from swing center 5742mm (18’10”)
R
G Rollback angle 45° -with extendable arm 6755mm (22’2")
H Digging depth 138mm (5’4”) Maximum digging depth 4423mm (14’6”)
S
I Bucket reach (transport) 2023mm (6’8”) -with extendable arm 5533mm (18’2")
J Ground clearance 430mm (1’5”) T Digging reach 2320mm (7’7”)
K Wheel base 2175mm (7’2”) U Rear tread 1800mm (5’11”)
L Backhoe swing center distance 1175mm (3’10”) V Front tread 1874mm (6’2”)
M Transport length 7432mm (24’5”) W Overall width (with bucket) 2356mm (7’9”)
Dumping height (SAE) 3676mm (12’1") Backhoe transport height 3676mm (12’1”)
X
N -arm retracted 3658mm (12’0’’) -with extendable arm 3746mm (12’4")
-arm extended 4369mm (14’4")
01-2 3 WB146-5
BACKHOE ARM
WITH STANDARD ARM
WB146-5 01-3 3
WITH EXTENDABLE ARM (RETRACTED)
01-4 3 WB146-5
WITH EXTENDABLE ARM (EXTENDED)
WB146-5 01-5 3
GENERAL MACHINE SYSTEMS SPECIFICATIONS
MACHINE SYSTEMS SPECIFICATIONS
ENGINE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu S4D102LE-2

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vertical, 4-cycle water-cooled diesel engine
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharged
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 x 135 mm (4.49 x 5.31 inches)
Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ltr (275 in3)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18:1
Horsepower rating
Gross horsepower @ 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kW 92 HP
Net horsepower (SAE J 1349) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66kW 88 HP
Max. torque @ 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 Nm (300 ft/lbs)
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry-type with double elements and dust evacuator, condition indicator
Lubrication system
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator water cooled system
Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric motor with air pre-heating system for cold climate
ELECTRICAL SYSTEM
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ah (860 CCA)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95A
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2kw
SERVICE REFILL CAPACITIES

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 l (2.4 US.gal)
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 l (3.7 US. gal)
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 l (39.3 US. gal)
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 l (10.8 US. gal)
Hydraulic system capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 l (25.6 US. gal)
Front axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 l (2.0 US. gal)
Rear axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 l (3.8 US. gal)
Gearbox oil, Power Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 l (5.3 US. gal)
TIRE PRESSURE
Standard Front Tire
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 x 17.5
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 ± 5 kg/cm2 (47±1 psi)
Standard Rear Tire

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5L x 24
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.88 ± 5 kg/cm2 (27±1 psi)
01-6 3 WB146-5
GENERAL MACHINE SYSTEMS SPECIFICATIONS
TRANSMISSION
Shifting between 2WD and 4WD is achieved through an electrohydraulic system. The transmission is operated through a
torque converter and a power shift reversing shuttle; the mechanical 4-speed gearbox is synchronized.
FORWARD REVERSE
Gears 1st 2nd 3rd 4th 1st 2nd 3rd 4th
km/h 6.3 11.4 21.3 37.8 6.3 11.4 21.3 37.8
m/h 3.9 7.1 13.2 23.5 3.9 7.1 13.2 23.5
TOTAL MASS
Maximum total mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,298 - 8.328 kg (16,090 - 18,360 lb)
LOADER
• The design of the front loader allows for better tensile strength distribution and parallel movement when raising and
lowering the bucket. Due to the linkage geometry, the number of greasing points has been dramatically reduced.
Standard bucket width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,356 mm (7ft 9in)
Front bucket capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAE) 0.95 m3 (1.25 yd3)
Standard bucket weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 kg (1,000 lb)
Lifting capacity at maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,900 kg (8,598 lb)
Lifting capacity at ground level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,000 kg (11,020 lb)
Breakout force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 kg (13,224 lb)
BACKHOE
• The boom has a rounded profile and reinforced structure built with cast ends allowing for 180° rotation while maintaining
high rotation torque.
Bucket breakout force (ISO 6015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,936 kg (13,087 lb)
Arm breakout force (ISO 6015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,005 kg (8,830 lb)
Backhoe bucket capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAE) 0.20 m (3 0.24 yd3)
WB146-5 01-7 3
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
★ This weight table is for reference when handling components or when transporting the machine.
Unit: kg (lbs)
Machine model WB146-5
Engine assembly - Muffler and exhaust pipe 394 kg (869 lbs)
Radiator 37 kg (82 lbs)
Hydraulic oil tank (empty) 10 kg (22 lbs)
Fuel tank (empty) 62 kg (137 lbs)
Front counterweight 170 kg (375 lbs)
Front guard 110 kg (243 lbs)
Engine hood 32 kg (71 lbs)
Canopy (without seat) 580 kg (1,279 lbs)
Cab (without seat) 595 kg (1,312 lbs)
Operator’s seat 62 kg (137 lbs)
Engine - transmission - pump 657.5 kg (1,450 lbs)
Hydraulic pump 31.5 kg (70 lbs)
Transmission 232 kg (512 lbs)
Front axle 262 kg (578 lbs)
Rear axle 430 kg (948 lbs)
Front wheel (complete with rim) 52 kg (115 lbs)
Rear wheel (complete with rim) 133.3 kg (294 lbs)
Front End Loader Assembly 1,763 kg (3,887 lbs)
• Boom Cylinder 46 kg (101 lbs) x 2
• Bucket Tilt Cylinder 35 kg (77 lbs) x 2
• Fulcrum Lever 32.5 kg (72 lbs) x 2
• Front Loader Bucket 436 kg (961 lbs)
• Loader Boom Assembly 1,100 kg (2,425 lbs)
Control Valve Assembly ⎯
• 8-spool Control Valve 45 kg (99 lbs)
• 10-spool Control Valve 50 kg (110 lbs)
Backhoe Assembly ⎯
• With Standard Arm 850 kg (1,874 lbs)
• Standard Arm, Bucket, and Bucket Cylinder 464 kg (1,023 lbs)
• Standard Arm 257 kg (567 lbs)
• With Long Arm 885 kg (1,951 lbs)
• With Extendable Arm 1,030 kg (2,271 lbs)
• Extendable Arm 439 kg (968 lbs)
• Bucket Cylinder 49 kg (108 lbs)
• Arm Cylinder ⎯
• Extendable Arm Cylinder ⎯
• Boom Cylinder
• Bucket 158 kg (348 lbs)
• Swing Cylinder 37.2 kg (82 lbs) x 2
• Backhoe Boom 267 kg (589 lbs)
Outrigger Cylinder 52.6 kg (116 lbs) x 2
Outrigger Arm 173.2 kg (382 lbs) x 2
01-8 3 WB146-5
GENERAL FUEL, COOLANT, AND LUBRICANTS
FUEL, COOLANT, AND LUBRICANTS
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE
Ambient Temperature Capacity

Type of
Reservoir
fluid -22 -4 14 32 50 68 86 104 122°F
Specified Refill
-30 -20 -10 0 10 20 30 40 50° C
SAE 5W-30 11 liter

13 liter
(11.6 US
Engine oil SAE 10W 30 (13.7 US gal)
gal)
pan Aspirated
Aspirated
SAE 15W-40 engine
engine
SAE 5W*
SAE 10W 150 liter

Hydraulic 92 liter
(39.6 US
system SAE 30 (24.3 US gal)
gal)
SAE 10W-30
Hydraulic
150 liter
Oil API CI-4
system with 92 liter

See page 3-12 (39.6 US
biodegrad- (24.3 US gal)
gal)
able oil
Front axle: 6.5 liter 6.5 liter

Differential (1.7 US gal) (1.7 US gal)
Final 1 liter
1 liter
reduction (0.26 US
(0.26 US gal)
gear (ea.) (See Note 1) gal)
Axle oil
Rear axle: 14.5 liter 14.5 liter
Differential (3.8 US gal) (3.8 US gal)
Final
1.5 liter 1.5 liter
reduction
(0.4 US gal) (0.4 US gal)
gear (ea.)
DEXRON II D
Hydraulic 20 liter 17 liter

transmission (5.3 US gal) (4.5 US gal)
Brake 0.8 liter 0.8 liter

system (0.2 US gal) (0.2 US gal)
ASTM 130 liter

Diesel D975 No. 1
Fuel tank (34.4 US -
fuel
ASTM D975 No. 2 gal)
Cooling 14 liter
Coolant AF-NAC Supercoolant -
system (3.7 US gal)
OPTION FOR VERY COLD AREAS:If the temperature exceeds 10° C (50° F), contact your Komatsu distributor for advice
on the type of oil to be used.
WB146-5 01-9 3
GENERAL FUEL, COOLANT, AND LUBRICANTS
GREASE
Lubrication Points Consistency Type
Articulations, grease fittings NLGI 2 (See note 2)
Note 1: For axle oil, use only the recommended oil as follows.
SHELL: DONAX TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TEXTRAN TDH OIL
MOBIL: MOBILFLUID 422 or 424
Note 2: The recommended lubricating grease is No.2 multi-purpose lithium grease with 3% molybdenum disulfide
(Lithio EP + MoS2).
FUEL REMARKS
• When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this
manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur content Change interval of oil in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
• When starting the engine in an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil of SAE10W,
SAE20W-20 and SAE10W-30, even though an atmospheric temperature goes up to 10°C (18°F) more or less in the day
time.
• Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 10W-40), but be sure to add single
grade oil that matches the temperature in the table.
• Use Komatsu genuine oil which has been specifically formulated and approved for use in the engine, hydraulic work
equipment, transmission, axles, and brakes.
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.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
01-10 3 WB146-5
GENERAL HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS

Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils
indicated in the following table is authorized and recommended:
Supplier HEES Synthetic Biodegradable Oil
KOMATSU ---
AGIP ARNICA S 46
ARAL HEF 46 vitam
AVIA SYNTOFLUID N 46
BP BIOHYD SE-S 46
CONDAT CONDAT D 46 K
ELF HYDRELF BIO 46
ESSO HYDRAULIKOIL HE 46
FINA BIOYIDRAN TMP 46 SE 46
FUCHS PLANTOHYD S 46
KENDALL SYNTH NATURA 46 HV
KUWAIT PETROLEUM K8 HOLBEIN 46
MOBIL EAL SYNDRAULIC
MOBIL (USA) ENVIROSYN 46 H
PAKELO GEOLUBE HYDRAULIC EP-46
PANOLIN HLP SYNTH 46
SHELL NATURELLE HFE-46
TAMOIL GREEN HYDRO SAFETY 46
TEXACO HYDRA 46
TOTAL EQUIVIS BIO 46
VAVOLINE UNISYN HLP 32/68
WARNING!
• It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the
temperature increases insoluble compounds are generated, which are deposited on filters and clog them (the
maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).
• The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic
motor, the transmissions, the braking system, etc.
• Before introducing synthetic biodegradable oil in the hydraulic system, completely empty the system,
disconnect the cylinders and all parts that may contain ordinary oil, and replace the filter with a new one.
• Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at
least 40°C (104°F), then operate the work equipment, so that all the parts of the system are filled with oil.
• Stop the engine and check the oil level.
WB146-5 01-11 3
GENERAL LUBRICATION DIAGRAMS
12
LUBRICATION DIAGRAMS
GENERAL VIEW
Remark
Use only recommended oil and grease.
01-12 3 WB146-5
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
POWER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
TRANSMISSION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
FORWARD REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
1ST THROUGH 4TH SPEED SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
4WD SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
WORK BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
MAIN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
DELIVERY CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
LS VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
PC VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
PC VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
OPERATING PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
PUMPING PLATE CONTROL ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
PRESSURE COMPENSATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
LS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
LS BY-PASS PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
PRESSURE COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
PPC REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
WB146-5 10-1 3
STRUCTURE, FUNCTION AND
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60

LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
OUTRIGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
LEFT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
RIGHT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
HYDRAULIC CONTROLS W/O MP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
HYDRAULIC CONTROLS WITH MP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
LOADER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
MP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
TELESCOPIC ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
OUTRIGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
10-2 3 WB146-5
MEMORANDUM
WB146-5 10-3 3
POWER TRAIN MAINTENANCE STANDARD
POWER TRAIN
1. Engine 5. Front Axle
2. Torque Converter 6. Rear Axle
3. Transmission 7. Front Drive Shaft
4. Hydraulic Pump 8. Rear Drive Shaft
DESCRIPTION
● The driving power for engine (1) is transmitted through the flywheel to the converter (2). The converter uses hydraulic oil
to convert the torque transmitted by the engine into driving power. The converter transmits motion to the drive shaft of the
transmission (3) and to the drive shaft of the hydraulic pump (4).
● Transmission (3) has two hydraulically activated clutches that can be selected by an electrically controlled gear selector.
The same switch also controls the four speed clutch packs.
● The driving power is transmitted from the transmission flanges to the front (5) and rear (6) axles through the drive shafts
(7) and (8). The driving power transmitted to the front (5) and rear (6) axles is reduced by the differentials and then
transmitted to the planetary gear through the differential shafts.
POWER FLOW
Front Axle
Gear Transmission Differential Planet Total
1st 5.533 81.722
2nd 3.36 49.627
2.462 6
3rd 1.532 22.627
4th 0.81 11.963
Rear Axle
Gear Transmission Differential Planet Total
1st 5.533 97.338
2nd 3.36 59.136
2.75 6.4
3rd 1.532 26.963
4th 0.81 14.256
10-4 3 WB146-5
MAINTENANCE STANDARD POWER TRAIN
1. Engine 5. Front Axle 9. Rear Tires

2. Convert 6. Rear Axle 10. Front Tires
3. Transmission 7. Front Drive Shaft
4. Hydraulic Pump 8. Rear Drive Shaft
WB146-5 10-5 3
TRANSMISSION DIAGRAM MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
1. Engine 4. Transmission 7. Rear Axle Flange

2. Torque Converter 5. Reverse Clutch 8. 4WD Clutch
3. Forward Clutch 6. Hydraulic Pump 9. Front Axle Flange
10-6 3 WB146-5
MAINTENANCE STANDARD TRANSMISSION DIAGRAM
1. Converter Valve 6. Reverse Clutch 11. Control Valve

2. Converter 7. Max Pressure Valve 12. Check Valve
3. Engine 8. Spin On Filter 13. Check Valve
4. Oil Cooler 9. Pump 14. 4WD Solenoid
5. Forward Clutch 10. Suction Strainer 15. 4WD Clutch
WB146-5 10-7 3
TRANSMISSION MAINTENANCE STANDARD
TRANSMISSION
COMPLETE ASSEMBLY
1. Shift Lever 5. Suction Strainer 9. 4WD Solenoid

2. Torque Converter 6. 4th Gear Sensor
3. Spin On Filter 7. Reverse Solenoid a. From Oil Cooler
4. Oil Temperature Sender 8. Forward Solenoid b. To Oil Cooler
10-8 3 WB146-5
MAINTENANCE STANDARD TRANSMISSION
1. Pump Drive Shaft 7. Rear Axle Flange 13. 4WD Clutch

2. Forward Reverse Shaft 8. 3rd Driven Gear 14. 4WD Clutch Shaft
3. Reverse Gear Clutch 9. 4th Driven Gear 15. Front Axle Flange
4. Forward Gear Clutch 10. 4WD Drive Gear 16. 2nd Driven Gear
5. Reverse Idler Gear Shaft 11. 1st Driven Gear 17. Rear Output Shaft
6. Drive Gears and Shaft 12. 4WD Driven Gear 18. Torque Converter
WB146-5 10-9 3
1. Gear Shift Lever 7. 3rd & 4th Selecting Rod 13. Spin On Filter
2. Centering Spring 8. 1st & 2nd Selecting Fork 14. Cold Oil Relief Valve
3. Return Spring 9. 4th Selecting Sensor 15. Return Spring
4. Check Ball 10. 3rd & 4th Selector 16. Return Spring
5. 3rd & 4th Selecting Fork 11. 1st & 2nd Selector 17. Return Spring
6. 1st & 2nd Selecting Rod 12. Suction Strainer
10-10 3 WB146-5
1. Forward Reverse Solenoid 7. Valve 13. Spool
2. 4WD Solenoid 8. Return Spring 14. Forward Solenoid
3. Piston 9. Valve 15. Reverse Solenoid
4. Return Spring 10. Rod 16. Check Ball
5. Return Spring 11. Return Spring 17. Return Spring
6. Spring Guide Pin 12. Spool Return Spring
WB146-5 10-11 3
FORWARD REVERSE CLUTCH
1. Reverse Gear 4. Reverse Clutch Piston a. Reverse Clutch Port

2. Forward Gear 5. Thrust Ring b. Forward Clutch Port
3. Forward Clutch Piston 6. Shaft c. Lubrication Port
1ST THROUGH 4TH SPEED SHAFT
1. 2nd Driver Gear 4. 4th Driven Gear 7. Thrust Ring

2. 1st Driven Gear 5. 3rd Driven Gear 8. Synchronizer
3. 4WD Gear 6. Rear Output Shaft
10-12 3 WB146-5
4WD SHAFT
1. Front Output Shaft 4. Cylinder a. 4WD Pressure Port

2. 4WD Driven Gear 5. Spring
3. Thrust Ring 6. Disc
WB146-5 10-13 3
FRONT AXLE MAINTENANCE STANDARD
FRONT AXLE
COMPLETE ASSEMBLY
1. Steering Cylinder 4. Tie Rod Nut 7. Mounting Pin Bushing

2. Oil Refill Plug 5. Adjustment Screw a. Left Cylinder Port
3. Oil Drain Plug 6. Lock Nut b. Right Cylinder Port
Unit:mm
Criteria
Check Item Standard Tolerance Standard Clearance Remedy
Size Shaft Bushing Clearance Limit
0 +0.04
8. Pin and Bushing Clearance 50 50 -0.039 50.19 --- --- Replace
0
10-14 3 WB146-5
MAINTENANCE STANDARD FRONT AXLE
DIFFERENTIAL
1. Side Gear 5. Adjustment Lock Nut 9. Bearing Spacer 13. Bearing Lock Nut
2. Ring Gear 6. Axle Shaft 10. Outboard Bearing 14. Inboard Bearing
3. Dowel Pin 7. Dowel Pin 11. Lip Seal Ring 15. Pinion Gear
4. Driven Gear 8. Differential Housing 12. Lip Seal Ring Cover 16. Oil Drain Plug
Unit: mm (inch)
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
17. Axle Clearance --- ---
0.18 - 0.28 mm 0.28 mm
18. Ring and Pinion Gear Backlash
(0.007 - 0.011 in) (0.011 in) Adjust
19. Pinion Preload - w/o lip seal 92 - 137 N•m (814 - 1213 lbf ft)
20. Ring and Pinion Gear Preload - w/o lip seal 129.5 - 194.5 N•m (1146 - 1722 lbf ft)
WB146-5 10-15 3
FRONT AXLE MAINTENANCE STANDARD
PLANETARY
1. Planetary Carrier 9. Belleville Washer 17. Lip Ring Seal

2. Planetary Gear 10. Upper King Pin Bushing 18. Tapered Roller Bearing
3. Ring Gear 11. Lip Ring Seal 19. Retaining Ring
4. Carrier Gear 12. Axle Housing 20. Bolt Bushing
5. Wheel Hub 13. Spherical Bearing 21. Stud Bolt
6. Lip Ring Seal 14. Lower King Pin Bushing 22. Oil Drain Plug
7. Upper King Pin 15. Lower King Pin
8. Adjustment Shim 16. Belleville Washer
Unit: mm
23 Hub Rotation Torque ---

Adjust
24 Axle Shaft Clearance ---
10-16 3 WB146-5
MAINTENANCE STANDARD REAR AXLE
REAR AXLE
COMPLETE ASSEMBLY
1. Input Flange 5. Planetary Portion 9 Oil Drain Plug

2. Differential Portion 6. Parking Brake Levers 10. Axle Housing Breather
Brake Port
3. Brake Portion 7. Brake Bleeder Screws a.
40.8 kg/cm² (580 psi)
Diff Lock Port
4. Axle Housing 8. Oil Fill And Level Plugs b.
1,295.4 kg/cm² (18,425 psi)
WB146-5 10-17 3
REAR AXLE MAINTENANCE STANDARD
DIFFERENTIAL
1. Tapered Roller Bearing 5. Differential Housing 9. Bearing Lock Nut 13. Pinion Gear
2. Side Gear 6. Bearing Lock Nut 10. Lip Oil Seal 14. Differential Housing
3. Rotating Gear 7. Axle Shaft 11. Input Flange
4. Ring Gear 8. Tapered Roller Bearing 12. Bearing Spacer
Unit: mm (inch)
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
15 Axle Clearance --- ---
0.21 to 0.29 mm 0.29 mm
16 Ring And Pinion Gear Backlash
(0.008 to 0.011 in) (0.011 in) Adjust
17 Pinion Gear Preload - w/o seal ring 115 to 138 N•m (85 to 102 lbf ft)
18 Pinion Ring Gear Preload - w/o seal ring 148 to 188 N•m (109 to 139 lbf ft)
10-18 3 WB146-5
PLANETARY
1. Stud Bolt 5. Axle Shaft 9. Tapered Roller Bearing

2. Planet Gear 6. Pressure Plate 10. Oil Seal
3. Wheel Hub 7. Retaining Ring 11. Wheel Flange
4. Sun Gear 8. Ring Nut
Unit: mm
Check Item Criteria Remedy
12. Hub Rotation Torque ---
Adjust
13. Axle Shaft Clearance ---
WB146-5 10-19 3
REAR AXLE MAINTENANCE STANDARD
WORK BRAKES
1. Bleed Screw 4. Middle Plate 7. Bushing

2. Brake Piston 5. Outer Plate 8. Parking Brake Control Caliper
3. Friction Disc 6. Belleville Washer 9. Set Screw
Unit: mm
Check Item Criteria Remedy
10. Hub Rotation Torque --- Adjust
10-20 3 WB146-5
DIFFERENTIAL LOCK
1. Engagement Pin 4. Piston 7. Fork

2. Sleeve 5. Bushing 8. Spacer
3. Cover 6. Control Rod a. Diff Lock Port
WB146-5 10-21 3
HYDRAULIC PUMP MAINTENANCE STANDARD
HYDRAULIC PUMP
COMPONENTS Ps From Hydraulic Tank Ps Oil Intake

1. Hydraulic Pump P1L From Control Valve Pp P1L Pump Delivery Pressure Input
2. Delivery Control Valve PLS From Control Valve LS P1C QD For Pump Delivery Pressure
3. Oil Refill Plug PM From EV1 Solenoid Valve Pd2 Drain Plug
PORT CONNECTIONS PORT FUNCTIONS Pen Delivery Control Pressure Check
P1 To Loader Valve P1 Pump Delivery PLS LS Signal Input
Pd To Hydraulic Tank Pd Drain PM Operating Mode Control Signal
10-22 3 WB146-5
MAINTENANCE STANDARD HYDRAULIC PUMP
MEMORANDUM
WB146-5 10-23 3
MAIN PUMP
PORT FUNCTIONS Pe Delivery Control Signal Pd5 Drain

Pa Delivery Control Group Feed Pd4 Drain PM2 Operating Mode Signal
10-24 3 WB146-5
1. Bearing 6. Piston 11. Control Piston

2. Input Shaft 7. Cylinder Block 12. Spring
3. Pump Housing 8. Swash Plate 13. Seal Ring
4. Swash Plate 9. Cover 14. Ball
5. Shoe 10. Shoe Guide
WB146-5 10-25 3
FUNCTION
The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered
according to the load requirements.
The amount of oil delivered can be modified by changing the angle of the swash plate.
STRUCTURE
● Groove a supports and makes cylinder block (1) an integral part of
shaft (2). The shaft is supported by front (3) and rear (4) bearings.
● The end of piston (5) is a concave ball, and the shoe (6) is staked to
it to form one unit. The piston and shoe form a spherical bearing.
● The swash plate (7) is supported by the pump body (8) and ball
(9), and has a flat surface A. The shoe (6) remains in contact
with the swash plate and slides in a circular movement.
Pressurized oil is introduced between the shoe and swash plate
forming a static bearing that allows the shoes to slip.
● Pistons (5) perform their relative movements in an axial direction,
inside the cylindrical chambers fashioned in the cylinder block (1).
● The rotation of the cylinder block (1) pressurizes the oil inside the
chambers of the block; pressure is adjusted by the valve plate (10).
The surface of the swash plate is so designed that the oil pressure
always remains within acceptable limits. The oil in each chamber is
drawn in and discharged through holes in the valve plate.
OPERATION
Pump Operation
1. Cylinder block (1) rotates with the shaft (2), and the shoe (6) slides
on the flat surface A. When this happens, swash plate (7) rotates on
the ball (9), and the angle a between the axis of the cylinder block
and the axis X of the swash plate changes. The angle a is known as
the swash plate angle.
10-26 3 WB146-5
2. When the axis X of the swash plate (7) retains the angle a in
relation to the axis of the cylinder block (1), flat surface A acts as a
cam for the shoe (6). This is why the piston (5) slides inside the
cylinder block, creating a difference between volumes E and F and
therefore causing the suction and delivery of oil in a quantity that is
equivalent to the difference between those volumes (F – E =
delivery). When the cylinder block rotates, chamber F decreases in
volume causing oil to be delivered to the circuits, while chamber E
increases in volume causing oil to be suctioned. The illustration
shows the state of the pump when suction at chamber F and
delivery at chamber E are complete.
3. When the center line X of the swash plate (7) and the center line of
the cylinder block (1) are perfectly aligned, the swash plate angle
a = 0, the difference between the volumes E and F within the
cylinder block becomes 0 and the pump does not take in or deliver
any oil. The angle of the swash plate a is proportional to pump
delivery.
Control of Delivery
1. When angle a of the swash plate increases, the difference between

volumes E and F increases too, and this makes delivery Q increase
accordingly. Angle a of the swash plate is varied by the servo
piston (11).
2. The servo piston (11) moves in a reciprocating linear motion caused

by pressure signals from the PC and LS valves. The linear motion
is transmitted to the swash plate (7). The swash plate is supported
by the pump body (8) through the ball (9), and this is the reason
why the swash plate moves in a semicircular alternate motion.
WB146-5 10-27 3
DELIVERY CONTROL VALVE
PORT FUNCTIONS P1 Delivery Control Group Feed PE Delivery Control Signal Output
T Drain Pd4 Drain PM Operating Mode Signal Input
10-28 3 WB146-5
COMPONENTS 8. Gasket PORT FUNCTION

1. Lever 9. Piston T Drain
2. Spring 10. Spool PA Pump Delivery Pressure
3. Retainer 11. Plug PM Operating Mode Signal Output
4. Seal 12. Seat PPL Delivery Control Signal Input
5. Spool 13. Spring PE Delivery Control Signal
6. Sleeve 14. Nut PLS LS Signal Input
7. Piston 15. Plug PPLS LS Pump Signal Input
WB146-5 10-29 3
LS VALVE FUNCTION
● The LS valve controls the pump delivery according to the stroke of
the control valve lever, the function of the delivery demands made
by the actuators.
● The LS valve detects the actuator’s delivery needs by means of the
differential pressure UPLS existing between pressure PPLS,
control valve input pressure, and pressure PLS, control valve
output pressure. The sensing of this differential pressure permits
control of the main pump delivery Q. PPLS, PLS and UPLS
are, respectively, the pump pressure, the Load Sensing pressure,
and the difference in pressure between these two values.
● The LS valve detects the pressure difference UPLS generated by
the passage of the oil flow through the surface freed by the control
valve spool, and controls the pump delivery Q so as to keep the
pressure drop constant. It can therefore be assumed that the pump
delivery is proportional to the demands made known by the control
valve.
● Pump pressure PPLS, pump pressure at control valve input, and
pressure PLS, Load Sensing pressure, are introduced into the
LS valve. The relation between differential pressure UPLS and
pump delivery varies as shown in the diagram on the right.
PC VALVE FUNCTION
● The PC, Power Control, valve performs an approximate power
check, and ensures that the hydraulic horsepower absorbed by the
pump does not exceed the horsepower delivered by the
endothermal engine.
● This is achieved by limiting the pump delivery Q function of the
delivery pressure PPLS, even if the LS valve requests an increase
in delivery Q due to the larger section freed by the control valve
spool, in the presence of high pressure pump delivery.
● When during operation the delivery Q increases and the delivery
pressure PPLS also increases simultaneously, the PC valve
reduces the pump delivery Q. When the delivery pressure PPLS
decreases, the PC valve increases the pump flow.
● As pressure PC increases, the relation between pressure PA and
delivery Q is switched in accordance with the force applied by
pressure PC.
● When the force applied by pressure PC is added to the force
applied by the pump's delivery pressure against the spool (5), the
relation between pump delivery pressure and delivery is switched
from (1) to in accordance with increment X.
10-30 3 WB146-5
PC VALVE OPERATION
Spring Operation
● PC valve spring loading (3) is defined by swash plate position.

● If control piston (6) moves to the right, spring (3) is compressed by the lever (2) and the spring load increases.
When Pump Pressure PA is Low
● The force applied by the pressure against the spool (4) decreases, and the spool (5) shifts slightly to the right. At the same
time, a connection opens between ports C and D, and pressurized oil from valve LS is sent for discharge, PT.
● Simultaneously, ports F and G on valve LS are interconnected, and pressure at port J is sent for relief, PT; the control
piston (2) shifts to the left. Pump delivery increases as a result.
● When the control piston (2) moves, the lever (3) moves to the left, and the spring (1) expands, thereby reducing its load on
the spool (5). Consequently, the spool moves to the left and stops the oil flow between ports C and D, and a passage opens
between ports B and C. The pressure at port C increases, and the control piston stops.
WB146-5 10-31 3
When Pump Pressure PA Is High
● The force applied by the pressure against the spool (4) increases, and the spool (5) shifts slightly to the left. At the same
time, a connection opens between ports C and B, and the pressure of the oil sent to valve LS becomes equivalent to the
pump's delivery pressure, PA.
● Simultaneously, ports F and G on valve LS are interconnected, and pressure at port J becomes equivalent to the pump's
delivery pressure, PA, and the control piston (2) shifts to the right. Pump delivery decreases as a result.
● When the control piston (2) moves, the lever (3) moves to the right, and the spring (1) compresses, thereby increasing its
load on spool (5). Consequently, the spool moves to the right and stops the oil flow between ports C and B, and a passage
opens between ports D and C. The pressure at port C decreases, and the control piston (2) stops.
10-32 3 WB146-5
When Equilibrium Has Been Reached
● The equilibrium between the force applied by pressure PA against spool (4) and the force applied by spring (1) against
spool (5) is what determines the position at which the control piston (2), pump stops.
WB146-5 10-33 3
MAIN CONTROL VALVE MAINTENANCE STANDARD
MAIN CONTROL VALVE
10-34 3 WB146-5
MAINTENANCE STANDARD MAIN CONTROL VALVE
A1 Arm Cylinder Rod B8 Loader Boom Cylinder Rod PA6 Solenoid Valve EV1, A1 Port
A2 Swing Cylinder Head B9 Right Outrigger Cylinder Rod PA7 Solenoid Valve EV2, A2 Port
A3 Loader Bucket Cylinder Head B10 Left Outrigger Cylinder Rod PA8 Loader PPC Valve, P3 Port
A4 Backhoe Boom Cylinder Head LS Hydraulic Pump, PLS Port PA9 Outrigger PPC Valve, P1 Port
A5 Backhoe Bucket Cylinder Rod P Hydraulic Pump, P1 Port PA10 Outrigger PPC Valve, P3 Port
A6 Mp Bucket Cylinder Head D Steering Unit, P Port PB1 Left Backhoe PPC Valve Port 1
A7 Jig Arm Cylinder Head DLS Steering Unit, LS Port PB2 Left Backhoe PPC Valve Port 2
A8 Loader Boom Cylinder Head PP Hydraulic Pump, P1L Port PB3 Loader PPC Valve, P1 Port
A9 Right Outrigger Cylinder Head T Drain PB4 Right Backhoe PPC Valve Port 1
A10 Left Outrigger Cylinder Head TS Drain PB5 Right Backhoe PPC Valve Port 2
B1 Arm Cylinder Head PPPC Solenoid Valve EV1, P Port PB6 Solenoid Valve EV1, B1 Port
B2 Swing Cylinder Rod PA1 Left Backhoe PPC Valve Port 3 PB7 Solenoid Valve EV2, B2 Port
B3 Loader Bucket Cylinder Rod PA2 Left Backhoe PPC Valve Port 4 PB8 Loader PPC Valve, P4 Port
B4 Backhoe Boom Cylinder Rod PA3 Loader PPC Valve, P2 Port PB9 Outrigger PPC Valve, P1 Port
B5 Backhoe Bucket Cylinder Head PA4 Right Backhoe PPC Valve Port 3 PB10 Outrigger PPC Valve, P4 Port
B7 Mp Bucket Cylinder Rod PA5 Right Backhoe PPC Valve Port 4
WB146-5 10-35 3
1. ACV - Jig Arm Extend 10. ASCV - Loader Bucket Curl 19. Backhoe Boom Spool
2. ACV - Backhoe Bucket Curl 11. ACV - Backhoe Boom Lower 20. Loader Bucket Spool
3. ASCV - Backhoe Boom Raise 12. ACV - Backhoe Bucket Dump 21. Backhoe Swing Spool
4. ACV - Loader Bucket Dump 13. ACV - Jig Arm Retract 22. Backhoe Arm Spool
5. ASCV - Backhoe Left Swing 14. ACV - MP Loader Bucket Dump 23. Priority Valve Spool
6. ACV - Backhoe Arm Out 15. Loader Boom Arm Spool 24. Unloading Valve
7. Safety Valve 16. Jig Arm Spool 25. LS By-Pass Plug
8. ACV - Backhoe Arm In 17. MP Bucket Spool
9. ASCV - Backhoe Right Swing 18. Backhoe Bucket Spool
ACV - Anti-Cavitation Valve ASCV - Anti-Shock/Cavitation Valve
10-36 3 WB146-5
Unit: mm (inch)
Spring Criteria
Standard Size Repair Limit
Remedy
Free Installed Installed Free Installed
Check Item Length Length Load Length Load
24.2 mm 23.7 mm 30.4 N 24.3N
26 Backhoe Arm In Spool Spring --
(0.953 in) (0.933 in) (6.834 lbf) (5.463 lbf)
27.2 mm 26.7 mm 30.38 N 24.3N
27 Backhoe Arm Out Spool Spring --
(1.071 in) (1.051 in) (6.830 lbf) (5.463 lbf)
56.8 mm 48.5 mm 29.6 N 23.7 N
28 Priority Valve Spring --
(2.236 in) (1.909 in) (6.654 lbf) (5.328 lbf)
25.5 mm 18.0 mm 121.5 N 97.2 N
29 Unloading Valve Spring --
(1.004 in) (0.709 in) (27.314 lbf) (21.851 lbf)
29.0 mm 28.5 mm 22.5 N 18.0 N
30 Backhoe Swing Spool Spring --
(1.142 in) (1.122 in) (5.058 lbf) (4.047 lbf)
42.3 mm 40.5 mm 54.9 N 43.9 N
31 Loader Bucket Spool Spring --
(1.665 in) (1.595 in) (12.342 lbf) (9.869 lbf)
41.1 mm 40.5 mm 34.3 N 27.4 N
32 Backhoe Boom Spool Spring -- Replace
(1.618 in) (1.595 in) (7.711 lbf) (6.160 lbf)
41.1 mm 40.5 mm 34.3 N 27.4 N
33 Backhoe Bucket Spool Spring --
(1.618 in) (1.595 in) (7.711 lbf) (6.160 lbf)
29.0 mm 28.5 mm 22.5 N 18.0 N
34 MP Bucket Spool Spring --
(1.142 in) (1.122 in) (5.058 lbf) (4.047 lbf)
29.0 mm 28.5 mm 22.5 N 18.0 N
35 Backhoe Jig Spool Spring --
(1.142 in) (1.122 in) (5.058 lbf) (4.047 lbf)
27.1 mm 26.7 mm 14.7 N 11.8 N
36 Loader Boom Raise Spool Spring --
(1.067 in) (1.051 in) (3.305 lbf) (2.653 lbf)
38.7 mm 27.6 mm 355.7 N 284.5 N
37 Loader Boom Lower Spool Spring --
(1.524 in) (1.087 in) (79.965 lbf) (63.958 lbf)
19.4 mm 19.0 mm 14.7 N 11.8 N
38 Loader Boom Float Spool Spring --
(0.764 in) (0.748 in) (3.305 lbf) (2.653 lbf)
WB146-5 10-37 3
Pressure Reducing Valve Delivery Control Valve 18. Check Valve

1. Loader Boom 9. Backhoe Arm 19. Check Valve
2. Backhoe Jig Arm 10. Backhoe Swing 20. Check Valve
3. MP Bucket 11. Loader Bucket 21. Check Valve
4. Backhoe Bucket 12. Backhoe Boom 22. Check Valve
5. Backhoe Boom 13. Backhoe Bucket 23. Check Valve
6. Loader Bucket 14. MP Bucket 24. Check Valve
7. Backhoe Swing 15. Backhoe Jig Arm 25. Check Valve
8. Backhoe Arm 16. Loader Boom 26. LS By-Pass Plug
17. Main Relief Valve 27. LS, DLS Pressure Check Valve
10-38 3 WB146-5
Unit: mm (inch)
Spring Criteria
Remedy
15.4 mm 8.0 mm 7.44 N 5.96 N
28 PDV Tension Spring --
(0.606 in) (0.315 in) (1.673 lbf) (1.340 lbf)
31.4 mm 21.8 mm 63.7 N 51.0 N
(1.236 in) (0.858 in) (14.320 lbf) (11.465 lbf)
18.9 mm 15.0 mm 15.7 N 12.5 N
(0.744 in) (0.591 in) (3.530 lbf) (2.810 lbf)
37.1 mm 24.0 mm 34.3 N 27.4 N
(1.461 in) (0.945 in) (7.711 lbf) (6.160 lbf)
Replace
20.0 mm 15.0 mm 4.32 N 3.45 N
(0.787 in) (0.591 in) (0.971 lbf) (0.776 lbf)
27.2 mm 21.0 mm 4.7 N 3.76 N
33 Check Valve Spring --
(1.071 in) (0.827 in) (1.057 lbf) (0.845 lbf)
27.2 mm 22.0 mm 3.92 N 3.14 N
(1.071 in) (0.866 in) (0.881 lbf) (0.706 lbf)
21.9 mm 15.8 mm 1.96 N 1.57 N
(0.862 in) (0.622 in) (0.441 lbf) (0.353 lbf)
WB146-5 10-39 3
1. Backhoe Right Outrigger Spool 4. Backhoe Swing Spool 7. Backhoe Boom Spool
2. Backhoe Left Outrigger Spool 5. Loader Boom Spool
3. Loader Bucket Spool 6. Backhoe Bucket Spool
Unit: mm (inch)
Spring Criteria
Remedy
18.0 mm 17.5 mm 39.2 N 31.4 N
8. Outrigger Spool Outer Spring --
(0.709 in) (0.689 in) (8.813 lbf) (7.059 lbf)
Replace
20.2 mm 10.4 mm 30.4 N 24.3 N
9. Outrigger Spool Inner Spring --
(0.795 in) (0.410 in) (6.834 lbf) (5.463 lbf)
10-40 3 WB146-5
1. PPC Maximum Pressure Valve 4. Blow Out Plug 7. Arm Spool

2. Maximum Pressure Valve Spool 5. Unloading Valve
3. Sequential Reducing Valve 6. LS By-Pass Plug
WB146-5 10-41 3
CLSS MAINTENANCE STANDARD
CLSS
DESCRIPTION
CHARACTERISTICS
The term CLSS means Closed center Load Sensing System, which
has the following characteristics:
● High precision control that is independent of the load applied to the
movement;
● High precision control of digging action even during delicate
manoeuvres.
● Ability to perform complex operations, guaranteed by control of oil
flow in function of the aperture surfaces of the shuttles.
● Energy savings guaranteed by control of pump delivery.
STRUCTURE
● The CLSS system includes the variable flow pump, the control
valve and the working equipment.
● The pump includes the main pump, the PC valve and the LS valve.
10-42 3 WB146-5
MAINTENANCE STANDARD CLSS
OPERATING PRINCIPLES
PUMPING PLATE CONTROL ANGLE
● The angle of the swash plate and the pump delivery, is controlled in
such a way that the differential pressure UPLS between the
delivery pressure PP of the pump and the pressure PLS at the outlet
of the control valve towards the actuator is maintained at a constant
value. UPLS = pump delivery pressure PP minus pressure PLS of
delivery to the actuator.
● If the differential pressure UPLS becomes lower than the set pressure
of the LS valve, the angle of the swash plate increases and delivery
increases.
● If the differential pressure UPLS increases, the angle of the swash
plate decreases.
WB146-5 10-43 3
PRESSURE COMPENSATION CONTROL

● The pressure compensation valves are installed downstream from the control valve in order to balance the differential
pressure between the loads. When two or more movements, cylinders, are activated simultaneously, the pressure differences
UP between the delivery at the control valve inlet and outlets of the control valve are compensated by these valves. This
will obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
10-44 3 WB146-5
MAIN CONTROL VALVE
1. Unloading Valve Pressure . . . . . . . . . LS + 28.02 kg/cm² (399 psi)
2. Main Pressure Relief Valve . . . . . . . . . . 222.14 kg/cm² (3,160 psi)
3. Safety Valve . . . . . . . . . . . . . . . . . . . . . . 275.13 kg/cm² (3,913 psi)
4. Check Valve
5. Anti Shock/Cavitation Valve . . . . . . . . . 219.08 kg/cm² (3,116 psi)
8. Pressure Compensation Valve
9. Priority Valve
10. PPC Reducing Valve
WB146-5 10-45 3
UNLOADING VALVE
Neutral Position
FUNCTION
● When the control valve is in NEUTRAL position, pump delivery Q, resulting from the swash plate being at its min. angle,
is sent into the tank circuit. When this happens, the pump's delivery pressure PP is regulated at 28 kg/cm² (398 psi) by means of
the spring (2) inside the valve. LS signal with PLS pressure = 0 kg/cm² (0 psi).
OPERATING
● Pump pressure PP acts on spool (1) on surface S1, and on surface S2, whereas PLS pressure acts on surface S2. Since
no LS signal with PLS pressure is generated when the control valve is in NEUTRAL position, the only pressure acting
on spool in this condition is the pump's delivery pressure PP as regulated by spring compression (2).
● As the pump's delivery pressure PP increases and the resulting force equals spring loading (2), the spool (1) shifts to the
right. The pump's delivery circuit PP is then connected to the tank circuit T by means of the holes in spool. This ensures
that the pump delivery pressure PP stays regulated at 28 kg/cm² (398 psi).
PP ..........................................................................Pump circuit
PLS .......................................................... Load Sensing circuit
T.............................................................................. Tank circuit
10-46 3 WB146-5
Control Valve Fine Control
FUNCTION
l When the actuators' delivery needs during fine control are within the delivery values related to the minimum angle of the
swash plate, the pump's delivery pressure PP is regulated by pressure PLS at +28 kg/cm² (398 psi). Since the unloading valve
opens when the differential pressure between the pump's delivery pressure PP and pressure PLS of the LS equals spring
load (2), 28 kg/cm² (398 psi), the differential pressure UPLS becomes 28 kg/cm² (398 psi).
OPERATING
● When fine controls are performed at the control valve, a PLS pressure is generated. This pressure acts on surface S3 on
the right hand side of the spool (1). Since pressure PLS of LS is low, because the control valve passage is small, the
difference with the pump's delivery pressure PP is great.
● When the differential pressure between the pump's delivery pressure PP and pressure PLS of the LS equals spring
loading (2) 28 kg/cm² (398 psi), the spool (1) shifts to the right and, in turn, the pump circuit PP connects to the tank
circuit T.
● The pump's delivery pressure PP is regulated by the combination of the pressure from the spring, 28 kg/cm² (398 psi), and
the pressure PLS of the LS, when the differential pressure UPLS reaches a value of 28 kg/cm² (398 psi).
WB146-5 10-47 3
Control Valve Is In Use
FUNCTION
● When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control
valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the actuators.
OPERATING
● When the control valve spool is caused to perform a longer travel, this generates a pressure PLS of the LS, which acts on
the right side of the spool (1). Since the control valve passage is wide, the difference between the pressure PLS of the LS
and the pump's delivery pressure PP is small.
● For this reason, since the differential pressure between the pump's delivery pressure PP and the pressure PLS of the LS
fails to reach the spring loading pressure value of spring (2) 28 kg/cm² (398 psi), the spool (1) is pushed to the left by the
spring.
● The result is that the connection between the pump delivery circuit PP and the tank circuit T is excluded and the entire
pump delivery Q is sent to the actuators.
10-48 3 WB146-5
LS PRESSURE
Function
● LS pressure is the actuator's pressure at control valve output. This pressure actually reduces the pump's PP pressure – via
the pressure compensation group reducing valve (3) to the same A pressure of the actuator circuit and then sends it into
the PLS circuit of the LS. In the outriggers control valve, the actuator's pressure A is introduced directly into circuit
PLS of the LS.
Operation w/o Outriggers
● When the spool (1) is operated, pump pressure PP starts flowing into the circuit of actuator A from the delivery control
valve (2) and from the notch a via the duct b. At the same time, the pressure reducing valve (3) moves to the right making
the pump's pressure PP drop as it flows through the bottleneck c, and causing the pressure to flow into the circuit PLS of
the LS and into the chamber of spring PLSS. At this point, the PLS circuit of the LS is connected to the tank circuit T
by means of the by-pass plug (4).
● The pressure acting on the left side of the reducing valve (3) is pressure PA of the actuator, and the pressure acting on the
right hand side is the reduced pressure PP of pump delivery. The reducing valve balances out when pressure PA of the
actuators and pressure PLSS of the spring chamber are balanced. This in turn allows the pressure PP, now reduced by
the bottleneck c, to be introduced into the PLS circuit of the LS at the same pressure A as the actuator's circuit.
WB146-5 10-49 3
Operation w/o Outriggers
● When the spool (1) is operated, pump pressure PP starts flowing into the circuit of actuator A through the duct a.
● At the same time, pressurized oil is introduced into the PLS circuit of the LS through holes b.
★ The outriggers circuit differs from the working equipment circuit in that the operating pressure of actuator A is
introduced directly into the PLS circuit of the LS.
10-50 3 WB146-5
LS BY-PASS PLUG
Description
● The LS by-pass plug unloads residual pressure from the load sensing's PLS circuit.
● This makes the increment rate of load sensing's PLS pressure smoother. By eliminating oil, through the bottleneck, a loss
of pressure is generated in the flow that is controlled by the spool, and stability is increased as a result, thereby reducing
the actual differential pressure LS.
Operation
● Pressurized oil in the Load Sensing PLS circuit flows through filter a, through orifice b and into the tank circuit T.
WB146-5 10-51 3
PRESSURE COMPENSATION
Function
● Pressure compensation occurs during simultaneous operation of several movements, specifically when the pressure of an
actuator becomes lower than the pressure of the actuator on the opposite side, and pump delivery is on the verge of being
increased. In this case, the right actuator withstands a higher pressure than the left actuator.
Operation
● During operation together, when right actuator pressure increases, delivery in circuit A of the left actuator tends to
increase. The PLS pressure of the LS for the right actuator acts on chamber PLS1 of the spring and pushes the pressure
reducing valve (1) and the delivery control valve (2) to the left. The delivery control valve produces a bottleneck between
the pump's delivery PP circuit and the PPA circuit upstream of the control valve spool. This bottleneck generates a
pressure loss between circuits PP and PPA.
● The delivery control valve (2) and the pressure reducing valve (1) are balanced out at a point where the differential
pressure between PA and PLS, these two acting on both surfaces of the pressure reducing valve, equals the loss of
pressure between PP and PPA, these two acting on both surfaces of the delivery control valve.
● The differential pressure between the upstream pressure PPA and the downstream pressure of both spools in the control
valves concerned in the movement together are equalized, and pump delivery is distributed proportionally to the sections
a that are responsible for opening the notches of each spool.
10-52 3 WB146-5
PRESSURE COMPENSATION VALVE

Function
● In order to equalize the characteristics of each actuator, the pressure compensation valve will determine the compensation
characteristics by performing a micrometer adjustment of the surface ratio S1/S2. This is the ratio of area S1, delivery
control valve (2) end, to area S2, pressure reducing valve (1) end.
S1 surface of delivery control valve (2) minus surface of piston (3).
S2 surface of pressure reducing valve (1) minus surface of piston (3).
Compensation Characteristics
● When the ratio is 1.00: Pump pressure PP minus pressure PPA upstream of spool ≅ load sensing PLS pressure - actuator
PA pressure (= A). Delivery is distributed proportionally to the opening surfaces of the spool.
● When the ratio is > 1.00: PP - PPA > PLS - PA (= A). Delivery distribution is lower than the proportion of the opening
surfaces of the spool.
● When the ratio is < 1.00: PP - PPA < PLS - PA (= A). Delivery distribution is higher than the proportion of the opening
surfaces of the spool.
WB146-5 10-53 3
PRIORITY VALVE
Function
● The purpose of the priority valve is to feed pressurized oil to the steering unit and to the other actuators.
● Oil distribution is determined by the position of spool (1) of the priority valve, which is in turn determined by LS signal,
pump delivery, steering circuit pressure, and hydraulic circuit pressure.
● The position of the spool (1) is determined in such a way as to ensure that the oil delivered to the steering unit matches the
delivery needs at any time.
10-54 3 WB146-5
PPC REDUCING VALVE

Function
● This valve regulates the PPC feed pressure at 30 kg/cm² (427 psi). When actuator pressure is low, the sequential valve
closes to permit an increase in the pump's delivery pressure PP in order to supply pressure to the servo controls.
Neutral Condition
● The spool (1) of the unloading valve moves, and delivery pressure is regulated at 30 kg/cm² (427 psi).
● The spool (2) and valve (3) reduce the pump's delivery pressure PP to 30 kg/cm² (427 psi). Pressure is then sent to the
controls via port PC.
WB146-5 10-55 3
Control Valve Operated
● The spool (1) of the unloading valve moves to the left, and the pump's delivery pressure exceeds the pressure of the
actuator circuit (5) by an amount equivalent to LS differential pressure.
● If the pump's delivery pressure PP exceeds 30 kg/cm² (427 psi), valves (2) and (3) reduce pressure PP to 30 kg/cm² (427 psi).
The reduced pressure is then sent to the controls via port PC.
● When this occurs, the sequential reducing valve (4) stays open.
10-56 3 WB146-5
● When the pump's delivery pressure PP is lower than 30 kg/cm² (427 psi), the sequential reducing valve shifts to the right,
thereby reducing the flow of the PP pressure to the actuator circuit (5).
● This generates a pressure gap between PP pressure and actuator pressure. PP pressure is incremented in excess of
30 kg/cm² (427 psi) and is then reduced to 30 kg/cm² (427 psi) by valves (2) and (3) to guarantee pressure feed to the
controls.
WB146-5 10-57 3
STEERING UNIT MAINTENANCE STANDARD
STEERING UNIT
a Port L - To Steering Cylinder c Port T - To Hydraulic Oil Tank e Port P - From Control Valve
b Port R - To Steering Cylinder d Port P - To Control Valve
TECHNICAL DATA
Steering unit type ......................................................... OSPC200LS
Normal flow ...............................................................................20 l.
OPERATION
● The steering unit consists of a control valve and a rotating oil dispenser, and is of the hydrostatic type. When the steering
wheel is turned, the control valve sends oil from the pump P2, by means of the rotating oil dispenser, to one side of the
steering cylinder.
● The rotating dispenser ensures that the oil volume supplied to the cylinder is proportionate to the angle of rotation of the
steering wheel. In the event of malfunction, the rotating oil dispenser will function automatically as a hand pump, thus
guaranteeing auxiliary steering.
10-58 3 WB146-5
MAINTENANCE STANDARD STEERING UNIT
MEMORANDUM
WB146-5 10-59 3
PPC VALVE MAINTENANCE STANDARD
PPC VALVE
LOADER
10-60 3 WB146-5
MAINTENANCE STANDARD PPC VALVE
PORTS 1. Spool - Ports P1, P2 & P4 8. Protective Boot

P1 To Control Valve - PB3 Port 2. Spool - Port P3 9. Electro Detent - Ports P2 & P3
P2 To Control Valve - PA3 Port 3. Plunger - Ports P2 & P3 10. Lower Spring Retainer
P3 To Control Valve - PA8 Port 4. Plunger - Ports P1 & P4 11. Center Spring Retainer
P4 To Control Valve - PB8 Port 5. Adjusting Screw 12. Upper Spring Retainer
P From EV1 Solenoid Valve 6. Actuator Disc 13. Mounting Plate
T To Hydraulic Tank 7. Handle Mount 14. Valve Housing - Three Section
Unit: mm (inch)
Spring Criteria
Remedy
30.6 mm 41.2 N
15. Bottom Outer Spring - Ports P1
(1.205 in) (9.262 lbf)
31.6 mm 39.1 N
(1.244 in) (8.790 lbf)
31.9 mm 38.5 N
(1.256 in) (8.655 lbf)
31.6 mm 64.9 N
(1.244 in) (14.590 lbf)
23.6 mm 5.3 N
19. Bottom Inner Spring - Ports P1
(0.929 in) (5.306 lbf)
24.6 mm 5.3 N
20. Bottom Inner Spring - Ports P2 Replace
(0.969 in) (5.306 lbf)
25.3 mm 5.3 N
(0.996 in) (5.306 lbf)
24.9 mm 5.3 N
(0.980 in) (5.306 lbf)
21 mm 12.3 N
23. Center Spring - All Ports
(0.827 in) (2.765 lbf)
11.4 mm 28.4 N
24. Top Spring - Ports P1 and P4
(0.449 in) (6.385 lbf)
11 mm 13.7 N
25. Top Spring - Ports P2 and P3
(0.433 in) (3.080 lbf)
WB146-5 10-61 3
OPERATION
Neutral Position
BUCKET PORTION
● Control valve ports A and B and PPC valve ports P1 and P2 are
connected to discharge chamber D by means of the calibrated hole f
in spool (1).
10-62 3 WB146-5
BOOM PORTION
● Control valve ports A and B and PPC valve ports P3 and P4 are
connected to discharge chamber D by means of the calibrated hole f
in spool (1).
Fine Control, Neutral J Actuator
● When the disk (5) starts pushing down on piston (4) and
piston (10), the retainer (9) moves as a result. This movement will
compress the spring (2) which will in turn act on the spool (1) and
push it downwards.
● As a result of this action, the calibrated hole f will be isolated from
the drain chamber D and at almost at the same time it will be put in
connection with the PP chamber, which is directly connected to the
loader control circuit.
● Pressure in the loader control circuit will flow through the
calibrated hole f and into the circuit thereby increasing the pressure
in port P1/ B.
● When pressure P1 increases, spool (1) is pushed upwards, and
calibrated hole f is connected back to discharge chamber D thereby
compressing the spring (2).
● The floating of the spool (1) will continue until calibrated hole f is
halfway between discharge chamber D and pressure chamber PP,
until the pressure in duct P1, the pressure acting on the section of
stem (1), offsets the force applied by the spring (2).
● The spring (2) is compressed proportionally to the movement of the
disk (5) and pressure at P1 increases in proportion to the travel of
the disk. The equilibrium position is then kept until the position of
piston (4) is changed:
1. As long as pressures at ports B and P1 are perfectly balanced;
2. Until pressure in section B/P1, the pressure acting on
stem (1), is enough to counteract the force of the spring (2).
● This ensures proportionality between control lever position, B/P1
circuit pressure, and main control valve stem displacement.
WB146-5 10-63 3
Fine Control, Actuator J Neutral
● When the disk (5) is released and moved to neutral position, the
piston (4) is pushed upwards by the spring (3) acting on the retainer
(9), and spool (1) is thrusted upwards both by the force of spring (2)
and by the force that the pressure in section B/P1 applies against
the stem. This movement moves the calibrated hole f of spool into
the discharge chamber D, thereby allowing pressure in section
B/P1 to be released.
● If pressure P1 drops too quickly, spool (1) is pushed downwards by
spring (2) and the calibrated hole f becomes cut off from the
discharge chamber D; at almost the same time, the calibrated hole f
is put in connection with pressure chamber PP and starts supplying
pressure to section P1 until the pressure corresponding to the
control lever position is balanced.
● When the spool of the control valve returns, oil flows back into
chamber D, through calibrated hole f, and into chamber B of the
control valve spool opposite the operating one. Oil flows through
duct P2 and into chamber B to ensure it is filled properly.
Fine Control, Neutral J Full Stroke
● When the disk (5) pushes down on the piston (4), and the
retainer (9) pushes down on the spool (1), calibrated hole f is put in
direct connection with chamber PP, which is in turn connected to a
constantly pressurized loader control circuit.
● Oil is then allowed to flow directly into section B/P1 thereby
pushing the stem of the main control valve to the end of its travel.
This causes the main control valve to send the oil contained in
chamber AB towards input P2, through calibrated hole f and into
relief chamber D.
10-64 3 WB146-5
Control Lever To Float Position
● If piston (4) and piston (10) of the spool controlling the arm, port
P4, are pushed downwards by disk (5), the mechanism inside the
PPC valve will start locking the spool halfway along its travel.
● If piston (4²) is pushed upwards and the solenoid in the PPC valve
is energized, the force generated by the solenoid will retain the
piston in place and the arm float condition will be retained, even if
the lever is released.
● At the same time, the control valve will also be activated and
retained in the arm float position.
Control Lever From Float Position
● The disk (5) can be moved back to neutral position by applying a

force that exceeds the force applied by the solenoid.
● The floating state can also be cancelled, and the lever can move
back to neutral position, de-energizing the solenoid.
WB146-5 10-65 3
OUTRIGGER
PORTS P From EV1 Solenoid Valve 4. Boot

P1 To Control Valve - PA9 Port T To Hydraulic Tank 5. Mounting Plate
P2 To Control Valve - PB9 Port 1. Handle Knob 6. Left Outrigger
P3 To Control Valve - PA10 Port 2. Stop 7. Right Outrigger
P4 To Control Valve - PB10 Port 3. Handle
10-66 3 WB146-5
OPERATION
Neutral Position
● Ports A and B of the main control valve and ports P1 and P2 of the outrigger valve are connected to the tank circuit, the
spool is in neutral position.
WB146-5 10-67 3
Fine Control, Neutral J Actuator
● When the lever (1) is moved in the direction shown by the arrow, the valves (2) are rotated and a passage is opened
between delivery duct a and port P1, while port P2 remains connected to the tank circuit.
● Pressure at port P1 increases as the travel of lever (1) increases. Consequently, the spool of the control valve moves to the
left by a distance that is proportional to the travel of the lever.
10-68 3 WB146-5
Full Lever, Actuator J Neutral
● When lever (1) is moved fully to the left, the valves (2) are fully rotated.
● Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only, and the spool of
the control valve performs its full travel.
WB146-5 10-69 3
BACKHOE
LEFT VALVE
PORTS
1. To Arm Out Valve, PB1 Port 3. To Arm In Valve, PA1 Port P To EV1 Solenoid Valve, VBH Port
2. To Swing Right Valve, PB2 Port 4. To Swing Left Valve, PA2 Port T To Hydraulic Tank
10-70 3 WB146-5
RIGHT VALVE
PORTS
1. To Boom Raise Valve, PB4 Port 3. To Boom Lower Valve, PA4 Port P To EV1 Solenoid Valve, VBH Port
2. To Bucket Curl Valve, PB5 Port 4. To Bucket Dump Valve, PA5 Port T To Hydraulic Tank
WB146-5 10-71 3
SOLENOID VALVE MAINTENANCE STANDARD
SOLENOID VALVE
HYDRAULIC CONTROLS W/O MP BUCKET
PORTS 1. Differential Lock Solenoid, Y94

ACC Accumulator VBH To Backhoe PPC Valves, Port P 2. Boom Lock Solenoid, Y95
P1 Pressure Tap VL To Loader PPC Valves, Port P 3. Backhoe PPC Solenoid, Y90
P2 To Outrigger PPC Valve, Port P PM To Hydraulic Pump, Port PM 4. Loader PPC Solenoid, Y93
A2 To Boom Lock Cylinder P From Control Valve, Port PPPC 5. Ecopower Solenoid, Y91
B2 To Rear Axle T To Hydraulic Tank 6. Boom Lock Solenoid, Y95
10-72 3 WB146-5
MAINTENANCE STANDARD SOLENOID VALVE
HYDRAULIC CONTROLS WITH MP BUCKET
PORTS 1. Differential Lock Solenoid, Y94

ACC Accumulator VL To Loader PPC Valves, Port P 2. Boom Lock Solenoid, Y95
P1 Pressure Tap A1 To Control Valve, Port PA6 3. Backhoe PPC Solenoid, Y90
P2 To Outrigger PPC Valve, Port P B1 To Control Valve, Port PB6 4. Loader PPC Solenoid, Y93
A2 To Boom Lock Cylinder PM To Hydraulic Pump, Port PM 5. Bucket Open Solenoid, Y98
B2 To Rear Axle P From Control Valve, Port PPPC 6. Bucket Close Solenoid, Y99
VBH To Backhoe PPC Valves, Port P T To Hydraulic Tank 7. Ecopower Solenoid, Y91
WB146-5 10-73 3
LOADER CYLINDERS MAINTENANCE STANDARD
LOADER CYLINDERS
BOOM
0. Piston Rod Bushing 3. Piston Retaining Nut 6. Cylinder Rod

1. Barrel Bushing 4. Four Piece Piston Seal 7. Cylinder Head
2. Cylinder Barrel 5. Cylinder Piston 8. Piston Stop
Unit: mm (inch)
Criteria
Size OD ID Clearance Limit
36 mm
9. Piston Rod to Head
(1.417 in)
67 mm 67.25 mm 67.2 mm 0.05 mm
10. Bushing in Piston Rod Replace
(2.638 in) (2.451 in) (2.449 in) (0.002 in)
67 mm 67.25 mm 67.2 mm 0.05 mm
11. Bushing in Barrel
(2.638 in) (2.451 in) (2.449 in) (0.002 in)
CHARACTERISTICS
Unit: mm (inch)
Piston Rod Diameter ....................................................................................................................................... 50 mm (1.969 in)
Max Cylinder Length .................................................................................................................................1740 mm (68.504 in)
Min Cylinder Length ................................................................................................................................. 1170 mm (46.063 in)
Cylinder Barrel Bore ....................................................................................................................................... 90 mm (3.543 in)
Piston Stroke................................................................................................................................................ 570 mm (22.441 in)
Rod Thread for Piston Nut ...................................................................................................................................................M36
10-74 3 WB146-5
MAINTENANCE STANDARD LOADER CYLINDERS
BUCKET

2. Cylinder Barrel 5. Cylinder Piston
Unit: mm (inch)
Criteria
33 mm
(1.417 in)
52.20 mm 0.05 mm
52 mm 52.25 mm (2.055 in) (0.002 in)
9. Bushing in Piston Rod
(2.047 in) (2.057 in) 52.30 mm -0.05 mm
Replace
(2.059 in) (-0.002 in)
57.20 mm 0.05 mm
57 mm 57.25 mm (2.252 in) (0.002 in)
(2.244 in) (2.254 in) 57.30 mm -0.05 mm
(2.256 in) (-0.002 in)
CHARACTERISTICS
Unit: mm (inch)
Max Cylinder Length ................................................................................................................................ 2145 mm (84.449 in)
Piston Stroke................................................................................................................................................ 745 mm (29.331 in)
WB146-5 10-75 3
LOADER CYLINDERS MAINTENANCE STANDARD
MP BUCKET
0. Piston Rod Bushing 3. Cylinder Piston 6. Cylinder Barrel

1. Cylinder Rod 4. Four Piece Piston Seal
2. Cylinder Head 5. Retaining Nut
Unit: mm (inch)
Criteria
40 mm
h Piston Rod to Head (1.575 in)
Replace
51.88 mm 52.39 mm 0.51 mm

50 mm (2.043 in) (2.063 in) (0.020 in)
i Bushing in Piston Rod (1.969 in) 52.12 mm 52.39 mm 0.27 mm
(2.052 in) (2.063 in) (0.011 in)
CHARACTERISTICS
Unit: mm (inch)
Max Cylinder Length .................................................................................................................................. 705 mm (27.756 in)
Min Cylinder Length ................................................................................................................................... 475 mm (18.701 in)
Piston Stroke.................................................................................................................................................. 230 mm (9.055 in)
10-76 3 WB146-5
MAINTENANCE STANDARD BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
0. Piston Rod Bushing 4. Four Piece Piston Seal 8. Set Screw

1. Barrel Bushing 5. Cylinder Piston 9. Stop Pin
2. Cylinder Barrel 6. Cylinder Rod 10. Check Valve
3. Stop Ball 7. Cylinder Head 11. Check Valve Spring
Unit : mm
Criteria
43 mm
(1.693 in)
75 mm
(2.953 in)
75 mm Replace
(2.953 in)
Spring Criteria
35 mm
15. Check Valve Spring
(1.378 in)
CHARACTERISTICS
Unit: mm
Piston Rod Diameter......................................................................................................................................... 60 mm (2.362 in)
Max Cylinder Length ................................................................................................................................... 2160 mm (85.039 in)
Min Cylinder Length .................................................................................................................................... 1310 mm (51.575 in)
Cylinder Barrel Bore........................................................................................................................................ 120 mm (4.724 in)
Piston Stroke................................................................................................................................................. 850 mm (33.465 in)
Rod Thread for Piston Nut .................................................................................................................................................... M42
WB146-5 10-77 3
BACKHOE CYLINDERS MAINTENANCE STANDARD
ARM

2. Cylinder Barrel 5. Cylinder Piston 8. Piston Spacer
Unit: mm (inch)
Criteria
60 mm
(2.362 in)
60 mm
10. Bushing in Barrel Replace
(2.362 in)
60 mm
11. Piston Rod
(2.362 in)
CHARACTERISTICS
Unit: mm (inch)
Max Cylinder Length ................................................................................................................................ 1795 mm (70.669 in)
Cylinder Barrel Bore ..................................................................................................................................... 115 mm (4.528 in)
Piston Stroke....................................................................................................................................................700 mm (27.559 in)
10-78 3 WB146-5
BUCKET

Unit: mm (inch)
Criteria
55 mm
(2.165 in)
55 mm
(2.165 in)
55 mm
(2.165 in)
CHARACTERISTICS
Unit: mm (inch)
Rod Thread for Piston Nut .................................................................................................................................................... M36
WB146-5 10-79 3
TELESCOPIC ARM CYLINDER
0. Piston Rod Bushing 3. Wear Rings 6. Cylinder Rod

1. Barrel Bushing 4. Piston Seal 7. Cylinder Head
Unit: mm (inch)
Criteria
40 mm
(1.575 in)
47.21 mm 0.01 mm
47 mm 47.2 mm (1.859 in) (0.0004 in)
(1.850 in) (1.858 in) 47.3 mm 0.1 mm
Replace
(1.862 in) (0.004 in)
47.21 mm 0.01 mm
47 mm 47.15 mm (1.859 in) (0.0004 in)
(1.850 in) (1.856 in) 47.3 mm 0.1 mm
(1.862 in) (0.004 in)
CHARACTERISTICS
Unit: mm (inch)
Max Cylinder Length ................................................................................................................................. 2590 mm (101.968 in)
Cylinder Barrel Bore.......................................................................................................................................... 85 mm (3.346 in)
Piston Stroke............................................................................................................................................... 1140 mm (44.882 in)
Piston Rod Thread ................................................................................................................................................................ M30
10-80 3 WB146-5
SWING
0. Piston Rod Bushing 3. Cushion Valve 6. Retaining Screw

1. Cylinder Rod 4. Piston Seal 7. Cylinder Head
Unit: mm (inch)
Criteria
50 mm
i Piston Rod to Head
(1.969 in)
68 mm
9. Piston Rod Bushing
(2.677 in)
Replace
50 mm
10. Inner Pivot Bushing
(1.969 in)
60 mm
11. Outer Pivot Bushing
(2.362 in)
CHARACTERISTICS
Unit: mm (inch)
Max Cylinder Length .................................................................................................................................. 514.5 mm (20.256 in)
Min Cylinder Length ................................................................................................................................................ Not Available
Piston Stroke................................................................................................................................................... 230 mm (9.055 in)
WB146-5 10-81 3
OUTRIGGER
0. Piston Rod Bushing 4. Piston Seal 8. Piston Retaining Nut

1. Barrel Bushing 5. Cylinder Piston 9. Detent Ball
2. Cylinder Barrel 6. Cylinder Rod
3. Retarder Pin 7. Cylinder Head
Unit: mm (inch)
Criteria
50 mm
(1.969 in)
55 mm
(2.165 in)
55 mm
(2.165 in)
CHARACTERISTICS
Unit: mm (inch)
Min Cylinder Length ...................................................................................................................................... 850 mm (33.465 in)
Cylinder Barrel Bore............................................................................................................................................100 mm (3.967)
10-82 3 WB146-5
MEMORANDUM
WB146-5 10-83 3
WORK EQUIPMENT MAINTENANCE STANDARD
WORK EQUIPMENT
LOADER
10-84 3 WB146-5
MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm (inch)
Criteria
52.10 mm 52.20 mm -0.20 mm

52 mm (2.051 in) (2.055 in) (-0.008 in)
1. Bushing in Boom to to to
(2.047 in) 52.40 mm 52.30 mm 0.20 mm
(2.063 in) (2.059 in) (0.008 in)
44.911 mm 45.08 mm 0.13 mm
45 mm (1.768 in) (1.775 in) (0.005 in)
2. Pin to Bushing to to to
(1.772 in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
52.10 mm 52.20 mm -0.20 mm
52 mm (2.051 in) (2.055 in) (-0.008 in)
3. Bushing in Lever to to to
(2.047 in) 52.40 mm 52.30 mm 0.20 mm
(2.063 in) (2.059 in) (0.008 in)
44.911 mm 45.08 mm 0.13 mm
45 mm (1.768 in) (1.775 in) (0.005 in)
4 Pin to Bushing to to to
(1.772 in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
54.85 mm 55.00 mm -0.15 mm
55 mm (2.159 in) (2.165 in) (-0.006 in)
5. Bushing in Lever to to to
(2.165 in) 55.15 mm 55.046 mm 0.196 mm
(2.171 in) (2.167 in) (0.008 in)
44.911 mm 45.08 mm 0.13 mm
45 mm (1.768 in) (1.775 in) (0.005 in)
6. Pin to Bushing to to to Replace
(1.772 in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
75.046 mm 75.00 mm -0.076 mm
75 mm (2.955 in) (2.953 in) (-0.003 in)
7. Bushing in Lever and Cylinder to to to
(2.953 in) 75.076 mm 75.046 mm 0.0 mm
(2.956 in) (2.955 in) (0.0 in)
59.894 mm 60.137 mm 0.197 mm
60 mm (2.358 in) (2.368 in) (0.008 in)
(2.362 in) 59.94 mm 60.197 mm 0.303 mm
(2.360 in) (2.370 in) (0.012 in)
57.2 mm 57.25 mm -0.05 mm
57 mm (2.252 in) (2.254 in) (-0.002 in)
9. Bushing in Cylinder to to to
(2.244 in) 57.3 mm 57.25 mm .05 mm
(2.256 in) (2.254 in) (0.002 in)
49.911 mm 50.08 mm 0.13 mm
50 mm (1.965 in) (1.972 in) (0.005 in)
(1.969 in) 49.95 mm 50.24 mm 0.329 mm
(1.967 in) (1.978 in) (0.013 in)
57.2 mm 57.25 mm -0.05 mm
57 mm (2.252 in) (2.254 in) (-0.002 in)
(2.244 in) 57.3 mm 57.25 mm .05 mm
(2.256 in) (2.254 in) (0.002 in)
Unit: mm (inch)
WB146-5 10-85 3
Criteria
49.911 mm 50.08 mm 0.13 mm

50 mm (1.965 in) (1.972 in) (0.005 in)
(1.969 in) 49.95 mm 50.24 mm 0.329 mm
(1.967 in) (1.978 in) (0.013 in)
67.10 mm 67.2 mm -0.20 mm
67 mm (2.642 in) (2.646 in) (-0.001 in)
13. Bushing in Cylinder to to to Replace
(2.638 in) 67.40 mm 67.2 mm 0.10 mm
(2.654 in) (2.646 in) (0.0004 in)
59.894 mm 60.13 mm 0.19 mm
60 mm (2.358 in) (2.367 in) (0.008 in)
(2.362 in) 59.94 mm 60.29 mm 0.396 mm
(2.360 in) (2.374 in) (0.016 in)
10-86 3 WB146-5
MEMORANDUM
WB146-5 10-87 3
BACKHOE
10-88 3 WB146-5
WB146-5 10-89 3
Unit: mm (inch)
Criteria
80.059 mm 80.00 mm -0.005 mm
(3.152 in) (3.150 in) (-0.0002 in)
80 mm
1. Top Bushing in Main Frame (3.150 in) to to to Replace
80.089 mm 80.054 mm -0.089 mm
(3.153 in) (3.152 in) (-0.004 in)
64.894 mm 65.19 mm 0.25 mm
(2.555 in) (2.567 in) (0.010 in)
65 mm
(2.559 in) 64.94 mm 65.264 mm 0.37 mm
(2.557 in) (2.569 in) (0.015 in)
50.034 mm 50.0 mm -0.009 mm
(1.970 in) (1.968 in) (-0.0004 in)
50 mm
3. Inner Bushing on Cylinder Stud to to to
(1.969 in) 50.05 mm 50.025 mm -0.05 mm
(1.970 in) (1.970 in) (-.0002 in)
75.043 mm 75.0 mm -0.013 mm
(2.954 in) (2.953 in) (-0.0005 in)
75 mm
4. Outer Bushing in Bracket to to to
(2.953 in) 75.062 mm 75.03 mm -0.062 mm
(2.955 in) (2.954 in) (-0.002 in)
59.894 mm 60.06 mm 0.12 mm
(2.358 in) (2.365 in) (0.005 in)
60 mm
5. Inner Bushing in Outer Bushing to to to
(2.362 in) 59.94 mm 60.09 mm 0.196 mm
(2.360 in) (2.366 in) (0.008 in)
6. Outer Bushing in Frame --- --- --- ---
54.894 mm 55.137 mm 0.257 mm
(2.161 in) (2.171 in) (0.010 in)
55 mm
(2.165 in) 54.94 mm 55.197 mm 0.303 mm
(2.163 in) (2.173 in) (0.012 in)
80.059 mm 80.0 mm -0.029 mm
(3.152 in) (3.150 in) (-0.001 in)
80 mm
8. Bottom Bushing in Swing Frame to to to
(3.150 in) 80.089 mm 80.03 mm -0.089 mm
(3.153 in) (3.151 in) (-0.004 in)
64.894 mm 65.19 mm 0.25 mm
(2.555 in) (2.567 in) (0.010 in)
65 mm
(2.559 in) 64.94 mm 65.264 mm 0.37 mm
(2.557 in) (2.569 in) (0.015 in)
44.911 mm 45.08 mm 0.13 mm
(1.768 in) (1.775 in) (0.005 in)
45 mm
10. Pin to Rod Bushing to to to
(1.772in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
44.911 mm 45.08 mm 0.13 mm
(1.768 in) (1.775 in) (0.005 in)
45 mm
11. Pin to Head Bushing to to to
(1.772in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
54.985 mm 55.0 mm -0.015 mm
(2.165 in) (2.165 in) (-0.0006 in)
55 mm
12. Bushing in Stabilizer to to to
(2.165 in) 55.015 mm 55.03 mm 0.045 mm
(2.166 in) (2.167 in) (0.002 in)
44.911 mm 45.08 mm 0.13 mm

(1.768 in) (1.775 in) (0.005 in)
45 mm
(1.772in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
10-90 3 WB146-5
Unit: mm (inch)
Criteria
75.137 mm 75.0 mm -0.107 mm
(2.958 in) (2.953 in) (-0.004 in)
75 mm
(2.953 in) 75.197 mm 75.03 mm -0.197 mm
(2.961 in) (2.954 in) (-0.008 in)
59.894 mm 60.137 mm 0.197 mm
(2.358 in) (2.368 in) (0.008 in)
60 mm
(2.362 in) 59.94 mm 60.197 mm 0.303 mm
(2.360 in) (2.370 in) (0.012 in)
59.95 mm 60.0 mm -0.08 mm
(2.360 in) (2.362 in) (-0.003 in)
60 mm
(2.362 in) 60.15 mm 60.03 mm -0.15 mm
(2.368 in) (2.363 in) (-0.006 in)
49.911 mm 50.08 mm 0.13 mm
(1.965 in) (1.972 in) (0.005 in)
50 mm
(1.969 in) 49.95 mm 50.024 mm 0.329 mm
(1.967 in) (1.969 in) (0.013 in)
52.10 mm 52.0 mm -0.07 mm
(2.051 in) (2.047 in) (-0.003 in)
52 mm
18. Bushing in Bucket Lever to to to
(2.047 in) 52.40 mm 52.03 mm -0.40 mm
(2.063 in) (2.048 in) (-0.016 in)
44.911 mm 45.08 mm 0.13 mm
(1.768 in) (1.775 in) (0.005 in)
45 mm
(1.772in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
44.911 mm 45.08 mm 0.13 mm
(1.768 in) (1.775 in) (0.005 in)
45 mm
20. Pin to Cylinder Bushing to to to
(1.772in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
52.2 mm 52.10 mm -0.13 mm
(2.055 in) (2.051 in) (-0.005 in)
52 mm
21. Lever Bushing in Arm to to to
(2.047 in) 52.23 mm 52.40 mm -0.20 mm
(2.056 in) (2.063 in) (-0.008 in)
44.911 mm 45.08 mm 0.13 mm
(1.768 in) (1.775 in) (0.005 in)
45 mm
(1.772in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
52.10 mm 52.0 mm -0.07 mm
(2.051 in) (2.047 in) (-0.003 in)
52 mm
23. Bushing in Bucket Lever to to to
(2.047 in) 52.40 mm 52.03 mm -0.40 mm
(2.063 in) (2.048 in) (-0.016 in)
44.911 mm 45.08 mm 0.13 mm
(1.768 in) (1.775 in) (0.005 in)
45 mm
(1.772in) 44.95 mm 45.24 mm 0.329 mm
(1.770 in) (1.781 in) (0.013 in)
56.45 mm 57.20 mm -0.85 mm
(2.222 in) (2.252 in) (-0.034 in)
57 mm
25. Bucket Bushing in Arm to to to
(2.244 in) 58.05 mm 7.23 mm 0.78 mm
(2.285 in) (2.253 in) (0.031 in)
49.911 mm 50.08 mm 0.13 mm

(1.965 in) (1.972 in) (0.005 in)
50 mm
(1.969 in) 49.95 mm 50.24 mm 0.329 mm
(1.967 in) (1.978 in) (0.013 in)
WB146-5 10-91 3
Unit: mm (inch)
Criteria
59.894 mm 60.10 mm 0.16 mm
(2.358 in) (2.366 in) (0.006 in)
60 mm
27. Pin to Boom Rod Bushing to to to
(2.362 in) 59.94 mm 60.174 mm 0.28 mm
(2.360 in) (2.369 in) (0.011 in)
59.894 mm 60.10 mm 0.16 mm
(2.358 in) (2.366 in) (0.006 in)
60 mm
28. Pin to Boom & Arm Head Bushing to to to
(2.362 in) 59.94 mm 60.174 mm 0.28 mm
(2.360 in) (2.369 in) (0.011 in)
49.911 mm 50.08 mm 0.13 mm
(1.965 in) (1.972 in) (0.005 in)
50 mm
29. Pin to Arm Rod Bushing to to to
(1.969 in) 49.95 mm 50.142 mm 0.231 mm
(1.967 in) (1.974 in) (0.009 in)
44.911 mm 45.08 mm 0.13 mm
(1.768 in) (1.775 in) (0.005 in)
45 mm
30. Pin to Bucket Head Bushing to to to
(1.772in) 44.95 mm 45.142 mm 0.231 mm
(1.770 in) (1.777 in) (0.009 in)
39.911 mm 40.05 mm 0.10 mm
(1.571in) (1.577 in) (0.004 in)
40 mm
31. Pin to Jig Head Bushing to to to
(1.575 in) 39.95 mm 40.10 mm 0.189 mm
(1.573 in) (1.579 in) (0.007 in)
39.911 mm 40.05 mm 0.10 mm
(1.571in) (1.577 in) (0.004 in)
40 mm
32. Pin to Jig Rod Bushing to to to
(1.575 in) 39.95 mm 40.10 mm 0.189 mm
(1.573 in) (1.579 in) (0.007 in)
10-92 3 WB146-5
MEMORANDUM
WB146-5 10-93 3
AIR CONDITIONING MAINTENANCE STANDARD
AIR CONDITIONING
0. Magnetic Clutch 4. Safety Pressure Switch 8. Cab Air Circulation Fan

1. Compressor 5. Expansion Valve 9. Air Conveyor
2. Condenser 6. Evaporator
3. Dryer Filter Tank 7. Clutch Control Sensor
10-94 3 WB146-5
MAINTENANCE STANDARD AIR CONDITIONING
The compressor (1) is driven directly by the engine shaft by means of a

belt, and made to rotate by a pulley fitted with an electromagnetically
engaged clutch (0). A thermostatic sensor (7) controls the engagement
and disengagement of the clutch. It disengages the clutch when the
evaporator reaches the lower temperature limit and engages when the
evaporator reaches the upper temperature limit.
The coolant fluid, in gaseous phase is drawn into the compressor where
it is subjected to compression and an intense heating process. In these
conditions the fluid is then sent into the condenser (2) where, due to the
heat extracted by ambient temperature air flowing over fins, it reaches
condensation temperature, and passes into a high pressure liquid state.
Subsequently the coolant passes into the dryer filter group (3) which
performs three functions: it filters out impurities, absorbs any moisture
present in the circuit and, finally, also functions as a reserve tank. The
coolant in its liquid state is then transferred to the evaporator (6), first
passing through an expansion valve (5). The task of this valve is the
constant metering of the quantity of fluid in order to maintain optimum
evaporation. In the evaporator the coolant fluid is subjected to
expansion, bringing it up to the critical evaporation point at a
temperature of approximately -8°C (18°F).
The air flow generated by the centrifugal fan (8) which passes through
the evaporator (6) at ambient temperature is considerably warmer than
8°C (18°F). For this reason it yields heat to the coolant fluid, bringing it
up to boiling point and complete evaporation. On leaving the evaporator
(6) the coolant is drawn once more into the compressor (3) and a new
cycle commences. The yielding of heat from the atmosphere in which
the evaporator is positioned leads to the condensation of the water
suspended in the air, and hence to dehumidification. The condensate is
deposited on the evaporator fins where, if a temperature higher than 0°C
(32°F) is not maintained, it freezes and inhibits the functioning of the
evaporator. The task of keeping the temperature of the evaporator above
0°C (32°F), and thus within the optimum limits for heat exchange, is
entrusted to a thermostatic sensor (7).
The condensate that forms on the evaporator fins (6) also contains dust,
pollens and particles suspended in the air. Continual condensation
therefore effectively purifies the air, and the droplets of condensate are
discharged to the exterior. A fixed quantity of anti freeze oil is also
introduced into the circuit, with the function of lubricating all the
mechanical parts of the unit. A percentage of this oil circulates
constantly throughout the unit in nebulized form, lubricating the
compressor, pistons and bearings and the expansion valve. A pressure
switch (4) has been inserted in the electrical control circuit to protect the
unit in the case of a lack of coolant fluid or if the quantity becomes
insufficient due to leakages. This switch will inhibit the engagement of
the electromagnetic clutch and hence the functioning of the air
conditioning unit.
WB146-5 10-95 3
AIR CONDITIONING MAINTENANCE STANDARD
MEMORANDUM
10-96 3 WB146-5
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

12
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
ENGINE WITHOUT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
MACHINE IN POWER MODE AT MIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
WITH CONVERTER STALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . 20-12
ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
AC COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
BLEED AIR FROM CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
BLEED AIR FROM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
BLEED AIR FROM BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
RELEASING RESIDUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17
ACCELERATOR PEDAL AND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
ACCELERATOR PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
ACCELERATOR LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
LEAKAGE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
INDIVIDUAL PUMP CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
BRAKE GROUP LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
SECONDARY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
SETTING RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32
CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32
ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET . . . 20-32
SWING, LOADER DUMP, HAMMER, AND BOOM RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
LS DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
PPC SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
WB146-5 20-1 3
TESTING AND ADJUSTING
PC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
STEERING CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
POWER TRAIN GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
CLUTCH ENGAGEMENT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
TRANSMISSION CLUTCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
BOOM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
BUCKET CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
BOOM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
ARM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
BUCKET CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
OUTRIGGERS CIRCU1T - W/O LOCK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
WORK TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
UNIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
EMPTYING THE AC UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
FUSE AND RELAY PANEL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
FUSE AND RELAY PANEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
HEATING AND AIR CONDITIONING FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-69
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-69
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-69
WARNING! When working with others, use agreed upon signals and do not let unauthorized persons
near the machine.
WARNING! Before checking coolant level, wait until it has cooled. If the radiator cap is removed when
the coolant is hot, the coolant will spurt out and cause burns. Be careful when working close
to moving parts, fan, fan belt, etc. Entanglement with moving parts can cause serious injury.
WARNING! Before testing, adjusting or troubleshooting, make sure the machine is parked on firm, level
ground. Check that all machine safety devices are applied and that blocks are in place to
prevent the machine from moving.
20-2 3 WB146-5
TESTING AND ADJUSTING STANDARD VALUE TABLE
STANDARD VALUE TABLE
ENGINE
Machine Model WB146-5
Engine Model S4D102LE-2
Item Measurement Conditions Unit Standard Value Service Limit Value

• High idle 2457 2407 - 2507
Engine speeds • Low idle RPM 1050 1000 - 1100
• Rated speed --- ---
New
• At torque converter stall and 381
Intake air restric- element
full throttle mm H2O
tion Used
• At restriction indicator port 635
element
Lubricating oil
pressure with SAE • Minimum at low idle 0.7
15W-40 oil and kg/cm²
coolant tempera-
ture in operating • Minimum at high idle 2.1
range
New
101
Fuel filter inlet re- • Maximum restriction at high element
mm Hg
striction idle
Used
203
element
• Coolant temperature in operat-
ing range
Blow by pressure • Service Tool orifice size 5.613 mm H2O Max 101.6 Max 431.8
mm
• Full load at rated speed
Exhaust back pres- • Maximum at converter stall

mm Hg 76
sure and full throttle
Coolant tempera- • Maximum coolant operating

°C 105
ture temperature
Valve clearances • Intake valves 0.254

mm
with engine cold • Exhaust valves 0.504
• Deflection when pressed with
Fan Belt Tension finger force of approximately mm 10 10 - 15
10 kgf (22 lbf)
WB146-5 20-3 3
CHASSIS
Applicable Model WB146-5
Permissible
Cat. Item Measurement Condition Unit Standard Value
Value
• Engine coolant temperature: Within Max. 2457 2407 - 2507

operation range
Accelerator pedal • Engine oil temperature: Within operation
range
Min. 1050 ±50 1000 - 1100
Engine speed
• Measurement taken on drive shaft pulley

with tachometer.
rpm
• Engine coolant temperature: Within
operation range Max. 2200 2150 - 2250
• Engine oil temperature: Within operation
Accelerator fuel range
• Measurement taken on drive shaft pulley
with tachometer. Min. 1050 ±50 1000 - 1100
l a b c l a b c
Control valve
Bucket arm command only

mm - 6 5.5 2 - - - -
Raise 95 80 - 110
Bucket arm control lever Neutral J
Lower 95 80 - 110
Dump 95 80 - 110
Bucket control laver Neutral J
Curl 95 80 - 110
Raise 50 40 - 60
Boon backhoe control Neutral J
Travel of levers and pedals
• Engine stopped Lower 50 40 - 60

• Knob lever: at center and at
90° from the lever. Open 50 40 - 60
Arm backhoe control lever Neutral J
• Value reading at end of work-
Close mm 50 40 - 60
ing stroke plus half measured
backlash Open 50 40 - 60
Bucket backhoe control lever • Attachments on ground Neutral J
• Instrument metric divisions Close 50 40 - 60
Right 50 40 - 60
Boom swing control lever Neutral J
Left 50 40 - 60
Up 35 25 - 45
Outrigger control lever Neutral J
Down 35 25 - 45
Fuel control lever Min J.Max 40 30 - 50
20-4 3 WB146-5
12
Applicable model WB146-5
Permissible
Cat. Item Measurement condition Unit Standard value
value
• Engine stopped
Levers and pedals
Accelerator pedal • Knob lever: at center and at 90o from Min J Max mm 80 65 - 95
lever.
travel
• Value reading at end of work stroke Right J Left 3.5 3.1 - 3.9
Wheel swing plus half measured backlash rev
• Attachments on ground Left J Right 3.5 3.1 - 3.9
Bucket arm lever 1.5 1.0 - 2.0

Force for lever, pedal and steering wheel operation
Bucket lever • Engine speed: min. 1.5 1.0 - 2.0

• Oil temperature within operating
Boom lever range 1.8 1.3 - 2.3
• Tool connection at center of
Arm lever knob 80 mm away from handle 1.8 1.3 - 2.3
base.
Bucket lever kg 1.3 0.8 - 1.8
• Value reading at the 10 mm
Boom swing lever before end of work stroke. 1.3 0.8 - 1.8
• Instrument force gauge
Outrigger lever 1.5 1.0 - 2.0
• Ambient temperature 15 - 35oC
Fuel lever 6.0 5.0 - 7.0
Accelerator pedal 4.0 2.5 - 5.5
Steering wheel • Force measured on steering wheel knob at min. RPM −−− −−− −−−
for approximately half a rev under steady motion at a
speed of 2.5 per rev.
• Engine speed: 2200 rpm

• Oil temperature within operating range
Main valve pressure
• Move arm cylinder to end of stroke and measure pres-

Control valve sure 249 238 - 264
• Instrument: 0 to 100 kg/cm² pressure gauge mounted kg/cm²
on adapter at port P1C
• Working mode switch: POWER
Steering unit • Engine speed: 1500 ±50 rpm 178 173 - 188
WB146-5 20-5 3
12
Permissible
value
Bucket curled 274 264 - 284
Bucket dump 244 234 - 259
Bucket open close 274 264 - 284

Pressures of secondary valves circuits
Boom raise 351 323 - 365
Boom lower • Engine speed: 2200 rpm 274 264 - 284
Arm close) • Oil temperature within operating range 274 264 - 284
• Move arm cylinder to end of stroke and measure pres-
Arm out sure kg/cm² 274 264 - 284
• Instrument: 0 to 100 kg/cm² pressure gauge mounted on
Boom swing adapter at port P1C 234 223 - 249
Bucket curl • Working mode switch: POWER 274 264 - 284
Bucket dump −−− −−−
Extenda arm out - in −−− −−−
Hammer delivery 193 183 - 213
Steering unit safety 228 228 - 249
• Engine speed, w/o load: 2400 ±50 rpm

With converter • Machine in 3rd gear 2175 ±50 2125 - 2225
• Work brakes: engaged
• Work mode switch: POWER
Engine speed with load - Converter

• Machine in 3rd gear
With converter and
• Work brakes: engaged 2075 ±50 2025 - 2125
hydraulic circuit rpm
• Bucket raised bottom of stroke
• Steering held at end of stroke

Hydraulic circuit at • Machine in Neutral
600 Min. 600
Low idle • Parking brake: applied
• Bucket dump bottom of stroke
20-6 3 WB146-5

Permissible
value
• In this position check in feedback of each cylinder and
leakage with applied load on tip of bucket teeth.
Work equipment • On level ground. 150 300
• GP Bucket: load 1800 kg MP Bucket: load 1550 kg
• Engine stopped
• Oil temperature: 45 - 55 °C
• Check measures as soon as engine stops.
Loader
• Check changes every 5 min and total change in 15 min.

Boom cylinder 12 20
Hydraulic drift working equipment
Bucket cylinder 35 50
mm
Working equip-
• In this position check extension of each cylinder and 200 350
ment
leakage with normal load on bucket.
• On level ground.
• Bucket: load with standard arm: 340 kg
• Bucket load with tele arm: 0 kg Fully extend arm
Boom cylinders 10 20
• Engine stopped
Backhoe
• Check measures as soon as engine stops.

• Check changes every 5 min and total change in 15 min.
Arm cylinder 10 20
Bucket cylinder 8 15
WB146-5 20-7 3
.

Cat. Item Measurement condition Unit Standard value Permissible value
• Backhoe balanced on guides bucket in
• Transport condition.
• Fully retract arm and bucket cylinder Lift
bucket fulcrum pin 1 m off ground and swing
boom to bottom of stroke in either direction.
• Move machine on a slope of 15° and apply
parking brake.
Boom swing • Stop engine and, after 1 minute, check inner 15 15
cylinder feed back opposite to boom every 5
min for a total of 15 minutes.
Hydraulic drift work equipment
Backhoe
mm
• Backhoe balanced.
• Boom and arm cylinders in, bucket cylinder
out
• Outriggers at maximum extension.
• Engine stopped
• Check frame lowering for each side every 5
Outriggers min. for a total of 15 minutes. 7 15
Boom 2 each Max. 8

Loader
Bucket • Engine: Max speed 1.6 each Max. 6

Cylinder Leakage
Boom • Oil temperature: 45 - 55 °C 3.3 Max. 13.5

Arm • Leaking check: on cylinder opposite side to 3 Max. 12
pressure one.
Backhoe
Bucket cm³/min 2.4 Max. 9.5

• Check 1 cylinder at a time.
Boom swing • For loader bucket and boom and for swing, 3.2 Max. 13
Outriggers check the two cylinders separately. 3.3 Max.13.5
Jig arm 1.6 Max 6
20-8 3 WB146-5
12 Applicable model WB146-5
Standard Permissible
Cat. Item Measurement condition Unit
value value
Arm bucket
• Engine speed:
Lifting
max.
• Oil tempera- 3.6 3.1 - 4.1
ture: 45 - 55 °C
• Bucket speed
Cylinders fully button: applied
out
Lowering
Loader bucket
2.6 2.2 - 3.0
Bucket at ground
level
Bucket • Engine speed:
max.
Curl
2.3 2.0 - 2.6
• Oil tempera-
ture: 45 - 55 °C
• Bucket speed
button: applied
Cylinders fully
Dump
2.8 2.4 - 3.2
out
Work equipment speed
Lifting U
Boom cylinder • Engine speed: 2200 rpm
fully in sec. 2.7 2.3 - 3.1
• Oil temperature: 45 - 55
°C
↕ • Backhoe balanced Lowering
• Power mode ON
2.0 1.7-2.3
Bucket on ground
Arm cylinder
Opening

fully in 2.9 2.5 - 3.4
Backhoe
↕ •
•
Backhoe balanced
Power mode ON
Closing U
Arm cylinder 3.2 2.7 - 3.7

fully out
Bucket cylinder
Dump
fully in 2 1.7 - 2.3

• Oil temperature: 45 - 55
°C
↕ • Backhoe balanced
• Power mode ON
Curl
Bucket cylinder 2.5 2.1 - 2.9

fully out
WB146-5 20-9 3

Standard Permissi-
Cat. Item Measurement condition Unit
value ble value
Right U
Boom swing to
Work equipment speed
3.2 2.7 - 3.7

tight end of travel • Engine speed: 2200 rpm
Backhoe
↕ • Arm vertical
• Power mode ON
Left U
Boom swing to left
3.2 2.7 - 3.7
end of travel
• Engine speed: min.

• Check item necessary to lift
bucket from level ground
Arm bucket 0 Max. 2

Boom • With attachments fully extended, 0 Max 2
lower boom and check necessary sec
time from beginning of lift until
bucket is on level ground
Work equipment
Time lag
• Place boom at 45°, open completely with

Arm bucket curled. Extend arm cylinder and 0 Max 2
check time passing between arm stop at dead
center and restart movement.

• Place arm in horizontal position.
Bucket Tilt back bucket cylinder and then 0 Max.2
extend it. Check time passing
between bucket stop at dead center
and then restart movement
• Boom arm and bucket retracted and
centered on machine
Outriggers 0 Max. 2
• Check time necessary for outriggers to
raise machine from when they lean on
level ground.
• Check each outrigger at a time.
20-10 3 WB146-5
TESTING AND ADJUSTING SPECIAL TOOLS
SPECIAL TOOLS
Measurement Point Symbol Code Name Qty Note
Engine speed A Available Locally Multi scale tachometer 1 20 to 4000 rpm
Valve clearance B Available Locally Feeler gauge 1 –
Oil and coolant temp D 1 Available Locally Digital thermometer 1 -50 to 1200°C
1 Available Locally Pressure gauge 2 Full scale 61 kg/cm²

E
Hydraulic pressure
5
Servo control kit 1 0 to1020 kg/cm²
6
ATR800200
1 Flow meter 1 Delivery 0 to 300 l/min.
F
2 Pipe fitting kit 1 –
Air bleeding G ATR201490 Tank cap 1 Pump air bleeding
Hand brake L Available Locally Spring dynamometer 1 Full scale 20 kg
1 Available Locally Maintenance station 1 For coolant R134a
Air Conditioning unit M 2 Available Locally Thermometer hygrometer 1 Sampling every 15 sec
3 Available Locally Leak detector 1 For coolant R134a
WB146-5 20-11 3
TESTING AND ADJUSTING ENGINE SPEED
ENGINE SPEED
WARNING! When checking the engine speed be careful. Do not touch high temperature parts or get
caught in rotating parts.
★ Check the engine speed with a tachometer A under the following conditions:
● Engine coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 - 80°C (154 - 176°F)
● Hydraulic oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 - 55°C (113 - 131°F)
ENGINE WITHOUT LOAD

1. Start the engine and check:
Low idle speed without load, accelerator pedal released. High idle
speed without load, accelerator pedal at the travel end.
● Low idle speed ................................................. 1050 ±50 rpm
● High idle speed ................................................ 2400 ±50 rpm

★ If the idle speeds are not within limits, without a load on the engine,
check the accelerator pedal stop and wiring insulation before going
on with other operations.
MACHINE IN POWER MODE AT MIN
1. With the transmission in neutral, idle the engine.
2. Dump the loader bucket and hold the movement; let the engine stabilize and then read the engine speed.
● Normal speed ...................................................................................................................................................600 rpm
● Minimum speed ...............................................................................................................................................600 rpm
WITH CONVERTER STALLED
1. Increase speed to high idle and brake with the foot brakes.
2. Hold the brakes while simultaneously engaging 3rd gear; let the engine stabilize, and read the rpm value.
● Minimum speed ............................................................................................................................................ 2125 rpm
● Maximum speed............................................................................................................................................ 2225 rpm
3. Hold the machine stalled as long as necessary, in any case for not more than 30 seconds, and carry out the tests at least 15
seconds apart.
CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD
1. Increase speed to high idle and brake with the working brakes.
2. While holding the brakes:
A. Engage 3rd FORWARD
B. Raise the loader and hold in this position;
C. Steer the wheels fully;
20-12 3 WB146-5
TESTING AND ADJUSTING ENGINE SPEED
3. In the above conditions, let the engine stabilize, then read the engine rpm.
● Minimum speed .............................................................................................................................................2025 rpm
● Maximum speed.............................................................................................................................................2125 rpm
4. Hold the machine stalled as little as necessary, in any case for not more than 30 seconds, and carry out the tests at least 15
seconds apart.
ANALYSIS
1. If readings are not within the required interval, check the ENGINE SHOP MANUAL.
2. If the engine has no abnormal conditions, adjust the pump's power absorption, PC valve.
WB146-5 20-13 3
TESTING AND ADJUSTING VALVE CLEARANCE
VALVE CLEARANCE
1. Park the machine on solid, level ground, apply the parking brake, and remove the ignition key.
2. Remove the air filter and muffler. For details see Section 30.
3. Release the coolant temperature sensor the wiring harness.
4. Adjust the valve clearance according to the instructions provided in the ENGINE SHOP MANUAL.
20-14 3 WB146-5
TESTING AND ADJUSTING AC COMPRESSOR BELT TENSION
AC COMPRESSOR BELT TENSION

1. Turn the screw (1) clockwise to tension the belt (2).
2. Apply a 10 kg (22 lbf) force halfway between compressor pulley

(4) and engine pulley (3).
3. Check the resulting arrow F.

●Normal tensioning ............................. 4 - 6 mm (0.158 - 0.236 in)
● New belt............................................................... 3 mm (0.118 in)
4. Recheck the belt tension after 15 minutes of operation.
WB146-5 20-15 3
TESTING AND ADJUSTING BLEED AIR FROM CIRCUITS
BLEED AIR FROM CIRCUITS
BLEED AIR FROM HYDRAULIC CIRCUIT

★ When hydraulic cylinders or associated tubes have been removed, it is necessary to bleed air before using the machine
again. Perform bleeding on one cylinder at a time.
1. Start the engine and run at high idle for about 5 min. to heat the oil.
2. Reduce speed to low idle and extend and retract the 1st cylinder to be bled several times.
★ Extend and retract pistons until about 100 mm (4 inches) from their end of stroke.
3. Stop the engine, check and top off the oil in the tank.
4. Bring again the engine at high idle and repeat Step 2; return the engine to low idle speed and make a complete travel of the
cylinder until the pump reaches its maximum pressure.
5. Repeat Steps 2 and 3 for all cylinders, frequently checking the oil level in the tank.
BLEED AIR FROM BRAKING CIRCUIT

★ This operation is to be carried out every time maintenance is made
on the braking circuit to remove or replace a component, or when
air entered into the circuit. Machine must be stopped with attach-
ments on level ground.
1. Make sure that oil in the brake system tank (1) is at maximum level.
Remove safety plugs on the bleed screws (2). Attach a vinyl hose
(3) to catch oil.
2. Push the brake pedal to the bottom and, while keeping it pushed,
loosen the bleed screw (2) of the brake unit that is being bled until
the pedal reaches the end of its stroke. Keeping the pedal at the end
of its stroke, tighten the bleed screw.
3. Release the brake pedal, wait for few seconds and repeat step 2 of
this above operations two or three times until oil flows out the
bleeding screw without air bubbles.
4. Repeat the same steps for the opposite braking unit.

★ Frequently check the oil level in the tank and refill every time
the level approaches minimum.
20-16 3 WB146-5
TESTING AND ADJUSTING BLEED AIR FROM CIRCUITS
5. After bleeding air, install screws (2) safety plugs (4).
RELEASING RESIDUAL PRESSURE

1. Lower all work attachments on level ground, stop the engine.
2. Move all control levers in all directions to completely release residual pressure in the hydraulic system.
WB146-5 20-17 3
TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
ACCELERATOR PEDAL AND LEVER

★ Measurement conditions:
● Machine ........................................................................................................ Shut down with safety features engaged
● Engine ............................................................................................................... Stopped and at operating temperature

● Idle speeds.................................................................................................................................. Within standard value
★ In order to check high speed engine idle, push the accelerator pedal (1) manually.
ACCELERATOR PEDAL TRAVEL

1. Make sure that the accelerator pedal (1) is fully raised and the ac-
celerator lever (2) is at minimum stroke.
2. Push the accelerator pedal until the accelerator lever (5) contacts
the injection pump high idle adjusting screw.
3. Adjust the end travel stopper (6) of the accelerator pedal (1) in this
position and lock it with the nut (7).
4. Release the accelerator pedal (1).
20-18 3 WB146-5
TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
ACCELERATOR LEVER TRAVEL

1. Remove the front mat.
2. Remove the metal sheet (1) closing the bottom of the cab and the
upright guard (2).
3. Check that the hand accelerator (3) is at end of travel at MIN.
4. Loosen and unscrew the locking nut (4).
5. Start the engine and move the hand accelerator (3) to MAX.
6. Tighten the nut (5) to the required speed for hand accelerator.
● Engine idle speed............................................................2200 rpm
7. Return to engine low idle speed and retain the position of the nut
(5) with the locking nut (4).
8. Check the MAX speed once more by pushing the hand accelerator
to the end of travel.
WB146-5 20-19 3
TESTING AND ADJUSTING BRAKE SYSTEM
BRAKE SYSTEM
★ Working condition:
● Set the machine on level surface with attachments on ground
level
● Apply the parking brake and remove the ignition key
● Pedal connection pin (0) inserted.
CONTROL
1. Remove the floor mat.
2. Check the height A between the floor and pedal (1) lower edge.
3. Depress the pedals by hand and check height B to determine slack

G.
★ Standard clearance ..........................3 - 8 mm (0.118 - 0.315 in)
20-20 3 WB146-5
ADJUSTMENT
1. Remove the front cover (2).
2. Loosen the nuts (3) and adjust the slack using the stoppers (4).
3. When adjustment is complete, secure the stoppers (4).

★ When the stoppers are secured, double check to ensure that slack
G is within the range and that the pedals touch the stoppers
simultaneously.
WB146-5 20-21 3
CHECKS
★ Working condition:
● Engine stopped
● Place the vehicle on firm level ground with the equipment raised and the safety devices activated.
● Independent brake pedals and oil pan at maximum level.
★ The brake system checking procedure consists of two steps:
● Checking the brake pumps and checking the braking groups for leaks.
LEAKAGE CHECKS
1. Disconnect the hose (1) from the tubes (2) connecting to the axle
braking groups. Plug the tube.
● Plug all open tubes and hoses to prevent contamination.
2. Connect a pressure gauge E2 to the hose (1).
3. Apply the brake pedals until a pressure of 122.2 kg/cm² (1,738 psi)
is reached.
★ Do not exceed the max permitted pressure
............................................................ 152.8 ±5 kg/cm² (2,173 psi)
4. Hold the pressure on the pedal for at least 2 minutes and verify that
the pressure and pedal position remain unchanged.
★ If the position of the pedal needs to be changed in order to hold
the pressure, then the loss of pressure is to be blamed on leaks
inside either pump. To confirm whether this is the case, check
the oil. If a leak condition exists, the oil will be stirred.
20-22 3 WB146-5
INDIVIDUAL PUMP CHECK
1. Remove the front lining (3).
2. Disconnect the pressure equalizer hose (5) from the brake circuit
pump (4) that is being inspected.
3. Seal the hole of the equalizer plug A.
4. Remove the clamp (6).
5. Disconnect the delivery hoses (7) from the pump that is being tested.
Connect a pressure gauge E2 to the pump during the inspection.
6. Apply the brake pedal corresponding to the pump and pressurize
the circuit to 122.2 kg/cm² (1,738 psi).
★ Do not exceed the max permitted pressure
.....................................................152.8 ±5 kg/cm² (2,173 psi)
7. Hold the pressure on the pedal for at least two minutes and verify
that pressure and pedal position remain unchanged.
★ If the position of the pedal needs to be changed in order to hold
the pressure, then the loss of pressure is to be blamed on leaks
inside the pump, and in this case the pump needs to be
changed. To confirm whether this is the case, check the oil. If a
leak condition exists, the oil will be stirred.
8. Repeat for the other pump.
WB146-5 20-23 3
BRAKE GROUP LEAKAGE
1. Disconnect the delivery hose (1) from the braking group that is
being inspected.
2. Connect a suitable tool between the delivery hose (1) and the
braking group.
★ Check to ensure that the pressure tap (8) is installed between the
braking group and the cut out valve (9).
3. Connect a pressure gauge E2 to the tool pressure tap and open the
cut out valve (9).
4. Operate the brake pump and pressurize the circuit to

152.8 ±56 kg/cm² (2,173 ±797 psi) max.
5. Hold the pressure while simultaneously closing the valve (9) to keep the braking circuit that is being inspected
under pressure.
6. Release the brake pedal and monitor the pressure gauge E2 for two minutes.
★ If the pressure reading changes in the negative, then there is a brake piston seal failure.
WARNING! Further evidence of leak is an increase in the level of oil in the axle, and the fact that the oil is
stirred as a result. Replace all sealing rings in the various axle sections and completely
change the lubricant.
7. Repeat the test for the other brake group using the same procedure as above.
8. Restore the brake circuit to operating condition.
WARNING! When checks and repair are complete, bleed the air from the braking groups
20-24 3 WB146-5
TESTING AND ADJUSTING PARKING BRAKE ADJUSTMENT
PARKING BRAKE ADJUSTMENT

★ Test conditions:
● Tire pressure................................Within the prescribed range
● Machine in operating conditions.............................................

................................................W/O load and on level ground
● Working brake pedals .................... Connected by a cotter pin
1. Remove the screws (1) and parking brake housing (2).
2. Engage the parking brake.
3. Press and hold the microswitch (3) while engaging 2nd gear and
selecting a direction of movement.
4. Accelerate engine gradually up to 1530 ±50 rpm.

WARNING! If machine moves, release the microswitch to
return to N, Neutral.
5. Rotate the end of the lever (4) by two or three turns

counterclockwise.
★ Direction of rotation is from the operator’s point of view when
sitting in the driver’s seat.
6. Apply the parking brake and repeat the test.

★ If a normal braking condition is not achieved after 2 attempts
to adjust the lever, check control cable for slackness and brake
disc for wear and replace components as necessary.
WB146-5 20-25 3
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT
INTRODUCTION
1. Engine 3. Hydraulic Pump 5. LS Safety Valve

2. Transmission 4. Steering Unit 6. Main Control Valve
INTRODUCTION
1. The machine is equipped with a single control valve with hydraulically controlled spools. The control valve is protected
against over pressure by a main relief valve, referred to as the LS safety valve, with an adjustable pressure setting.
2. The full pump delivery supplies the control valve.
3. Pump delivery is shut by the priority valve, inside the control valve, when the steering unit is used for a
steering manoeuvre.
20-26 3 WB146-5
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
MAIN CONTROL VALVE
Cylinder and Movement Port kg/cm² (psi)

191.02 kg/cm²
Hammer B0
(2,717 psi)
275.13 kg/cm²
Open A1
(3,913 psi)
Backhoe Arm
275.13 kg/cm²
Close B1
(3,913 psi)
234.37 kg/cm²
Right A2
(3,334 psi)
Backhoe Swing
234.37 kg/cm²
Left B2
(3,334 psi)
244.56 kg/cm²
Dump A3
(3,479 psi)
Loader Bucket
275.13 kg/cm²
Curl B3
(3,913 psi)
275.13 kg/cm²
Lower A4
(3,913 psi)
Backhoe Boom
346.02 kg/cm²
Raise A4
(4,922 psi)
Dump A5 ---
Backhoe Bucket 275.13 kg/cm²
Curl B5
(3,913 psi)
275.13 kg/cm²
Close A6
(3,913 psi)
MP Bucket
275.13 kg/cm²
Open B6
(3,913 psi)
Out A7 ---
Telescopic Arm
In B7 ---
Raise A8 ---
Loader Arm
Lower B8 ---
Down A9 ---
Right Outrigger
Up B9 ---
Down A10 ---
Left Outrigger
Up B10 ---
WB146-5 20-27 3
TESTING AND ADJUSTING RELIEF VALVES
RELIEF VALVES
TESTING
UNLOADING VALVE
1. Connect a pressure gauge E1 to the tap P1C on the pump. Start

the engine and run at low idle with all levers in neutral position.
2. In this condition, check the pressure in the hydraulic circuit.

● Normal pressure . . . . . . . . . . . 41.8 ±4.1 kg/cm² (595 ±58 psi)
● The unloading valve cannot be reset; replace if necessary.
MAIN RELIEF VALVE

● Engine . . . . . . . . . . . . . . . . . . . . . . . At Operating Temperature
● Hydraulic oil . . . . . . . . . . . . . . . . . . . .45 - 55°C (113 - 131 °F)
● Working brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applied
1. Connect a pressure gauge E3 to the tap P1C of the pump. Start the
engine, move the hand accelerator lever to full throttle and check
setting pressure for main relief valve by forcing the loader arm raise
movement the full travel span.
● Nominal pressure . . . . . 239.4 - 270 kg/cm² (3,405 - 3,840 psi)
★ If the main relief valve pressure does not correspond to the
nominal pressure value, it must be reset.
SECONDARY VALVES
Boom Swing, Loader Bucket Dump and Hammer
● Engine . . . . . . . . . . . . . . . . . . . . . . . At Operating Temperature
● Hydraulic oil . . . . . . . . . . . . . . . . . . . .45 - 55°C (113 - 131 °F)
● Working brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applied
★ The pressure readings are to be operated from the same check
point.
1. Connect a pressure gauge E3 to the tap P1C of the pump. Start the
engine and bring the hand accelerator lever up to 2200 rpm.
2. Check pressure for each movement, with the control lever at the
end of its travel and at stabilized pressure.
★ Move piston to the end of stroke to check the pressure.
Cylinder and movement Setting kg/cm² (psi)
Hammer 183.4 – 213.9 kg/cm² (2,609 - 3,042 psi)
Right 229.2 – 254.7 kg/cm² (3,259 - 3,623 psi)

Boom swing
Left 229.2 – 254.7 kg/cm² (3,259 - 3,623 psi)
Loader Dump 239.4 – 264.9 kg/cm² (3,405 - 3,768 psi)
20-28 3 WB146-5
Backhoe Boom Raise
● Engine ...........................................At Operating Temperature
● Hydraulic oil .....................................45 - 55°C (113 - 131°F)
● Working brakes ..........................................................Applied
1. Set the machine with the arm in the vertical position and the bucket
on level ground.
2. Stop the engine and release the residual hydraulic pressures
3. Disconnect the hose (1) and connect a tee (2) with an adapter.
Connect a pressure gauge E3 to the adapter.
4. Start the engine, connect a 1500 kg (3,307 lbs) weight to the

bucket, and completely lower the outriggers.
5. Slowly extend the arm and boom and take the pressure when the
boom lowers.
★ Normal pressure ...............326 - 366.7 kg/cm² (719 - 808 psi)
WB146-5 20-29 3
Arm In, Loader Bucket, Backhoe Bucket, Boom Raise, And
MP Bucket
● Engine .............................................. At Operating Temperature
● Hydraulic oil ........................................45 - 55°C (113 - 131°F)
● Working brakes ............................................................. Applied
★ The pressure readings are to be operated from the same check point.
1. Connect a pressure gauge E3 to pressure tap P1C of the pump.
2. Start the engine and bring the hand accelerator lever up to

2200 rpm.
3. Set the main relief valve (1) to a value 30.5 kg/cm² (67 psi) higher
than the maximum pressure to be tested.
4. Check pressure for each movement, with the control lever at the
end of its travel and at stabilized pressure.
★ Move piston to the end of stroke to check the pressure of the
working equipment.
Cylinder and movement Setting kg/cm² (psi)
Arm Close 264.9 – 285.3 kg/cm² (584 - 629 psi)
Loader bucket Curl 264.9 – 285.3 kg/cm² (584 - 629 psi)

Boom Left 264.9 – 285.3 kg/cm² (584 - 629 psi)
Dump 264.9 – 285.3 kg/cm² (584 - 629 psi)
Loader Close 264.9 – 285.3 kg/cm² (584 - 629 psi)
Open 264.9 – 285.3 kg/cm² (584 - 629 psi)
★ If one movement fails to reach the setting pressure, then the malfunction is in the tested element.
★ If all movements fail to reach the setting pressure, then you need to pressure set or replace the secondary valve.
20-30 3 WB146-5
MEMORANDUM
WB146-5 20-31 3
TESTING AND ADJUSTING SETTING RELIEF VALVES
SETTING RELIEF VALVES
MAIN RELIEF VALVE

1. Loosen lock nut (1).
2. Adjust the pressure using the screw (2).

★ To increase pressure . . . . . . . . . . . . . . . . . . . Turn Clockwise
★ To decrease pressure . . . . . . . . . . . . . .Turn Counterclockwise
3. Lock the nut (1).
Lock Nut: 29.4 - 39.2 N•m (22 - 29 lbf ft)
★ When adjustment is complete, check the setting of the main

relief valve using the procedures used for measurements.
CIRCUIT RELIEF VALVES

ARM IN, LOADER CURL, BACKHOE BUCKET
CURL, BOOM RAISE, AND MP BUCKET
1. Loosen the lock nut (1).

A Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . Hammer Circuit
B Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . Swing Left
C Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . Loader Dump
D Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . Swing Right
E Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . Boom
2. Adjust the pressure using the nut (2).

★ To increase pressure . . . . . . . . . . . . . .Turn Clockwise
3. Tighten the lock nut (1) while holding the adjusting nut (2).
Lock Nut (1): 39 - 49 N•m (29 - 36 lbf ft)
20-32 3 WB146-5
TESTING AND ADJUSTING SETTING RELIEF VALVES
12
SWING, LOADER DUMP, HAMMER, AND BOOM RAISE
1. Loosen the lock nut (1).
2. Adjust the pressure using the nut (2).

★ To increase pressure . . . . . . . . . . . . . .Turn Clockwise
3. Tighten the lock nut (1) while holding the adjusting nut (2).
Lock Nut (1): 39 - 49 N•m (29 - 36 lbf ft)
WB146-5 20-33 3
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
LS DIFFERENTIAL PRESSURE
CONTROL
★ Engine . . . . . . . . . . . . . . . . . . . . . . .Stopped but at working
temperature.
★ Hydraulic oil . . . . . . . . . . . . . . . . . .45 - 55°C (113 - 131°F).
★ Machine: front equipment on the ground, parking brake
applied and boom and arm fully extended.
★ Working mode. . . . . . . . . . . . . . . . .POWER
1. Disconnect the hose (1) from the LS line, Install a tee with a
pressure tap (2) and reconnect the hose (1).
2. Connect a differential pressure gauge E4 to adaptor (2) and to tap

P1C on the pump.
3. Start the engine and run it at low idle, 1050 ±50 rpm, and, without
any lever movement, in neutral position, read the U pressure.
★ Normal value............................... 41.7 ±4 kg/cm² (593 ±57 psi)
★ If UPLS pressure is not within the permissible range, replace
the control valve unloading valve.
4. Simultaneously perform a boom raise and a backhoe bucket curl

movement to end of travel and then read the U pressure.
★ Normal value............................... 28 ±1.5 kg/cm² (398 ±21 psi)
★ If the UPLS value is not within the permissible range, set the
unloading valve.
ADJUSTMENT
★ If the UPLS value is not within the specified range, adjust the LS
valve as follows:
1. Loosen the retaining nut (1) and turn the adjustment screw (2).
★ To increase pressure..........................................Turn Clockwise
★ To decrease pressure .............................Turn Counterclockwise
★ Each turn of the adjustment screw (2) will change the pressure
by approximately 13.2 kg/cm² (188 psi).
Lock Nut: 39 - 49 N•m (29 - 36 lbf ft)
3. When adjustment is complete, check the setting of the LS valve

using the procedures used for checking.
20-34 3 WB146-5
TESTING AND ADJUSTING PPC SUPPLY PRESSURE
PPC SUPPLY PRESSURE
CHECK
★ Engine ............................................At operating temperature.
★ Hydraulic oil temperature .................45 - 55°C (113 - 131°F)
1. Connect a pressure gauge E1 to the pressure tap (1) of the solenoid

valve group (2).
2. Start the engine and run the engine at low idle with all levers in
neutral position.
3. Check the pressure.

★ Normal pressure ..........................38 ±3 kg/cm² (540 ±43 psi)
ADJUSTMENT
★ If the pressure value is not within the tolerance range, adjust the
valve (1) as follows:
1. Loosen the retaining nut (2) and turn the adjustment screw (3).
★ To increase pressure...................................... Turn Clockwise
★ To decrease pressure ......................... Turn Counterclockwise
★ Each turn of the adjustment screw (3) will change the pressure.
Lock Nut (2): 22 ±2.5 N•m (16 ±2 lbf ft)
WB146-5 20-35 3
TESTING AND ADJUSTING PC VALVE
PC VALVE
ADJUSTMENT
★ If pump delivery and LS differential pressure are within permissible values, but you notice that
the engine rpm drops as a result of a change in the load, or that working equipment is very
slow, it is time to adjust the PC valve (1).
1. Loosen the nut (2) and turn the adjustment screw (3).
★ To decrease the pump's torque absorption, turn the adjustment
screw (3) counterclockwise
★ To increase the pump's torque absorption (i.e. to increase the
speed of working equipment) turn the adjustment screw (3)
clockwise.
★ Turn the adjustment screw by not more than 180° in relation to
the 0° line, in both directions
★ Adjustment screw position on first installation shown
Lock Nut (2): 27.4 - 34.4 N•m (20 - 25 lbf ft)
20-36 3 WB146-5
TESTING AND ADJUSTING STEERING CONTROL SYSTEM
STEERING CONTROL SYSTEM

● Engine .................................................Operating temperature
● Hydraulic oil .....................................45 - 55°C (113 - 131°F)
CONTROL
1. Connect a pressure gauge E3 to the tap P1C on the main control
valve.
2. Start the engine and bring it to idle speed 1500 ±50 rpm and carry
out a total steering.
3. Force the steering wheel at the end of stroke, check pressure.

★ Normal pressure ......178.3 - 188.5 kg/cm² (2,536 - 2,681 psi)
4. Check the other steering direction.
SETTING
★ If pressure is not within permissible value, set the upper valve (1) of the
steering unit (2).
1. Remove the plug (3). Insert a wrench and loosen the screw (4).
★ To increase pressure..........................................Turn Clockwise
★ To decrease pressure .............................Turn Counterclockwise
2. Stop the engine and replace the plug (3); ensure that the seal (5) is in
its proper position.
Plug (2): 40 - 60 N•m (30 - 44 lbf ft)
WB146-5 20-37 3
TESTING AND ADJUSTING STEERING CYLINDER
STEERING CYLINDER
● Engine.................................................At operating temperature
● Hydraulic oil........................................45 - 55 °C (113 - 131°F)
● Working brakes.............................................................Engaged
● Maximum steering pressure ............. Within permissible limits.
1. Start the engine and full steer the wheels in either direction, then stop the engine.
2. Disconnect the supply hose (2) from the cylinder (1) on the side
where the rod is fully out (3); plug the hose tightly.
3. Connect a provisional hose to the cylinder (1) to collect any leaking

fluid.
4. Start the engine and operate the engine at high idle speed.
5. Force the steering wheel to the end of its travel and retain the
position for 30 seconds; measure any leak during the following
minute.
6. Release the steering wheel, run the engine at low idle, and then stop
the engine.
7. Check if leakage is normal.

★ Test cylinder on one side only, as there is only one gasket separating the two chambers.
8. Restore the hydraulic connection, steer the wheel several times in both directions to remove any air from the circuit.
20-38 3 WB146-5
TESTING AND ADJUSTING POWER TRAIN GROUP
POWER TRAIN GROUP

The power train group can be used to perform pressure tests on the
internal hydraulic circuit. These are useful for identifying malfunctions.
Specifically, the tests involve:
Converter Oil Pressure
Clutch Engagement Pressure
Supply Pressure
★ Test condition:
● Engine............................................................................... Stopped
● Brake pedals ......................................... Connected by a cotter pin
● Machine: on solid and level ground with the equipment raised
and safety devices engaged.
● Lower cab closeout........................................................Removed.
CONVERTER OIL PRESSURE

1. Remove the plug P22 and connect the pressure gauge E6.
2. Start the engine and heat the engine and all the fluids up to working temperature. In particular make sure that the power
train oil reaches a temperature of 80 ±5°C (176°F).
3. With the engine at MIN, check the pressure on the pressure gauge
E6.
★ Idle pressure ...............................................3.05 kg/cm² (43 psi)
4. Gradually increase engine speed to 2200 rpm; take a new reading

on pressure gauge E6.
★ Normal pressure .....................3.05 - 9.17 kg/cm² (43 - 130 psi)
5. Bring the engine back to MIN and compare the pressure with the
normal value.
★ Min pressure ..............................................3.05 kg/cm² (43 psi)
★ If the pressure value drops to below the permissible lower
limit, the power train pump needs an replacement.
Plug: 30 N•m (22 lbf ft)
WB146-5 20-39 3
TESTING AND ADJUSTING POWER TRAIN GROUP
CLUTCH ENGAGEMENT PRESSURE

2. Start the engine and heat the engine and all the fluids up to working
temperature. In particular make sure that the power train oil reaches
a temperature of 80 ±5°C (176°F).
3. Bring the engine up to low idle and check the pressure on pressure
gauge E6.
★ Normal pressure ................................... Max. 0.3 kg/cm² (4 psi)
4. With the working brakes applied, select reverse gear and gradually
increase rev speed up to MAX, then take a new reading from the
pressure gauge E6.
★ Normal pressure ...................13.7 - 16.8 kg/cm² (195 - 239 psi)
5. Bring the engine back to MIN and the transmission in neutral position; compare the pressure with the normal value.
★ Normal pressure ................................... Max. 0.3 kg/cm² (4 psi)
6. Remove the pressure adapter and replace the plug P19.
7. Repeat the same test for the FORWARD gear, reading the pressure from the orifice protected by the plug P18.
● If the pressures are different for the two travel directions, there is a loss of pressure on the clutch piston with lower
pressure.
SUPPLY PRESSURE
2. Start the engine and heat the engine and all the fluids up to working temperature. In particular make sure that the power
train oil reaches a temperature of 80 ±5°C (176°F).
3. Bring the engine up to low idle and check the pressure on the pressure gauge.
★ Normal pressure ...................14.2 - 17.3 kg/cm² (202 - 246 psi)
4. Gradually increase engine speed to 2200 rpm; take a new reading on pressure gauge.
★ Min. pressure ...........................................14.2 kg/cm² (202 psi)
★ If reading drops below minimum, the transmission pump needs replacing.
20-40 3 WB146-5
TESTING AND ADJUSTING TRANSMISSION CLUTCH FUNCTION
TRANSMISSION CLUTCH FUNCTION

● Engine: stopped.
● Brake pedals: connected by a cotter pin.
● Machine: on solid and level ground with the equipment raised
and safety devices engaged.
★ This test must be performed after having checked the pressures
of the power train group.
MACHINE PREPARATION
WARNING! Make sure that the brake pedals are fastened together by the cotter pin (1). During the
following tests, during the engine acceleration phase with the gear engaged, the condition of
the brake disks can also be checked If, while force is being exerted on the brake pedals, the
machine starts to travel, even slowly:
1. Prepare a tachometer to measure the engine rpm.

● Release the accelerator immediately and stop the engine.
● Check the wear on the brake disks and change them before
completing the tests.
CONTROL
1. Start the engine and heat the engine and all the fluids up to working
temperature. In particular make sure that the power train oil reaches
a temperature of 80 ±5°C (176°F).
2. With the engine in idling condition, accelerate to MAX and check

that in this condition the revs remain within permissible limits.
3. Brake hard and bring the engine up to MAX.
4. Engage the 3rd gear while braking and accelerating as above;

confirm that engine speed decreases to the permissible range
5. Repeat this test in REVERSE gear.

★ If the revs are high than the permissible limits, the clutches are
worn, and must be replaced.
WB146-5 20-41 3
TESTING AND ADJUSTING HYDRAULIC DRIFT
HYDRAULIC DRIFT
★ If working attachments have a hydraulic drift, it is necessary to check if reason is due to cylinders gaskets or to control
valve.
★ All testing conditions:
● Engine ................................................At operating temperature
● Hydraulic oil ........................................45 - 55°C (113 - 131°F)
● Removal and install tubes only after residual pressure’s removed.
LOADER
BOOM CIRCUIT
1. Put the machine with the bucket edge on blocks A of about 10 cm

(4 in) and in vertical position in relation to the ground.
2. Stop the engine and release the residual hydraulic pressures.
3. Disconnect the tubes (1) and (2) from the lift cylinders (3) and plug
them.
4. Plug the cylinders, base side, and apply a temporary tube, rod side,
to catch any possible oil leakage.
5. Start the engine and curl the bucket until the teeth are in the tilt
position by 10°.
6. Stop the engine and check bucket link position for movement five
minutes.
● If the bucket link has no lowering movement, drift is due to the
control valve.
To test the individual cylinders, proceed as follows:
7. Move the bucket to let the edge lean on the ground in

vertical position.
8. Remove from one of the cylinders the plug fitted on the cylinder
bottom side in Step 4.
9. Start the engine and retract the bucket to bring the teeth in a tilt
position of about 10° upwards.
10. Stop the engine and check the loader position for five minutes.
● If the bucket link lowers, drift is due to seal leakage of the
plugged cylinder.
11. Repeat Steps 8 to 10 to check the other cylinder.
20-42 3 WB146-5
BUCKET CIRCUIT
1. Put the machine with the loader on level ground and bucket edge
tilted 10°. Put a 1500 kg (3,307 lbs) weight in the bucket.
2. Disconnect the tubes (1) and (2) from both bucket cylinders (3) and
plug them to prevent contamination.
3. Plug the bucket cylinder, head side, and install a temporary tube on
the rod side to catch oil leakage.
4. Start the engine and raise the loader until the bucket hinge pin is
aligned with boom hinge pin.
5. Stop the engine and check the position of the bucket edge for five
minutes.
● If the bucket has no movement, drift is due to the control valve.
To test the individual cylinders, proceed as follows:
6. Lower the loader to the ground.
7. Remove from one of the cylinders the plug fitted on the cylinder
head side in Step 3.
8. Start the engine and raise the loader as indicated in Step 4.
9. Stop the engine and check the position of the bucket edge for five
minutes.
● If the bucket edge turns, the drift is due to seal leakage of the
plugged cylinder.
10. Repeat operation from Steps 6 to 9 to check the other cylinder.
WB146-5 20-43 3
BACKHOE
★ Test condition:
★ Backhoe aligned
★ Lifted outriggers
BOOM CIRCUIT
1. Set the machine with the boom in vertical position and with the
bucket on level ground leaned on the side.
3. Disconnect the hoses (1) and (2) that feed cylinder (3).
4. Plug the two hoses to avoid impurity inlet.
5. Plug the cylinder head side.
6. Apply a temporary tube to tube (4) base side to catch oil leakage.
7. Start the engine and extend the arm.
8. Stop the engine and check the boom position for 5 minutes.
● If boom has a lowering movement, drift is due to cylinder
gaskets.
● If boom has no lowering movement, drift is due to control
valve.
20-44 3 WB146-5
ARM CIRCUIT
1. Set the machine with the arm fully extended and with the bucket
teeth on ground.
3. Disconnect the tubes (1) and (2) the tubes from the arm cylinder (3)
and plug them to avoid impurity inlet.
★ If a safety valve is fitted, remove it.
4. Plug the arm cylinder hole on the head side and fit a temporary tube
on the base side to catch oil leakage.
5. Start the engine and raise the boom.
6. Stop the engine and check the arm position for five minutes.
● If the arm has a lowering movement, drift is due to the cylinder
seals.
● If the arm has no movement, drift is due to the control valve.
WB146-5 20-45 3
BUCKET CIRCUIT
1. Set the machine with the arm vertical and the bucket at level ground
on the side. Put a 450 kg (992 lbs) weight in the bucket or fill it
with dirt.
3. Disconnect the bucket cylinder (3), then hoses (1) and (2) and plug
them to avoid impurity inlet.
4. Plug the bucket cylinder port on the base side and fit a temporary
tube on the rod side to catch oil leakage.
5. Start the engine and raise the boom.
6. Stop the engine and check the bucket position for five minutes.
● If the bucket has an movement, drift is due to the cylinder
seals.
● If the bucket has no movement, drift is due to the control valve.
20-46 3 WB146-5
OUTRIGGERS CIRCUIT - W/O LOCK VALVES
1. Set the machine with the arm in vertical position and with the
bucket on level ground leaned to the side.
2. Put 20 cm (4 in) blocks under the outriggers.
3. Without forcing them, lower the outriggers onto the blocks.
5. Disconnect from the cylinders (1), the tubes (2) and (3) after the
lock valve (4).
6. Plug the cylinders base head tube (2). Add a temporary tube to the
rod side (3) tube to catch oil leakage.
7. Start the engine, use the boom to raise the machine, and remove the
blocks supporting the outriggers.
8. Lower the machine and stop the engine.
9. Check the outriggers position for five minutes.

● If one or both outriggers lower, drift is due to one or both
cylinders.
● If there is no lowering, drift is due to control valve.
WB146-5 20-47 3
TESTING AND ADJUSTING AIR CONDITIONING
AIR CONDITIONING
● Machine on level ground with the working equipment raised
and in safety conditions with the parking brake engaged
WORK TEMPERATURE
1. Connect the maintenance station to the high pressure, HP, valve and the low pressure, LP, valve.
2. Start the engine and bring it up to a speed of 1500 rpm.
3. Switch on the AC unit using the switch. Select an intermediate ventilation speed inside the cab.
4. Use the thermometer M2 to check that the temperature inside the cab is equal to or lower than the ambient temperature.
★ If the temperature of the cab is higher than the ambient temperature, open the doors and widows and wait until the cab
temperature stabilizes at the outside value.
5. Close the doors and windows and let the AC unit operate in these conditions for five to ten minutes.
6. Use the thermometer M2 to check the temperature of the air at the central outlets.
★ Position the probe as close as possible to the air outlets.
7. Compare the average value of the measured temperatures using the following table:
Ambient temp 20°C (68°F) 25°C (77°F) 30°C (86°F) 35°C (95°F)
Outgoing air temp 6 -8°C (43-46°F) 8 - 10°C (46-50°F) 8 -12°C (46-54°F) 9 -14°C (48-57°F)
8. If the average value of the temperature measured does not fall within the values given in the table, it will be necessary to
thoroughly check the unit.
20-48 3 WB146-5
UNIT CHECK
Check the unit after the Steps 1, 2, 3 and 5 of the preceding paragraph. A diagnosis of faults in the unit is based upon the
working pressures.
When the pressures do not fall within the values given in the following table, the causes must be found by checking the
high pressure and low pressure gauges.
Unit: kg/cm² (psi)

Unit with R134a.
Outside Air Temp Low Pressure High Pressure
Min Max Min Max
20°C (68°F) 1.2 kg/cm² (17 psi) 2.5 kg/cm² (36 psi) 6.0 kg/cm² (85 psi) 9.0 kg/cm² (128 psi)
The following conditions may be found:
CONDITIONS CAUSES - FAULTS

● Electromagnetic pulley that slips or does not engage correctly
LP high to HP normal or low ● Expansion valve blocked in open position
● Compressor damaged
● Expansion valve blocked in closed position or obstructed
LP low to HP high or normal ● Filter saturated with moisture
● Obstruction in the LP line or in the HP line between the filter and the evaporator.
● Infiltration of hot air into the evaporator group, the pipes or the cab
LP normal to HP normal ● Hot air circulating in the heating group
● Formation of ice on the evaporator
● Normal condition with very high ambient temperature, higher than 43°C (109°F)
● Excess coolant, 30 to 35% more
● Overheating of condenser
LP high to HP high
● Air present in the unit
● Obstruction in the HP line between the compressor and the condenser filler tube
behind the measurement point of the HP
● Normal condition with very low temperature, lower than 5°C (41°F)
● Lack of coolant, 70 to 75% less, probable leakages
LP normal or low to HP low ● Obstruction in the HP line between the compressor and the condenser filler tube before
the measurement point of the HP
● Compressor belt missing
LP roughly equal to HP ● Electromagnetic pulley that slips or does not engage
WB146-5 20-49 3
EMPTYING THE AC UNIT

1. Connect the maintenance station M1 to service valves (1) and (2)
and follow the specific maintenance station instructions relative to
the drainage of the unit.
2. Disconnect the group to be substituted or reconditioned

immediately after switching off the maintenance station. Plug the
removed or disconnected connection tubes tightly and with a
minimum of delay.
3. Carefully check the quantity of refrigerant recovered and contained

in the disassembled parts, since the same quantity must be replaced
when the air conditioning unit is filled.
20-50 3 WB146-5
MEMORANDUM
WB146-5 20-51 3
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
FRONT AXLE
Wheel vibration; front tire resistance; half shaft breakage.

CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Remove excessive weight and redistribute load following instructions
Overloading incorrect weight distribution
related to the vehicle
Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tires
Bent half shaft Replace half shaft
No differential action; jamming while steering.
CAUSES REMEDY
Defective axle
phases
Overloading incorrect weight distribution
Steering is difficult; vehicle goes straight while trying to turn it.
CAUSES REMEDY
Defective axle
phases
Overloading/incorrect weight distribution
Broken half shaft Replace half shaft
Excess noise
CAUSES REMEDY
Defective axle
phases
Bent or broken half shaft Replace half shaft
Incorrect wheel adjustment Verify group integrity and wheel side bearings
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various
of parts parts of the axle.
20-52 3 WB146-5
12
Uneven wear of tires
CAUSES REMEDY
Defective axle
phases
Blocked half shaft:
● Abnormal functioning of the differential or ● Verify assembly of all components
breakage/blockage of control device
● Vehicles with wide steering angle may proceed ● Reduce the steering angle to minimum and decelerate when the
with kicks, have steering difficulty or cause pneu- vehicle begins to kick.
matic wear on sharp turns.
Friction noise
CAUSES REMEDY
Defective axle
phases
Check the condition of the ring gear, pinion gear, bearings, etc.
Damaged or worn out axle parts
Replace when necessary.
Incorrect adjustment of bevel gear set. Parts of the
Replace or adjust as required.
trans worn out transmission gears, U joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Defective axle
phases
WB146-5 20-53 3
12
Noise while driving
CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and ring gear Replace
Worn out pinion bearings Replace
Pinion bearings loose Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loose Adjust
Ring gear out of round Replace
Low oil level Oil level
Poor or worn oil Replace
Bent half shaft Replace
Noise while driving in neutral
CAUSES REMEDY
Noises coming from axle are usually heard but not
Replace or adjust (see above)
loud when vehicle moves in neutral gear.
Incorrect backlash between pinion and ring, sound
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Noise while steering
CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
20-54 3 WB146-5
12
Ring gear teeth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set. Carefully follow the recommended operations
Incorrect gear adjustment (excessive backlash)
for the adjustment of the bevel gear set free backlash.
Pinion nut loosened
Ring gear tooth broken
CAUSES REMEDY
Load bump
Incorrect gear adjustment insufficient backlash Replace bevel gear set. Adjust bevel gear set free backlash
Pinion nut loosened
Pinion or ring gear teeth worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication for the adjustment of the bevel gear set free play. Use correct lubri-
cants, fill to proper levels and replace according to the recommended
Worn out pinion bearings schedule.
Overheated ring and pinion teeth
CAUSES REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule.
lubrication
Pinion teeth pitting
CAUSES REMEDY
Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication replace according to the recommended schedule.
Axle beam body bent

CAUSES REMEDY
Vehicle overloaded
Vehicle accident Replace axle beam body
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings, use correct lubricants, fill to proper levels and
Normal wear out replace according to the recommended schedule.
Pinion nut loosened
WB146-5 20-55 3
12
Oil leakage from gaskets and seals
CAUSES REMEDY
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged. Use cor-
rect lubricants, fill to proper levels and replace according to the recom-
Seal lip damaged mended schedule.
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
Pinion nut loosened
worn. Replace bevel gear set if required
Pinion axle backlash
Fatigue failure of pinion teeth
CAUSES REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out
CAUSES REMEDY
Excessive use Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Use correct lubricants, fill to proper levels and replace according to the
Insufficient lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing. Check pinion axial backlash Use correct lubricants,
Excessive pinion axial backlash fill to proper levels and replace according to the recommended sched-
Insufficient lubrication; contaminated oil ule.
Bent or broken half shaft or half shaft broken at wheel side

CAUSES REMEDY
Vehicle intensively operated or overloaded
Replace. Check that wheel support is not worn out or incorrectly
Wheel support loosened
adjusted.
Beam body bent
20-56 3 WB146-5
REAR AXLE
Wheel vibration; front tire resistance; half shaft breakage.

CAUSES REMEDY
Defective axle
phases
Steering is difficult; vehicle goes straight while trying to turn it.
CAUSES REMEDY
Defective axle
phases
No differential action; jamming while steering.
CAUSES REMEDY
Defective axle
phases
Excess noise
CAUSES REMEDY
Defective axle
phases
WB146-5 20-57 3
12
Uneven wear of tires
CAUSES REMEDY
Defective axle
phases
Blocked half shaft:
● Abnormal functioning of the differential or break- ● Verify assembly of all components
age/blockage of control device.
● Vehicles with wide steering angle may proceed ● Reduce the steering angle to minimum and decelerate when the
with kicks, have steering difficulty or cause pneu- vehicle begins to kick.
matic wear on sharp turns.
Friction noise
CAUSES REMEDY
Defective axle
phases
Check the condition of the ring gear, pinion gear, bearings, etc.
Damaged or worn out axle parts
Replace when necessary.
Incorrect adjustment of bevel gear set. Parts of the
Replace or adjust as required.
trans worn out transmission gears, U joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Defective axle
phases
20-58 3 WB146-5
12
Noise while driving
CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and ring gear Replace
Worn out pinion bearings Replace
Pinion bearings loose Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loose Adjust
Ring gear out of round Replace
Low oil level Oil level
Poor or worn oil Replace
Noise while driving in neutral
CAUSES REMEDY
Noises coming from axle are usually heard but not
Replace or adjust (see above)
loud when vehicle moves in neutral gear.
Incorrect backlash between pinion and ring sound
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Noise while steering
CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
WB146-5 20-59 3
12
Ring gear teeth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set. Carefully follow the recommended operations
Incorrect gear adjustment, excessive backlash
for the adjustment of the bevel gear set free backlash.
Pinion nut loosened
Ring gear tooth broken
CAUSES REMEDY
Load bump
Incorrect gear adjustment, insufficient backlash Replace bevel gear set. Adjust bevel gear set free backlash.
Pinion nut loosened
Pinion or ring gear teeth worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication for the adjustment of the bevel gear set free play. Use correct lubri-
cants, fill to proper levels and replace according to the recommended
Worn out pinion bearings schedule.
Overheated ring and pinion teeth
CAUSES REMEDY
Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule.
lubrication
Pinion teeth pitting
CAUSES REMEDY
Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication replace according to the recommended schedule.
Axle beam body bent

CAUSES REMEDY
Vehicle overloaded
Vehicle accident Replace axle beam body
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings. Use correct lubricants, fill to proper levels and
Normal wear out replace according to the recommended schedule.
Pinion nut loosened
20-60 3 WB146-5
12
Oil leakage from gaskets and seals
CAUSES REMEDY
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged. Use cor-
rect lubricants, fill to proper levels and replace according to the recom-
Seal lip damaged mended schedule.
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
Pinion nut loosened
worn. Replace bevel gear set if required
Pinion axle backlash
Fatigue failure of pinion teeth
CAUSES REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out
CAUSES REMEDY
Excessive use Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Use correct lubricants, fill to proper levels and replace according to the
Lack of lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing. Check pinion axial backlash. Use correct lubricants,
Excessive pinion axial backlash fill to proper levels and replace according to the recommended sched-
Insufficient lubrication; contaminated oil ule.
Bent or broken half shaft or half shaft broken at wheel side

CAUSES REMEDY
Vehicle intensively operated or overloaded
Replace. Check that wheel support is not worn out or incorrectly
Wheel support loosened
adjusted.
Beam body bent
WB146-5 20-61 3
TRANSMISSION
Vehicle does not move

CAUSES REMEDY
Faulty supply to solenoid valves Check/Replace
Damaged wiring connections between transmission
Repair/Replace
and vehicle
Oxidized contacts in electrical wiring Clean
Break in electrical cable Replace
Damaged solenoids Replace
Damaged sensors Replace
Short circuits or open connections Check/replace fuses
Incorrect oil level Fill oil to proper level
Check for leaks Repair
Blocked intake filter Clean
Damaged oil pump Replace
Damaged oil pump relief valve Replace oil pump
Blocked/damaged transmission filter Replace
Damaged/jammed control valve Replace
Damaged converter Replace
Oil temperature below 0°C Wait for oil to reach operating temperature (stall test)
Damaged rotary seals Replace
Damaged synchronizers Replace
Blocked reverse lever Repair
Worn clutch Replace/repair clutch
No drive transmission, broken gears, shafts, bear-
Check/Repair/Replace
ings, etc.
Vehicle has reduced power transmission
CAUSES REMEDY
Incorrect oil temperature Wait for oil to reach operating temperature (stall test)
Transmission oil overheating See “Overheating”
Incorrect operating pressure Check hydraulic circuit and replace, oil pump, filters, control valve
Incorrect oil level Fill oil to proper level
Worn clutch Replace/Repair
4WD clutch failure Repair/Replace 4WD shaft group
Overheating solenoids Replace
Damaged transmission and vehicle wiring connec-
Repair/Replace
tions
Damaged sensors Replace
20-62 3 WB146-5
12
Overheating
CAUSES REMEDY
Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing, broken gears, shafts, bearings, etc. Check/Repair/Replace
Braking force outside transmission: irregular axle
Check/Repair axle
operation
Clutch plate drag Repair/Replace
Damaged oil thermostat Replace
Incorrect oil level Add oil
Worn oil pump Replace
Wheels rotate when vehicle is raised
CAUSES REMEDY
Clutch plate drag Repair/Replace
Low oil temperature (high oil viscosity) Wail for oil to reach operating temperature (stall test)
Incorrect oil specifications Replace oil and filters
Damaged control valve Replace
Faulty reverser locking Repair/Replace
Noise
CAUSES REMEDY
Damaged oil pump Replace
Aeration/Cavitation Check oil level
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace
Irregular actuation
CAUSES REMEDY
Electrical system fault Repair/Replace
Worn clutch plates Replace
Low oil temperature (high oil viscosity) Wait for oil to reach operating temperature (stall test)
Overheating See “Overheating”
Damaged hydraulic system Repair/Replace
WB146-5 20-63 3
12
Gear remains engaged
CAUSES REMEDY
Damaged/jammed shuttle shaft lever Repair/Replace
Damaged hydraulic system Repair/Replace
Damaged clutch Repair/Replace
Damaged gear lever rod Replace
Damaged synchronizer Replace
No 4WD power transmission
CAUSES REMEDY
Damaged 4WD clutch Replace
Hydraulic system fault Repair/Replace
Faulty brake sensor Check/Replace
Gear shift will not engage
CAUSES REMEDY
Damaged shifter Replace
Damaged synchronizer Replace
20-64 3 WB146-5
TESTING AND ADJUSTING FUSES AND RELAYS
FUSES AND RELAYS
WARNING! When replacing fuses or relays, always check the condition of the contacts for corrosion.
Never replace a fuse with a fuse of higher or lower amp rating. Damage to the electrical
system may result.
FUSE AND RELAY PANEL LOCATION

The fuses and relays are grounded on a single board positioned on the
right side of the cab. Removing cover (1) exposes the fuses and relays,
if it is necessary to service them.
If an electrical system fails during operation, it is important to check
the fuses or relays first.
Once cover (1) is removed, the fuses and relays are easily accessible.
With the starter key in the “ON” position, check each fuse with a test
light. This will indicate which bank of fuses or relays has failed.
To replace a fuse or relay, the starter switch must be in the
“OFF” position.
WB146-5 20-65 3
FUSE AND RELAY PANEL LAYOUT

FUSES
Position Color Amps Circuit

F1 Light blue 15 Front work lamps
F2 Light blue 15 Rear work lamps
F3 Violet 3 Parking lights front left and rear right, warning lamps and dash lamps
F4 Violet 3 Parking lights front right and rear left, cigarette lighter
F5 Red 10 Front horn
F6 Light blue 15 Lateral rear work lights
F7 Brown 7.5 Rear windshield wiper and rear horn
F8 Brown 7.5 Stop lights and stop light relay
F9 Light blue 15 Lateral front work lights
F10 Red 10 Front windshield wiper, windshield washer pump
F11 Brown 7.5 Boom lock solenoid valve
F12 Orange 5 Buzzer power supply, general alarm and warning lamps supply
F13 Red 10 Optional equipment, differential and 4-wheel drive solenoid power supply
20-66 3 WB146-5
Fuse
Description
Position
F14 High/low beam, horn and safety solenoid valve
F15 Engine stop solenoid, A/C relay and functions relay
F16 Rotating beacon
F17 Hour meter memory, hazard warning light
F18 Cigarette lighter and cab lamp
F19 Left and right low beam
F20 Left and right high beam
F21 Return-to-dig sensor, LSS solenoid valve, loader arm
float solenoid, return-to-dig solenoid valve and
direction indicator
F22 Joystick control lock solenoid, EC power solenoid
valve, PPC power supply
F23 Steering unit
F24 Direction indicator power supply
F25 Declutching relay, forward gear solenoid valve,
reverse gear solenoid valve and reverse alarm
F27 General system fuse, starter key, start relay, and
preheat power supply
WB146-5 20-67 3
RELAYS
Relay
Description
Position
K1 Safety unit (against repeated start)
K2 Turn signal and/or flasher
K3 Low beam relay
K4 High beam relay
K5 Front horn relay
K6 Return-to-dig relay
K7 Stop light relay
K8 Start enabling relay
K9 Forward gear relay
K10 Reverse relay
K11 Directional indicator power supply relay (declutch)
K12 Machine function relay
K13 Start relay
K14 Preheating relay
K15 Multifunction unit
20-68 3 WB146-5
HEATING AND AIR CONDITIONING FUSES AND RELAYS

The fuses and relays are grouped on a single board positioned under the
storage compartment and can be reached after opening the door (1) and
removing the container (2).
The following tables indicate the characteristics and the functions of

the single fuses and relays.
FUSES
Fuse
Color Amps Circuit
Position
1 Yellow 20 1 and 2 fan speed power supply
2 Orange 40 3rd fan speed power supply
3 Brown 7.5 Refrigerant compressor
RELAYS
Relay
Description
Position
4 3rd fan speed relay
5 General heating relay
6 Refrigerant compressor relay
WB146-5 20-69 3
MEMORANDUM
20-70 3 WB146-5
30 DISASSEMBLY AND ASSEMBLY
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6

REMOVAL AND INSTALLATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
OVERHAUL OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
ASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN PERFORMING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
BLEED AIR FROM CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
BLEED AIR FROM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
BLEED AIR FROM BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
RELEASING RESIDUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
FRONT GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
AIR CONDITIONING CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
REFRIGERANT COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
REFRIGERANT COMPRESSOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
WB146-5 30-1 3
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
EXHAUST STACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
CAB HEATING AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
STEERING AND FRONT DASH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
FRONT DASH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68
HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
TRANSMISSION OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
PLUGS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
OIL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
4 WHEEL DRIVE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
30-2 3 WB146-5
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
TRANSMISSION HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
CLUTCH PACK (A) AND GEAR SHAFT (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
CLUTCHES AND DISC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-147
CHECKING CLUTCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
GEAR SHAFTS (B) AND (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-157
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-157
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
GEAR SHAFT (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
SHIFTER TOWER AND FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-191
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-191
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
STEERING SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
FRONT AXLE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
STEERING CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
FRONT AXLE END PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
AXLE END HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-235
REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
REAR AXLE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
PARKING BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
WB146-5 30-3 3
SERVICE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-252
REAR AXLE END PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-263
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-267
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-267
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-269
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-277
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-280
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-280
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-284
PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-290
FRONT LOADER PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-294
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-294
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-295
FRONT-END LOADER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-296
LOADER BOOM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-296
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-297
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-298
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-298
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-299
FRONT LOADER BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-300
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-300
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-300
LOADER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-302
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-302
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-303
BACKHOE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-305
PPC VALVE SUPPORT RELEASE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-306
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-306
INSTALLATION AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-308
PPC VALVE GAS STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-309
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-309
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-311
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-312
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-312
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-314
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-316
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-316
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-317
BACKHOE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-319
EXTENDABLE ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-320
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-320
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-320
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-322
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-322
30-4 3 WB146-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-323
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-324
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-324
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-326
SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-327
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-327
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-329
BOOM LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-331
BACKHOE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-332
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-332
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-332
BACKHOE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-333
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-333
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-335
EXTENDABLE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-336
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-336
EXTENDABLE ARM GIBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-337
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-337
BACKHOE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-338
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-338
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-339
BACKHOE SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-340
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-340
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-340
OUTRIGGER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-342
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-342
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-343
OUTRIGGER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-344
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-344
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-344
WORK EQUIPMENT CYLINDER OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-345
LOADER AND BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-345
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-345
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-347
SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-350
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-350
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-351
WB146-5 30-5 3
DISASSEMBLY AND ASSEMBLY HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
REMOVAL AND INSTALLATION OF COMPONENTS
REMOVAL
• The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained.
• Various symbols used in the REMOVAL Section are explained and listed below.
WARNING! This indicates safety-related precautions which must be followed when doing the work.
Remark This mark gives guidance or precautions when doing the procedure.
This mark shows oil or water to be drained.
Weight of a part or component.
INSTALLATION
• Except where otherwise instructed, install parts is the reverse order of removal.
• Marks shown in the INSTALLATION Section stand for the following.
WARNING! This mark indicates safety-related precautions which must be followed when doing the work.
★ This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil or coolant to be added.
30-6 3 WB146-5
DISASSEMBLY AND ASSEMBLY HOW TO USE THIS MANUAL
12
OVERHAUL OF COMPONENTS
DISASSEMBLY PROCEDURES
• The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained.
• Various symbols used in the DISASSEMBLY Section are explained and listed below.
Remark This mark gives guidance or precautions when doing the procedure.
This mark shows amount of oil or coolant to be drained.
ASSEMBLY PROCEDURES
• Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil
or water to be added.
• Various symbols used in the ASSEMBLY Section are explained and listed below.
★ This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil or coolant to be added.
WB146-5 30-7 3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATIONS
12
PRECAUTIONS WHEN PERFORMING OPERATIONS
When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given
below when carrying out the operation.
1. Precautions when carrying out removal work

● If draining a system always dispose of the fluids correctly.
● After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
● Confirm the match marks showing the installation position, and make match marks in the necessary places before
removal to prevent any mistake when assembling.
● To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the
connectors. Do not pull the wires.
● Install wires and hoses with tags to show their installation position to prevent any mistake when installing.
● Check the number of thickness of the shims, and keep in a safe place.
● When raising components, be sure to use lifting equipment of ample strength and always stand clear of what you are
lifting.
● When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
● Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering
after removal.
2. Precautions when handling piping during disassembly install the following blind plugs into the piping after disconnecting
it during disassembly operations.
A. Face seal type hoses and tubes

Nominal Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
B. Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
C. If the part is not under hydraulic pressure, the following plugs can be used.
Nominal Dimensions (mm)
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-8 3 WB146-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATIONS
3.Precautions when carrying out installation work
● Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
● Install the hoses without twisting or interference.
● Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
● Bend the cotter pins and lock plates securely.
● When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3
drops of adhesive.
● When coating with gasket sealant, clean the surface and remove all oil and grease, check to be sure there is no dirt or
damage, then coat uniformly with gasket sealant.
● Clean all parts, and correct any damage, dents, burrs, or rust.
● Coat rotating parts and sliding parts with engine oil.
● When press fitting parts, coat the surface with anti-friction compound (LM-P).
● After fitting snap rings, check to be sure snap ring is fitted securely in the ring groove.
● When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
● When using eyebolts, check to be sure there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
● When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic
equipment removed for repair, always bleed the air as follows:
A. Start the engine and run at low idling.
B. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm
(4.0 in) from the end of its stroke.
C. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
WB146-5 30-9 3
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
12
SPECIAL TOOL LIST
Symbol
Qty.
Component Part No. Part Name
Removal of piston pump 1 ⎯ Pump support tool 1

B
Removal of transmission 2 ⎯ Transmission support tool 1
1 CA119099 Closed end wrench 1
2 CA119143 Plunger 1
3 CA119200 False differential box 1
4 CA119202 False pinion 1
9 CA715022 Key 1
Disassembly and assembly of front
D 11 CA715027 Plunger 1
axle
16 CA715265 Key 1
21 CA722521 Sensor test system 1
1 CA119099 Key 1
2 CA119143 Bushing 1
5 CA715022 Key 1
Disassembly and assembly of rear
E 7 CA715027 Plunger 1
axle
13 CA715128 False pinion 1
30-10 3 WB146-5
Symbol
Qty.
15 CA715265 Key 1
16 CA715380 Bearing assembly kit 1
Disassembly and assembly of rear 19 CA715456 Backlash tool 1
E
axle 20 CA715505 Plunger 1
23 CA715706 Preload tool 1
25 CA715521 Sensor system test 1
5 CA715495 Protection and shims 1
7 CA715356 Calibrator 1
9 CA715358 Clutch installation tool 1
Disassembly and assembly of
F 10 CA715499 Protection 1
transmission
12 CA715743 Protector and shims 1
14 CA715745 Calibrator 1
15 CA715496 Latch for B and C shafts 1
17 CA715493 Stop ring removal and installation tool 1
18 CA715257 Protection 1
19 CA715263 Protection 1
790-502-1003 Equipment 1
1
790-101-1102 Pump 1
2 790-102-3802 Key 1
Disassembly and assembly of
U 790-302-1310 Key 65 mm 1
cylinders
790-302-1280 Key 55 mm 1
3
790-302-1270 Key 50 mm 1
790-302-1390 Key 46 mm 1
WB146-5 30-11 3
Symbol
Qty.
4 790-102-4300 Expander 1
796-720-1670 Calibrator for boom cylinder 1
07281-01279 1
796-720-1660 Calibrator for arm and swing cylinder 1
07281-01159 1
5
796-720-1650 Calibrator for bucket and arm cylinder 1
07281-01029 1
796-720-1640 Calibrator for outriggers and bucket 1
cylinders
07281-00909 1
790-201-1702 Driver kit 1
790-101-5021 · Handle 1
01010-50816 · Screw 1
790-201-1781 · Driver for boom cylinder 1
Disassembly and assembly of 6
U 790-201-1771 · Driver for bucket cylinder 1
cylinders
790-201-1761 · Driver for bucket and arm cylinder 1
790-201-1751 · Driver for bucket cylinder 1
790-201-1741 · Driver for outrigger cylinder 1
790-201-1500 Driver kit 1
790-101-5021 · Handle 1
01010-50816 · Screw 1
790-201-1590 · Driver for boom cylinder 1
7
790-201-1570 · Driver for swing and bucket cylinder 1
790-201-1550 · Driver for outriggers cylinder 1
790-102-4300 Key 1
8
790-102-4310 Pin 2
30-12 3 WB146-5
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
CONTACT TERMINAL REMOVAL (HD30 TYPE)
1. Obtain the correct removal tool according to the wire size used in
the connector.
2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will hinder
wire removal and may damage the connector or removal tool.
Always use the correct removal tool size for the wire gauge
you are servicing.
3. In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to the tool or
connector may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
WB146-5 30-13 3
12
CRIMPING CONTACT TERMINAL (HD30 TYPE)
1. After insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact.
Use Crimp tool HDT04-08 for size 8 and 4 contacts.
30-14 3 WB146-5
12
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
1. Grasp contact terminal approximately 25.2 mm (1 in) behind the
crimped barrel.
2. Holding connector with rear grommet facing you.
3. Insert completed contact terminal straight into connector grommet

until a positive stop is felt.
4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.
5. For unused wire cavities, insert sealing plugs for full environmental
sealing.
WB146-5 30-15 3
12
CONTACT TERMINAL REMOVAL (DT TYPE)
1. Remove the wedge lock using needle nose pliers or a hooked
shaped wire.
2. Pull the wedge lock straight out and save for reinstallation.
3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
30-16 3 WB146-5
12
CRIMPING CONTACT TERMINAL (DT TYPE)
1. After insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact.
Use Crimp tool HDT04-08 for size 8 and 4 contacts.
WB146-5 30-17 3
12
INSERTION OF CONTACT TERMINAL (DT TYPE)
1. Grasp the crimped contact terminal approximately 25.2 mm (1 in)
behind the crimped barrel.
2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.
3. Push the contact terminal straight into the connector until a “click”
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.
4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The wedge
lock will snap into place. Rectangular wedges are not oriented and
may fit either way.
Remark
As the connector receptacle is shown - use the same
procedures for a plug.
30-18 3 WB146-5
12
STRIPPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 -.218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 -.218)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 -.312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 -.312)
0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 -.312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 -.312)
0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 -.284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 -.284)
0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 -.492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 -.492)
0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 -.492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 -.492)
Using wire insulation strippers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:

● Corrosion, straightness and uniformity
● Broken or nicked wire strands are unacceptable and may cause
high resistance in the circuit.
● Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
WB146-5 30-19 3
DISASSEMBLY AND ASSEMBLY BLEED AIR FROM CIRCUITS
BLEED AIR FROM CIRCUITS
BLEED AIR FROM HYDRAULIC CIRCUIT

★ When hydraulic cylinders or associated tubes have been removed, it is necessary to bleed air before using the machine
again. Perform bleeding on one cylinder at a time.
1. Start the engine and run at high idle for about 5 min. to heat the oil.
2. Reduce speed to low idle and extend and retract the 1st cylinder to be bled several times.
★ Extend and retract pistons until about 100 mm (4 inches) from their end of stroke.
3. Stop the engine, check and top off the oil in the tank.
4. Bring again the engine at high idle and repeat Step 2; return the engine to low idle speed and make a complete travel of the
cylinder until the pump reaches its maximum pressure.
5. Repeat Steps 2 and 3 for all cylinders, frequently checking the oil level in the tank.
BLEED AIR FROM BRAKING CIRCUIT

★ This operation is to be carried out every time maintenance is made on the
braking circuit to remove or replace a component, or when air entered into
the circuit. Machine must be stopped with attachments on level ground.
1. Make sure that oil in the brake system tank (1) is at maximum level.
Remove safety plugs on the bleed screws (2). Attach a vinyl hose
(3) to catch oil.
2. Push the brake pedal to the bottom and, while keeping it pushed,
loosen the bleed screw (2) of the brake unit that is being bled until
the pedal reaches the end of its stroke. Keeping the pedal at the end
of its stroke, tighten the bleed screw.
3. Release the brake pedal, wait for few seconds and repeat step 2 of
this above operations two or three times until oil flows out the
bleeding screw without air bubbles.
4. Repeat the same steps for the opposite braking unit.
★ Frequently check the oil level in the tank and refill every time
the level approaches minimum.
30-20 3 WB146-5
DISASSEMBLY AND ASSEMBLY BLEED AIR FROM CIRCUITS
5. After bleeding air, install screws (2) safety plugs (4).
RELEASING RESIDUAL PRESSURE

1. Lower all work attachments on level ground, stop the engine.
2. Move all control levers in all directions to completely release residual pressure in the hydraulic system.
WB146-5 30-21 3
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
12
ENGINE HOOD
REMOVAL
WARNING! Before any disassembly procedures are started, be sure the machine is sitting on a
smooth level surface. Lower all work equipment to the ground, set the parking brake,
chock the wheels and disconnect the battery.
1. Raise the front loader arms fully up and set the lock as shown in
(A).
A. Raise the front end loader unit completely in the air extending
the lifting cylinders rods completely.
B. Remove the cylinder lock assembly small pin (3). Holding on

to the lock unit (1), pull out lock pin (2).
C. Using both hands lower the lock unit (1) down from its
storage position onto the extended lift arm cylinder rod.
D. Once on the cylinder rod, install lock pin (2) and small pin (3)
and slowly lower the loader arms until it rests on the loader
lock (1).
2. Remove the four grill mounting screws (1) and remove the front
grill assembly (2).
30-22 3 WB146-5
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
3. Fully raise the engine hood (3) and remove the safety pins (4) then
disconnect the gas struts (5) from the chassis.
4. Remove the snap rings (6) and retaining washers (7) from the pivot
pins (8).
5. Remove the pivot pins (8) and carefully lift the hood assembly (3)
off the machine using two people.
Engine hood: 32 kg (71 lb)
INSTALLATION
★ Installation is done in the reverse order.
★ After installing hood (3) be sure to line up hood latch bracket (9)
when closing the hood.
WB146-5 30-23 3
DISASSEMBLY AND ASSEMBLY FRONT GUARD
12
FRONT GUARD
REMOVAL
★ Before removing the front guard, the grill and hood assembly must
be removed first. See "ENGINE HOOD."
1. After the grill and hood are removed, sling the front guard (4) as
shown in the illustration. Lift up slightly to relieve tension on the
mounting bolts (3) before removing them.
Front guard: 110 kg (243 lb)
2. Carefully remove the four mounting bolts (3) that hold the guard
(4) in place.
WARNING! When doing this procedure be sure to

keep upward tension on the guard frame
(4). When removing the four mounting
bolts (3) be sure to stand clear of the
guard frame (4).
3. Once the four mounting bolts (3) are removed, move guard frame
(4) forward then lift up on frame to remove from machine.
INSTALLATION
★ Installation is done in the reverse order.
Mounting bolts (3): Locktite 242
Bolts (3) torque: 300 N·m (221 lbf ft)
30-24 3 WB146-5
DISASSEMBLY AND ASSEMBLY RADIATOR
12
RADIATOR
REMOVAL
★ Before removing the radiator, the grill, hood and front guard assembly must be removed first. See "ENGINE HOOD" and
"FRONT GUARD."
1. Open the drain valve (3) and drain the engine coolant at the front of
the radiator.
WARNING! Slowly loosen the radiator cap to release

the pressure inside the cooling system.
A. Set a suitable size container under the engine coolant drain to

catch the coolant that is drained from the cooling system.
B. Place the drain hose into the container and open the drain valve
two to three turns to drain the engine coolant.
Remark
Do not drain coolant on the ground, in rivers or lakes or in
a city sewer system. Coolant must be captured and recycled.
Engine coolant: Approximately 15 liters (4 gal)
2. Disconnect the connector (4) and remove the horn (5).
3. Disconnect hose (7) from radiator (6) and remove surge tank (8).
WB146-5 30-25 3
4. Remove four bolts and fan guard (10).
5. Partially loosen fittings (11) and (12) to drain hydraulic oil from the
oil cooler. Once it is drained, remove hoses (13) and (14)
★ Plug all hoses, lines and connections to prevent contamination.
Hydraulic oil: Approximately 40 liters (10.5 gal)
6. Disconnect transmission oil cooler oil hoses (15) and (16) from the
oil cooler and plug them to prevent contamination.
★ Mark the hoses and their respective positions for reconnecting.
On machines equipped with air-conditioning
Remark
Do not release refrigerants into the atmosphere.
All refrigerants must be captured and recycled.
7. After capturing refrigerants, remove hoses (17) and (18).

30-26 3 WB146-5
8. Disconnect the upper (19) and lower (20) radiator hoses.
9. Remove the self-locking nuts (21), washers (22) and anti-vibration

dampers (23).
10. Remove the bolts (24) retaining the brackets (25).
11. Move the radiator (6) to the front of the machine to disengage it
from the cooling fan and lift it off the machine frame.
Radiator: 37 kg (82 lb)
WB146-5 30-27 3
12
INSTALLATION
★ To install, reverse removal procedure.
★ Refill the cooling system.
Coolant: 15 liters (4 gal)
★ Fill the tank with hydraulic oil up to maximum level.
Hydraulic oil: 40 liters (10.5 gal)
★ Ensure that the level of transmission oil is at maximum.

★ Start the engine at low idle to circulate all the fluids and to fill up
the systems.
★ Accelerate gradually to 1700 rpm; after about one minute, stop the
engine and check or top up the level. Top up all oil levels.
★ Align radiator (6) with fan, making sure the fan protrudes from fan
shroud by "a" 25 ± 2 mm (1.0 ± 0.1 in).
30-28 3 WB146-5
DISASSEMBLY AND ASSEMBLY AIR CONDITIONING CONDENSER
12
AIR CONDITIONING CONDENSER
WARNING! Do not release refrigerants into the atmosphere. All refrigerants must be captured and
recycled.
REMOVAL
1. Remove the front grille and the front guard. For details see
"FRONT GUARD."
2. After capturing refrigerants, remove hoses (1) and (2).

3. Disconnect the connector (3) and remove the horn (4).
4. Remove four bolts (5) and washers then remove condenser (6)
together with receiver-dryer.
INSTALLATION
★ Refill the air-conditioning unit.
WB146-5 30-29 3
DISASSEMBLY AND ASSEMBLY MUFFLER
12
MUFFLER
WARNING! Be sure the engine and exhaust system have fully cooled down before removing any
exhaust components. Failure to do so may result in a burn injury.
REMOVAL
1. Raise the front loader arms fully up and set the lock as shown
in (A).

storage position on to the extended lift arm cylinder rod.
lock (1).
2. Loosen the nuts (1) on the clamp (2) retaining the muffler pipe (3)
to the exhaust stack.
30-30 3 WB146-5
DISASSEMBLY AND ASSEMBLY MUFFLER
3. Remove clamp (4), disconnect the pipe (3) from the muffler (5) and
remove pipe (3).
4. Loosen clamp (6) retaining the muffler pipe to the turbocharger.
5. Remove the four bolts (7) and washers.
6. Sling and remove the muffler (5).
Muffler: 30 kg (66 lb)
INSTALLATION
WB146-5 30-31 3
DISASSEMBLY AND ASSEMBLY AIR FILTER
12
AIR FILTER
REMOVAL
1. Park the machine on hard, level ground, apply the parking brake,
stop the engine and remove the ignition key.
2. Fully open engine hood, loosen straps (1) and (2), and disconnect
pipes (3) and (4).
3. Disconnect connector (6) from filter clogging sensor (5).
4. Remove bolts (7) and remove the filter (8) together with the filter
housing.
INSTALLATION
30-32 3 WB146-5
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
12
TURBOCHARGER
WARNING! Be sure the engine and exhaust system have fully cooled down before removing any
exhaust components. Failure to do so may result in a burn injury.
REMOVAL
in (A).

lock (1).
2. Disconnect the coolant tube (2) from around suction pipe (1).
3. Disconnect the suction pipe (1) from the turbocharger (3).
WB146-5 30-33 3
4. Disconnect the connector (4) from the filter clogging lamp.
5. Remove bolts (5) and the air filter (6).
6. Remove bolts (7) and waste gate (8), then remove exhaust
flange (9).
7. Remove the muffler (10). For details see "MUFFLER."
30-34 3 WB146-5
8. Remove the turbocharger (3) according to the instructions provided
in the engine Shop Manual.
INSTALLATION
WB146-5 30-35 3
DISASSEMBLY AND ASSEMBLY REFRIGERANT COMPRESSOR
12
REFRIGERANT COMPRESSOR
recycled.
REMOVAL
in (A).

C. Using both hands lower the lock unit (1) down from its storage
position on to the extended lift arm cylinder rod.
lock (1).
2. Recover refrigerant at ports (1) and (2) using the proper recovery
equipment.
30-36 3 WB146-5
3. Disconnect supply and return lines (5) and (6) from compressor (4).
★ Collect the O-rings and discard them.
4. Remove air filter (8).
5. Remove the fan guard (7).
6. Loosen bolt (9) retaining tensioner (10).
7. Loosen nut (11) and rotate screw (12) to loosen the belt tension.
8. Disengage belt (13) from pulley (14).
WB146-5 30-37 3
9. Remove bolt and nut (15).
10. Remove bolts (15) and remove the compressor (4).
INSTALLATION
1. Replace O-rings with new ones
2. Adjust the compressor belt.
3. Recharge the system
30-38 3 WB146-5
DISASSEMBLY AND ASSEMBLY REFRIGERANT COMPRESSOR BELT
12
REFRIGERANT COMPRESSOR BELT
REMOVAL
(A).

C. Using both hands lower the lock unit (1) down from its storage
position on to the extended lift arm cylinder rod.
lock (1).
2. Remove fan guard (7).
3. Loosen the bolt (9) retaining the tensioner bracket (10).
4. Loosen nut (11) and adjust belt (13) tension by rotating bolt (12).
INSTALLATION
Bracket lock nut: 117.6 N·m (87 lbf ft)

Fan fastening nuts: 42 N·m (31 lbf ft)
WB146-5 30-39 3
DISASSEMBLY AND ASSEMBLY EXHAUST STACK
12
EXHAUST STACK
REMOVAL
(A).

lock (1).
2. Remove exhaust clamp nuts (1) and clamp (2) from pipe (3).
3. Loosen the bolts (4) on the stack flange and remove one bolt only
for safety to hold stack in place.
30-40 3 WB146-5
DISASSEMBLY AND ASSEMBLY EXHAUST STACK
4. Remove bolt (5) and lift stack (6) off of the machine after removing
last bolt (4) from flange.
INSTALLATION
WB146-5 30-41 3
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT
12
OPERATOR’S SEAT
★ This job requires two people to perform the removal and installation tasks.
REMOVAL
★ Before proceeding with any removal procedures, be sure the seat is locked in position.
1. Unplug connector (1) and remove seat mounting bolts (3).
2. Using two people, lift the seat (2) off the machine.
Seat: 62 kg (137 lb)
INSTALLATION
30-42 3 WB146-5
DISASSEMBLY AND ASSEMBLY CAB HEATING AND COOLING SYSTEM
12
CAB HEATING AND COOLING SYSTEM
recycled.
WARNING! Do not drain coolant on the ground, in rivers or lakes or in a city sewer system. Coolant
must be captured and recycled.
REMOVAL
★ If the machine does not have an air-conditioning system installed,
perform only those operations relating to the heating system.
1. Drain the engine coolant.
Coolant liquid: 15 liters (4.0 gal)
2. Evacuate the refrigerant from the air-conditioning system.
3. Remove the floor-mat (1); disconnect the connector (2) then

remove the seat (3).
4. Remove screws (4) and remove the control unit panel (5).
5. Remove four screws (6) and remove PPC valve and parking brake
cover (7).
WB146-5 30-43 3
6. Remove four screw covers and screws (8).
7. Remove the lower side instrument panel (9).

★ Cut the wiring harness strap and position the instrument panel
(9) inside the RH case (10).
★ To install, reverse removal procedures.
8. Remove four screw covers and screws (11).
9. Remove the upper side instrument panel (12).
10. Disconnect the connector (13) from the instrument panel (12).
11. Disconnect connectors (14) and (15) from the lighter.
12. Extract screws (16) and remove the throttle lever handle (17).
13. Remove screws (18) from the throttle lever assembly.
30-44 3 WB146-5
14. Remove the screws (19) and (20).
15. Remove knobs (21) from outrigger PPC valves.
16. Remove PPC valve mounting plate (22).
17. Extract screws (23) and remove contact carrier plate (24) for rear
wiper.
18. Extract the lower screws (25) retaining the right hand cover (10).
WB146-5 30-45 3
19. Extract three screw covers (26) and screws retaining the right hand
cover (10) at the rear.
20. Extract two screw covers (27) and screws; extract the lower screw
(28) and washer.
21. Extract the upper screw (29) retaining the right hand cover (10) and
its washer.
22. Move the rear of the right hand cover (10) towards the middle of
the cab, remove pin (30), and disconnect hand throttle cable (31).
23. Loosen nut and disconnect sheath (32).
30-46 3 WB146-5
24. Disconnect the contact carrier cover connector (33).
25. Engage the parking brake.
26. Raise right hand cover (10) until PPC valve control and parking
brake lever are disengaged; fully remove the cover.
FAN
1. Disconnect the connector (34).
2. Remove screw (35), then rotate fan group (36) counterclockwise.
3. Extract the fan group (36).
WB146-5 30-47 3
5. Disconnect connectors (38) and (39); slide it off and move it to one
side of the fuse and relay group (40).
6. Disconnect the heating system inlet and outlet lines (42) from the
heater core (41).
7. Only for machines with air-conditioning.
A. Disconnect the pressure switch connector (43).
B. Remove the screw (44), the washer and the plate (45); discon-
nect delivery and return lines (46) and (47).
C. Collect the O-rings and discard them.
HEATER CORE
1. Remove the four screws (48) and remove the unit (41).
30-48 3 WB146-5
12
INSTALLATION
Screw: 6 N·m (53 lbf in)
★ Refill the coolant liquid.
★ Recharge the air-conditioning unit.
Quantity of fluid (R134a): 2250 ±150 g
★ Quantity of oil: see the amount recovered.

★ Start the engine and use a leak detector to check the air-conditioning unit.
WB146-5 30-49 3
DISASSEMBLY AND ASSEMBLY BATTERY
12
BATTERY
WARNING!
Be careful when working around batteries:
• Keep metal tools away from battery if possible.
• Do not set tools or parts on battery tops.
• The battery generates flammable gas and there is danger of explosion. Do not bring fire or
sparks near the battery.
• Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large
amounts of water and consult a doctor.
REMOVAL
1. Lift the door (1) and disconnect the catch lever (2).
2. Remove the lower right-hand guard (3) off the cab.
3. Remove the protection shield (4).
4. Remove the platform (5) and door.
30-50 3 WB146-5
DISASSEMBLY AND ASSEMBLY BATTERY
5. Disconnect the battery (8) negative (-) terminal (6) and disconnect
battery terminal (7) (+) positive.
6. Loosen wing nut (9) and remove tie rod (10) and hold down
bracket (11).
7. Remove the battery (8).
INSTALLATION
★ Connect the battery positive (+) cable first, and then the negative (-) last.
WB146-5 30-51 3
DISASSEMBLY AND ASSEMBLY FUEL TANK
12
FUEL TANK
WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking
brake and chock the wheels. Remove the ignition key and disconnect the battery.
REMOVAL
1. Remove the fuel cap (1) off the fuel tank (2) and remove plug (3) in
order to drain the fuel.
WARNING! Do not remove or install fuel tank with fuel

in it. Tank may become unstable causing
fuel to spill.
Fuel tank: Approximately 150 liters (40 gal)
2. Reinstall the fill plug (3) and fuel cap (1).
3. Remove screws and remove the lower left trim panel (4) from the
cab.
4. Disconnect connector (5) from the level gauge sending unit (6).
★ Mark then disconnect the fuel inlet and return hoses (8)
and (7).
★ Plug all pipes and hoses to prevent contamination.
30-52 3 WB146-5
DISASSEMBLY AND ASSEMBLY FUEL TANK
5. Place a lift under the fuel tank (2); remove four retaining bolts (10)
and washers, then remove the tank.
Fuel tank: 62 kg (137 lb)
INSTALLATION
Tank retaining bolts: 120 N·m (89 lbf ft)
1. Refill the fuel tank.
Fuel fill: 150 liters (40 gal)
2. Bleed the air from the fuel circuit.
3. Start the engine.
WB146-5 30-53 3
DISASSEMBLY AND ASSEMBLY STEERING AND FRONT DASH ASSEMBLY
12
STEERING AND FRONT DASH ASSEMBLY
STEERING WHEEL
★ Before proceeding with any steering wheel or dash removal the
operator’s seat must be removed. See "OPERATOR’S SEAT."
1. Use a thin bladed screwdriver placed under each spoke of the

steering wheel to pry away the cover (1).
2. Remove the retaining nut (2) and remove the steering wheel (3).
3. Remove four screw covers (4) and loosen four screws (5) retaining
the instrument panel.
30-54 3 WB146-5
4. Lift off instrument panel (6) from steering column; disconnect
connectors (7) and (8), and remove instrument panel.
5. Remove screws (9) and (10) and release direction indicator group
(11) and transmission control group (12).
6. Disconnect connectors (13) and (14) and remove (11) and (12).
INSTALLATION
★ Before attempting to tighten the screws, check the anti-rotation
stake (15) for proper engagement into the steering column (16).
WB146-5 30-55 3
12
FRONT DASH ASSEMBLY
REMOVAL
1. Remove the upper screws (4) retaining the instrument panel (5).
2. Remove the covers (6) and extract screws (7) at the front trim
cover (8).
3. Remove the screws (9) retaining the front trim cover (8).
4. Lower the steering column and remove the knob (10).
5. Slide the front trim cover (8) up to remove it.
30-56 3 WB146-5
6. Take out the screws (11) and remove the instrument panel holder
(5).
7. Remove the cap (12) and draw the brake fluid from the tank (13).
8. Reinstall the cap and disconnect connectors (14) and pressure

switch connectors (15) and (16).
★ Connector (15) left (X54)
★ Connector (16) right (X53)
9. Remove the tank (13).
10. Disconnect the delivery pipes (18) from the master cylinder (17).
11. Take off four nuts (19) and remove the master cylinders.
★ If only one pump is to be removed, disconnect the pressure
equalizing pipe (20) and remove master cylinders individually.
WB146-5 30-57 3
INSTALLATION
★ Bleed the air from the braking circuit. See "BLEED AIR FROM
BRAKING CIRCUIT."
30-58 3 WB146-5
12
STEERING UNIT
REMOVAL
WARNING! Eliminate residual pressure from all circuits by moving all control levers in all directions.
1. Remove the steering wheel and the direction indicator, transmission

reverse and headlight dipper beam control groups For details, see
"STEERING AND FRONT DASH ASSEMBLY."
2. Loosen and remove the upper screws (4) retaining the instrument
panel holder (5).
3. Remove the screws (6) retaining the side of the instrument panel
holder.
WB146-5 30-59 3
4. Slide the instrument panel holder (5) up to remove it.
5. Loosen screw (7) and remove two screws (8); remove the front
guard (9).
6. Mark the respective positions of connectors and disconnect five

pipes (10) from steering unit (13).
★ Plug all pipes to prevent contamination.
7. Loosen the screws (11) fastening the column (12) and steering unit
(13); remove the steering unit.
INSTALLATION
★ Start the engine and perform several complete steering maneuvers in
both directions, to bleed the air out of the steering system.
30-60 3 WB146-5
DISASSEMBLY AND ASSEMBLY CAB
12
CAB
WARNING! Lower the backhoe work equipment completely until it is resting on the ground. Set the
parking brake and chock the wheels. Remove the ignition key and disconnect the battery.
REMOVAL
(A).

lock (1).
2. Open drain (3) and drain the cooling system.
WB146-5 30-61 3
Machines Equipped with Air-Conditioning
3. Evacuate the air conditioning unit using ports (1) and (2).
4. Remove the exhaust pipe (6). For details see "EXHAUST STACK."
5. Remove the front mat, remove screws (3) and loosen screw (4) and
remove cover (5).
6. Remove the front seat. See "OPERATOR’S SEAT" for details on

procedures.
7. Remove the five mounting bolts (3) and lift off floor cover (4).
30-62 3 WB146-5
8. Disconnect the injection pump control rod (2) from the pitman
arm (1).
9. Disconnect hoses (7) from steering unit.

★ Mark the positions of the lines to prevent exchanging positions
when reconnecting.
★ Plug the lines and pipe-fittings to prevent entry of impurities.
10. Remove nut (8) and disconnect strap (9) from frame.
11. Disconnect the lines (10).

12. Remove screws (11) and remove cover (12).
WB146-5 30-63 3
13. Disconnect connectors (14) from fuse block (13).
★ Disconnect connectors marked:
X7 - X8 - X11 - X12 - X126 - X128 - X153 - GND6
14. Lift rear window (15) to the top and remove the rear mat.
Servo-Controls
1. Remove the bolts (22) and remove the platform (23).
★ Only if equipped.
2. Disconnect connectors (25) and (26) from foot button (24).

★ Mark the position of connectors to avoid mixing them up
during re-installation.
30-64 3 WB146-5
3. Disconnect the servo-controls upper and lower pipes (27) from the
control valve.
★ Check to be sure all the hoses are marked and routing patterns.
★ Cap lines, hoses and openings to prevent contamination.
4. Lay the hoses inside the cab to gain access to the feed and exhaust
hoses.
5. Disconnect servo-control supply hoses (29) and (30) from solenoid

valve group (28).
★ Mark the lines to avoid exchanging them during installation.
6. Remove nuts (31) and disconnect the parking brake cable (33) from
the axle (32).
7. Disconnect connector (34); remove screw (35), and disconnect gear

lever (36).
WB146-5 30-65 3
8. Remove screws (37) and remove the cover (38).
9. Remove nuts (39) as well as front and rear bolts.
Version with Air-Conditioning Unit
1. Disconnect the suction line (41) from the compressor (40).
2. Remove screws (42) and remove the cover (43).
30-66 3 WB146-5
3. Disconnect hose (45) from condenser (44).
4. Remove the hole plugs and install two lifting eyes into the lifting
holes provided.
5. Connect cab (46) to the lifting equipment and apply light tension.
6. Lift the cab by about 30 cm (12 inches) and place some safety
blocks under it.
7. Remove bolts (47) and disconnect the ground wire (48).
8. Remove screws (49) and remove cover (50).
WB146-5 30-67 3
9. Loosen straps (51) and disconnect heater hoses (52).
★ Mark the lines to avoid exchanging them during installation.
10. Remove the cab.
Cab: 595 kg (1,312 lb)
INSTALLATION
1. Recharge the air conditioning unit
Quantity of refrigerant (R134a): 2250 ±150 g

Quantity of oil: see the amount recovered.
2. Bleed the air from the steering circuit.
3. Bleed the air from the braking circuit.

★ Perform all possible backhoe movements to bleed the servo-control system.
4. Adjust the stroke of the parking brake lever.
Cab retaining screws: 200 N·m (148 lbf ft)

Suction pipe union: N·m (lbf ft)
Union (38): 16 N·m (12 lbf ft)
5. Refill the cooling system.
30-68 3 WB146-5
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL TANK
12
HYDRAULIC OIL TANK
WARNING! Lower the working equipment completely until it rests on the ground. Engage the parking
brake, chock the front and rear wheels. Eliminate all residual pressure from all circuits by
moving all control levers in all directions. Disconnect the cable from battery negative
terminal (-). For details, see “BATTERY”.
REMOVAL
1. Remove the plug (1) and drain the hydraulic oil.
2. Remove the operator’s seat. See "OPERATOR’S SEAT."
3. Remove the steering wheel and remove the transmission control

lever (5) and the direction indicator and headlight control lever (6).
For details, see "STEERING AND FRONT DASH ASSEMBLY."
4. Remove the covers (9) and remove the screws (10) from cover (11).
WB146-5 30-69 3
5. Remove screws (7) holding the instrument panel housing (8).
6. Remove the screws (9) retaining the front trim cover (8).
7. Fully lower the steering column and extract knob (10).
8. Slide the front trim cover (11) up to remove it.
9. Remove the instrument panel holder (5).
30-70 3 WB146-5
10. Remove the fill cap (13) and draw the brake fluid out.
★ Replace cap to prevent contamination.
11. Disconnect oil level and pressure switch connectors (14) and (15).
12. Disconnect the brake fluid delivery tubes (16) and (17).
13. Loosen mounting bolt (18).
14. Remove bolts (19) and remove the cover (20).
15. Remove five bolts (21) and remove the metal floor cover (22)
off the cab floor.
WB146-5 30-71 3
16. Remove nuts (23) and disconnect the throttle cable (25) from the
relay rod (24).
17. Disconnect rod (26) from the relay rod (24).
18. Disconnect the strap (27) holding the steering unit and brake hoses.
19. Remove nut (28) and washer.
20. Disconnect the washer hoses (29) and remove the complete wiper
arm (30).
21. .Disconnect connector (32) from washer pump (31)
22. Disconnect connector (33) from wiper (34).
30-72 3 WB146-5
23. Remove bolts (35) and washers.
24. Remove the complete bulkhead (36) and move it to the rear of the
machine.
25. Remove bolts (37) and remove the cover (38).
26. Lift the rubber bulkhead and disconnect the discharge hose (40)
from the tank (39).
★ Plug the pipe to prevent contamination.
27. Disconnect union (41) and pipe (42).

★ Plug the union to prevent contamination.
WB146-5 30-73 3
28. Disconnect the pump suction pipe (43).
★ Plug the pipe to prevent contamination.
29. Disconnect the vent hose (44) and filter and remove.
30. Remove the screws and remove the fill sleeve (45).
★ Discard the old O-ring.
31. Remove screws (46) and washers and remove the tank's front
holder (47).
32. Remove bolts (48) and washers and remove the tank's rear support
(49).
30-74 3 WB146-5
33. Remove two bolts (50) and washers to release the complete tank
(39).
34. Remove the tank (39).
Hydraulic oil tank (empty): 10 kg (22 lb)
INSTALLATION
★ Bleed the air from the braking circuit. For details, see "BLEED AIR FROM BRAKING CIRCUIT."
★ Check and adjust the stroke of the throttle lever.
1. Refill the hydraulic oil.
2. Start the engine and check for leaks.
3. Stop the engine, check the oil level in the tank and, if necessary, top it up.
WB146-5 30-75 3
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
HYDRAULIC PUMP
REMOVAL
Remove plug (1) and drain the hydraulic oil.
★ Replace plug to prevent contamination.
1. Disconnect rear drive shaft (3) from transmission (2).
2. Disconnect lines (5), (6), (7), and (8) from the pump (4).
★ Cap all hoses and openings to prevent contamination.
30-76 3 WB146-5
3. Disconnect the intake line (8) from the pump and drain hose (9).
4. Remove the lower bolt (10) retaining the pump (4) and its washer.
5. Loosen upper bolt (11) but leave it in place.
Remark
Do not remove bolt (11) at this stage.
6. Install a hydraulic jack (B1) under the pump until the pump is fully
supported and stable.
7. Remove the upper bolt (11) and remove the pump (4).
Pump: 31.5 kg (70 lb)
WB146-5 30-77 3
12
INSTALLATION
Drive shaft bolts: 38 ± 1 N·m (28 ± 1 lbf ft)
Pump bolts: 220 N·m (162 lbf ft)
★ Refill the hydraulic oil.
1. Start the engine and run it at minimum speed to bleed any air.
2. Stop the engine and check the oil level in the tank and top up if necessary.
30-78 3 WB146-5
DISASSEMBLY AND ASSEMBLY TRANSMISSION
12
TRANSMISSION
REMOVAL
1. Drain the hydraulic oil.
2. Drain the oil from the transmission.
Transmission oil:
Approximately 20 liters (5.2 gal)
3. Remove the pump (1). See "HYDRAULIC PUMP."
4. Remove the floor panel (2) at the bottom of the cab.
5. Disconnect the connector (3) on the transmission disengagement

button, remove the bolt (4) and remove the control lever (5).
WB146-5 30-79 3
6. Disconnect rear drive shaft (7) from transmission (6).
7. Remove front drive shaft (8).
8. Disconnect solenoid valve connectors (9), (10), 4th gear sensor

connector (11), and oil temperature sensor connector (12) from
transmission (6).
9. Disconnect the dual-traction engagement solenoid connector (13).
10. Disconnect the feed and discharge hoses (14) and (15) for the
differential lock. Disconnect backhoe boom safety solenoid valve
group from transmission (6).
30-80 3 WB146-5
11. Disconnect delivery hose (16) to oil cooler and return hose (17)
from transmission (6).
13. Remove the bolts and remove the cover (19) giving access to the
converter coupling flange.
14. Slowly rotate the engine flywheel until the converter retaining bolts
(20) are centred in the hole; remove the four bolts.
15. Remove the bolts (21) and (22) retaining the wiring harness brace
(23).
16. Support the engine (24) with a stand “C” placed under the engine
bell housing.
WB146-5 30-81 3
17. Disconnect the transmission oil level pipe (25), remove bolt (26)
and remove the complete pipe (25).
18. Remove the nuts (27) on the vibration dampers (28), the bolts (29)
and remove the transmission supports (30).
19. Install the transmission holding tool “B2” to a stand that is capable
of supporting approximately 60 cm (24 inches).
20. Using the holes on the supports, secure the tool “B2” to the
transmission.
21. Loosen and remove the two bolts (31) retaining the transmission (6)
to the engine (24).
30-82 3 WB146-5
22. Move the transmission assembly (6) towards the rear of the
machine and remove.
Transmission: 232 kg (512 lb)
INSTALLATION
Transmission: 20 liters (5.3 gal)
Hydraulic oil: 40 liters (10.5 gal)
Front drive shaft bolts (6): 38 N·m (28 lbf ft)

Flywheel bolts (20): 64 N·m (47 lbf ft)
Support bolts (30): 90 ± 5 N·m (66 ± 4 lbf ft)
Anti-vibration nuts (27): 195 ± 20 N·m (144 ± 15 lbf ft)
Engine-bell-housing (31): 50 ± 5 N·m (37 ± 4 lbf ft)
Gear shift bolt (4): 120 N·m (89 lbf ft)
Flywheel bolts (20): Loctite 242

Support bolts (30): Loctite 262
Engine-bell-housing (13): Loctite 262
1. Tighten the bolts using the alternating crosswise method.
2. Start the engine to circulate the oil. Check that there are no leaks.
3. Bleed the air from the working equipment circuits. For details see "BLEEDING AIR FROM HYDRAULIC CIRCUITS."
4. Stop the engine, check the levels and, if necessary, top them up.
WB146-5 30-83 3
DISASSEMBLY AND ASSEMBLY TRANSMISSION OVERHAUL PROCEDURES
12
TRANSMISSION OVERHAUL PROCEDURES
WARNING! Before proceeding with any overhaul procedures be sure the transmission is sitting on a
level stable surface. Clean up any oil spills immediately and keep your work area clean
and clear of debris.
TORQUE CONVERTER
REMOVAL
★ Remove the engine and transmission. See "TRANSMISSION."
1. Remove the converter (1).
INSTALLATION
★ Ensure that the mating surfaces are clean and free of dents.
★ To aid in mating flywheel, engine and transmission, install a
threaded stud “A” as a guide.
Bolts: Loctite 262
Bolts: 39 N·m (29 lbf ft)
30-84 3 WB146-5
12
PLUGS AND FILTERS
DISASSEMBLY
1. Drain plug 7. Oil filter 13. Priority valve

2. Cap screw 8. O-ring 14. Port plug
3. Cover 9. Cover 15. Vent
4. Oil screen 10. O-ring 16. Temperature sending unit
5. O-ring 11. Spool
6. Cap 12. Spring
WB146-5 30-85 3
1. Remove the drain plug (1) and drain the oil from the transmission.
2. Remove the two cap screws (2) which fasten the cover for the oil
screen.
3. Remove the cover (3).
4. Remove the oil screen (4) and the O-ring (5).
5. Remove the connector for the oil filter (7) and its elements: plugs
(6) and cover (9).
30-86 3 WB146-5
6. Remove the connector (7) from the cover (9). Remove the
O-Ring (8).
7. Remove O-Ring (10) from cover (9).
8. Remove the spool (11).
9. Remove the spring (12).
WB146-5 30-87 3
10. Using a puller, remove the priority valve (13).
★ Do not remove or adjust the valve (13). If valve is already
damaged, replace it with a new one.
11. It is not necessary to remove the port plugs (14), the breather (15),
or the oil temperature sensor (16).
30-88 3 WB146-5
12
ASSEMBLY
1. Assemble the port plugs (14), the breather (15) and the oil
temperature sensor (16).
Sensor: 30 N·m (22 lbf ft)
2. Assemble valve (13).
3. Install the spring (12).
4. Install the spool (11).
WB146-5 30-89 3
5. Assemble O-Ring (10) on the cover (9).
6. Assemble O-Ring (8) on the connector (7), and the connector on the
cover (9).
7. Assemble the connector (7) and plugs (6).
Union: 50 N·m (37 lbf ft)
8. Assemble filter (4) and O-ring (5) after having washed or replaced
it.
30-90 3 WB146-5
9. Assemble cover (3) and bolt (2).
Bolt: 23 N·m (17 lbf ft)
10. Install the plug (1).
WB146-5 30-91 3
12
PUMP
DISASSEMBLY
1. Mounting bolts (4 of them) 3. O-ring

2. Pump 4. Front seal
1. Remove the bolts (1).

★ Reference mark the pump and bell housing before removing
the bolts.
30-92 3 WB146-5
2. Remove the pump (2) by means of two levers.
3. Remove the oil pump (2).
4. Remove O-ring (3).

★ Inspect the condition of the O-ring (3) and replace if necessary.

★ Inspect the condition of the sealing ring (4) and replace if
necessary.
WB146-5 30-93 3
12
ASSEMBLY
1. Use the tool F1, assemble the seal ring (2) on the oil pump (2).
2. Assemble O-ring (3).
3. Check oil passage holes between pump (2) and half-case or the
visual marks aligned.
4. Grease the ring to the half boxes to keep it centred with respect to
the shaft slot center line and to make the introduction onto the
pump easier.
30-94 3 WB146-5
5. Apply a thin coat of grease to the seat of the oil pump (2) and
install.
6. Install the bolts (1).
WB146-5 30-95 3
12
OIL LINE
REMOVAL
1. Fitting 3. Oil line

2. Fitting 4. Seals
5. Remove banjo fittings (1) and (2) and remove the clutch oil supply
line (3)
★ Replace the seals (4) at each disassembly of the banjo fittings.
ASSEMBLY
1. Install the clutch oil supply line (3) and the banjo fittings (1) and (2).
Fittings (1) and (2): 40 N·m (30 lbf ft)
30-96 3 WB146-5
12
VALVE BODY
DISASSEMBLY
1. Plug 19. O-ring 37. Plate gasket

2. O-ring 20. Nut 38. Outward piston
3. Snap ring 21. Spool 39. Outer spring
4. Piston 22. Washer 40. Middle spring
5. Spring 23. Spring 41. Center spring
6. Plug 24. Solenoid tube 42. Pin
7. O-ring 25. Spring 43. Inward piston
8. Spool 26. Ball 44. O-ring
9. Spring 27. O-ring 45. Plug
10 Washer 28. Solenoid 46. O-ring
11. O-ring 29. O-ring 47. Body housing
12. Cap plug 30. Solenoid 48. Plate bolts
13. Bolt 31. O-ring 49. Gasket
14. Cap plug 32. Nut 50. Plate
15. O-ring 33. Bolts 51. Gasket
16. Cap plug 34. Cap 52. Transmission
17. O-ring 35. Gasket 53. Valve body assembly
18. Solenoid valve 36. Plate
WB146-5 30-97 3
1. Remove bolts (13) and remove the valve body.
2. Remove the gasket (49).
3. Remove plate bolts (48) and remove the plate (50).
30-98 3 WB146-5
5. Clamp the valve body (53) in a vise.
6. Remove plug (1) and discard the O-ring (2).
7. Push down the piston (4) then remove the snap ring (3).
8. Remove the piston (4), the spring (5) and check the wear conditions
of the components.
9. Remove plug (6) and collect the O-ring (7).
WB146-5 30-99 3
11. Remove the washer (10).
12. Turn the body housing (47) over and remove the screws (33).
13. Remove the valve cover (34).
30-100 3 WB146-5
14. Remove the plate gasket (35).
15. Remove the plate (36).
16. Remove the outward piston (38), the springs (39, 40, 41), the
pin (42) and the inward piston (43).
★ Check the wear conditions of removed parts.
WB146-5 30-101 3
17. Remove the plate gasket (37).
18. Remove the ball (26).
20. Remove the nut (32) and the O-ring.
21. Remove the solenoid (30) and remove the O-Ring (29).
30-102 3 WB146-5
22. Remove the solenoid (28) and remove the O-Ring (27).
23. Unscrew the solenoid tube (24).
24. Remove the cartridge (24) and spool (21).
25. Disassemble the spool (21) from the cartridge (24).
26. Remove the spring (23) and the washer (22).

WB146-5 30-103 3
27. Remove the nut (20).
28. Remove the O-ring (19), the solenoid valve (18) and the
O-ring (17).
29. Loosen the cartridge (18).
30. Remove the O-Rings (17).

30-104 3 WB146-5
12
ASSEMBLY
1. Install the O-Rings (17).
2. Install the cartridge (18).
Cartridge: 25 - 30 N·m (18 - 22 lbf ft)
3. Install the O-Ring (17), the solenoid (18) and assemble the
O-Ring (19).
4. Install the nut (20).
Nut: 5 -7 N·m (44 - 62 lbf in)
WB146-5 30-105 3
5. Install the cartridge (24) and spring (23) to spool (21), and the
washer (22).
6. Install the cartridge (24) and spool (21) to control valve.
7. Tighten the cartridge (24).
Cartridge: 21.5 - 24.5 N·m (16 - 18 lbf ft)
8. Install O-Ring (27) and the solenoid (28).
30-106 3 WB146-5
9. Install O-Ring (29) and the solenoid (30).
10. Install O-ring (31) on the plug.
11. Install the nut (32).
Nut: 7 -10 N·m (62 - 88 lbf in)
13. Install the ball (26).
WB146-5 30-107 3
14. Install the gasket (37) being careful not to dislodge ball (26).
★ Reassemble the components.
15. Install the outward piston (38), springs (39, 40, 41), pin (42) and
inward piston (43).
16. Install the plate (36).
30-108 3 WB146-5
17. Install the gasket (35).
18. Assemble the valve cover (34).
Bolts: 9.8 -11.8 N·m (87 - 104 lbf in)
20. Turn the valve body (47) over.
21. Install the washer (10).
WB146-5 30-109 3
23. Install O-ring (7) on the plug.
25. Install piston (4) and spring (5).
26. Push down the piston (4) then install the snap ring (3) in its seat.
30-110 3 WB146-5
27. Install the O-ring (2) on the plug.
29. Install the gasket (51) on the transmission (52).
30. Install the plate (50) and the screws (48).
31. Install the gasket (49).
WB146-5 30-111 3
32. Install the valve body and the bolts (13).
30-112 3 WB146-5
12
4 WHEEL DRIVE SOLENOID VALVE
DISASSEMBLY
1. Mounting bolts 4. Gasket 7. Solenoid valve

2. Valve body 5. O-rings 8. Nut
3. Valve 6. Spool valve
1. Remove the bolts (1) and remove the solenoid valve body (2).
WB146-5 30-113 3
2. Remove the nut (8).
3. Remove the solenoid (7).
4. Remove spool valve (6) from housing.
5. Remove O-rings (5) from the cartridge.
7. Remove the valve (3).
Remark
DO NOT try to disassemble the valve (3). If valve is
already damaged, replace it with a new one.
30-114 3 WB146-5
12
ASSEMBLY
1. Assemble valve (3) to the housing.
2. Install O-rings (5) into the spool valve (6) in the housing.
Spool valve: 22 N·m (16 lbf ft)
3. Assemble the 4WD solenoid valve (7) and the nut (8).
Nut: 5 - 8 N·m (44 - 71 lbf in)
4. Install new gasket (4).
WB146-5 30-115 3
5. Install the housing (2) and bolts (1).
30-116 3 WB146-5
12
TRANSMISSION HOUSING
DISASSEMBLY
1. Snap ring 15. Shift tower 29. Snap ring

2. Bolt 16. O-ring 30. Shaft
3. Washer 17. Bolt 31. Snap ring
4. O-ring 18. Rear housing 32. Snap ring
5. Yolk flange 19. Seal 33. Bearing
6. Bolt 20. Pins 34. Bolt
7. Cover 21. Shift collars 35. Bolt
8. O-ring 22. Bolt 36. Front housing
9. Seal 23. Plate 37. Bearing
10. Bolt 24. Balls 38. Bearing
11. Washer 25. Plugs 39. O-rings
12. Yolk flange 26. Washers 40. Bearing
13. O-ring 27. Springs
14. Bolt 28. Balls
WB146-5 30-117 3
1. Remove bearing snap ring (1).
2. Remove yolk flange retaining bolts (2).

★ Use a pry bar and two screws to prevent yolk flange rotation.
4. Remove yolk flange (5) and O-ring (4).
30-118 3 WB146-5
5. Take out the bolts (6).
6. Remove the cover (7).
7. Remove O-Ring (8) from cover (7).
8. Remove the seal (9) from the cover (7).
WB146-5 30-119 3
9. Remove yolk flange retaining bolt (10).
★ Use a pry bar and two screws to prevent yolk flange rotation.
11. Remove yolk flange (12) and O-ring (13).
12. Remove out the bolts (14).
30-120 3 WB146-5
13. Remove the shift tower assembly (15) and the O-ring (16).
★ Replace the O-ring (16) with a new one at each disassembly.
15. Remove the six cap screws (17) and the two cap-screws (42) which
fasten the rear cover (18) to the rear half housing.
16. Use a pry bar to separate the rear cover from the housing.
17. Remove the rear cover (18).
18. Remove the seal (19) from the rear cover.
WB146-5 30-121 3
19. Use a punch to remove the pins (20) which fasten the shift collars to
the shift rods.
20. Remove the centering pins (41).
21. Remove the shift collars (21).
22. Remove the two screws (22) which hold the plate between the two
shift rods.
23. Remove the plate (23).
30-122 3 WB146-5
24. Remove the two detent balls (24) from the groove between the two
shift rods.
25. Remove bolts (25) and washers (26).
26. Remove springs (27).
27. Remove balls (28).
WB146-5 30-123 3
28. Pull the secondary shaft to the rear so that there is clearance
between the snap ring and the rear housing.
29. Remove the snap ring (29).
30. Remove transmission shaft PTO (30) by pushing lightly on the

opposite side.
31. Replace Teflon seal ring (31) by cutting it.
32. Remove snap ring (32).
30-124 3 WB146-5
33. Use the tool F2 to take the bearing (33) out.
36. Use lever to remove the front half housing (36).

★ Lift the front half housing by means of two hooks.
WB146-5 30-125 3
37. Remove the outer bearing cups (37) and (38).
38. Remove bearing (40).
★ Inspect the condition of O-rings (39) and replace if necessary.
30-126 3 WB146-5
12
ASSEMBLY
1. Push the secondary shaft toward the rear of the rear housing so that
there is clearance between the snap ring groove and rear housing.
2. Install the snap ring (29).
3. Install the O-Rings (39).
★ Apply a thin film of sealant on the edge of the rear half

housing.
Contact surface: Loctite 510
4. Lubricate the bearings (37) and (38) and mount them on the shaft.
WB146-5 30-127 3
5. Install front half housing (36) to rear half housing.
★ Make sure the bearings on the shafts are correctly positioned in
the front half housing.
★ Press the front half housing onto rear half housing.
★ Use clean transmission oil to lubricate the bearing for the

4WD shaft.
8. Install the bearing (40) on the 4WD shaft.

★ Use tool F3.
30-128 3 WB146-5
9. Use the F4 special tool to install a new seal (9) in the cover (7).
★ Push just until the seal stops moving. DO NOT use excessive
force.
10. Fill the cavity under the lip of the seal with high temperature wheel
bearing grease.
11. Assemble O-ring (8).
12. Install the cover (7) in the front housing.
13. Install the three cap screws (6) which fasten the cover to the front
housing.
WB146-5 30-129 3
14. Install a new O-ring (4) in the four-wheel drive yolk flange.
★ Use clean transmission oil to lubricate the O-ring.
15. Install the four-wheel drive yolk flange (5) on the four-wheel drive
shaft.
17. Tighten screw (2) using a pry bar to prevent yolk flange rotation.
30-130 3 WB146-5
18. Install snap ring (1).
19. Install the ball (28).
21. Install the washer (26) and the bolts (25).
WB146-5 30-131 3
★ Repeat steps 19 through 21 to install the upper detent ball and
spring.
22. Install bearing (33) on transmission shaft PTO (30).
23. Assemble snap ring (32).

★ Use tools F5 - F6 - F7.
24. For the assembly of the Teflon seal ring (13), see "CLUTCH PACK
(A) AND GEAR SHAFT (D)."
30-132 3 WB146-5
25. Insert transmission shaft PTO (30).
26. Grease and install the two detent balls (24).
27. Install the plate (23).
★ Apply sealant to the threads of the Allen head screws (22) and
attach the plate in position.
Bolts: Loctite 542
WB146-5 30-133 3
28. Install shift collars (21) on the shift rods.
29. Install the pins (20) to fasten the shift collars to the shift rods.
30. Install the centering pins (41).
★ Use the F8 special tool to install a new seal (19) on rear cover.
★ Push until the seal touches the lip in the hole.
31. Position the rear cover (18).

★ Make sure that the pin (41) is correctly installed both in the
rear housing and through the hole in the rear cover.
32. Install the six cap screws (17) and the two cap screws (42) to fasten
the cover to the rear half housing.
Screw: 50 N·m (37 lbf ft)
33. Install the O-ring (43).
30-134 3 WB146-5
34. Install a new O-ring (16) on the shift tower assembly (15).
★ Use clean oil to lubricate the O-ring and assembly it on the rear
housing.
35. Tighten the bolts (14) to fasten the shift tower assembly to the rear
cover.
36. Install a new O-ring (13) in the output yolk flange (12).
★ Use clean oil to lubricate the O-ring.
WB146-5 30-135 3
38. Tighten the bolts (10) using a lever to prevent yolk flange rotation.
30-136 3 WB146-5
12
CLUTCH PACK (A) AND GEAR SHAFT (D)
DISASSEMBLY
1. Teflon seal ring 15. Spring 29. Clutch pack assembly

2. Snap ring 16. Bearing 30. Lock ring
3. Bearing 17. Drive plate 31. Roll pin
4. Spacer 18. Clutch plate 32. Lock spring cover
5. Race 19. Piston 33. Snap ring
6. Gear 20. Outer O-ring 34. Spring
7. Needle bearing cage 21. Inner O-ring 35. Drive plate
8. Spacer 22. Teflon seal rings 36. Clutch plate
9. Roll pin 23. Snap ring 37. Bearing
10. Snap ring 24. Bearing 38. Piston
11. Clutch pack assembly 25. Thrust washer 39. Outer O-ring
12. Needle bearing cage 26. Gear 40. Inner O-ring
13. Lock spring cover 27. Race
14. Snap ring 28. Thrust washer
WB146-5 30-137 3
12
Shaft A (Clutch Pack)
1. Simultaneously remove shafts A and D.
2. Remove the Teflon seal ring (1).
4. Install a split bearing puller under the gear as shown in the

illustration.
Remark
Do not install the split bearing puller between the gear and
the bearing and do not use the puller on the gear without
the split bearing puller. Doing so will damage the bearing
or the gear.
★ Use a two jaw puller on the split bearing puller.
★ Pull the bearing, gear and spacer until it is free on the shaft.
30-138 3 WB146-5
6. Remove spacer (4).
7. Remove gear (6).
8. Remove needle bearing cage (7).
WB146-5 30-139 3
9. Remove spacer (8).
10. Remove roll pin (9).
12. Use pry-bars to evenly lift and remove clutch plate lock ring (11).
30-140 3 WB146-5
13. Remove the clutch plates (18) and the drive plates (17).
Remark
After removing the clutches and plates, be sure to keep
them assembled and in order of assembly. Mark the top
and bottom for reassembly order.
14. Place a reference mark below the groove on the clutch housing.
15. Place a mark on each plate lock ring (11), clutch plate (18) and
drive plate (17).
★ These marks will be used for reference during the reassembly
procedure.
16. Use the tool F9 push down lock spring cover (13).
WB146-5 30-141 3
18. Loosen the handles of the threaded rods to release the tension on
the spring.
19. Remove the top piece of the F9 special tool.
20. Remove lock spring cover (13) and spring (15).
21. Remove sleeve (5).
30-142 3 WB146-5
22. Using low pressure compressed air into the delivery hole, expel
piston (19).
WARNING! Do not use high pressure air to remove

piston (19), doing so will cause the piston
to fly out of the clutch housing.
23. Remove Teflon seal ring (20) and inner O-ring (21) from piston.
★ To remove the rings it is necessary to cut them.
24. Rotate the shaft.
25. Remove Teflon seal rings (22) by cutting them.
WB146-5 30-143 3
27. Remove bearing (24) by means of a two jaw puller.
28. Remove bearing (24) and thrust washer (25).
29. Remove gear (26) and needle bearing cage (12).
★ Repeat the procedure described so far to remove the

components of this clutch.
30-144 3 WB146-5
Gear Shaft D
1. Remove bearing (16) of shaft D by means of a two jaw puller.
2. Remove bearing (37) of shaft D by means of a two jaw puller.
WB146-5 30-145 3
12
CLUTCHES AND DISC INSPECTIONS
• Inspect grooves on shafts for wear or damage.
• Replace parts if necessary.
• Inspect output shaft for wear or damage.
• Check oil passages in the output shaft for restrictions or foreign
matter.
• Check all bearings for smooth areas, pits, galling or other damage.
• If the clutch discs are to be used again, keep the clutch packs in the
same previous dismantling order separate and record which clutch
pack goes with each clutch.
• At each disassembly, use a gauge to check the total thickness of
clutch plates to see if they are within the permissible wear limits. If
it is not, replace the clutch plates (18) with new ones.
• Check all clutch plates for burns and inspect the friction material
for damage. Inspect the grooves in the friction material for any
abnormal wear.
• Also inspect the clutch drive plates (17) for warpage, overheating
and for pits or scratches.
• If any of the above conditions exists on any of the plates, replace
the clutch pack with a new one.
• If a new clutch pack is to be used, soak it in transmission oil for at
least one hour before installing. See "FUEL, COOLANT AND
LUBRICANTS" in the Operators manual for fluid type.
• Lubricate the contact surfaces of the clutch drive plates with
transmission oil. See "FUEL, COOLANT AND LUBRICANTS" in
the Operators manual for fluid type.
• Check the hole on the input shaft entering the rear half housing for
any damage, this may cause leaks when clutch is installed.
• Check the splines on the input shaft for damage caused by steel
plates.
• Replace parts as necessary during installation.
Number of clutch plates (each side) 6

Number of drive plates (each side) 7
Drive plate thickness 2.5 ± 0.05 mm (0.098 ± 0.002 in)
Clutch plate thickness 1.75 ± 0.05 mm (0.069 ± 0.002 in)
Maximum clutch plate wear (each side) 0.2 mm (0.008 in)
30-146 3 WB146-5
12
ASSEMBLY
Shaft (A) Clutch Pack
1. Install the new Teflon ring (20) and O-rings (21) onto the piston
outer and inner seats.
★ Apply a thin film of Petroleum Jelly or transmission oil on the

sealing rings just inserted. See "FUEL, COOLANT AND
LUBRICANTS" in the Operators manual for fluid type.
2. Insert clutch piston (19) with special tool F10 as protection of seal
rings (21).
3. Assemble sleeve (5).
WB146-5 30-147 3
4. Assemble spring (15) and cover (13).
5. Press down on the lock cover (13). Insert lock ring (14).
★ Use tool F9.
6. Remove tool F9 and install roll pin (9).
7. Install thrust washer (8).
30-148 3 WB146-5
8. Insert needle bearing cage (7).
★ To assemble the clutch pack start with the gear (6) on a bench.
Install the clutch plate lock ring (11) so that the reference mark
on top of the plate made during disassembly is facing towards
the gear.
★ Assemble clutch plates (18) and drive plates (17) on the gear
(6). The assembled clutch pack must contain seven drive plates
and six clutch plates.
9. Install the pack assembly by using two screwdrivers.
WB146-5 30-149 3
11. Install washer (4).
12. Heat the bearing (3) to 80 -100°C (176 - 212°F) and install using
tool F2.
13. Install the stop ring (2).

★ Measure clearance between clutch plate lock ring and first
drive plate (17).
★ The clutch plate lock ring must be lifted against the stop ring.
★ Distance must be 2.3 - 4.3 mm (0.091 - 0.169 inches).
★ If distance is not within the specified range, the likelihood is
that the clutch has been installed incorrectly.
★ Check clutch for proper operation.
30-150 3 WB146-5
14. Insert the Teflon seal ring (1) as follows:
A. Install the F5 spacer onto the input shaft with the chamfered
end facing in.
B. Slide the F5 expander/protector onto the input shaft and on the

spacer.
★ The expander/protector will stop in the correct position to
install the seal ring in the groove.
C. Heat the Teflon seal ring to 60 - 80°C (140 -176° F) for five
minutes.
★ Install the Teflon seal ring onto the expander/protector.
WB146-5 30-151 3
D. Install the F6 pusher over the expander/protector and slide the
seal ring until it reaches the groove in the shaft.
★ Remove the pusher, expander/protector, and spacer from
the shaft.
E. Install the end of the seal installer F7 with the chamfer onto the
shaft and over the sealing ring.
★ Use a back and forth twisting motion to allow the seal
installer to slip over the top of the sealing ring and seat the
sealing ring into the groove.
★ Be careful not to damage the seal ring.
★ After the sealing ring is seated in the groove, remove the
seal installer from the shaft.
F. Turn the seal installer around and slide the end with the narrow
chamfer over the shaft and over the seal ring.
★ Leave the seal installer in place for 15 minutes until the
sealing ring has cooled and is properly sized and seated in
the groove.
★ After the sealing ring has cooled, remove the seal installer
from the shaft.
G. Using a feeler gauge between the lock ring (10) and the first
drive plate: Check clutch pack backlash.
★ Standard clearance: 2.3 - 4.3 mm (0.091 - 0.169 inches).
★ If backlash is not within specifications, check for proper
assembly of the clutch packs.
30-152 3 WB146-5
15. Turn the shaft around and carry out steps A - G for the other clutch.
★ Lubricate the ring (25) with transmission oil. See "FUEL,
COOLANT AND LUBRICANTS" in the Operators manual
for fluid type. Install the ring (25) so the notch on the inside
rim falls onto the pin.
★ Make sure that the side with the oil grooves is down.
16. Heat the bearing (24) to 80 - 100 oC (176 - 212 oF).

★ Use driver F11 to drive the bearing (24) onto the input shaft
until the bearing makes contact with the thrust washer.
18. Install the Teflon seal rings (22) as follows:
A. Place the F12a spacer into the F12b expander/protector.
WB146-5 30-153 3
B. Slide the F12b expander/protector and the spacer onto the
shaft.
★ The expander/protector will stop in the correct position to
install the seal ring in the groove.
C. Heat the Teflon seal ring to 60 - 80°C (140 -176° F) for 5

minutes.
★ Install the Teflon (22) seal ring onto the expander/
protector.
D. Install the F13 pusher over the expander/protector and slide the
seal ring until it reaches the groove in the shaft.
★ Remove the pusher, expander/protector, and spacer from
the shaft.
E. Install the end of the seal installer F14 with the deep chamfer
onto the shaft and over the sealing ring.
★ Use a back and forth twisting motion to allow the seal
installer to slip over the top of the sealing ring and seat the
sealing ring into the groove. Be careful not to damage the
seal ring.
★ After the sealing ring is seated in the groove, remove the
seal installer from the shaft.
30-154 3 WB146-5
19. Turn the seal installer around and slide the end with the narrow
20. Leave the seal installer in place for 15 minutes until the sealing ring
has cooled and is properly sized and seated in the groove. After the
sealing ring has cooled, remove the seal installer from the shaft.
★ For the introduction of the other three Teflon rings, repeat the
operations from step 18 to step 20, using the following spacer rings:
• F12/2 for the 2nd Teflon ring,
• F12/3 for the 3rd Teflon ring,
• F12/4 for the 4th Teflon ring.
Gear Shaft D
1. Assemble D shaft bearing (16).

★ Use tool F3.
2. Install D shaft bearing (37).

★ Use tool F3.
3. Lubricate shaft seat A.
WB146-5 30-155 3
4. Install shaft assembly D and shaft assembly A.
★ The operation is correctly done if the two shafts are installed at
the same time.
CHECKING CLUTCH FUNCTION
1. Lubrication oil passage 4. Forward gear 7. Reverse gear

2. Forward clutch passage 5. Forward clutch pack 8. Input shaft
3. Reverse clutch passage 6. Reverse clutch pack
• Apply compressed air to the forward clutch passage. Listen to hear the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward gear must not turn on the input shaft. Try to move the reverse gear. The
reverse gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble the clutches to find the
problem.
• Apply compressed air to the reverse clutch passage. Listen to hear the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The forward gear must not turn on the input shaft. Try to move the forward gear. The
reverse gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble the clutches to find the
problem.
30-156 3 WB146-5
12
GEAR SHAFTS (B) AND (C)
DISASSEMBLY
1. Bearing 15. Bearing 29. Sintered ring

2. Thrust washer 16. Stop ring 30. Friction ring
3. Third speed gear 17. Thrust washer 31. Sleeve
4. Third/fourth speed synchronizer 18. Second speed gear 32. Synchronizer
5. Clutch ring 19. Roll pin 33. Block
6. Tapered friction ring 20. Shims 34. Spring
7. Sleeve 21. Spacer 35. Inner hub
8. Plate 22. Synchronizer 36. Spacer
9. Ball 23. Synchronizer assembly 37. First speed gear
10. Spring 24. Steel ring 38. Snap ring
11. Inner hub 25. Sintered ring 39. Bearing
12. Fourth speed gear 26. Friction ring 40. Bearing
13. Snap ring 27. Synchronizer ring 41. Gear shaft (B)
14. 4WD gear 28. Steel ring
WB146-5 30-157 3
1. Remove the shafts B and C using special tool F15.
2. Remove the gear shift forks.
Gear Shaft (C)
1. Install a split bearing puller under the gear as shown in the

illustration and remove bearing (1).
Remark
Do not install the split bearing puller between the gear and
the bearing and do not use the puller on the gear without
the split bearing puller. Doing so will damage the bearing
or the gear.
★ Use a two jaw puller on the split bearing puller.
★ Pull the bearing until it is free on the shaft.
2. Remove thrust washer (2) and third speed gear (3).
30-158 3 WB146-5
3. Remove third/fourth speed synchronizer assembly (4).
4. Remove the clutch ring (5) from each side of the synchronizer
assembly.
★ The synchronizer assembly component parts are serviced as a
complete unit.
★ The synchronizer assembly may be disassembled for
inspection and cleaning.
★ If any of the parts are damaged, the entire synchronizer
assembly must be replaced.
5. Use a feeler gauge to measure the clearance between the bottom of

the teeth on the synchronizer ring and the edge of the sleeve on the
outside of the synchronizer assembly.
★ This clearance should be approximately 1.0 mm (0.039 inches)
with used parts in good condition.
★ If clearance is equal to or less than 0.5 mm (0.020 inches),
replace the complete synchronizer.
6. Inspect both sides of synchronizer for wear.

★ Thickness must be not less than 1 mm (0.039 inches).
7. Remove the tapered friction ring (6) from each side of the
synchronizer assembly.
★ Do not remove the sleeve (7) from synchronizer hub unless it is
absolutely necessary.
Remark
When removing the sleeve from the hub, be aware that
spring plates, hub pins and hub springs are not attached
to the hub and will be expelled quickly once the hub is
removed.
WB146-5 30-159 3
★ Do not mix up these parts.
★ The synchronizer hub contains three plates (8), three balls (9),
and three hub springs (10).
8. Remove fourth speed gear (12).
9. Rotate the shaft and remove bearing outer ring (15).
10. Using a puller, remove bearing inner ring (15).
Remark
Do not extract the bearing using the gear as a puller. The
snap ring (16) will prevent removal.
30-160 3 WB146-5
12. Remove the shims (20) and the thrust washer (17).
13. Remove roll pin (19).
14. Remove second speed gear (18).
WB146-5 30-161 3
15. Remove the spacer (21).
16. Remove the first/second speed synchronizer assembly (23).
17. Remove synchronizer ring (22).
18. Remove the steel ring (24) and the sintered ring (25).
19. Remove the tapered friction ring (26).
30-162 3 WB146-5
20. Turn the synchronizer assembly (23) over and remove the
synchronizer ring (27) from the other side.
21. Remove the steel ring (28) and the sintered ring (29).
22. Remove the tapered friction ring (30).
23. Support the sleeve on blocks.
24. Push down on the hub while you use a punch to push the detent
assemblies out of the sleeve and hub.
25. Remove the sleeve (31) from the hub.
WB146-5 30-163 3
27. Remove first speed gear (37).
29. Remove the 4WD gear (14).
30-164 3 WB146-5
Gear Shaft B
1. Remove bearing inner race (39) using a puller.
2. Turn shaft (41) around and remove bearing (40).
WB146-5 30-165 3
12
ASSEMBLY
Gear Shaft C
1. Place shaft on bench so the side with serrated edge is facing

upwards.
2. Install the stop ring (13).
3. Install 4WD gear (14).
5. Install the first speed gear (37).
30-166 3 WB146-5
6. Install spacer (36).
7. Install the first/second speed synchronizer (23).
8. Install the hub (35) the spring (34), the blocks (33), the balls (32),
and the sleeve (31).
9. Using a punch or screwdriver push in the balls (32) to complete hub

assembly (35).
10. Install the tapered friction ring (30) on the synchronizer assembly.
WB146-5 30-167 3
11. Use clean transmission oil to lubricate the sintered ring (29) and the
steel ring (28).
12. Install the synchronizer ring (27) as shown.

★ The flat sides of the teeth must be up.
13. Turn the synchronizer assembly over and install the tapered friction
ring (26) on the other side.
14. Use clean transmission oil to lubricate the sintered ring (25) and the
steel ring (24). Install the sintered ring (25) and the steel ring (24).
30-168 3 WB146-5
15. Install the upper synchronizer ring (22) so the smooth sides of the
teeth are facing upwards.
16. Install the complete first/second speed synchronizer (23).
17. Install the spacer (21) on the second speed gear (18).
18. Install the second speed gear (18).

★ Be sure the spacer (21) and gear (18) make solid contact with
the synchronizer (23).
19. Install the pin (19).
WB146-5 30-169 3
20. Install thrust washer (17) and shims (20).
21. Install the snap ring (16).
22. Using a feeler gauge, measure distance X between gear (18) and
ring (17).
★ Standard clearance: 0.2 - 0.42 mm (0.008 - 0.017 inches)
23. Use a thickness gauge.
★ If distance X is incorrect, rearrange the shim pack to obtain the

specified clearance using the shims available.
30-170 3 WB146-5
24. Heat the inner race of the bearing (15) to 80 - 100°C (176 - 212°F)
and use the tools F16 on the shaft.
25. Install the outer race of the bearing (15).
26. Rotate the shaft.
27. Install the fourth speed gear (12).
28. Install the third/fourth speed synchronizer (4).
WB146-5 30-171 3
29. Install springs (10), blocks (8), balls (9) and sleeve (7) to hub (11).
30. Using a punch or screwdriver, push in the balls (9) to complete

assembly of hub (11).
31. Install the tapered friction ring (6) on each side of the synchronizer
assembly.
32. Lubricate clutch ring (5) with transmission oil and install each side
of the synchronizer assembly.
33. Install the third/fourth speed synchronizer assembly (4) onto the
shaft.
★ Use clean transmission oil to lubricate the thrust washer (2).
30-172 3 WB146-5
34. Install third speed gear (3) and the thrust washer (2) onto the shaft.
35. Heat the bearing (1) to 80 - 100°C (176 - 212°F).

★ Use the tool F2 to assemble bearing (1).
Gear Shaft B
1. Heat the inner race of the bearing (39) to 80 - 100°C (176 - 212°F)
and use the tools F16 install the ring inside the bearing (39).
2. Rotate shaft (41).
3. Heat the bearing to 80 - 100°C (176 - 212°F). Use the tool F2

assemble bearing (40).
WB146-5 30-173 3
4. Using tool F16, position and install shafts B and C to half housing.
★ Complete shafts should be installed with pins and forks.
5. Install pre-assembled 3rd and 4th speed forks and 1st and 2nd speed
forks as shown.
6. Position the group with care, paying attention to the location of fork
pins in their seats.
30-174 3 WB146-5
12
GEAR SHAFT (E)
DISASSEMBLY
1. Snap ring 7. Clutch pipe 13. Cylinder

2. Washer 8. Seal ring 14. Snap ring
3. Spacer 9. O-ring 15. Gear
4. Spring 10. Valve 16. Bearing
5. Sleeve 11. Spring
6. O-ring 12. O-ring
1. Remove the shaft E.
WB146-5 30-175 3
2. Remove shafts B and C. Remove the four-wheel drive clutch
gear (15).
4. Using tool F17, push down on the spring cover until stop ring (1) is
exposed.
5. Remove stop ring (1) from its seat and remove tool F17, then
remove washer (2).
30-176 3 WB146-5
7. Remove springs (4).
9. Remove the two O-rings (6) and (9) from the shaft.
10. Remove the Teflon sealing rings (8) from the shaft.
WB146-5 30-177 3
12. Remove cylinder (13).
13. Remove O-rings (12) from cylinder (13).
14. Remove valve (10) and spring (11) from cylinder (13).
30-178 3 WB146-5
★ Do not remove 4WD clutch pipe (7) from front housing unless
absolutely necessary.
ASSEMBLY
1. Install spring (11) and valve (10) in cylinder (13).
2. Install O-rings (12) on cylinder (13).
3. Install cylinder (13) in the shaft.
WB146-5 30-179 3
5. Install the O-rings (6) and (9) on the shaft.
6. Install sleeve (5).
7. Install springs (4).
30-180 3 WB146-5
8. Install spacer (3).
9. Position washer (2) and snap ring (1).
10. Using tool F17, push down on spring cover until the stop ring seat
(1) is exposed and complete the assembly of the stop ring (1).
11. Release tension and remove the tool.
12. Ensure that the stop ring (1) is correctly positioned in the recess of
the spring cover.
13. Place the protector F18 onto the shaft. The expander/protector will
stop in the correct position to install the Teflon sealing ring in the
groove.
14. Heat the Teflon sealing ring (8) to 60 - 80°C (140 - 176°F).
15. Install it onto the expander/protector.
WB146-5 30-181 3
16. Install the F6 pusher over the expander/protector and slide the seal
ring until it reaches the groove in the shaft.
★ Remove the pusher, expander/protector, and spacer from the
shaft.
17. Install the end of the F7 seal compressor with the deep chamfer
onto the shaft and over the sealing ring.
★ Use a back and forth twisting motion to allow the seal installer
to slip over the top of the sealing ring and seat the sealing ring
into the groove.
★ Be careful not to damage the seal ring.
★ After the sealing ring is seated in the groove, remove the seal
compressor from the shaft.
★ Turn the seal installer around and slide the end with the narrow
★ Leave the seal installer in place for 15 minutes until the sealing
ring has cooled and is properly sized and seated in the groove.
★ After the seal ring has cooled, remove the seal compressor
from the shaft.
18. Install protector F19.

★ Repeat steps 13 -18 to introduce the second Teflon ring.
30-182 3 WB146-5
12
★ Apply air to 4WD clutch oil passage (see arrow) by plugging the opposite hole with a finger. The sleeve (5) should be
moving when compressing the springs (4). The 4WD gear (15) should move freely on 4WD shaft. Valve (10), if operating
correctly, reaches the end of stroke making a noise. If the operation is incorrect, dismantle to find the problem.
1. Snap ring 7. Clutch pipe 13. Cylinder

2. Washer 8. Seal ring 14. Snap ring
3. Spacer 9. O-ring 15. Gear
4. Spring 10. Valve 16. Bearing
5. Sleeve 11. Spring
6. O-ring 12. O-ring
17. Install bearing (16).
WB146-5 30-183 3
18. Install gear (15).
19. Install shafts B and C. Assemble shaft E.
20. Reinstall the 4WD clutch pipe (7).
Hose (7): 26 - 30 N·m (19 - 22 lbf ft)
30-184 3 WB146-5
12
SHIFTER TOWER AND FORKS
DISASSEMBLY
1. Bolts 6. Shift lever 11. Pins

2. Shift tower assembly 7. King pins 12. 2nd and 3rd fork
3. O-ring 8. Stop ring 13. 1st and 2nd fork
4. Clamp 9. Bushing
5. Boot 10. Spring
1. Remove bolts (1).
WB146-5 30-185 3
2. Remove the shift tower assembly (2) and the O-ring (3).
★ Replace the O-ring at each disassembly.

★ Replace the clamp at each disassembly.
4. Remove the boot (5).
5. Remove the king pins (7).
30-186 3 WB146-5
6. Remove the steel stop ring (8) from transmission lever.
7. Remove the bushing (9) from transmission lever.
9. Slide the gear shift lever (6) out.
WB146-5 30-187 3
★ Only if necessary - remove the pins (11) and separate the forks
from the gear control rods.
★ Mark the forks and the shifters to prevent mixing them during
installation.
ASSEMBLY
1. Lubricate the shift lever ball.
2. Install the shift lever (6) in the cover (2).
Ball: ASL 800050
★ The illustration shows the correct position of the control lever (6) in
relation to the gear case (2)
★ Recess A must be facing the curved side B of case.
★ Slots C must be aligned with holes D in the case.
3. Install spring (10) to lever.
30-188 3 WB146-5
4. Install the bushing (9).
5. Install the stop ring (8) to the shift lever.
6. Insert pins (7) through the holes in the case flange (2) so they
engage into the slots on the shift lever.
7. Install the boot (5) into the case carrier (2) so as to hold the pins (7).
WB146-5 30-189 3
8. Install a new clamp (4) around the boot (5).
9. Install a new O-ring (3) to case flange.
O-ring: Transmission oil.
10. Tighten the screws (1).
Bolt (1): 23 N·m (17 lbf ft)
11. Install the two pins (11) to lock gear control fork 3rd and 4th speed
(12) and gear control 1st and 2nd speed (13).
30-190 3 WB146-5
DISASSEMBLY AND ASSEMBLY ENGINE
12
ENGINE
REMOVAL
★ Before proceeding with engine removal procedures, remove the

engine hood, front guard and disconnect the front loader assembly
from the machine as shown in the illustration.
● See "ENGINE HOOD"
● See "FRONT GUARD"
● See FRONT-END LOADER ASSEMBLY"
1. Disconnect fuel inlet line (1).

★ Cap all lines, hoses and openings to prevent contamination.
2. Disconnect fuel return line (2).

WB146-5 30-191 3
3. Disconnect starter electrical supply (3) from the starter.
4. Disconnect the ground (4) engine to chassis connection.
5. Open the drain valve (5) and drain the engine coolant at the front of
the radiator.
WARNING! Slowly loosen the radiator cap to release

the pressure inside the cooling system.
A. Set a suitable size container under the engine coolant drain to

catch the coolant that is drained from the cooling system.
B. Place the drain hose into the container and open the drain valve
two to three turns to drain the engine coolant.
Remark
Do not drain coolant on the ground, in rivers or lakes or in
a city sewer system.
Coolant must be captured and recycled.
Engine coolant: Approximately 15 liters (4 gal)
30-192 3 WB146-5
6. Disconnect alternator connection (6) and remove lower radiator
hose (8) as well as lower heater hose (7).
7. Disconnect and remove upper radiator hose (9) and upper heater
hoses (10).
8. Disconnect turbo intake hose (11) and remove air cleaner assembly
(12) from the engine.
★ Be sure to cap the turbocharger inlet after removing hose (11)
to prevent debris from entering the turbo inlet side.
9. Remove the muffler and piping assembly (13).

★ Be sure to cap the turbocharger outlet after removing muffler
(13) to prevent debris from entering the turbo outlet side.
WB146-5 30-193 3
10. Disconnect refrigerant lines (14) and remove the refrigerant
compressor (15) from the engine.
● See "REFRIGERANT COMPRESSOR."
11. Disconnect wiring harness (16) from the related engine connectors.
12. Remove fan guard (17) and related radiator shroud components.
● See "RADIATOR."
13. Remove belts (18) and fan assembly (19) from engine.
● See "AC COMPRESSOR BELT TENSION."
30-194 3 WB146-5
14. Remove upper heat shrouding (20) from top of fire wall.
15. Remove hydraulic tank (21).

● See "HYDRAULIC OIL TANK."
16. Install a lifting eye “A” to the muffler inner mounting hole.
17. Attach a lifting device to lifting eye “A” and to engine front bracket
and apply a slight tension to the chains or cables.
WB146-5 30-195 3
18. Remove access cover (22) and remove the four flywheel to con-
verter mounting bolts.
19. Support the front of the transmission with a lifting device.
20. Remove mounting bolts (23) on each side and remove engine guard
(24) from under machine.
21. Remove hose bracket (25) and remove the fourteen flange bolts
(26) from the top, left and right side and bottom of the transmission
bell housing.
30-196 3 WB146-5
22. Remove the front engine mounting bolts (27) and prepare to lift the
engine from the chassis.
23. Remove the engine (28).
Engine: approximately 350 kg (770 lb)
INSTALLATION
Nuts: 200 N·m (148 lbf ft)
★ Check transmission oil level before starting the engine.

★ Thoroughly check the connectors to ensure that they are properly connected.
★ Start the engine and let it idle for a couple of minutes.
WB146-5 30-197 3
DISASSEMBLY AND ASSEMBLY STEERING SOLENOID VALVE
12
STEERING SOLENOID VALVE
REMOVAL
1. Mark and disconnect all hoses (2) from solenoid valve group (1).
2. Mark and disconnect all connectors (5) (No. 2) and (6) (No. 2) from
solenoid valve (3) and (4) (No. 4).
3. Remove bracket (8) mounting bolts (7) (No. 2), disconnect

connectors (9) and remove steering solenoid valve group (1).
INSTALLATION
★ Run the engine and steer few times in both direction, using alternatively the 2 wheel steering mode and one of the 4 wheel
steering mode.
30-198 3 WB146-5
DISASSEMBLY AND ASSEMBLY STEERING SOLENOID VALVE
MEMORANDUM
WB146-5 30-199 3
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
12
FRONT AXLE ASSEMBLY
REMOVAL
★ Start the engine and force the bucket downwards in order to raise
the machine and the front wheels.
★ Place two stands “A” and some blocks beneath the chassis.
★ Slowly lower the machine onto the blocks, checking to be sure the
wheels remain at least 5 cm (2 inches) above the ground.
★ Fully raise the front working equipment and engage the safety stop.
See "ENGINE HOOD."
1. Remove the engine hood (3) and the front guard. See "ENGINE
HOOD."
★ If equipped, remove the front counterweight.
Counterweight: 170 kg (375 lb)
2. Remove the front wheels.
Wheel: 52 kg (115 lb)
3. Remove front drive shaft cover (1) by removing two bolts (2) on
each side.
30-200 3 WB146-5
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
4. Disconnect the front drive shaft (4) from the axle (3).
5. Disconnect the lines (5) from the steering cylinder and plug them to
prevent entry of impurities.
6. Disconnect the lubrication tube (6) for the axle pin (7).
7. Position a jack “B” and some blocks “C” beneath the axle. Raise
the jack until the blocks can be forced under the axle arms (3).
★ It should be possible to lower the jack 10 cm (4 inches) in order
to disengage the axle from the supports.
8. Remove the nut and remove the retaining bolt (8) from the axle pin
(7).
9. Install a slide hammer into the central hole of the axle pin (7); pull
out the axle pin.
10. Lower the jack until the axle is disengaged.
11. Remove the entire front axle assembly (3).
4WD: approximately 262 kg (578 lb)
INSTALLATION
Front closing bolts: 300 N·m (221 lbf ft)

Nuts for front wheels: 370 N·m (273 lbf ft)
Bolts on transmission side: 38 N·m (28 lbf ft)
★ Bleed the air from the Load Sensing circuit.
Axle pin - bushings: ASL800050
★ Check the oil level in the tank and start the engine.
★ Perform a few complete steering maneuvers in both directions to bleed the air from the steering circuit.
WB146-5 30-201 3
DISASSEMBLY AND ASSEMBLY FRONT AXLE OVERHAUL PROCEDURES
12
FRONT AXLE OVERHAUL PROCEDURES
WARNING! Before proceeding with any overhaul procedures be sure the front axle is sitting on a
level stable surface. Clean up any oil spills immediately and keep your work area clean
and clear of debris.
STEERING CYLINDER ASSEMBLY

DISASSEMBLY
1. Castellated nut 8. Ball joint 15. Gland

2. Tie rod 9. Nut 16. Seal ring
3. Steering knuckle 10. Tie rod 17. Cylinder rod
4. Nut 11. Axel end 18. Seal ring
5. Ball joint 12. Castellated nut 19. Cylinder
6. Bolt 13. Scraper 20. O-ring
7. Cylinder 14. O-ring 21. Scraper
30-202 3 WB146-5
1. Loosen tie rod end (2) locknut (1) until it is over the end of the
threaded pin.
2. Drive the nut (1) with a hammer in order to loosen the tie rod (2)
from the steering knuckle housing (3).
★ Do not strike the end of the threaded pin, this will damage the
pin.
3. Loosen the nuts (4) and (9) and remove the tie rods (2) and (10).
4. Remove the fastening bolts (6) from the cylinder, then remove the
cylinder (7) from its housing using a rubber hammer.
5. Remove only those parts that need to be overhauled and/or

replaced.
6. Remove the cylinder gland (15) from the cylinder (19).
7. Remove the cylinder gland and the rod (17) from the cylinder case
(19).
★ Replace all sealing rings (16) and (18), O-rings (14) and (20),
and scrapers (21) and (13) in cylinder body (19) and rod (17).
ASSEMBLY
1. Install all new sealing rings (16) and (18), O-rings (14) and (20),
and scrapers (21) and (13) to gland (15), to rod piston (17) and into
cylinder body (19).
WB146-5 30-203 3
2. Slide the pre-assembled (17) rod into the cylinder body (19).
3. Install ball joints (5) and (8), nuts (4) and (9) and tie rods (2) and
(10) at the rod (17) ends and tighten.
Tie rods: 300 N·m (221 lbf ft)
4. Install steering cylinder to centre body (7) together with tie rods.
5. Assemble and tighten the steering cylinder bolts (6) with torque
wrench.
6. Align the steering knuckle with the axle (parallel wheel hub).
7. Adjust the ball joint (5) so that the ball joint can be inserted into the
steering knuckle arm.
★ It is important to unscrew the locking nut (9) to carry out this
operation.
30-204 3 WB146-5
8. Insert the tie rod (2) into its own housing on the steering knuckle
(3).
9. Assemble and tighten the lock nut (1) with a torque wrench.
Nut: 220 N·m (162 lbf ft)
★ Repeat the operation for the opposite side.
10. Install lock nuts (4) and (9) of the tie rods (3) and (10) only when
the toe-in adjustment has been carried out.
Checking Toe-In
1. Install 2 one-meter-long linear “A” bars that are identical to each

other to the wheel flanges; lock them into position by tightening
two nuts onto the wheel hub studs.
2. Position the bars so they are centered in relation to the middle of the
wheel axle, then check to ensure that they are perfectly resting
against the hub.
★ Ensure that the piston is centered in relation to the cylinder.
3. Using a tape measure, measure the distance in mm “M” from the

farthest bar ends, and tighten or loosen the tie rods until the distance
is the same on both sides.
★ Keep the minimum value, swinging the measurement point.
WB146-5 30-205 3
4.Check the difference of the measurements between the wheel hubs
diameter ends to be sure it is within the requested tolerance range.
★ The nominal toe-in (A) value is referred to the external diameter of
the wheel hubs flange, therefore the measured toe-in value (M) at
the bars ends must be related to the ratio between length of the bar
and flange diameter.
★ Nominal toe-in = A 2 mm (0.1 inches)
★ Measured toe-in = M 5 mm (0.2 inches)
5. If toe-in is incorrect, adjust with two wrenches the tie rods nuts in
or out to set the tie rods equally until the toe-in is within the
required tolerance.
6. Once adjustment is complete, tighten the retaining nuts on the tie

rods.
30-206 3 WB146-5
Camber Angle Adjustment
1. Use the same bars “A” for the toe-in adjustment and a long bar to
extend over the machined part of the central body (pinion side), so
that the two bars form an acute angle at the maximum steering.
★ Adjust the angle of 65° and position it on the long bar.

★ Move a wheel side till it forms the angle.
2. Adjust the steering angle retainer, bolt in or out using the bolts (1)
on the bar body, locking them with a locknut (2).
Lock nut: 150 N·m (111 lbf ft)
3. Steer completely towards the other side and repeat the same
operations.
WB146-5 30-207 3
12
FRONT AXLE END PLANETARY ASSEMBLY
DISASSEMBLY
1. Screw 5. Bearings 9. Snap ring

2. Plug 6. Gear 10. O-ring
3. Carrier 7. Bearings
4. Pin 8. Thrust washer
★ Before draining the oil, position the axle end (3) with the plug (2) on the upper part and loosen it in order to eliminate any
possible inner pressure, then remove it completely.
1. Turn the hub upside-down till the drain hole (2) is at its lowest
point.
2. Drain the oil completely.
30-208 3 WB146-5
3. Remove the screws (1).
4. Remove the planetary carrier (3) from the epicyclic reduction gear
and remove the O-ring (10).
Removing the Planetary Gears (If Necessary)
1. Remove snap ring (9) from each pin (4).
2. Remove the gears (6) from the pins.
3. Recover the rollers (7) and (5) and inspect their condition.
4. Remove the thrust washers (8).

★ When new planetary gears are used it is advisable to install
new roller bearings.
WB146-5 30-209 3
12
ASSEMBLY
★ Reinstall all epicyclic reduction gear components: the planetary
gears carrier (3), the gears (6), the needle bearings (5) and (7),
washer (8) and the snap rings (9) of every pin (4).
★ With new gears, it is advisable to install new needle rollers.
1. Insert the needles (5) and (7) into the gears (6).
2. Grease the needles (5) and (7).
3. Insert the gears (6) with assembled needles in the planetary carrier
pins.
4. Install a new O-ring (10).
5. Install planetary gear carrier (3) to epicyclic reduction gear.
6. Install retaining screws (1).
Screws: 25 N·m (18 lbf ft)
★ Use recommended oil in epicyclic reduction gear and axle

body.
7. Install plug (2) to axle end.
Plug: 80 N·m (59 lbf ft)
30-210 3 WB146-5
12
AXLE END HUB ASSEMBLY
DISASSEMBLY
1. Snap ring 10. Stud 19. Bolt

2. Washer 11. Hub 20. Nut
3. Washer 12. Bearing cup 21. Bolt
4. Ring gear 13. Seal ring 22. Bushing
5. Screw 14. Steering knuckle 23. Seal
6. Bushing 15. Bearing cone 24. Axel shaft
7. Carrier 16. Lower king pin 25. Beveled washer
8. Retaining ring 17. Bolt 26. Axle housing
9. Bearing cone 18. Upper king pin
WB146-5 30-211 3
WARNING! Before disassembling the wheel hub, it is advisable to secure it with a belt or a sling on a
hoist or any other supporting device, in order to avoid its accidental fall that could dam-
age either the technician or the wheel hub group.
1. Insert a lever between the steering knuckle (14) and the axle beam
and fit it into the double U-Joint. With the lever push the double
U-Joint in the direction of the wheel hub to allow the lock ring (1)
removal.
★ Do not damage the double U-Joint.
2. Remove the lock ring (1) from the double U-Joint shaft and collect
the washers (2) and (3).
3. Remove the bolts (5) from the wheel carrier (7) group.
30-212 3 WB146-5
★ In order to remove the wheel carrier group (7) from its hous-
ing, insert two of bolts (5) in the threaded extraction holes.
4. Extract and remove the hub-lock ring gear (7) together with the
epicyclic ring gear (4).
5. Remove the hub-lock ring gear (8) from the epicyclic ring gear (4).
★ Check the wear conditions of the components.
Only if Necessary
1. Remove the centering bushings (6) of the hub lock ring gear with a
hammer and special tool D1.
2. Remove the hub (11), using levers and a hammer to facilitate the
operation.
★ Collect the bearing (9) cone.
3. Position unit on a flat surface and remove the seal ring (13) with a
pry-bar.
★ This is a destructive operation for the seal ring.
4. Take the bearing cups (9) and (12) out on both sides of the hub,
using a hammer and a suitable tool.
5. Remove the bearing cone (12) from the steering knuckle using a
suitable, commercially available puller.
WB146-5 30-213 3
6. Remove bolts (19) from the upper (18) and (17) lower (16) king
pin.
★ Before removing the king pins, secure the steering knuckle
with a hoist or other supporting device.
7. Remove the king pins (18) and (16) and collect the bevelled
washers (25) and (27).
8. Remove the steering knuckle (14) from the axle beam and from the
shaft (24).
9. Lay the steering knuckle (14) on a flat surface and remove the seal
ring (23) with a pry-bar.
10. Turn the steering knuckle (14) and take the bush (22) out, using a
driver and a hammer.
30-214 3 WB146-5
12
ASSEMBLY
1. Install bushing (22) into the steering knuckle (14) with the special
tool D2. and a hammer or a press.
2. Assemble the seal ring (23) into the steering knuckle (14) with the
special tool D3 and a hammer.
3. Lubricate the ring with grease ASL800050.
4. Position the lower king pin (16) on a workbench and assemble the
cone of the spherical joint (15) with the special tool D4 using a
press. Grease the king pin housings with grease ASL800050.
5. Install the beveled washers (25) and (27) on to the king pin
housings (16) and (18).
6. Secure the steering knuckle (7) group using a sling.
7. Lubricate the seal ring lip and protect the splined end of the axle
shaft by wrapping it in adhesive tape to avoid damage to the seal
ring. After assembly, remove the adhesive tape. Assemble the
steering knuckle on the axle beam.
8. Install the two king pins, the upper (16) and the lower (18), and
tighten the retaining screws (17) and (19).
Screw: 190 N·m (140 lbf ft)
★ Make sure the beveled washers (25) and (27) remain in their
position.
★ If bearings (9) and (12) need to be replaced, make sure the distances
“A”, “B” and “C” are within the permissible range.
★ A = 5.900 - 5.905 mm (0.232 - 0.232 in)
★ B = 52.229 - 52.279 mm (2.056 - 2.058 in)
★ C = 23.072 - 23.173 mm (0.908 - 0.912 in)
WB146-5 30-215 3
9. Place the wheel hub (11) on a workbench and install both cups of
the taper roller bearings (9) - (12) in position using a special tool
D5 under a press or with a hammer.
10. Insert the seal ring (13) into the wheel hub (11) with the special tool
D6 and a hammer.
11. Install the cone of the tapered roller bearing (12) on the steering
knuckle end (14).
12. Install the wheel hub (11) on the steering knuckle (14) and place the
other cone of the taper roller bearing (9) in position.
13. Position the wheel carrier (7) on a workbench and install the bush-
ings (6) to the carrier surface level with the special tool D1.
★ At least two bushes (diametrically-opposed) should be set
slightly higher than the carrier surface level to be used as
dowel pins.
14. Preassemble the wheel carrier - (7) epicyclic ring gear group (7)
and (4) with the special locking ring (8) shown in figure.
30-216 3 WB146-5
15. Install the wheel carrier group on to the wheel hub using the two
projecting bushes (6) as dowel pins.
16. Install the relative bolts (5) in order to attach the ring bevel gear
with the wheel hub.
17. Install all the hub dowel bushes completely using special tool D1
and a hammer.
18. Install the wheel carrier (7) bolts (5) and tighten.
19. Install washers (2) and (3) to the axle shaft and install the stop ring
(1) by pushing it from the end of the serrated hub.
WB146-5 30-217 3
12
AXLE HOUSING
DISASSEMBLY
1. Axle housing 4. Axle busing 7. Seal

2. King pin bushing 5. Seal 8. Bushing
3. Cup 6. Axle shaft
1. Remove the axle shaft (6) from the axle housing (1).
30-218 3 WB146-5
2. Remove the seal (5) from the axle (1).
★ This is a destructive operation for the seal rings.
3. Remove the axle bushing (4) from the axle housing.

★ Examine the bushing before removal and replace only if the
wear conditions require this.
4. Remove the upper king pin bushings (2) and cup (3) from the king
pin housings.
★ Examine the bushing and housing before removal and replace
depending on wear conditions.
5. Remove the seal (7) from the axle (1).

★ This is a destructive operation for the seal rings.
★ If necessary, remove the Pivot bushings (8) with a three point
extractor or a suitable driver and a hammer.
★ Do not damage the bushing housing.
WB146-5 30-219 3
12!
ASSEMBLY
1. Using tool D7 and a hammer, install bushing (2) and cup (3).
★ To make installation easier, allow the bushings and cups to
cool in liquid nitrogen at less than -100°C (-148°F)
2. Install the bushing (4) into the axle beam with tool D9 and a
hammer.
3. Install the seal (5) in the axle with tool D10 and a hammer.
★ Fill 3/4 of the seal ring cavity with grease ASL800050.
4. Lubricate the bushing (4) and the seal ring lip (5). Insert the axle
shaft (6) into the housing.
★ Take care not to damage the sealing ring.
5. Install two new bushings (8) and two new seal rings (7) in the
housing (1) using tools D8 and D11.
30-220 3 WB146-5
12
DIFFERENTIAL
DISASSEMBLY
1. Differential housing 6. Bolt 11. Bolt

2. Bolt 7. Adjuster ring nut 12. Guide pin
3. Adjuster ring nut 8. Guide pin 13. Carrier
4. Bearing cup 9. Guide pin 14. Axle housing
5. Ring nut retainer 10. Bearing cap
1. Remove bolts (2) on the differential housing (1). Remove the

differential assembly (1) from the axle housing (14).
★ Support the differential carrier with a sling or other appropriate
means when removing.
WB146-5 30-221 3
2. Remove bolts (6) and remove the two ring nut retainers (5).
★ Before removing bolts, mark mounting caps (10) and the

differential housing with a permanent reference marks to avoid
inverting them when reassembling the unit.
★ Mark the area between the ring (3) and (7) adjusters and the
differential (1) housing as well.
3. Remove the adjuster ring nuts (3) and (7) using tool D12.
4. Remove the four bolts (11) and remove the two caps (10).
★ Ensure that the center bushings (9) remain seated in the
differential housing.
30-222 3 WB146-5
5. Remove the carrier assembly (13).
★ Take care not to lose the bearings that are removed together
with the differential carrier (13).
★ Do not mismatch the cups (4) if bearings are not to be replaced.
ASSEMBLY
1. Assemble the complete differential carrier (13), with the outer cups
(4) of the tapered roller bearings.
★ Take care not to invert the outer races of the tapered roller
bearings.
2. Place the differential carrier (13) and the two bearing caps (10) and
bolts in their holes.
★ Check the positions of the bushings and caps using the
reference marks on them and on the differential housing (1).
3. Install the caps loosely with their respective bolts (11).
4. Install the two adjustment ring nuts (3) and (7) in the differential
housing using tool D12, so as to preload on the carrier bearings is
slightly.
★ Tap lightly with a soft hammer in order to properly set the
bearings in position.
WB146-5 30-223 3
5. Install a magnetic dial indicator “A” to the differential housing so
that the dial indicators foot is at a right angle with the side of the
gear teeth.
6. Lock the pinion in place and move the ring gear alternatively taking
note the pinion-ring gear backlash.
7. Repeat the operation on two or more points (teeth), rotating the ring
gear, so as to obtain an average value.
8. Check to be sure it is within the requested range: 0.18 - 0.28 mm

(0.007 - 0.011 inches)
9. Adjust the ring nuts (3) and (7) using tool D12.
★ If the measured backlash is less than the given tolerance range,
tighten ring nut (3) and loosen ring nut (7).
★ If the measured backlash is higher than the given tolerance
range, tighten ring nut (7) and loosen ring nut (3).
10. Make sure that the bearings are slightly pre-loaded; if necessary,
repeat previous adjustment until the specified conditions are
reached.
11. Once pinion/ring gear backlash is determined, measure total

bearing preload (T) (pinion/ring gear system) using a spring gauge
with the cable wound around the spindle pinion end.
★ The reading should be within the following values:
T=(P+3.75) - (P+5.75) daN where P is the effectively
measured pinion pre-loading.
★ All pre-loadings should be measured without the seal (13) in

place.
30-224 3 WB146-5
12. If the measurement is not within the required range, check each
component and adjust ring nuts (3) and (7) of the differential carrier
mounting.
A. If total preload is less than the specified values, tighten the ring
nuts (3) and (7) at the same amount, while keeping pinion/ring
gear backlash unchanged.
B. If total preload is greater than the specified values, loosen the

ring nuts (3) and (7) at the same amount, while keeping pinion/
ring gear backlash unchanged.
13. When all adjustments are complete, install the ring nut retainers (5)
and their respective bolts (6), and tighten to the specified torque.
14. Tighten bolts (11).
★ Before installing into housing, make sure they are perfectly clean.
★ Spread a film of adhesive on the contact surface between the axle
housing (14) and the differential housing (1).
Loctite: 510
15. Check the two dowel pins (12) and (8) are in their proper locations.
WB146-5 30-225 3
16. Tighten the retaining bolts (2) to the proper torque.
17. Refill the tank with oil.
Pinion Gear Contact Test

★ To check the gear tooth contact between the ring and pinion gear,
paint the ring gear with red lead paint.
★ The marking test should be always carried out on the ring gear teeth
and on both sides.
★ OK - Correct contact: If the pinion gear is properly adjusted,
the mark on the ring gear surfaces will be within specifications.
★ Z - Excessive contact on the tip of the tooth: Move the ring
gear away from the pinion in order to adjust the backlash.
★ X - Excessive contact at the tooth base: Move the pinion away
from the ring gear and then adjust the ring gear to the pinion in
order to reset the backlash.
★ To correct:
★ Move the pinion for X contact adjustment.
★ Move the pinion for Z contact adjustment.
30-226 3 WB146-5
12
PINION
DISASSEMBLY
1. Pinion gear 6. Washer 11. Seal

2. Shim 7. Housing 12. O-ring
3. Bearing 8. Bearing 13. Cover
4. Washer 9. Retaining washer
5. Collapsible spacer 10. Lock nut
1. Remove the cover (13) from the differential housing.
WB146-5 30-227 3
2. Remove seals (12) and (11) from the cover (13).
★ This is a destructive operation for the seals.
3. Install the differential carrier (1) in a vise.
4. Remove lock nut (10) using special tools D14-D15.

★ This operation will damage the lock nut (10).
5. Remove the lock nut (10) and collect its retaining washer (9).
★ Tap the shaft with a soft hammer to remove the pinion gear (1).
★ Be careful not to drop the pinion gear (1).
6. Recover washers (4) and (6), discard spacer (5) and bearing
cone (8).
30-228 3 WB146-5
7. Place differential housing (7) on a firm flat surface and extract
bearing outer bearing cups (3) and (8).
8. To remove bearing cone (3) from pinion gear (1), use a

commercially available puller.
9. Recover bearing cone (3) and the shim (2) under it.
10. Check all pinion components for wear.

★ The lock nut (10) and spacer (5) must be replaced when
reassembling the unit.
WB146-5 30-229 3
12
ASSEMBLY
1. Place differential support (7) on a work bench.
2. Install bearing cups (3) and (8) into housing using special tool D16
and a hammer.
★ Use the kit consisting of the special tools called “false pinion”
D17 and “false differential box” D18 and D19 and a depth
gauge.
3. Install bearing cones (3) and (8) to their respective seats.
4. Assemble the “false pinion” and nut (10).
5. Tighten nut - but do not overtighten - until backlash is eliminated.
6. Install tool D18, D19 to bearing seats in differential housing (7) and
retain with bearing caps.
30-230 3 WB146-5
7. Installation method D18, D19:
★ Use a depth gauge to measure distance “X” (distance between
the axis of the differential bearings and the point at which the
pinion head, or base of bearing, is supported).
★ In order to determine the thickness (S) required between the

pinion and the bearing, subtract the value (V), stamped on the
pinion head (Vaguer depth), from the measured value (X).
S=X-V mm
★ Pick the (S) shim (2) from the range of shims available.
Shim Range
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
8. Remove special tool D18, D19 from differential support.
9. Remove nut (10), false pinion, and bearing cones (3) and (8).
WB146-5 30-231 3
10. Install the selected shim (2) to the pinion shaft (1) with the chamfer
facing the gear.
11. Install bearing (3) onto the pinion shaft (1) using a press and driver
D20, and ensure that the bearing is fully locked into position.
12. Install shims (4) and (6), and a new collapsible spacer (5).
★ Use only one new spacer.
13. Install pre-assembled pinion gear (1) to the differential housing (7),
and install bearing inner cone (8) to pinion shaft end as shown.
14. To install bearing (8), use driver D20 and a hammer.
15. Insert washer (9) and install a new lock nut (10) on to the pinion
end.
16. Tighten the nut in (10), using the wrench for nut D14 and for pinion
retainer D15.
17. The torque setting is given by the preload measurement on bearings

(3) and (8).
18. Tighten the nut (10) step by step.

★ If it is tightened too much, the spacer (5) should be replaced
and the procedure repeated.
★ When you check the preload, it is advisable to tap both pinion
ends with a soft hammer, so as to help seat the bearings (3)
and (8).
30-232 3 WB146-5
19. Measure preload P of tapered bearings (3) and (8) using a force
gauge with the string wound around the splined end of pinion (1).
★ Adjustment is carried out by gradually increasing the
tightening torque of the ring nut (10), paying attention not to
overtighten.
★ All pre-loadings should be measured without the seal.
★ P=9.2-13.7 daN
20. Once you have reached the pre-loading value, stake the lock nut
(10).
★ Do not carry out the steps below until you have completed the
adjustment of preload T.
21. Assemble seals (11) to cover (13) using tool D21 and a hammer.
22. Install a new O-ring (12) to cover (13). Lubricate O-ring (12) and
seal (11).
23. Install cover (13) to differential support.
WB146-5 30-233 3
12
CARRIER
DISASSEMBLY
1. Bolt 5. Axle gears 9. Spider shaft

2. Bearing 6. Thrust washer 10. Carrier half
3. Carrier half 7. Spider gears 11. Ring gear
4. Counter-discs 8. Pin
1. Lock the carrier in a vise.
2. Remove all bolts (1) on ring gear (11).

★ This will separate both halves (3) and (10), so take care not to
drop the internal components.
3. Remove the gear (11).
30-234 3 WB146-5
4. Disassemble the differential carrier in two separate halves (3) and
(10), complete with the relevant components.
★ Scribble the two half housings with reference marks.
★ Recover the components from both halves.
★ Check the wear conditions of the components.
5. Remove the bearings (2) from the carrier halves (3) and (10), using
a puller.
ASSEMBLY
1. Assemble the cones of the new taper roller bearings (2) on the half
carriers (3) and (10) using the special tool D13 and a hammer.
2. Position the housing (3) on a workbench and assemble all inner

components: locking differential counter-discs (4), axle gears (5),
spider shaft (9), spider gears (7), thrust washers (6), pin (8), as
shown in illustration.
3. Join the two halves, aligning the reference marks made during
disassembly.
WB146-5 30-235 3
4. Install the ring gear (3) and then tightening the bolts (4).
Bolt: Loctite 270
30-236 3 WB146-5
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
12
REAR AXLE ASSEMBLY
REMOVAL
★ For added safety, place the backhoe bucket with its back on the
ground while holding the arm in the upright position.
★ Lower the bucket to the ground as well.
1. Lower the backhoe outriggers (1) and force them downwards in

order to raise the rear wheels (2) by approximately 5 cm (2 inches).
2. Prepare a safety stand “A” approximately 65 cm (26 inches) high,

beneath the backhoe chassis. Pull up the outriggers until the
machine is resting on the stand “A.”
3. Stop the engine and take off the rear wheels (2).
Wheel 163 kg (359 lb)
4. Remove the rear wheels with jack stands “A” in place and
outriggers (1) in the lowered position as shown in the illustration.
WARNING! Completely lower the machine on to the

jack stands before removing the tires.
Lower the outriggers (1) to the ground
after the machine is resting on the jack
stands for extra safety.
WB146-5 30-237 3
5. Disconnect cable (3) from parking brake (4).
6. Disconnect differential lock hose (5).

★ Cap the hose to prevent contamination.
7. Disconnect service brake lines (7) from axle (6).
8. Disconnect lines (7) from hoses (8); loosen and remove clamp (9)
and lines (7).
★ Cap pipes and hoses to prevent contamination.
9. Disconnect the drive shaft (10) from the rear axle.
30-238 3 WB146-5
10. Position a jack “C” beneath the axle.
11. Raise the jack until it can be forced under the axle.
★ It should be possible to lower the jack by approximately 20 cm
(8 in).
12. Remove bolts (11) and (4).
13. Lower the jack until the axle (6) is disengaged from the chassis.
14. Remove the entire axle.
Rear axle: 430 kg (948 lb)
INSTALLATION
Lug nuts: 500 ± 9.8 N·m (369 ± 7 lbf ft)
1. Bleed the air from the braking circuits, see "BLEEDING AIR FROM CIRCUITS."
2. Adjust the stroke of the parking brake lever.
Drive shaft bolts: 38 N·m (28 lbf ft)

Axle retaining bolts: 1000 N·m (738 lbf ft)
Axle retaining bolts: Loctite 262
WB146-5 30-239 3
DISASSEMBLY AND ASSEMBLY REAR AXLE OVERHAUL PROCEDURES
12
REAR AXLE OVERHAUL PROCEDURES
WARNING! Before proceeding with any overhaul procedures be sure the rear axle is sitting on a level
stable surface. Clean up any oil spills immediately and keep your work area clean and
clear of debris.
PARKING BRAKE ASSEMBLY

DISASSEMBLY
1. Lock nut 5. Rotor 9. Caliper support

2. Bolts 6. Shim 10. Seal
3. Brake caliper 7. O-ring 11. Differential housing
4. Snap ring 8. Bolt 12. Dowel pin
30-240 3 WB146-5
1. Loosen nut (1).

★ Proceed with care, in order to avoid damaging the brake pads.
3. Remove the brake caliper (3).
4. Remove snap ring (4) and rotor (5).

★ Collect the shim (6) and the O-ring (7).
5. Remove bolts (8) caliper support (9).
6. Remove the caliper support (9) from the differential housing.
WB146-5 30-241 3
7. Remove the seal (10) from the differential housing (11) with a
puller.
ASSEMBLY
1. Install a new seal (10) into in the differential housing using special
tool E1.
2. Install dowel pin (12) and the brake caliper support (9) on the
differential housing (11).
3. Tighten bolts (8).
4. Lubricate O-ring (7).
O-ring: ASL800050
5. Insert the shim (6) on the spined pinion end, a new O-Ring (7), the
input flange (5) and the lock ring (4).
30-242 3 WB146-5
6. Position the brake caliper (3) on the disc (9).
★ Be careful to avoid damaging the brake pads.
7. Install bolts (2) and tighten the nuts (1) to the prescribed torque.
★ Once the nuts are tightened, check to make sure that a 1 ± 0.5
mm (0.039 ± 0.020 in) gap remains between nuts (1) and the
spacers shown.

WB146-5 30-243 3
12
MAINTENANCE
1. Lever arm 8. Balls plate 15. Sleeve

2. Adjustment bolt 9. Bolt/sleeve 16. Shim
3. Boot 10. Retention spring 17. Shim
4. Cam assembly 11. Shim 18. Sleeve
5. Torque plate 12. Nut 19. Bolt
6. Brake pads 13. Nut 20. Mounting bracket
7. Torque plate 14. Balls
1. Install mounting bolts through sleeves (9) and attach brake mounting locking nuts as far as possible on mounting bolts.
This is not required if brake assembly comes with the sleeve/bolt subassembly. Position the brake over disc gap and align
with mounting holes in mounting bracket.
2. Thread mounting bolts (9) into mounting bracket, adjusting bolts until a 0.5 - 1.5 mm (0.020 - 0.059 inches) exists
between the sleeves and the locking nuts. Tighten the locking nuts to 115 N·m (85 lbf ft) of torque against the bracket.
3. Refer to Adjustment Procedure to set backlash of installed brake assembly.
Brake Pad Adjustment Procedure

1. Loosen adjustment nuts (12 and 13).
2. Tighten inner adjustment nut (12) until firm contact is made with the disc by the linings. Torque to 13-14 N·m (10 lbf ft).
3. Be sure the control lever is in the brake apply position.
4. Back off inner adjustment nut (12) four to six turns and check that disc is free to move.
5. Tighten outer locking nut (13) against inner adjustment nut (12) to lock adjustment bolt (2) in place. Torque to 61-74 N·m
(45 - 55 lbf ft).
30-244 3 WB146-5
Ball and Cam Replacement
1. Remove both adjustment locking nuts (12, 13), thrust, stainless steel and hardened washer (11, 16, 17), lever (11), and
boot (3) from adjustment bolt (2).
2. Remove outer cam (4) and ball assembly (8) from adjustment bolt (2).
3. Use a screwdriver, or similar tool, to gently pry inner cam (4) protrusions on back of cam, loose from torque plate (5), and
remove from adjustment bolt (2). Remove seal (15) from adjustment bolt (2).
4. Install new seal (15) on adjusting bolt (2), inserting it through inner cam (4) until seal (15) bottoms out on torque plate.
5. We recommend lubricating the cams' thrust surfaces before installing the cams (4).
Cam surface: ASL800050
6. Install new cam (4) on adjustment bolt (2), taking care to orient protrusions into holes in torque plates (5).
7. Install ball assembly (8) onto adjusting bolt (2), orienting balls into pockets of inner cam (4). Install outer cam (4) onto
adjustment bolt (2), orienting pockets onto ball assembly (8). Install boot (3) over cam assembly.
8. Install lever (1), using protrusions on back of outer cam (4) and holes in lever (1) to orient lever to proper operating
position.
9. Install remaining washer and nuts and follow adjustment procedures.
10. Check to ensure that the coated side of shim (11) is oriented towards the steel washer (17).
Lining Replacement
1. Loosen two adjustment locking nuts (12, 13) enough to remove each torque plate (5, 7) away from disc far enough to
provide backlash to remove old carrier and lining assemblies and install new ones. (It may be necessary to remove one or
both Nuts)
2. Collapse the two lining retraction springs (10) and remove them from brake head assembly.
3. Remove torque plates (5 and 7) away from disc, move carrier and brake pads (6) out of pockets, and remove the brake
head assembly from the side.
4. Before installing new pads, it is necessary to apply grease between bushings (9) and pad supports (5 and 7).
Bushings: ASL800050
★ Once grease has been applied, slide the supports onto the bushings to distribute grease evenly.
5. Install new carrier and lining assemblies (6) in each torque plate (5 and 7).
6. Install the two lining retention springs (10) into brake head assembly. Be sure spring’s “feet” are positioned properly in
holes in both lining carrier assemblies (6).
7. Adjust brake.
WB146-5 30-245 3
12
Sleeve Seal Replacement
1. Loosen the two locking nuts on the mounting bolts and remove the mounting bolt/sleeve assembly (9) from the brake.
2. Insert sleeve seals (18) between the torque (5 and 7) and align with the sleeve bores.
3. Lubricate the mounting bolt/sleeve fit before installing.
Bushings: ASL800050.
4. Install the mounting bolt / sleeve assembly through the front pad support (5), the sleeve seals (18) and the rear pad support
(7).
Replacing the Cable Attachment Bracket
1. Remove the bolts (19) from the bracket (20) pad support (5).
2. Remove the bracket (20).
3. Position the bracket (20) in correspondence with the threaded holes of the pad support (5).
4. Attach the bracket (20) to the front torque plate (5) with the appropriate bolts (19).
30-246 3 WB146-5
12
SERVICE BRAKE ASSEMBLY
DISASSEMBLY
1. Bolt 8. Shouldered bolt 15. Inner cylinder

2. Hub 9. Washers 16. O-ring
3. Axle housing 10. Brake cylinder 17. O-ring
4. Axle half shaft 11. Lock ring 18. O-ring
5. Brake disc 12. Shouldered bolt kit 19. O-ring
6. Brake plate 13. Washers
7. Pin 14. Bushing
1. Completely drain oil from the differential.
Differential oil: approximately 15 liters (4 gal)
WB146-5 30-247 3
2. Remove all but two of the cap screws (1).
3. Sling the outer hub (2).
4. Insert two dowel rods to enable removal.
5. Remove last two cap screws (1) and separate the hub (2) from the
axle (3).
6. Carefully pull hub (2) away from axle and the half shaft (4), make
sure that brake disks (5) and plates (6) stay with the hub.
7. Stand the hub up, mark the reaction plat (5) that was against the
axle housing (3). Remove the reaction (6) and brake disks (5) and
pins (7).
★ Check friction plate and brake separator condition.
★ If brake discs are to be replaced, soak the new discs (for each
differential) in oil for at least 24 hours.
30-248 3 WB146-5
8. Remove axle shaft (4) from wheel hub assembly (2).
9. Remove bolts (8) and beveled washers (9) from brake cylinder (10).
★ Check to ensure that shouldered bolts (8) and beveled

washers (9) are not damaged.
10. If brake discs are being replaced, replace bolts and washers with the
new kit.
11. Remove the lock ring (11) and remove the self adjuster (12).
WB146-5 30-249 3
12. Place self adjuster (12) onto special tool E2 and drive out the spring
clips (13) from the adjuster.
13. Inspect adjuster bushing (14) for wear.

★ Repeat procedure for the remaining two kit self adjust.
14. Use an acceptable flat bar and pry the brake piston (10) up from the
hub.
15. Remove the brake piston (10) and the inner cylinder (15).
30-250 3 WB146-5
16. Remove O-rings (16) and (17) from the brake piston (10).
17. Remove O-ring (18) from inner cylinder (15).
18. Remove and replace O-ring (19).

★ Replace the O-ring at each disassembly.
WB146-5 30-251 3
12
ASSEMBLY
1. Install a new O-ring (19) onto hub (2).
2. Install O-ring (18) onto inner cylinder (15).
3. Install O-rings (16) and (17) onto brake piston (10).
4. Lubricate O-rings (16), (17) and (18), and install complete piston
(15) to brake cylinder (10).
O-ring: ASL800050
30-252 3 WB146-5
★ Use hydraulic oil to lubricate the brake cavity of the hub
housing (2) and mount pins (7).
Cylinder cavity: ASL800050
5. Install the complete brake cylinder (10) and remove pins (7).
6. Place bushing (14) inside calibrated ring E2 with the chamfer

facing upwards.
7. Place pin E2 into brake adjuster (14).
8. Install spring clips (13) taking care to rotate them 90° clockwise
respect to the one mounted before.
WB146-5 30-253 3
9. Using driver E2, push the rings (13) until solid contact against
calibrated ring E2 is obtained.
★ Repeat procedure for the remaining self adjusts.
10. Insert the adjuster (12) into the brake piston (14), make sure that the
chaffered side is up.
11. Install the snap rings (11) into the self adjuster bore.
★ Check to ensure that spring ring teeth are facing the self adjust
kit as shown in the following illustration.
★ Snap ring (11) orientation and beveled washers (9).
30-254 3 WB146-5
12. Install bevelled washers (9) to shouldered bolt (8) taking care to
orient them as shown in the previous illustration.
13. Install the shouldered bolts (8) and spring washers (9) and tighten
to the required torque
14. Install the half shaft (4) and brake separator plate pins (7) into the
axle housing.
15. Using the reference mark made during disassembly, place the inner
brake separator plate (5) into the axle housing (3).
WB146-5 30-255 3
16. Place the inner brake disk (6) and the second brake separator (5).
★ If brake discs (6) are replaced, soak discs (for each differential)
in oil at least 24 hours prior to installation.
17. Install the outer brake disk (6) and make sure the slots of the inner
and outer brake disks are aligned with each other.
18. Sling the hub assembly (2) and guide onto the axle (3).
19. Lift and rotate the half shaft while pushing the hub onto the axle.
20. Install bolts (1) tighten to the required torque
Bolts: Loctite 270
21. Tighten using the alternating crosswise method.
30-256 3 WB146-5
22. Fill axle with oil.
WB146-5 30-257 3
12
REAR AXLE END PLANETARY ASSEMBLY
DISASSEMBLY
1. Bolt 6. Snap ring 11. Bearing

2. Planetary gear 7. Roller bearings 12. Hub seal
3. Retaining washer 8. Retainer nut 13. Bearing
4. Retaining washer 9. Axle end housing 14. Race
5. Planetary carrier 10. Wheel flange
1. Loosen bolts (1).

★ Replace bolts with a new set.
30-258 3 WB146-5
2. Mark planetary gears (2), retaining washer (3) and indexed
washer (4).
3. Remove bolts (1), retaining washer (3) and indexed washer (4).
4. Mark the mounting position of retaining washer (3) and indexed

washer (4) on the planetary carrier (5).
5. Sling the planetary carrier assembly (5).
WB146-5 30-259 3
6. Locate the snap ring (6) slot and open it while raising the planetary
carrier (5).
7. Only if necessary, remove from the planetary carrier (5) the gears
(2) and their related roller bearings (7) (66 per gear).
★ Keep all the components of each gear together as a set.
8. Using spanner E4, loosen and remove the ring nut (8).
9. Use suitable puller and separate hub housing (9) from wheel
end (10)
30-260 3 WB146-5
10. Sling the hub housing (9) and remove it from the wheel flange (10).
★ Collect the bearing cone (11).
11. Remove from hub housing (9) the outer race of the bearing (11).
WB146-5 30-261 3
14. Remove from wheel flange (10) spacer (14).
15. Using an angle grinder, cut the cage and etch the bearing race (13).
16. Use a chisel to cut and remove bearing inner race (13).
Remark
Do not use a cutting torch to remove this bearing, damage
to the axle end may occur.
30-262 3 WB146-5
12
ASSEMBLY
1. Install bearing outer races (13) and (11) to hub (9) using special tool
E5 and a press. Using special tool E6 install the hub seal (12).
2. Install bearing inner race (13) to wheel flange (10) using a suitable
driver and a press.
3. Install spacer (14) on wheel flange (10)
4. Sling the hub (9) and carefully install it onto wheel flange (10).
★ Clean all sealing surfaces.
★ Take care not to damage the hub seal (12).
WB146-5 30-263 3
5. Install bearing inner race (11) using a suitable driver and a hammer.
6. Install ring nut (8).
7. Using spanner E4, tighten ring nut (8) to the required torque.
Ring nut: 1000 N·m (738 lbf ft)
8. Apply a light coat of Lithium based grease to the planetary carrier

(5) stud to hold the needle bearings (7) (bearings 33) in place.
Grease: ASL 800050
★ Use all the components corresponding to the marks made during

disassembly.
9. Install the planetary gear (2) and the remaining needle rollers (7)
(bearings 33) into the side gear.
30-264 3 WB146-5
10. Sling the planetary carrier (5) and lower it into hub (9).
★ During installation the locking ears of the planetary carrier (5)

must engage the ring nut (8) as shown in illustration.
11. In order to simplify the installation, align the hole on the planetary
carrier (5) with the ring nut (8) as shown.
12. Open the snap ring (6) and slowly lower the planetary carrier (5).
WB146-5 30-265 3
13. Install washers (3) and (4) and tighten bolts (1); apply the specified
sealant and tighten to the required torque.
★ Replace bolts with new ones.
Bolts: Loctite 270
30-266 3 WB146-5
12
DIFFERENTIAL
DISASSEMBLY
1. Bolt 4. Bolt 7. Carrier

2. Axle housing 5. Ring nut 8. Bearing
3. Differential 6. Ring nut
1. Drain the oil completely from the differential.
WB146-5 30-267 3
3. Separate from axle housing (2) the differential (3) using pry bars in
slots.
4. Sling differential housing (3) and remove it.
5. Remove bolts (4) securing the ring nuts (5) and (6).
30-268 3 WB146-5
6. Use the tool E7, unscrew the adjuster ring nuts (5) - (6).
7. Remove out the differential case (7). The external rings (8) and (9)
are removed together with the differential housing.
★ Do not mismatch bearings if bearings are not to be replaced.
ASSEMBLY
1. Using driver E8, install bearing outer races (8) and (9) to
★ Do not mismatch bearings if bearings are not to be replaced.
2. Position the complete differential carrier (7) with bearings on the

WB146-5 30-269 3
3. Insert and tighten adjustment ring nuts (5) and (6) in the differential
support with tool E7, so as to preload the differential bearings
slightly.
★ Tap lightly with a soft hammer in order to properly set the
bearings in position.
4. Place a magnetic dial indicator on the differential support so that

the feeler is at right angles with the side of a tooth from the ring
gear.
A. Lock the pinion and move the ring gear alternatively and note
the pinion-ring gear backlash, measured with the dial indicator.
B. Repeat the operation on two or more points (teeth), rotating the

ring gear, so as to obtain an average value.
C. Check if the measured backlash value to see if it is within the

required range: 0.21 - 0.29 mm (0.008 - 0.011 inches)
5. Adjust by operating the adjuster ring nuts (5) and (6), using tool E7.
6. Adjust the ring nuts (5) and (6) remembering that:

★ If the measured backlash is less than the given tolerance range,
unscrew the adjuster ring nut (6) and screw in the adjuster ring
nut (5) by the same measure.
★ If the measured backlash is greater than the given tolerance
range, unscrew the adjuster ring nut (5) and screw in the
adjuster ring nut (6) by the same measure.
7. Repeat the whole sequence of the above mentioned operations till

the indicated conditions are reached.
30-270 3 WB146-5
8. Once the pinion-ring gear backlash has been established, measure
the total rotational torque Tr of the bearings (pinion-ring gear
system), using a torque wrench and special tool E9.
★ Total rotational torque should be measured without pinion
retaining ring.
★ Rotational torque Tr must be within the following range:
Tr = (Pr+0.58) - (Pr+0.87) N·m where Pr is the actual
rotational torque of pinion alone.
9. If the reading is not within the required range, thoroughly check the
assembly of each component and adjuster ring nuts (5) and (6) of
the differential support caps:
★ If total preload is less than the specified value, tighten the
adjuster ring nuts (5) and (6) by the same amount, while
keeping the pinion/ring gear backlash value unchanged.
★ If total preload is greater than the specified value, loosen the
adjuster ring nuts (5) and (6) by the same amount, while
keeping the pinion/ring gear backlash value unchanged.
10. To test the tooth contact on the ring gear teeth, paint the ring gear
with red lead paint.
★ The marking test should be always carried out on the ring gear
teeth and on both sides.
Contact
★ OK-Correct contact:
★ If the ring gear is well adjusted, the mark on the teeth surfaces
will be regular.
★ Z - Excessive contact on the tooth tip:
★ Adjust the pinion to the ring gear and then move the ring gear
away from the pinion in order to adjust the backlash.
★ X - Excessive contact at the tooth base:
★ Move the pinion away from the ring gear and then adjust the
ring gear to the pinion in order to adjust the backlash.
WB146-5 30-271 3
Movements to Correct
A. Move the pinion for type X contact adjustment.
B. Move the pinion for type Z contact adjustment.
11. When all adjustment procedures are complete, lock adjuster ring
nuts (5) and (6) into position with bolts (4). Tighten screws (4) to
the required torque.
Bolts: 10N·m (89 lbf in)
12. Before matching surfaces, make sure that they are perfectly clean,
de-grease and clean them with appropriate detergents. Spread a film
of adhesive on the contact surface between the axle housing (2) and
the differential carrier (3).
Contact surfaces: Loctite 510
13. Assemble the differential (3) to the axle housing.
30-272 3 WB146-5
14. Tighten all bolts (1) to the required torque.
15. Refill the hydraulic oil.
WB146-5 30-273 3
12
DIFFERENTIAL LOCK
DISASSEMBLY
1. Plug 6. Bushing 11. O-ring

2. Fork 7. Spring 12. O-ring
3. Shaft 8. Bushing 13. Snap ring
4. Spring 9. O-ring
5. Snap ring 10. Piston
1. Loosen plug (1) but do not remove it.
30-274 3 WB146-5
2. Hold the differential lock fork (2) down to release the block inside
of the housing, remove the plug (1).
3. Pull the differential fork lock (2) up, place a flat piece of steel under
the shaft (3) to keep it from moving.
4. Compress spring (4) until snap ring (5) is released.
6. Remove the bushing (6).
WB146-5 30-275 3
8. Remove shaft (3) from differential housing.
9. Remove fork (2), spring (7) and bushing (8) from the shaft (3).
10. Remove O-ring (9) from plug (1) and O-rings (11) and (12) from
the piston (10).
30-276 3 WB146-5
12
ASSEMBLY
1. Install new O-rings (11) and (12) on the piston (10) and O-ring (9)
on plug (1). Lubricate the O-rings.
2. Lubricate the shaft (3) with clean hydraulic oil.
3. Install the fork (2) on the shaft (3) as shown in figure.
4. Install bushing (8) and spring (7) onto shaft.

★ Mount the spacer (8) with the chamfer towards the snap ring
(13).
5. Insert in the differential housing the shaft (3).
WB146-5 30-277 3
7. Place the bushing (6) on the shaft, make sure the chamfer in the
bushing is facing out.
8. Pull the differential lock fork (2) up, place a flat piece of steel under
the shaft (3) to keep it from moving down.
9. Compress the spring (4) using a proper tool and install the snap ring
(5).
★ Remove the piece of steel under the shaft (3).
10. Hold the differential lock fork (2) down to catch a block inside of
the housing, remove the plug (1).
★ Hand tighten the plug (1).
30-278 3 WB146-5
11. Tighten plug (1) to the required torque.
Plug: 180 N·m (133 lbf ft)
WB146-5 30-279 3
12
CARRIER
DISASSEMBLY
1. Bearing race 8. Axle gear 15. Thrust washer

2. Bearing race 9. Plug 16. Spider gear
3. Sleeve 10. Pin 17. Thrust washer
4. Snap ring 11. Cap screw 18. Pin
5. Housing cover 12. Ring gear (not shown) 19. Spacer
6. Anti-rotation pin 13. Pin 20. Spider gear
7. Thrust washer 14. Spider gear 21. Thrust washer
★ If differential bearings are to be replaced, remove bearing outer

races (1) and (2).
30-280 3 WB146-5
3. Remove housing cover (5), remove the anti rotation pin (6) and the
thrust washer (7).
4. Remove the axle gear (8).
5. Remove three plugs (9) from the carrier.
WB146-5 30-281 3
6. Remove the three pins (10) securing the spider pins in the carrier.
7. Remove the ring gear cap screws (11), remove the ring gear (12).
8. Push the pin (13) towards the flat surface side (14).
★ The pin can be pushed in only one direction.
9. Remove the planetary gear (14) and thrust washer (15).
30-282 3 WB146-5
10. Push the pin (13) out of the housing and remove the planetary gear
(16) and thrust washer (17).
11. Push the short spider pins (18) out of the spacer (19) by pushing
them through the hole in the spacer (19).
12. Remove pins (18), spider gears (20) and thrust washers (21).
13. Remove axle gear (22) and thrust washer (23) from the housing.
WB146-5 30-283 3
14. Remove the differential locking pins (25) from the housing (24).
ASSEMBLY
1. Install and lubricate new O-rings (26) on the pins (25).
O-ring: ASL800050
2. Install the pins (25) in the differential housing (24).
3. Lubricate and install sun gear (22) and thrust washer (23).
Gear: Differential oil
30-284 3 WB146-5
4. Lubricate and install planetary gear (20) and its respective thrust
washer (21) and install pins (18) forward enough to support them.
★ Align the flats on the pins facing upward.
Gear and pin: Differential oil
5. Install spacer (19) and install pins (18), taking care to align the
holes with those on the differential housing (24).
6. Lubricate and install the spider gear (16) and thrust washer (17).
★ Install pin (13) as far as it will go.
★ Align pin (13) with the flats on the pin facing up.
Gear and pin: Differential oil
7. Lubricate and install the spider gear (14) and thrust washer (15)
then install pin (13).
★ Align the hole on the differential housing (24).
Gear and thrust washer: Differential oil
WB146-5 30-285 3
8. Install the differential ring gear (12), apply sealant and tighten cap
screws (11) to the required torque.
Cap screw: Loctite 270
Cap screw: 155 N·m (114 lbf ft)
9. Install pins (10) and tighten plugs (9) to the prescribed torque.
Plugs: 25 N·m (18 lbf ft)
10. Install the planetary gear (8).
11. Apply a thin coat of grease to the cover (5) and install the shoulder
ring (7).
Cover: ASL800050
12. Install anti-rotation pin (6) to cover (5) and install cover (5) to dif-
ferential housing.
30-286 3 WB146-5
13. Lock cover (5) into position with snap ring (4).
14. Install sleeve (3) and make sure that sleeve fits snugly into position.
★ To make installation easier, rotate the side gear (22).
15. Install bearing outer rings (1) and (2) using driver E8.
★ Do not invert bearings.
WB146-5 30-287 3
12
PINION
DISASSEMBLY
1. Lock nut 4. Washer 7. Bearing

2. Washer 5. Washer 8. Bearing
3. Pinion gear 6. Collapsible spacer 9. Housing
1. Place the differential carrier (1) in a vise.
2. Remove the lock nut (1) using special tools E9 - E10.

★ This operation will irretrievably damage the lock nut (1).
30-288 3 WB146-5
3. Remove the lock nut (1) and collect its retaining washer (2).
4. Tap the shaft with a soft hammer to remove the pinion gear (3).
★ Take care not to drop the pinion gear (3).
5. Recover washers (4) and (5), collapsible spacer (6) and bearing
inner ring (7).
6. Remove bearing outer races (7) and (8) from differential support (9)
using a driver and a hammer.
7. To remove bearing inner bearing (8) from pinion gear (3), use a
commercially available puller.
★ Recover bearing (8) and the shim (10).
WB146-5 30-289 3
8. Check all pinion components for wear.
★ The ring nut (1) and the collapsible spacer (6) must be
replaced.
ASSEMBLY
1. Place the differential housing (9) on a workbench.
2. Install outer bearing (7) and (8) using special tools E11 - E12 and a
hammer.
3. Insert inner bearing (7) and (8) in the housings.
4. Assemble the false pinion E13 and its lock nut (1).
5. Tighten till the backlash is eliminated.
6. Install special tool E14 to the differential housing (9).
30-290 3 WB146-5
7. Use a depth gauge to measure distance “X” (distance between the
axis of the housing bearings and the point at which the pinion gear
is supported, or base of the bearing).
8. To adjust ring gear/pinion measure the distance “A” with a depth

gauge. Calculate the value “X” as follows:
★ X =(A+C)-B mm where “B” and “C” are known.
9. In order to determine the necessary thickness value (S) between the

pinion and the bearing, subtract the value (V), stamped on the
pinion head (V= requested distance), from the measured value (X).
★ S = (X - V) mm
10. Select the shim with the thickness value (S) from among the range
of available shims (10), and install it onto shaft under the pinion
gear.
★ The chamfer on the ID of the shim (10) must be toward the
pinion gear (3).
Shim Range
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
WB146-5 30-291 3
11. Remove the special tool E14 from housing (9).
12. Remove the lock nut (1), the false pinion E13 and the bearing cones
(7) and (8).
13. Select a suitable shim (10) and install with the chamfer facing the
gear, then install bearing inner ring (8) to pinion (3) with a press
and tool E3, and check to ensure that it fits snugly in place.
14. Install the washers (4) and (5) and a new collapsible spacer (6) on
the pinion gear (3).
★ Always use a new collapsible spacer (6).
15. Install bearing (7) to pinion end.

★ To install bearing (8), use special tool E3 and a hammer.
30-292 3 WB146-5
16. Insert lock nut washer (2) and install a new lock nut (1) on the
pinion end.
17. Install the lock nut (1), using the wrench for lock nut E10 and for
pinion retainer E9.
★ The torque setting is given by the preload measurement on
bearings (7) and (8).
18. Tighten the lock nut (1) step by step.

★ If it is tightened too much, the spacer (6) should be replaced
and the procedure repeated.
★ When you check the preload, it is advisable to tap both pinion
(3) ends with a soft hammer, so as to help setting the bearings
(7) and (8).
19. To measure the rotational torque (Pr) of tapered bearings (7) and
(8), use a torque wrench and tool E9.
★ Adjustment is carried out by gradually increasing the
tightening torque of lock nut (1), paying attention not to
overtighten.
★ All preload settings should be measured without the seal.
★ Rotational torque should be within the following range:
Pr = 2.0 - 2.4 N·m (18 - 21 lbf in).
20. Once you got the requested preload value, stake the lock nut (1).
WB146-5 30-293 3
DISASSEMBLY AND ASSEMBLY FRONT LOADER PPC VALVE
12
FRONT LOADER PPC VALVE
REMOVAL
1. Lower the front loader to the ground and neutralize the controls.
2. Remove four screws (1) and remove PPC valve and parking brake
cover (2).
30-294 3 WB146-5
DISASSEMBLY AND ASSEMBLY FRONT LOADER PPC VALVE
4. Disconnect five hoses (5) from PPC valve (4).
★ Before disconnecting hoses, make sure they are marked for
there proper location.
5. Remove bolts (6) and remove the complete PPC valve (4).
INSTALLATION
★ Carefully inspect the hoses for the proper position when connecting
them.
WB146-5 30-295 3
DISASSEMBLY AND ASSEMBLY FRONT-END LOADER ASSEMBLY
12
FRONT-END LOADER ASSEMBLY
LOADER BOOM CYLINDERS

★ It is advised to do this procedure on a flat level smooth surface.
REMOVAL
1. Install blocks “A” between the bucket cylinders tie bar (1) and the
spacer (2) of the fulcrum lever (3) on the side to be removed.
2. Remove snap-ring (4) and the internal retaining spacer (5) for the
piston rod attachment pin (6).
3. Remove the tie strap (7) retaining the cylinder return hose (8).
4. Place a sling around the cylinder and connect it to a hoisting device.

★ Do not sling the cylinder return hose with the cylinder barrel.
5. Remove pin (6) to expose piston eye and rod end (9).
6. Remove rod.
30-296 3 WB146-5
7. Lower cylinder (10) until it rests on blocks “B”.
8. Start the engine to retract the cylinder rod.
9. Stop the engine and eliminate any residual pressure.
10. Remove hoses (8) and (11), and remove hose clamp (12).
11. Remove the snap-ring (13) and the spacer (14).
12. Remove cylinder assembly (10).
Cylinder: approximately 46 kg (101 lb)
INSTALLATION
★ When aligning the positions between the hole and the pin, run the engine at a low speed.
WARNING! Do not insert fingers into the holes to

check alignment.
Internal bushing: ASL800050
★ Start the engine and bleed the air from the cylinders, see "BLEED AIR FROM CIRCUITS."
★ After bleeding the air, check the oil level in the tank.
WB146-5 30-297 3
12
BUCKET CYLINDERS
REMOVAL
1. Remove the strap retaining the cylinder return hose (1).

For the Right-Hand Cylinder Only
2. If installed, disconnect the return-to-dig sensor, mark its location,

and then remove the lift bracket.
3. Remove bucket position rod (2).
4. Place a sling round the cylinder (3) and insert a block “A” between
the spacer (4) of the piston fulcrum lever (5) and the link (6).
★ Do not sling the cylinder return hose with the cylinder barrel.
5. Remove the snap-ring (7) and the internal retaining spacer (8) for
the cylinder attachment pin (9).
6. Remove pin (9) to expose cylinder rod eye.
7. Start the engine to retract the rod (10).
8. Stop the engine and eliminate any residual pressure from all
circuits.
9. Remove hoses (1) and (11), and remove hose clamp (12).
30-298 3 WB146-5
10. Remove the snap-ring (13) and the spacer (14).
Tilt cylinder; approximately 35 kg (77 lb)
12. Recover spacer (15) between frame and cylinder.
INSTALLATION
★ When aligning the positions between the hole and the pin, run the engine at a low speed.

check alignment.
★ Start the engine and bleed the air from the cylinders, see "BLEED AIR FROM CIRCUITS."
Machines Equipped With Return-to-dig Only
★ Check sensor position and adjust as necessary.
WB146-5 30-299 3
12
FRONT LOADER BUCKET
REMOVAL
1. Stop the engine and release residual pressures.
2. Remove bolts (1) and remove the pins (2) from lever (3).
3. Rest the lever (3) on the boom.
4. Remove bolts (4) and remove the pins (5) of the bucket.
5. Start the engine and put the machine into reverse gear in order to
disengage the boom (6).
Standard bucket: 436 kg (961 lb)
INSTALLATION
★ When aligning the positions between the hole and the pin, run the engine at a low idling speed.

check alignment.
30-300 3 WB146-5
MEMORANDUM
WB146-5 30-301 3
12
LOADER BOOM ASSEMBLY
REMOVAL
1. Remove the tilt cylinders. See "FRONT LOADER BUCKET."
2. Disconnect the cylinders from the boom (1) and rest them on
wooden blocks “A” placed on the front axle. See "BUCKET
CYLINDERS."
3. Open the front hood and remove bolts (2) that lock the oscillation
pins (3) for the boom (4).
4. Close the front hood.
5. Put a sling round the boom (4) as shown in the illustration, and
attach it to the hoist. Apply a slight tension to the cables.
30-302 3 WB146-5
6. Using a puller, remove the pins (5) of the arm (4) together with
snap ring and spacer.
7. Start the engine and put the machine into reverse gear travel until
the boom (4) is clear from the machine.
8. Place two stands (a) in position and lower the boom until it is
resting on them.
Front equipment: approximately 1,100 kg (2,425 lb)
INSTALLATION
★ To install, reverse the removal procedure, if necessary using the front towing hook.
★ When aligning the positions between the hole and the pin, run the engine at a low idling speed.

check alignment.
★ Start the engine and bleed the air from the cylinders.
WB146-5 30-303 3
DISASSEMBLY AND ASSEMBLY BACKHOE PPC VALVE
12
BACKHOE PPC VALVE
★ The following removal procedure applies to both PPC valves.
REMOVAL
1. Lower the outriggers to the ground: fold the bucket and rest the arm
at right angles with the ground.
2. Release the backhoe plate and stop the engine.
3. Release all residual pressure in all circuits.
4. Lift cab rear window up to the top.
5. Fully raise the boot (1).
6. Loosen and remove the screws (2) retaining the PPC valve (3) and
armrest (4).
7. Raise the armrest from the rear side and remove the screw (5)
retaining the rear guard (6).
8. Cut the retaining clamp and lower the lower boot (7).
9. Loosen and remove screw (8), and remove rear guard (6).
30-304 3 WB146-5
DISASSEMBLY AND ASSEMBLY BACKHOE PPC VALVE
11. Ensure that the hoses are marked (10), then disconnect the hoses
from the PPC valve.
when reconnecting.
★ Remove the PPC valve (11).
INSTALLATION
★ Carefully inspect the hoses for the proper position when connecting them.
WB146-5 30-305 3
DISASSEMBLY AND ASSEMBLY PPC VALVE SUPPORT RELEASE CABLES
12
PPC VALVE SUPPORT RELEASE CABLES
REMOVAL
1. Lower the outriggers and the equipment to the ground; stop the
engine.
2. Remove the rear mat (1).
3. Remove bolts (2) and remove the platform (3).
30-306 3 WB146-5
5. Remove the screws (5) that retain the PPC valve and armrest (6).
retaining the rear guard (8).
7. Cut the retaining clamp and release the lower boot (9).
8. Remove the screws (10) and remove the rear cover (8).
9. Remove the screws (11) and raise the boot (12) and the retaining
edge (13).
★ Raise until the lower fulcrum and locking assembly become
completely disengaged.
10. Remove the retaining screws (14) from the lock actuating lever
assembly (15).
11. Remove the entire lever assembly (15).
WB146-5 30-307 3
12. Loosen the nut (16) and disengage the sheath (18) from the support
(17).
13. Disconnect the cable (20) from the lower locking lever (19).
14. Loosen the nut (21) and unscrew the tensioner (22); disengage the
control cable (20) from the release control lever (15).
INSTALLATION AND ADJUSTING

1. Using the tensioner (22), adjust cable tension to obtain safe locking
and friction-free unlocking of the column.
2. Lock the nut while holding the tensioner into position (21).
30-308 3 WB146-5
DISASSEMBLY AND ASSEMBLY PPC VALVE GAS STRUT
12
PPC VALVE GAS STRUT
REMOVAL
engine.
2. Remove the rear mat (1).
3. Remove bolts (2) and remove the platform (3).
WB146-5 30-309 3
4. Loosen the stop knob (4) of the PPC valve support (5) you are
working on.
6. Remove the screws (7) that retain the PPC valve and armrest (8).
retaining the rear cover (10).
8. Cut the retaining clamp and release the lower boot (11).
9. Remove screw (12), and remove rear cover (10).
10. Remove the screws (13) and raise the boot (14) and the retaining
edge (15).
11. Raise until the gas strut (16) becomes fully disengaged.
30-310 3 WB146-5
12. Loosen the nut (17) and remove the snap ring (18) and washer (19).
13. Disconnect the gas strut (16) and remove it.
INSTALLATION
WB146-5 30-311 3
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
CONTROL VALVE
REMOVAL
1. Move backhoe assembly fully to the right or left and swing the
boom at a full 90° to access the rear of the machine.
2. Lower the outriggers to the ground, curl the bucket and allow it to
rest on the ground on its back as shown in the illustration.
3. Apply the parking brake, stop the engine.
4. Release all residual pressure.
5. Lift rear window (1) to the top.
6. Remove the rear mat.
7. Remove the four bolts (2) and remove the floor plate (3).
30-312 3 WB146-5
8. Loosen the clamp (4) on the control valve support frame (5)
(four bolts).
9. Disconnect lower servo control and actuator hoses (6) together with
all accessible side hoses (7) from control valve.
when reconnecting.
10. Disconnect upper servo control hoses (8) and actuator hoses (9)
from control valve.
when reconnecting.
11. Lay the servo control hoses inside the cab to gain access to the
delivery, exhaust, and actuator hoses.
12. Turn the tubes (10) that provide direct connection away from
control valve and retain their position by temporarily tightening
clamp (4) on frame (5).
WB146-5 30-313 3
13. Disconnect connector (11) from backhoe plate lockout solenoid
valve (12).
14. Support control valve (13) by means of two slings connected to a

lifting device to be introduced through the cab opening.
★ Apply a slight tension to the slings.
★ Pay special attention to sling routing to prevent damaging the
unions.
15. Loosen and remove the four bolts (14) and the relative washers.
16. Lift the valve out through the rear of the cab or lower it onto a
platform under the machine.
8-spool control valve: 45 kg (99 lb)

10-spool control valve: 50kg (110 lb)
INSTALLATION
★ Install control valve from top.
★ Start the machine to circulate the oil; check to ensure that there are no leaks.
★ Bleed the air from the working equipment circuits.
★ Stop the engine, check the hydraulic oil level and top up.
30-314 3 WB146-5
MEMORANDUM
WB146-5 30-315 3
DISASSEMBLY AND ASSEMBLY PPC VALVE
12
PPC VALVE
REMOVAL
engine.
2. Disconnect the connector (1) and remove the seat (2).
3. Remove the rear mat and remove the floor cover (5) closing off the
floor.
4. Disconnect all connectors (6) from the solenoid valves.
5. Check to ensure that all connectors have marks scribbled on them,

and note their plug positions.
★ Mark disconnected all hoses (7).
6. Remove two bolts (8) and washers; remove the solenoid valve
group (9) together with the accumulator. *
30-316 3 WB146-5
DISASSEMBLY AND ASSEMBLY PPC VALVE
INSTALLATION
★ Start the engine and perform all possible manoeuvres to eliminate the air from all circuits.
WB146-5 30-317 3
DISASSEMBLY AND ASSEMBLY BACKHOE ASSEMBLY
12
BACKHOE ASSEMBLY
BUCKET CYLINDER
REMOVAL
1. Extend the arm (1) completely and fully open the bucket (2).
2. Lower the boom (3) until the arm is resting on a stand (A) and tip of
the arm is on a block (B).
3. Rest the bucket teeth on the ground.
4. Stop the engine and release the pressures in the cylinder (4) by
moving the control lever several times.
5. Place a sling around the bucket cylinder (4).
6. Remove lock-nut (5) and the washer and remove pin (6) from rod
end (7).
★ Do not use a chisel and hammer or a pipe wrench to remove or
install lock nut (5). Use the proper spanner wrench as shown in
the illustration.
30-318 3 WB146-5
7. Disconnect the bucket supply lines (8) and (9).
8. Remove snap-ring (10) and remove the pin (11).
9. Once free, lift bucket cylinder (4) off the machine.
Bucket cylinder: 49 kg (108 lb)
Versions with Extendable Arm Only
1. Disconnect lines (11) and (12).
2. Remove bolts (13) and remove pin (14).
3. Remove cylinder (4)
INSTALLATION
★ To install, reverse the removal procedure.
★ Replace lock-nut (5) with a new one.
★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed.

check alignment.
★ Start the engine and bleed the air from the cylinders. For details, see "BLEED AIR FROM CIRCUITS."
WB146-5 30-319 3
12
EXTENDABLE ARM CYLINDER
REMOVAL
1. Open the arm (1) completely and lower it until it rests on stand “A”
that is roughly 40 cm (16 inches) high.
2. Extend the arm (2) until it rests on a block “B”, and let the bucket
teeth rest on the ground.
3. Stop the engine and release the cylinder (3) residual pressures, by
moving the command pedal several times.
4. Place a sling around the cylinder (3).
5. Remove snap ring and remove the pin (4).
6. Start the engine to retract the piston.
7. Stop the engine and release any residual hydraulic pressure from all
circuits by operating the control levers in all directions.
8. Take out the safety pin (5).
9. Disconnect the lines (6), (7), (8) and (9).

11. Remove the bolts (11) and the pin (12).
INSTALLATION
★ When aligning the positions between the hole and the pin, you may
have to run the engine at a low idle speed.

check alignment.
30-320 3 WB146-5
MEMORANDUM
WB146-5 30-321 3
12
ARM CYLINDER
REMOVAL
1. Extend the arm (1) partly to make room for cylinder rod (4)
clearance.
2. Completely rest the bucket and arm on the floor.
3. Using blocks (B) to elevate stand (A), lower the boom (2) until the
boom is resting on a stand (A).
★ At this time be sure there will be enough clearance when the

arm cylinder rod end (7) is retracted to clear the arm mounting
bosses.
5. Remove retaining bolt and nut (6).
6. Pull pin (8) out and allow arm cylinder (4) to rest on boom, then
retract the arm cylinder rod (7) completely.
7. Sling the arm cylinder (4) and remove supply lines (9) and (10).
Lift cylinder (4) to see if rod end (7) will clear the arm mounting
bosses then lower cylinder (4) back down to rest on boom.
30-322 3 WB146-5
8. Support boom cylinder (5) with block (B) and re-sling cylinder (4)
to prepare for final removal. Once both cylinders are supported,
remove pin (11).
★ When removing pin (11) from cylinders (4) and (5), be sure to
keep track of shims (12) on each side of the boom mounting
bosses and pivot points.
9. Once pin (11) is removed, lift arm cylinder (4) from the machine.
INSTALLATION
★ It is recommended to install pin (10) and shims (12) first.

check alignment.
★ After bleeding the air, check the oil level in the tank. Top off tank if necessary
WB146-5 30-323 3
12
BOOM CYLINDER
REMOVAL
1. Extend the arm (1) partly to make room for cylinder rod (4) and (5)
clearance.
2. Rest the bucket and arm completely on the floor.
4. Remove hydraulic supply lines (6) and (7) from boom cylinder (5).
5. Sling cylinders (4) and (5) and remove pin (11). Be sure to place
block (B) under boom cylinder (5) for support.
6. Once pin (11) has been removed, shims (12) can be retrieved.
30-324 3 WB146-5
7. Rest arm cylinder (4) on the boom and re-sling boom cylinder (5)
for removal.
8. Remove bolt and nut (13) and prepare to remove pin (16) from
cylinder (5).
9. Remove snap ring (14) and washer (15) then carefully almost
completely remove pin (16) being careful not to unseat backhoe
lock springs.
★ Do not remove the pin (16) completely, remove just enough to
free boom cylinder (5) from its mounting position.
10. Lift boom cylinder (5) off of the machine.
WB146-5 30-325 3
12
INSTALLATION
★ It is recommended to install pin (6) first. Be careful when aligning the springs for the lock mechanism.
★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idling speed.

check alignment.
30-326 3 WB146-5
12
SWING CYLINDERS
REMOVAL
★ Center the backhoe and leave the backhoe plate unlocked.
★ Lower the outriggers to the ground, curl the bucket and allow it to
rest on the ground on its back.
★ Apply the parking brake, stop the engine and remove the ignition
key.
★ Release all residual pressure by operating the hydraulic controls
(including any optional device pedals) several times in all
directions.
1. Remove hose bundle clamp bolts (1) and remove hose clamp
assembly.
2. Group the hoses and sling them up out of the way using a sling (A)
to hold them in place as shown in the illustration.
3. Remove two front hydraulic supply hoses (2) and (3) on the
cylinders you will be removing.
WB146-5 30-327 3
4. Remove one rear hydraulic supply hose (4) on the cylinders you
will be removing.
5. Remove four bolts (5) and prepare to lift top support frame (6) off
of the swing cylinders.
6. Using two people and a pry bar, lift top support frame (6) off of the
swing cylinders.
Top frame bracket: 27.2 kg (60 lb)
7. Remove nuts and bolts (7) on both swing cylinders to prepare for
removing both pins (8) completely.
★ It is important to remove both pins in order to be able to move
the swing cylinders for removal.
30-328 3 WB146-5
8. Remove both swing cylinder pins (8) to allow for removal of swing
cylinders.
9. Once the pins are removed, you can swing the cylinders (9) to the
right or left and remove them individually by lifting them out.
10. To remove a swing cylinder, slightly pry up on swing cylinder (9)

and lift it out.
★ It is advised to use two people to lift cylinder (9) out of the
machine.
Swing cylinder: 37.2 kg (82 lb)
INSTALLATION

check alignment.
WB146-5 30-329 3
12
BOOM LOCK CYLINDER
REMOVAL
1. Center the backhoe with the arm vertical and the back of the bucket
on the ground.
2. Make sure that the safety stop (2) is raised.
4. Remove nut (1) retaining linkage cover (2).
★ Once nut (1) is removed from linkage cover (2), lay linkage (2)
on to the boom cylinder so lock cylinder (3) is exposed.
5. Remove line (4) and remove the four bolts (5) to remove the lock
cylinder.
30-330 3 WB146-5
6. To remove boom lock (10) or lock arm linkage (2), remove nut (6)
from bolt (9).
7. Carefully retaining spring (7), slide bolt (9) out of boom lock (10)
and retain spacer (8).
8. Remove snap ring and spacer (11) and slide boom lock arm (10) off
of the boss.
9. Once the boom lock (10) is removed, spring (7) can be removed.
INSTALLATION
1. Start the engine and perform several lock and release maneuvers to fill up and bleed air from the unit.
WB146-5 30-331 3
12
BACKHOE BUCKET
REMOVAL
1. Place the bucket on a level surface, resting on its back.
2. Remove safety pin (1) and remove the connecting pin (2) between
bucket (3) and tie-rods (4).
3. Remove safety pin (5) and remove the pin (6) that attaches the
bucket to the arm (7).
Standard bucket: 158 kg (348 lb)
INSTALLATION
30-332 3 WB146-5
12
BACKHOE ARM
REMOVAL
1. Extend backhoe arm (1) and boom (2) enough to allow

disconnection of arm cylinder (4).
2. Rest the bucket and arm (1) completely on the floor.
★ At this time be sure there will be enough clearance when the

arm cylinder rod end (7) is retracted to clear the arm mounting
bosses.
5. Remove retaining bolt and nut (6).
6. Pull pin (8) out and allow arm cylinder (4) to rest on boom, then
retract the arm cylinder rod (7) completely.
★ Be sure there is enough clearance between arm cylinder (4) rod

end (7) and arm boss (1)
WB146-5 30-333 3
7. Remove hydraulic supply lines (5) from arm cylinder (3).
8. Remove retaining bolt and nut (6) from pin (9).
9. Sling arm (1) with bucket attached as shown in illustration.
10. Remove pin (9) from arm (1). Be sure to retrieve shims (10).
30-334 3 WB146-5
11. Once pin (9) is extracted and shims (10) are collected, lift arm (1)
off of boom (2).
Arm, bucket and bucket cylinder: 464 kg (1,022 lb)
INSTALLATION

check alignment.
★ After bleeding the air, check the oil level in the tank. Top tank off if necessary
WB146-5 30-335 3
12
EXTENDABLE ARM
REMOVAL
1. Remove the bucket (1). For details see "BACKHOE BUCKET."
2. Remove the bucket cylinder (2) and the link (3). For details, see
“BUCKET CYLINDER.’’
3. Remove the arm cylinder. For details, see "EXTENDABLE ARM

CYLINDER."
★ For safety, plug all the disconnected hoses.
4. Remove lock nut (4), and the washer and remove the pin (5) and the
links (6).
5. Connect the extendable arm (7) to a hoisting tackle.

★ Use the bucket pin hole and the safety pin holes.
6. Start the engine and, maintaining constant tension on the section of

cable or chain connected to the bucket coupling, slowly raise the
boom until both sections of cable or chain are under slight tension.
7. Stop the engine and loosen by several turns the jib adjustment bolts.
8. Loosen the bolts on both sides.
9. Slide out the extendable arm (7).
Extendable arm: 439 kg (968 lb)
INSTALLATION

check alignment.
★ Tighten locknut completely, then release it half a turn.
30-336 3 WB146-5
12
EXTENDABLE ARM GIBS
REMOVAL
1. Remove the bucket. For details see.
2. Partially extend the 2nd arm (1).
3. Rest the arm (2) on a trestle “A” about 80 cm (3.5 ft.) high.
4. Remove the bolts (3), the spring washers and remove the upper
guides (4).
5. Connect the extendable arm (1) to a hoisting tackle.

★ Use the bucket pin hole and the safety pin holes.
6. Slowly raise the extendable arm (1) until it rests on the supporting
surfaces of the upper gibs.
7. Loosen the nuts (5) and remove the adjustment dowel bolts (6).
8. Raise the lower gibs (7) and slide them out.
INSTALLATION
Guides and 2nd arm guides: ASL800040
★ Adjust the clearances, keeping the extendable arm (1) aligned with
respect to the arm (2).
WB146-5 30-337 3
12
BACKHOE BOOM
★ To remove the backhoe boom, the arm, bucket and boom cylinder must be removed. See "ARM CYLINDER," "BOOM
CYLINDER" and "BACKHOE ARM" before proceeding to remove the backhoe boom.
REMOVAL
1. After arm, bucket and related cylinders are removed from boom
(2), prepare to remove hoses (3).
★ Keep track of what cylinders and positions the hoses are in
before removing them.
2. Remove hose clamp (1) and remove hose bundle (3).
3. Sling the backhoe boom in the manner shown in the illustration.
30-338 3 WB146-5
4. Once backhoe boom is properly slung, remove the lower mounting
bolts (4) and pins (5) one on each side.
5. Once lower pins are removed, lift backhoe boom (2) from machine.
Backhoe boom: 267 kg (589 lb)
INSTALLATION

check alignment.
★ Start the engine and bleed the air from the cylinders. For details, see Section 30 “BLEED AIR FROM CIRCUITS."
WB146-5 30-339 3
12
BACKHOE SWING FRAME
REMOVAL
1. Remove the working equipment.
2. Remove bolts (1) and remove pins (2) that connect the swing
cylinders (3).
3. Remove boom safety cylinder (4). For details, see "BOOM LOCK
CYLINDER."
4. Remove snap ring (7), washer (8) and nut (4).
5. Slide bolt (5) out of linkage (6) and lock lever (9).
6. Remove lock lever (9) from boss pin (10).
7. Remove the swing bracket (8) and the relative shim (13)
adjustments to given clearance.
Bracket: 133 kg (293 lb)
INSTALLATION
When aligning the positions between the hole and the pin, run the
engine at low idle.

check alignment.

Pin: ASL800050
1. Insert the shims (13).
2. Start the engine and bleed the air from the cylinders. See “BLEED
AIR FROM CIRCUITS."
30-340 3 WB146-5
MEMORANDUM
WB146-5 30-341 3
12
OUTRIGGER CYLINDERS
REMOVAL
1. Center the backhoe with the arm vertical and the back of the bucket
on the ground.
2. Lower outriggers to the ground and prepare to remove the rear

wheel and cylinder.
Rear wheel (standard size): 133.3 kg (294 lb)
3. Remove the rear wheel and support the machine as shown in the
illustration using jack stand (A).
4. Sling outrigger cylinder (1) as shown in the illustration.
5. Remove hydraulic supply lines (2) and tag each line as to its
location on the cylinder connection.
30-342 3 WB146-5
6. Remove bolt and nut (3) and extract pin (4) from cylinder and boss.
7. Remove bolt and nut (6) and extract pin (6) from cylinder and boss.
8. After removing pins (4) and (6) lift cylinder off of the outrigger.
Outrigger cylinder: 52.6 kg (116 lb)
INSTALLATION

check alignment.
★ Install rear wheel
WB146-5 30-343 3
12
OUTRIGGER ARMS
★ Before removing outrigger arms, the outrigger cylinder must be removed. See “OUTRIGGER CYLINDERS“
REMOVAL
1. Sling outrigger arm (7) as shown in the illustration.
2. Remove bolt and nut (8) then remove pin (9).
3. Lift outrigger arm (7) from machine.
Outrigger arm: 173.2 kg (382 lb)
INSTALLATION

check alignment.
30-344 3 WB146-5
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
12
WORK EQUIPMENT CYLINDER OVERHAUL
WARNING! Before proceeding with any overhaul procedures be sure the cylinder you are
working on is sitting on a level stable surface. Clean up any oil spills immediately and
keep your work area clean and clear of debris.
LOADER AND BACKHOE CYLINDERS

DISASSEMBLY
1. Position cylinder to be disassembled (1) to equipment U1.
2. Using wrench U2 with torque amplifier, fully unscrew the gland nut
(2).
3. Extract the complete piston (3).

★ Place a receptacle to collect the oil.
4. Position the complete piston (3) to equipment U1.
5. Using a wrench U3 with torque amplifier, remove the nut (4)

retaining the piston (5) from the following cylinders:
★ For raising the front bucket.: 55 mm (2.2 inches)
★ For tilting the front bucket.: 55 mm (2.2 inches)
★ Boom: 65 mm (3.0 inches) (remove safety dowel)
★ Arm: 65 mm (3.0 inches)
★ Bucket: 55 mm (2.2 inches)
★ Outriggers: 65 mm (3.0 inches)
★ Extendable arm: Key 46 (1.8 inches)
WB146-5 30-345 3
6. Slide piston (6) and gland nut (2) off rod (5).
Arm Only
★ Note down direction of installation of stop bushing (5a).
Boom Cylinder Rod Only
1. Remove plug (7) and rotate end (8) to let the balls (9) out.
2. Remove end (8).
All Cylinders
1. Remove guide ring (10) and seal (11) from piston (5).
2. Remove O-ring (12) with anti-extrusion ring, O-ring (13), snap ring
(14) and scraper ring (15) from gland.
3. Remove packing (16) and (17).

★ Note down direction for installation of anti-extrusion ring and
position of seal (12).
Boom Gland Nut
1. Remove bushing (18).
30-346 3 WB146-5
ASSEMBLY
1. Lubricate surfaces to prevent damage to the gaskets, seals, O-rings,

scraper, etc.
Surface: Hydraulic Oil
★ Do not force sealing rings into place; heat them instead in hot
water at 50 - 60°C (122 - 140°F) before installing.
Boom Gland Only
1. Using tool U6, install bushing (18).
All Cylinders
1. Using tool U7, install scraper ring (15) and snap ring (14).
2. Assemble packing (16) and (17).

★ Check direction of installation.
Assemble Piston
1. Using tool U4 expand seal (11) and fit it on the piston.
2. Calibrate seal (11) using calibrator U5.
Boom Cylinder Only
3. Install anti-extrusion rings and O-ring (12).
4. Assemble the guide ring (10).
WB146-5 30-347 3
5. Install rod (6), end (8), and ten balls (9); install plug (7).
Plug: Loctite 262
Plug: 23 ± 2 N·m (17 ± 2 lbf ft)
6. Install piston (5) to rod (6).
Arm Cylinder Only

★ Check orientation of brake bushing (5a).
1. Assemble complete piston.
2. Install rod (6) to equipment U1.
3. Remove any existing dirt from the rod and install the head (2).
Boom Cylinder Only
1. Thread piston (5) onto rod (6) and lock into position with wrench
U3 and torque amplifier.
Piston: 280 - 290 N·m (207 - 214 lbf ft)
2. Install safety dowel (19) and tighten until snug.
Dowel: Loctite 542
30-348 3 WB146-5
All Cylinders
1. Install gland nut (2) and piston (5); coat piston thread with sealant.
Piston: Loctite 262
2. Install nut (4) and, using wrench U3 with torque amplifier, lock
piston in place using the following torque values:
Front bucket raise: 2845 ± 284 N·m (2,098 ± 210 lbf ft)
Front bucket tilt: 2845 ± 284 N·m (2,098 ± 210 lbf ft)
Arm: 2845 ± 284 N·m (2,098 ± 210 lbf ft)
Bucket: 2845 ± 284 N·m (2,098 ± 210 lbf ft)
Final Assembly
1. Lubricate piston seals (5) and head gaskets (2) and install piston
into cylinder (1).
2. Position cylinder (1) to equipment U1 and tighten gland nut (2)

using tool U2; tighten to the following torques:
For raising the front bucket: 677 ± 68 N·m (499 ± 50 lbf ft)
For tilting the front bucket: 539 ± 54 N·m (398 ± 40 lbf ft)
Arm: 961 ± 88 N·m (709 ± 65 lbf ft)
Bucket: 1177 - 1373 N·m (868 - 1,012 lbf ft)
Outriggers: 932 -981 N·m (687 - 723 lbf ft)
Boom: 981 ± 98 N·m (723 ± 72 lbf ft)
3. Loosen to 0 N·m (0 lbf), tighten up to 40 N·m (289 lbf ft), and then
tighten angle-wise for 3.5 - 4.5 mm (0.138 - 0.177 in).
★ When assembly is complete, plug union fitting holes to prevent
contamination.
WB146-5 30-349 3
12
SWING CYLINDERS
DISASSEMBLY
1. Cylinder 4. Rod 7. Seal

2. Gland nut 5. Piston 8. Spacer
3. Brake 6. Snap ring 9. Bushing
1. Place the cylinder (1) on the apparatus A1. Engage the fulcrum pins in the suitable support.
2. Using the specially-designed wrench A6, unscrew the gland nut (2) and extract it completely from the cylinder (1).
3. Remove brake cylinder (3).
4. Attach the piston head to the mobile group of the apparatus A1.
5. Extract the piston rod group (4) from the cylinder.
6. Remove the cylinder and the piston rod group.
7. Secure the complete piston rod (4) to the apparatus A1.
8. Raise the part caulked for safety purposes and unscrew the piston using the tool A7.
★ Check the piston (5) carefully. If both safety-staked areas have been used, the piston must be replaced.
9. Remove the snap-ring (6) from the piston and extract the ring (7) and the spacer ring (8).
10. Make a note of the order of assembly of the ring (7).
30-350 3 WB146-5
11. Using a puller remove the swing bushings (9) from the cylinder axle oscillation pins.
12. Dismantle the groups by removing all the seals, the guard rings, the guide rings and the piston fulcrum bushing.
★ The seals, guard rings and guide rings must not be used again.
ASSEMBLY
★ Take great care not to damage the seals and the sliding surfaces.
★ Prepare each individual component before the final assembly.
Assembly of the Gland Nut
1. Install packing (10) and the packing (11) in the cylinder gland (2).
★ Make sure that the packing lips (11) are turned towards the
inside of the cylinder.
2. Install the scraper ring (12).
3. Install the O-ring (13), the anti-extrusion ring (14) and lastly the O-
ring (15) of the front seal.
Reassembling the Piston
1. Use the tool A9 with the appropriate diameter, install the rubber
ring (16) and the seal ring (17) onto the piston.
2. Remove the tool A9 and mount the anti-extrusion rings (18).
3. Prepare the guide rings (19).
4. Install the O-ring (20) in the internal seating of the piston.
5. Gauge the diameter of the seal (16) of the piston mounting the
group under a press and use the tools A3 for the piston diameter.
WB146-5 30-351 3
Reassembling the Piston Rod
1. Using a press and tools A2 with the appropriate diameter, insert the
bushing (21) into the piston rod (4).
2. Insert the ring (8) into the piston rod (4).

★ Check carefully the direction of assembly of the ring (8).
3. Insert the spacer ring (7) and secure the group with the snap-ring
(6).
4. Install the bushing A10 of appropriate diameter on the tip of the

piston rod (4).
5. Lightly lubricate the gland nut packing (2) and slide the gland nut onto the piston rod (4).
Gaskets: ASL800050
6. Lubricate the O-ring seals (22) and screw the piston (5) onto the
piston rod (4) by hand for several turns.
Gaskets: ASL800050
7. Position the group on the tool A1 and tighten the piston with the
round prong wrench A7.
Piston: 932 - 980 N·m (687 - 723 lbf ft)
30-352 3 WB146-5
12
Reassembling Cylinders
1. Place the cylinder (1) on the apparatus A1. Engage the fulcrum pins in the suitable support.
2. Lubricate the threading and the first part of the cylinder (1).
Gaskets: ASL800050
3. Install the two halves of the tool A11 with the appropriate diameter at the opening of the cylinder (1).
4. Install the piston rod group on the apparatus A1.
5. Center the piston (5) in the tool A11.
6. Install the first guide ring (19) round the piston and insert part of the piston into the tool A11. Install the second guide ring
(19) and fully insert the piston.
7. Insert the piston slowly in order to calibrate the guide rings (19) without overheating them.
★ Insert the cylinder head (2) and screw it in by hand for several turns.
8. Use the special wrench A6 to screw the gland nut in.
Cylinder gland nut: 932 - 980 N·m (687 - 723 lbf ft)
9. Install the brake cylinder (3) into the cylinder (1).
Brake cylinder: Loctite 270
Brake cylinder: 804 N·m (593 lbf ft)
10. Remove the cylinder from the equipment A1.
11. Using a press and the appropriate tool A2, install the swing bushings (9).
WB146-5 30-353 3
MEMORANDUM
30-354 3 WB146-5
90 OTHERS
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

1 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
2 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
3 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
4 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
WIRING - 1 OF 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
WIRING - 2 OF 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
WIRING - 3 OF 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
WIRING - 4 OF 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
WIRING - 5 OF 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
WIRING - 6 OF 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
WIRING - 7 OF 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
LEGEND FOR WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
WB146-5 90-1 3
OTHERS
12
90-2 WB146-5
OTHERS HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
1 OF 4
WB146-5 90-3
12
90-4 WB146-5
12
2 OF 4
WB146-5 90-5
12
90-6 WB146-5
12
3 OF 4
WB146-5 90-7
12
90-8 WB146-5
12
4 OF 4
WB146-5 90-9
12
90-10 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
ELECTRICAL SCHEMATIC
WIRING - 1 OF 7
WB146-5 90-11
90-12 WB146-5
12
WIRING - 2 OF 7
WB146-5 90-13
12
90-14 WB146-5
12
WIRING - 3 OF 7
WB146-5 90-15
12
90-16 WB146-5
12
WIRING - 4 OF 7
WB146-5 90-17
12
90-18 WB146-5
12
WIRING - 5 OF 7
WB146-5 90-19
12
90-20 WB146-5
12
WIRING - 6 OF 7
WB146-5 90-21
12
90-22 WB146-5
12
WIRING - 7 OF 7
WB146-5 90-23
12
90-24 WB146-5
12
LEGEND FOR WIRING SCHEMATIC
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
A6 Machine Function Unit F19 Low Beam Light 15A Fuse S24 Starting Switch X27.s AC Harness Connector
B13 Return To Dig Sensor F20 Main Beam Light 15A Fuse S40 Seat Switch X28.s Heater Connector
B59 Brake Oil Low Level Switch F21 Return To Dig Sensor 10A Fuse S41 Rear Horn Switch X44.p Cab Harness Connector
B97 Rear Horn Switch F22 EC Power 7.5A Fuse S46 Parking Brake Switch X44.s Driver Site Harness Connector
B105 Transmission Oil Temperature Sender F23 Steering Unit 10A Fuse S53 Stop Light Switch X65.p Motor Harness Connector
B111 Fuel Level Sender F24 Flasher 7.5A Fuse S54 Stop 4WD Switch X128.s Driver Site Harness Connector
B112 Thermistor F25 Reverse Buzzer Switch 10A Fuse S57 Steering Column Gear Shift X140 Cab Harness Connector
B113 Air Filter Switch F27 General 175A Fuse S60 Steering Column Light Switch X142 Cab Harness Connector
B115 Engine Oil Pressure Switch S80 Ride Control Switch X166.p Switch Harness Connector
B121 Horn G1 Battery S81 Boom Unlock Switch X166.s Cab Harness Connector
G118 Starter Motor S83 EC Power Switch X177.s Work Light Harness Connector
E136 Right Rear Wok Light G119 Alternator S84 EMPI Solenoid Valve Switch
E138 Left Rear Work Light S85 Rear Horn Switch X30 Cigar Lighter
E143 Right Front Wok Light H17 Buzzer S86 General Light Switch Y48 Float Solenoid
E146 Left Front Work Light S87 4WD Switch Y49 Return To Dig Solenoid
E147 Left Indicator K1 Starter Lock Out Unit S88 PPC Switch Y60 EMPI Solenoid
E148 Beacon Lamp K2 Flasher S89 Warning Switch Y90 Rear PPC Solenoid
E151 Right Indicator K3 Low Beam Light Relay S97 Rear Horn Switch Y91 EC Power Solenoid
E152 Cab Light K4 Main Beam Light Relay S104 4th Speed Switch Y92 Back Up Alarm
E154 Rear Left Light K5 Front Horn Relay S107 Declutch Switch Y93 PPC Solenoid
E155 Left Indicator Light K6 Return To Dig Solenoid Relay S167 Beacon Light Switch Y94 Differential Lock Solenoid
E155 Right Indicator Light K7 Stop Light Relay S168 Front Working Light Switch Y95 Boom Unlock Solenoid
E156 Rear Right Light K8 Starter Relay S169 Rear Working Light Switch Y96 Solenoid
E400 Right Front Work Light K9 Forward Speed Relay Y98 MP Bucket Close Solenoid
E401 Left Front Work Light K10 Reverse Speed Relay X1.s Unit Connector Y99 MP Bucket Open Solenoid
E402 Left Rear Work Light K11 Declutch Relay X2.s Unit Connector Y106 4WD Solenoid
E403 Right Rear Work Light K45 Reheating Relay X3.s Unit Connector Y108 Forward Speed Solenoid
K56 Safety Start Relay X4.s Unit Connector
F1 Front Work Light 15A Fuse K61 Services Relay X5.s Unit Connector
F2 Rear Work Light 15A Fuse K111 X7.p Motor Harness Connector
F3 Right Position Light 3a Fuse X7.s Driver Site Harness Connector
F4 Left Position Light 3a Fuse M42 Rear Window Wiper X8.p Gear Harness Connector
F5 Horn 10A Fuse M55 Window Washer Pump X8.s Driver Site Harness Connector
F6 Rear Work Light 15A Fuse M58 Front Window Wiper X9.p Front Dashboard Harness Connector
F7 Front Window Washer 7.5A Fuse M116 AC Compressor Clutch X9.s Driver Site Harness Connector
F8 Stop Light Switch 7.5A Fuse X10.p Front Dashboard Harness Connector
F9 Front Work Light 15A Fuse P43 Instrument Panel X10.s Driver Site Harness Connector
F10 Front Wiper 10A Fuse P63 Front Control Panel X11.p Solenoid Valve Harness Connector
F11 Optional 7.5A Fuse X11.s Driver Site Harness Connector
F12 Instruments And Buzzer 5A Fuse R114 Preheater X12.p Chassis Harness Connector
F13 Lever Grip 10A Fuse X12.s Driver Site Harness Connector
F14 Light And Optional Switch 10A Fuse S2 EC Power Switch Solenoid Valve X15.p Optional Harness Connector
F15 Safety Starter 10A Fuse S3 MP Bucket Close Switch X25.p Switch Panel Harness Connector
F16 Beacon Light 10A Fuse S4 Declutch Switch X25.s Driver Site Harness Connector
F17 Warning Switch 10A Fuse S5 MP Bucket Open Switch X26.p Switch Panel Harness Connector
F18 Cab Light And Cigar Lighter 10A Fuse S6 Differential Locking Switch X26.s Driver Site Harness Connector
WB146-5 90-25
12
90-26 WB146-5

Retroexcavadora WB146

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Copyright:

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Retroexcavadora WB146

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Copyright:

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CEBM016503

SERIAL NUMBERS WB146-5 A23001 and up

Copyright 2010 Komatsu

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

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

● Page to be replaced Replace

( ) Page to be deleted Discard

● 00-1 d ● 01-1 d ● 10-17 d ● 10-46 d

● 00-2 d ● 01-2 d ● 10-18 d ● 10-47 d

● 00-2-1 d ● 01-3 d ● 10-19 d ● 10-48 d

● 00-2-2 d ● 01-4 d ● 10-20 d ● 10-49 d

● 00-2-3 d ● 01-5 d ● 10-21 d ● 10-50 d

● 00-2-4 d ● 01-6 d ● 10-22 d ● 10-51 d

● 00-2-5 d ❍ 01-7 d ● 10-23 d ● 10-52 d

● 00-2-6 d ❍ 01-8 d ● 10-24 d ● 10-53 d

00-3 ❍ 01-9 d ● 10-25 d ● 10-54 d

00-4 ❍ 01-10 d ● 10-26 d ● 10-55 d

00-5 ❍ 01-11 d ● 10-27 d ● 10-56 d

00-6 ❍ 01-12 d ● 10-28 d ● 10-57 d

00-7 ● 10-29 d ● 10-58 d

00-8 ● 10-1 d ● 10-30 d ● 10-59 d

00-9 ● 10-2 d ● 10-31 d ● 10-60 d

00-10 ● 10-3 d ● 10-32 d ● 10-61 d

00-11 ● 10-4 d ● 10-33 d ● 10-62 d

00-12 ● 10-5 d ● 10-34 d ● 10-63 d

00-13 ● 10-6 d ● 10-35 d ● 10-64 d

00-14 ● 10-7 d ● 10-36 d ● 10-65 d

00-15 ● 10-8 d ● 10-37 d ● 10-66 d

00-16 ● 10-9 d ● 10-38 d ● 10-67 d

00-17 ● 10-10 d ● 10-39 d ● 10-68 d

00-18 ● 10-11 d ● 10-40 d ● 10-69 d

00-19 ● 10-12 d ● 10-41 d ● 10-70 d

00-20 ● 10-13 d ● 10-42 d ● 10-71 d

00-21 ● 10-14 d ● 10-43 d ● 10-72 d

00-22 ● 10-15 d ● 10-44 d ● 10-73 d

● 10-16 d ● 10-45 d ● 10-74 d

WB146-5 WB146-5 00-2-1 3

● 10-75 d ● 20-11 d ● 20-44 d ● 30-6 d

● 10-76 d ● 20-12 d ● 20-45 d ● 30-7 d

● 10-77 d ● 20-13 d ● 20-46 d ● 30-8 d

● 10-78 d ● 20-14 d ● 20-47 d ● 30-9 d

● 10-79 d ● 20-15 d ● 20-48 d ● 30-10 d

● 10-80 d ● 20-16 d ● 20-49 d ● 30-11 d

● 10-81 d ● 20-17 d ● 20-50 d ● 30-12 d

● 10-82 d ● 20-18 d ● 20-51 d ● 30-13 d

● 10-83 d ● 20-19 d ● 20-52 d ● 30-14 d

● 10-84 d ● 20-20 d ● 20-53 d ● 30-15 d

❍ 10-85 d ● 20-21 d ● 20-54 d ● 30-16 d

❍ 10-86 d ● 20-22 d ● 20-55 d ● 30-17 d

❍ 10-87 d ● 20-23 d ● 20-56 d ● 30-18 d

❍ 10-88 d ● 20-24 d ● 20-57 d ● 30-19 d

❍ 10-89 d ● 20-25 d ● 20-58 d ● 30-20 d

❍ 10-90 d ● 20-26 d ● 20-59 d ● 30-21 d

❍ 10-91 d ● 20-27 d ● 20-60 d ● 30-22 d

❍ 10-92 d ● 20-28 d ❍ 20-61 d ● 30-23 d

❍ 10-93 d ● 20-29 d ❍ 20-62 d ● 30-24 d

❍ 10-94 d ● 20-30 d ❍ 20-63 d ● 30-25 d

❍ 10-95 d ● 20-31 d ❍ 20-64 d ● 30-26 d

❍ 10-96 d ● 20-32 d ❍ 20-65 d ● 30-27 d

● 20-33 d ❍ 20-66 d ● 30-28 d

● 20-1 d ● 20-34 d ❍ 20-67 d ● 30-29 d

● 20-2 d ● 20-35 d ❍ 20-68 d ● 30-30 d