Komatsu 5

REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
SHOVEL LIFT CYLINDERS

Removal
k Fully lower the front working equipment until it rests on 3
the ground; apply the parking brake, and stop the
engine. A
1 -Introduce non-slip blocks “A” between the shovel dump 1
tie bar (1) and the spacer (2) of the fulcrum lever (3) on
removal side.
2
RKZC2160
2 -Take off the snap-ring (4) and the internal retaining

spacer (5) for the piston attachment pin (6).
6
5
RKZC2170
3 -Remove the tie strap (7) retaining the piston return hose
(8).
4 -Place a sling around the cylinder and connect it to a

hoisting device. 8
a Do not engage the piston return hose with the sling. 9
5 -Extract pin (6) to expose piston eye and safety rod (9).
6 -Remove rod.
7
6
RKZC2180
7 -Lower cylinder (10) until it rests on blocks “B”.
8 -Start the engine to retract the piston.

[*1] [*2]
8
k Stop the engine and eliminate residual pressure. 10
B
RKZC2190
WB93R-5 30-275
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
8 -Remove hoses (8) and (11), and remove hose clamp

(12). 12
a Cap pipes, hoses and holes to prevent 14
contamination.
9 -Remove the snap-ring (13) and the spacer (14).
10 -Remove cylinder (10).
4 Cylinder: approx. 46 kg
11
8 13
RKZC2200
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the

pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050

1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
30-276 WB93R-5
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
SHOVEL DUMP CYLINDERS

Removal
2
k Fully lower the working equipment to the ground; apply
3
the parking brake, and stop the engine.
1 -Remove the strap retaining the piston return hose (1).
For the right-hand cylinder only

a If installed, disconnect the return-to-dig sensor, mark its A 5 1
location, and then remove the lift bracket. 6
2 -Remove shovel position rod (2). 4
3 -Place a sling round the cylinder (3) and insert a block “A”
RKZC2210
between the spacer (4) of the piston fulcrum lever (5)
and the link (6).
a Do not engage the piston return hose with the sling.

4 -Take off the snap-ring (7) and the internal retaining
spacer (8) for the piston attachment pin (9).
8 9
5 -Extract pin (9) to expose piston eye.
6 -Start the engine to retract the piston(10).

[*1] [*2]
k Stop the engine and eliminate completely residual
pressure from all circuits.
10 7
RKZC2240
7 -Remove hoses (1) and (11), and remove hose clamp

(12).
a Cap the hoses and holes to prevent contamination.
12
11
RKZC2250
8 -Remove the snap-ring (13) and the spacer (14).
4 Tilt cylinder; approx 35 kg

a Recover spacer (15) between frame and cylinder.
15
13
14
RKZC2260
WB93R-5 30-277
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
Installation
[*1]

[*2]

Machines equipped with return-to-dig only
2 -Check sensor position and adjust as necessary.
30-278 WB93R-5
REMOVAL AND INSTALLATION SHOVEL
SHOVEL
Removal
k Lower the shovel to the ground, resting on its back, but
without forcing it downwards.
1 -Stop the engine and release residual pressures.
RKZC2130
2 -Take out the screws (1) and remove the pins (2) of the
lever (3).
Rest the lever (3) on the boom. [*1] [*2]
1
RKZA1461
3 -Take out the screws (4) and remove the pins (5) of the
shovel fulcrum. [*1] [*2]
4 -Start the engine and put the machine into reverse gear in 4
order to disengage the boom (6).
4 Shovel: 436 kg
6
5
RKZA1471
Installation
[*1]

[*2]
WB93R-5 30-279
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
FRONT WORKING EQUIPMENT

Removal
k Lower the working equipment completely until it rests
on the ground stop the engine and remove the ignition
wrench.
k Release all residual pressure in all circuits.

(For details, see "20 TESTING AND
ADJUSTMENTS").
1 -Remove the tilt cylinders. (See "SHOVEL DUMP

CYLINDERS").
RKZC2270
2 -Disconnect the cylinders from the boom (1) and rest

them on wooden blocks «A» placed on the front axle.
(See "SHOVEL LIFT CYLINDERS").
A
RKZC2191
3 -Open the front hood and take out the screws (2) that lock
the axle oscillation pins (3) of the boom (4).
Close the front hood.
4 3
RKZC2290
4 -Put a sling round the boom (4) as shown in the figure,

and attach it to the hoisting tackle. Apply a slight tension
to the cables.
4
RKZC2280
30-280 WB93R-5
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
5 -Using a puller, remove the oscillation pins (5) of the arm

(4) together with snap ring and spacer.
[*1] [*2]
6 -Start the engine and put the machine into reverse gear
travel until the boom is disengaged.
4
a If the working equipment is to be detached while the
engine or gearshift is out of order and the machine
cannot travel automatically, it can be towed using
the towing hooks of the backhoe. 5
7 -Place two stands in position and lower the boom until it is
resting on them.
4 Front equipment: approx. 1100 kg

RKZC2300
Installation
• To install, reverse the removal procedure, if necessary
using the front towing hook.
[*1]

[*2]

• Start the engine and bleed the air from the cylinders.
WB93R-5 30-281
REMOVAL AND INSTALLATION BACKHOE PPC VALVES (Optional)
BACKHOE PPC VALVES (Optional)

Removal
k The following removal procedure applies to both PPC
valves.
1 -Lower the outriggers to the ground: fold the bucket and
rest the arm on an “A” block, keeping it at right angles
with the ground.
2 -Release the backhoe plate and stop the engine.
k Release all residual pressure in all circuits. (For details,
see "20 TESTING AND ADJUSTMENTS").
3 -Lift cab rear window up to the top.
RKZC2060
4 -Fully raise the boot (1).
5 -Loosen and remove the screws (2) retaining the PPC 1

valve (3) and armrest (4).
2
4 RKZB6813
6 -Raise the armrest from the rear side and remove the
screw (5) retaining the rear guard (6). 5 8
7 -Cut the retaining clamp and lower the lower boot (7). 7
8 -Loosen and remove screw (8), and remove rear guard
(6).
6
RKZB6823
9 -Disconnect the connector (9).
10 -Ensure that the hoses are marked (10), then disconnect

the hoses from the PPC valve. [*1]
a Mark the hoses, if necessary. 9
a Plug all pipes/hoses to prevent contamination.
10
RKZB6831
30-282 WB93R-5
REMOVAL AND INSTALLATION BACKHOE PPC VALVES (Optional)
11 -Remove the PPC valve (11).

11
RKZB6841
Installation
a Carefully inspect the hoses for the proper position

when connecting them.
(For details, see "10 STRUCTURE AND
FUNCTION").
WB93R-5 30-283
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
PPC VALVE SUPPORT RELEASE CABLES

Removal
1 - Lower the outriggers and the equipment to the ground;
stop the engine.
RKZC2060
2 -Remove the rear mat (1).
RKZB6772
3 -Take out the screws (2) and remove the platform (3).
3
2
RKZB6664
5 -Loosen and remove the screws (5) that retain the PPC 4
valve and armrest (6).
5
6 RKZB6814
30-284 WB93R-5
7 -Cut the retaining clamp and release the lower boot (9). 7
8 -Loosen and remove the screws (10) and remove the
rear guard (8).
8
RKZB6824
9 -Loosen and remove the screws (11) and raise the boot
(12) and the retaining edge (13). 12
a Raise until the lower fulcrum and locking assembly
become fully disengaged.
13 11
RKZB6852
10 -Remove the retaining screws (14) from the lock-

actuating lever assembly (15).
11 -Remove the entire lever assembly (15). 15
14
RKZB6861
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).
17 20
18
19
16
RKZB6871
WB93R-5 30-285
14 -Loosen the nut (21) and unscrew the tensioner (22);

disengage the control cable (20) from the release
control lever (15).
21
15
22
20
RKZB6971
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).
21
22
RKZB7071
30-286 WB93R-5
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
PPC VALVE SUPPORT RETURN GAS SPRING

Removal
1 - Lower the outriggers and the equipment to the ground;
stop the engine.
RKZC2060
2 -Remove the rear mat (1).
RKZB6772
3 -Take out the screws (2) and remove the platform (3).
3
2
RKZB6664
4 -Fully loosen the stop knob (4) of the PPC valve support
(5) you are working on.
RKZC2310
WB93R-5 30-287
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
6 -Loosen and remove the screws (7) that retain the PPC 6
valve and armrest (8).
7
8 RKZB6815
8 -Cut the retaining clamp and release the lower boot (11). 9
9 -Loosen and remove screw (12), and remove rear guard
(10).
10
RKZB6825
10 -Loosen and remove the screws (13) and raise the boot
(14) and the retaining edge (15). 14
a Raise until the gas spring (16) becomes fully
disengaged.
15 13
RKZB6853
11- Loosen the nut (17) and remove the snap ring (18) and
washer (19). 17 19
12- Disconnect the gas spring (16) and remove it.
18
Installation
16
RKZB7081
30-288 WB93R-5
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment)
SOLENOID VALVE GROUP (servocontrol and optional attachment)

Removal
1 -Lower the outriggers and the equipment to the ground;
engage the parking brake, stop the engine and extract
the ignition key.
k Release residual pressure from all circuits by moving all

control levers in all directions.
RKZC2060
2 -Disconnect the connector (1) and remove the seat (2).
RKZC1031
Standard version
3 -Remove rear mat, optional device control pedals (if
4
any), hood (3), and the metal sheet closing off the floor
(4).
RKZC1901
Version with backhoe servocontrols

3a -Remove the rear mat and remove the metal sheet (5)
closing off the floor.
5
RKZC1971
WB93R-5 30-289
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment)
4 -Disconnect all connectors (6) from the solenoid valves .
a Check to ensure that all connectors have marks 6

scribbled on, and note down their plugging
positions.
9
5 -Mark and disconnnect all hoses (7).
7
a Cap pipes, hoses and holes to prevent
contamination.
6 -Loosen and remove two screws (8) and washers; 7

remove the solenoid valve group (9) together with the 8
accumulator. RKZC2320
Installation
1 -Start the engine and perform all possible manoeuvres to

eliminate the air from all circuits.
30-290 WB93R-5
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
BACKHOE BOOM CYLINDER

Removal
1 -Fully extend the arm (1) and fully open the bucket (2). 3 1
Manoeuvre the boom until the outer end of the boom is in
a level position.
2
2 -Place and force a jack stand “A” and a non-slip block
under the boom.
3 -Lower the arm until the bucket teeth touch the ground.
A
RKZC2330
4 -Lower the outriggers to the ground, apply the parking

brake, and stop the engine.
6
k Release residual pressure from all circuits by
operating the control levers in all directions.
4
5 -Remove pins (4) and disconnect tie rod (6) from boom
retaining lever (5).
5
RKZC2340
6 -Loosen and remove the screws, remove the group (7)

controlling the levers (5) and position it aside.
7
RKZC2350
7 -Remove snap rings (8), shims (9), and levers (5).
8
9
RKZC2360
WB93R-5 30-291
8 -Remove springs (10), and remove the nut and screw

(11) retaining the piston attachment pin.
11
10
RKZC2370
9 -Place a safety block "B" under the cylinder (12)

controlling the arm. 12
RKZC2380
10 -Sling the cylinder (12) in a band and connect it to a

hoisting device; apply a slight tension. 14
12
a Do not engage the hoses with the band.
11 -Pull out pin (13) and recover spacers (14).
[*1] [*2]
13
RKZC2390
12 -Start the engine and retract the piston.

Stop the engine and release residual pressures.
13 -Remove snap ring (15). 15
RKZC2400
30-292 WB93R-5
14 -Disconnect hoses (13) and (14) from cylinder (12).

contamination.
14
13
RKZC2410
15 -Pull out pin (15) and remove cylinder (12).

16
a Recover shims (16) and note down their position of
installation between boom and cylinder and
between boom and arm. [*1] [*2] 15
4 Cylinder: 87.5 kg
RKZC2420
Installation
[*1]

[*2]

WB93R-5 30-293
REMOVAL AND INSTALLATION ARM CYLINDER
ARM CYLINDER
Removal
1 -Fully extend the arm (1) and fully open the bucket (2). 3 1
Manoeuvre the boom until the outer end of the boom is in
a level position.
2
under the boom.
3 -Lower arm (3) until bucket teeth touch the ground.

A
k Release residual pressure from all circuits by

RKZC2330
operating all hydraulic controls in all directions.
5 -Force a block “B” under the boom cylinder (4). 4
RKZC2430
6 -Remove the strap (5) retaining the hoses.

hoisting device; apply a slight tension. 7 6
8
5
8 -Remove the snap ring (6) retaining the cylinder fulcrum
pin (7) and the screw (8) retaining the piston pin (9).
RKZC2440
9 -Disconnect hoses (10) and (11) from cylinder (4).

contamination.
4 11
10
RKZC2450
30-294 WB93R-5
REMOVAL AND INSTALLATION ARM CYLINDER
10 -Pull out the piston attachment pin (9).

[*1] [*2]
RKZC2460
11 -Pull out the cylinder attachment pin (7) until the eye of
cylinder (4) is exposed. [*1] [*2]
7
4
12 -Remove cylinder (4) and recover shims (if any).
4 Arm cylinders: 67 kg
RKZC2470
Installation
[*1]

[*2]

WB93R-5 30-295
REMOVAL AND INSTALLATION JIG ARM CYLINDER
JIG ARM CYLINDER

Removal
k Open the arm (1) completely and lower it until it rests on 1
a trestle “A” that is roughly 40 cm high. Extend the jig 4
arm (2) until it rests on a block “B”, and let the bucket
teeth rest on the ground.
1 -Stop the engine and release the cylinder (3) pressures,
2
by moving the command pedal several times.
2 -Place a sling around the cylinder (3).

A
3 -Take off the snap ring and remove the pin (4).
B
[*1] [*2] RKZA7931
4 -Start the engine to retract the piston.
5 -Stop the engine and release residual hydraulic pressure

from all circuits by operating the control levers in all
directions. 4
6 -Take out the safety pin (5).
7 -Disconnect the tubes (6), (7), (8) and (9).

contamination. 3
8 -Remove the clamp (10).
9 -Remove the screws (11) and the pin (12). [*1] [*2] RKZA7941
5
11 10
6
Installation
8
• To install, reverse removal procedure. 12
[*1]

pin, turn the engine over at low idling speed. 9 7
Do not insert fingers into the holes to check alignment. RKZA7951
[*2]

30-296 WB93R-5
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
OUTRIGGER CYLINDER
Removal
k Set the backhoe with the centered attachments with the
arm in vertical position and the bucket leaned on the
back at level ground.
1 -Extend the outriggers (1) of about 15 cm, stop the

engine and release the cylinders pressures.
1 RKZC2480
2 -Place a lifting platform “A” beneath outrigger (2) of

cylinder to be remove.
Raise this until it is forced up against the outrigger.
RKZC2490
3 -Remove the clamps (3) retaining the pipes (4).
4 -Disconnect from cylinder (5) the pipes (4) and plug them
to avoid impurity entry. 3 4
a Plug also the union to avoid the movement of piston.
RKZC2500
5 -Take off snap ring (6) and slide pin (7) out until cylinder
(5) is disengaged. [*1] [*2]
7 6
RKZC2510
WB93R-5 30-297
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
6 -Raise the lifting platform “A” to disengage the cylinder

head (5) from frame.
Place a sling round the cylinder (5) and apply slight
tension to the cables.
5
RKZC2520
7 -Take out the screws and remove the pin (10).

[*1] [*2]
8 -Remove the cylinder(5).
8
4 Cylinder: approx. 27.5 kg
RKZC2530
Installation
[*1]
k Do not insert fingers into the holes to check alignment.

[*2]

30-298 WB93R-5
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
BACKHOE SWING CYLINDERS

Removal
k Set the backhoe with the centered attachments with the
arm in vertical position and the bucket leaned on the
back at level ground.
1 -Stop the engine and release all cylinder pressure by

moving the lockout control several times.
RKZC2060
2 -Loosen and remove screws (1) and release hose clamp

(2). 1
RKZC2540
3 -Loosen and remove the four screws (3) and washers.

[*1]
RKZC2550
4 -Lift the hoses (4) to the backhoe cylinders and retain

them in position with a band.
RKZC2560
WB93R-5 30-299
5 -Remove the upper support (5) with a vertical movement.

[*3]
RKZC2570
6 -Disconnect four tubes (6) from cylinders (7).

7
contamination.
6 RKZC2580
7 -Take out the screws (8) and remove the pins (9).
9
8 -Rotate the cylinders to disengage the piston heads from 8
the swing bracket (10) and remove the cylinders (6).
4 Cylinder: approx. 34 kg
10
RKZC2590
30-300 WB93R-5
Installation
1 -Mount the cylinders (6) and the upper cylinder fulcrum
support (2). Secure the support with the four screws (3). 5 3
[*1]
2 Support screws: Loctite 262

3 Support screws: 981±98 Nm
2 -Connect the four tubes (7) to the cylinders.
7
3 -Start the engine and swing the boom in order to center
6
one of two pins (6). Secure the 1st pin with the screw. RKZC2551
Perform the same operation for the other pin.
[*2]
9
k When aligning the positions between the hole and the 8
[*3]

4 -Bleed the air from the cylinders. (For details, see "20
TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank. RKZC2591
WB93R-5 30-301
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
BACKHOE BUCKET CYLINDER

Removal
2
1 -Extend the arm (1). 1
2 -Operate the boom (2) and bucket (3) until bottom of
bucket sits level.

k Release residual pressure from all circuits by operating

the control levers in all directions.
RKZC2600

hoisting device; apply a slight tension.
RKZC2610
5 -Take out the lock-nut (5) and the washer and remove the
pin (6). [*1] [*2] [*3]
6 -Start the engine and retract the piston.

5
k Stop the engine and release residual pressures.
RKZC2620
7 -Disconnect the tubes (7) and (8).
a Cap pipes, hoses and holes to prevent 8 7

contamination.
8 -Take off the snap ring (9) and remove the pin (10).
[*1] [*2] 10
RKZC2630
30-302 WB93R-5
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
Versions with jig arm only

9 -Disconnect the tubes (11) and (12).
10 -Take out screw (13) and remove pin (14).
[*1] [*2] 12 11
14
13
4
RKZA9951
4 Standard cylinder: approx. 52.5 kg
Installation
[*1]

[*2]

[*3]
a Tighten the locknut completely, then release it half a

turn.
WB93R-5 30-303
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
BACKHOE BOOM SAFETY CYLINDER

Removal
2
1 -Extend the arm (1). 1
2 -Operate the boom (2) and bucket (3) until bottom of
bucket sits level.


the control levers in all directions.
RKZC2600
4 -Remove pins (4) and disconnect yokes (6) from boom

retaining levers (5).
6
4
5
RKZC2341
5 -Loosen and remove nut (7) and remove tie rod (8).
8
8 7
RKZC2640
6 -Disconnect feed hose (9).
a Cap the hose and hole to prevent contamination.

7 -Loosen and remove the screws (10) and the cylinder 11
(11).
9
10
RKZC2650
30-304 WB93R-5
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
Installation
1 -Start the engine and operate the cylinder several times

to eliminate the air from the circuit.
2 -Lift the boom and check to ensure that the safety

connection is correct.
WB93R-5 30-305
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
BACKHOE WORKING EQUIPMENT

Removal
1 -Fully extend the arm (1) and fully open the bucket (2); 3 1
operate the boom (3) until the outer end of the boom is in
a horizontal position.
2
under the boom (3).
3 -Lower the arm until the bucket teeth touch the ground.
A
RKZC2330

all hydraulic controls in all directions.
5 -Position a lift “B” and some non-slip blocks under boom

fulcrum.
A B
RKZC2660
6 -Place a sling around the boom lift cylinder (4), connect it

to a hoisting device and apply a slight tension to the 4
cable.
RKZC2411
7 -Pull out the piston attachment pin (5).

8 4
8 -Release boom and arm cylinder hoses and bucket 7
cylinder hoses from the three hose clamps (6).
5
9 -Disconnect hoses (7) and (8) from boom and arm
cylinder.
a Mark the pipes to avoid exchanging them during

installation. 6 6
a Plug all pipes/hoses to prevent contamination.
6
RKZC2670
30-306 WB93R-5
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
9 -Disconnect hoses (9) from bucket cylinder.

9
contamination.
a Mark the pipes to avoid exchanging them during

installation.
10 -Slide all hoses off and place them aside.
RKZC2680
11 -Position a non-slip block “C” under the boom lift cylinder

and disconnect the hoisting device
C
RKZC2690
12 -Remove the screw (10) and the pin (11).
13 -Start the engine, draw in the outriggers and move the

machine rearward.
a Recover the shims between boom and swing 10

11
bracket.
4 Backhoe working equipment

with standard arm: 850 kg
RKZC2700
Installation
1 -Start the engine and bleed the air from all circuits.
2 -Stop the engine, check the level in the tank and, if

necessary, top it up.
WB93R-5 30-307
REMOVAL AND INSTALLATION BACKHOE BUCKET
BACKHOE BUCKET
Removal
7
k Place the bucket on a level surface, resting on its back. 4
1 -Take out the safety pin (1) and remove the connecting 6
pin (2) between bucket (3) and tie-rods (4). [*1] [*2] 2
2 -Take out the safety pin (5) and remove the pin (6) that 5
attaches the bucket to the arm (7).
[*1] [*2] 1
3
4 Bucket: 158 kg
RKZA1350
Installation
[*1]

[*2]
30-308 WB93R-5
BACKHOE BOOM CYLINDER

Removal
1 -Remove the arm cylinder.
(For details see "ARM CYLINDER").
2 -Remove the arm.

(For details see "ARM").
3 -Start the engine and rest the boom on the ground.

1 1
4 -Remove the boom cylinder.
(For details see "BACKHOE BOOM CYLINDER").
1
5 -Remove the hose clamps (1) retaining the boom, arm RKZC2671
and bucket hoses.

a Mark the tubes to prevent exchanging positions
during re-connection.
2
6 -Hook the boom (2).
7 -Take out the retaining screw and remove the pin (3).
[*1] [*2]
a Recover the shims (4) between boom and swing

bracket.
8 -Remove the boom (2).
4 Boom: 248 kg
RKZC2710
Installation
4
[*1]

[*2]
3

RKZC2720
WB93R-5 30-309
REMOVAL AND INSTALLATION ARM
ARM
Removal 4
1 -Remove the bucket.
(For details see "BACKHOE BUCKET").
2 -Remove the bucket cylinder and the link (1). 1

(For details, see "BACKHOE BUCKET CYLINDER"). 3
3 -Take out the lock nut (2), and the washer and remove the
pin (3) and the links (4). [*1] [*2]
2
4 -Start the engine, bring the arm into a vertical position
and lower it to the ground.
RKZA1360
5 -Stop the engine and release residual pressures from the

cylinder.
6 -Put a sling around the arm cylinder (5), remove the 7

screws (6) and remove the pin (7). [*2] [*3]
7 -Start the engine and retract the piston completely. 6 5
8 -Rest cylinder (5) on a block “A” and disconnect from the
hoisting device.
9 -Stop the engine.
10 -Connect the arm (8) to the hoisting device and apply a

slight tension to the cable.
11 -Take out the screws (9) and remove the pin (10). RKZC2441
[*1] [*2]
a Recover the shims.
12 -Remove the arm (8). 8 5
4 Arm: ______ kg
Installation
[*1]
k When aligning the positions between hole and pin, do A

not insert fingers into the holes to check on alignment.
RKZC2730
[*2]

turn. 10
[*3] 8 9

RKZC2740
30-310 WB93R-5
REMOVAL AND INSTALLATION JIG ARM
JIG ARM
Removal 4
1 -Remove the bucket.
2 -Remove the bucket cylinder and the link (1). 1

3 -Take out the lock nut (2), and the washer and remove the
pin (3) and the links (4). [*1] [*2]
2
RKZA1360
4 -Disconnect the jig arm hoses (5) and (6), the bucket
cylinder hoses (7) and (8), and the hoses of the auxiliary
equipment (9) and (10).
a Mark the hoses to avoid exchanging them during 11

6
INSTALLATION.
5 -Remove the clamp (11).
6 -Proceed with the removal as for the arm 7 10

. (See "ARM").
4 Jig arm cylinder: 460 kg

9 8
5
RKZA7970
Installation
[*1]
k When aligning the positions between hole and pin, do

[*2]

turn.
WB93R-5 30-311
REMOVAL AND INSTALLATION 2nd ARM
2nd ARM
Removal
1 -Remove the bucket (1).
2 -Remove the bucket cylinder (2) and the link (3). 1 2

3 -Remove the 2nd arm cylinder.
(For details see "JIG ARM CYLINDER").
a For safety, tightly plug all the disconnected hoses.

4 -Take out the lock nut (4), and the washer and remove the 7
RKZA7980
pin (5) and the links (6). [*1] [*2] [*3]
5 -Connect the 2nd arm (7) to some hoisting tackle.
a Use the bucket pin hole and the safety pin holes. 6
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 5
cable or chain are under slight tension. 3
7 -Stop the engine and loosen by several turns the gib
4
adjustment screws.
a Loosen the screws on both sides.

8 -Slide out the 2nd arm (7). RKZA7990
4 2nd arm: _______ kg
Installation
[*1]
k When aligning the positions between hole and pin, do

[*2]

RKZA8000
[*3]

turn.
30-312 WB93R-5
REMOVAL AND INSTALLATION 2nd ARM GUIDES
2nd ARM GUIDES

Removal
2
1 -Remove the bucket. 1
2 -Partially extend the 2nd arm (1).
3 -Rest the arm (2) on a trestle “A” about 80 cm (3.5 ft.)

high.
A
RKZA8010
4 -Loosen and remove the screws (3), the spring washers

and remove the upper guides (4). [*1]
5 -Connect the 2nd arm (1) to some hoisting tackle.
a Use the bucket pin hole and the safety pin holes.
6 -Slowly raise the 2nd arm (1) until it rests on the 3
supporting surfaces of the upper guides.
5 6
RKZA8020
7 -Loosen the nuts (5) and remove the adjustment dowel

bolts (6). 3
8 -Raise the lower guides (7) and slide them out. [*1]
4
6
7
RKZ02390
Installation
2
1
[*1]
2 Guides and 2nd arm guides: ASL800040

1 -Adjust the clearances, keeping the jig arm (1) aligned
with respect to the 2nd arm (2).
RKZA8030
WB93R-5 30-313
REMOVAL AND INSTALLATION BACKHOE SWING BRACKET
BACKHOE SWING BRACKET

Removal
2
1 -Remove the equipment. 1
(For details see "BACKHOE WORKING
EQUIPMENT").
2 -Take out the screws (1) and remove the pins (2) that
connect the swing cylinders (3). [*1] [*2] 3
3 -Remove boom safety cylinder (4).
(For details see "BACKHOE BOOM SAFETY
CYLINDER").
RKZC2592
4 -Sling the swing bracket (5)
5 -Take out screws (6) and (7) and remove pins (8) and (9)
4
from swing bracket. [*1] [*2]
6 -Remove swing bracket (5) and shims (10) and slide the
hoses off. [*3]
4 Bracket: 162.5 kg
RKZC2351
Installation
8
[*1]
k When aligning the positions between the hole and the 6

[*2]
2 Internal bushing: ASL800050 9 7

RKZC2750
[*3]
a Insert the shims.

13
13
13
RKZ01330
30-314 WB93R-5
REMOVAL AND INSTALLATION COMPLETE BACKHOE BACKFRAME
COMPLETE BACKHOE BACKFRAME

Removal
1
1 -Remove the equipment. 2
(For details see "BACKHOE WORKING
EQUIPMENT").
2 -Remove the swing bracket.

(For details see "BACKHOE SWING BRACKET").
3 -Disconnect the backhoe backframe lock piston feeding

hose (2) from union (1); plug hose and union to prevent
contamination.
RKZC2760
4 -Disconnect feed hoses (4) from swing cylinders (3).

3 4
RKZC2770
5 -Connect the backframe (5) to a hoisting device.
6 -Loosen nuts (6) and remove washers and four screws

(7).
Loose partially lateral nuts (4) to remove backframe (3) 6 5
from frame (8). [*1]
6
8
7
RKZC2780
7 -Put a sling round the backframe (5) and apply slight

tension to the cables.
10
9
8 -Remove external nuts (6), washers and screws (7). 10
[*1]
9 -Remove slide block (9) and spacers (10). 7
RKZC2790
WB93R-5 30-315
REMOVAL AND INSTALLATION COMPLETE BACKHOE BACKFRAME
10 -Lower backframe (5) and remove backframe together

with swing cylinders.
4 Complete backframe: approx. 246 kg 5
RKZC2800
Installation
[*1]
2 Nuts: Loctite 262

3 Nuts: 980±98 Nm
30-316 WB93R-5
REMOVAL AND INSTALLATION BACKFRAME LOCK PISTONS
BACKFRAME LOCK PISTONS

Removal
1 -Remove the complete backframe (1).
1
(For details see "COMPLETE BACKHOE
BACKFRAME").
RKZC2801
UPPER PISTON
1 -Remove two pipes (2) and (3).
2 -Plug the horizontal union (4).
3 -Introduce compressed air at low pressure (max. 2 bar)

through lower union (5) and recover piston (6).
k Be aware that the piston may be ejected rapidly. 2

6
Use a rag or non-slip gloves to accompany the 4
piston as it is being ejected. 3
RKZC2810
LOWER PISTON
1 -Remove pipe (3).
2 -Introduce compressed air at low pressure (max. 2 bar)

through union (7) and recover piston (6).
3
k Be aware that the piston may be ejected rapidly.
Use a rag or non-slip gloves to accompany the
piston as it is being ejected.
RKZC2820
REPLACING SEALS
8 9 10
1 -Remove seal (8), guide ring (9), and seal (10).
a Note down direction of installation of seal (10).
10
RKZC2830
WB93R-5 30-317
REMOVAL AND INSTALLATION BACKFRAME LOCK PISTONS
2 -Thoroughly clean the seats and install new seals and the
guide ring.
3 -Lubricate the seals, guide ring, and piston seat.
2 Seal and seat: Hydraulic oil: A
6
RKZC2840
4 -Apply a band “A” for seal compression and install piston

(6). A
RKZC2850
Installation
30-318 WB93R-5
40 STANDARD MAINTENANCE
TRANSMISSION.............................................................2 SHOVEL CYLINDERS ................................................. 52

FRONT AXLE..................................................................7 BACKHOE CYLINDERS .............................................. 54
REAR AXLE ..................................................................11 FRONT WORKING EQUIPMENT ................................ 58
HYDRAULIC PUMP ......................................................15 SWING BRACKET ....................................................... 60
CONTROL VALVE ........................................................18 BACKHOE WORKING EQUIPMENT ........................... 62
PPC VALVES................................................................50
WB93R-5 40-1
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
3 30 Nm
G
F
A
3 23 Nm
3 23 Nm 3 23 Nm
C C
H H
B B E E
3 23 Nm 3 23 Nm
RKZ10310
40-2 WB93R-5
3 50 Nm
3 50 Nm
3 23 Nm
3 40 Nm
3 139 Nm
2 Loctite 518
3 23 Nm
A-A
RKZ10320
WB93R-5 40-3
3 23 Nm 3 80 Nm 3 25 Nm
3 50 Nm
2 Loctite 542
B-B
3 23 Nm
D D
3 30 Nm 3 26-30 Nm
C-C
RKZ10330
40-4 WB93R-5
3 9-11 Nm
3 7-10 Nm
3 21.5-24.5 Nm
D-D
3 22 Nm 3 23 Nm
3 5-8 Nm
RKZ10340
E-E
WB93R-5 40-5
3 30 Nm
I I
3 100 Nm 3 23 Nm 3 50 Nm
2 Loctite 270
F-F G-G
3 40 Nm
2 Loctite 542
2 Loctite 638
H-H I-I RKZ10370
40-6 WB93R-5
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
Differential
3 95 Nm
2 Loctite 270
3 13 Nm
3 169 Nm
2 Loctite 510
2
2 Loctite 638
3
4
RKZ10380
WB93R-5 40-7
3 266 Nm
3 60 Nm RKZ10390
Unit: mm
No. Check item Criteria Remedy

Standard clearance Clearance limit
1 Axle clearance
---- ----
Backlash of crown wheel and
2 0.18–0.28 0.28
pinion
Pinion rotation force Adjust
3 (without sealing ring) 92-137 Nm
As measured on pinion Ø 34.8
Pinion-crown
rotation force
4 129.5-194.5 Nm
(without sealing ring)
40-8 WB93R-5
Planetary - Joint
3 190 Nm
3 8 Nm
3 120 Nm
1
3 70 Nm
3 8 Nm
2 Loctite 270
RKZ10400
Unit: mm

1 Hub rotation torque ---- Adjust
2 Drive shaft axle clearance ---- Replace
WB93R-5 40-9
Steering unit cylinder
3 350 Nm 3 120 Nm B
39.32°
50°
A
A 3 300 Nm
3 250 Nm
1920 -02
A-A B-B
Deatil C RKZ10410
Unit: mm
Standard Tolerance Standard Clearance Replace

Clearance between bushing and size Shaft Hole clearance limit bushing
1 pin and
50 ---- 50.19+0 0.04 ---- ---- pin
40-10 WB93R-5
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
Differential
A
3 10 Nm
3 155 Nm
A 2 Loctite 270
3 169 Nm
3 80 Nm
2
3 80 Nm 2 Loctite 638
3 25 Nm
2 Loctite 270
3
4
2 Loctite 542
A-A
RKZ10420
Unit: mm
Standard
Clearance limit
1 Axle clearance clearance
---- ----
2 Backlash of crown wheel and pinion 0.21–0.29 0.29 Adjust
Pinion rotation force (without sealing ring)
3 115-138 Nm
Pinion-crown rotation force (without sealing ring)
4 As measured on pinion Ø 34.8 148-188 Nm
WB93R-5 40-11
Planetary
3 70 Nm 3 8-12 Nm
3 500 Nm 2 Loctite 270
3 1000 Nm
3 79 Nm
2 Loctite 270
3 226 Nm 3 60 Nm
2 Loctite 270
RKZ09741
Unit: mm

1 Hub rotation torque ---- Adjust
2 Drive shaft axle clearance ---- Replace
40-12 WB93R-5
Brakes
3 16 Nm
Detail A
RKZ10430
Unit: mm

Standard thickness Min. thickness
1 Disc thickness Replace
6.73 -- 0.1
0
5.8
WB93R-5 40-13
Differential lock
3 180 Nm
RKZ09761
40-14 WB93R-5
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
3 19.6-24.5 Nm
View X
3 157-196 Nm
A A
3 68.6-83.4 Nm
Z
X
3 27.4-34.3 Nm
3 7.8-9.8 Nm
3 68.6-83.4 Nm
3 19.6-27.4 Nm
3 11.8-14.7 Nm RKZ10440
View Z
WB93R-5 40-15
STANDARD MAINTENANCE HYDRAULIC PUMP
3 27.4-34.3 Nm Z
3 27.4-34.3 Nm
X
3 27.4-34.3 Nm 3 27.4-34.3 Nm
A-A
RKZ10450
40-16 WB93R-5
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
8-SPOOL VERSION (WITH MECHANICAL CONTROL)
D
3 9.8-12.7 Nm
AC
Komatsu Ltd.
AC
AB AB
AA AA
3 9.8-12.7 Nm
N N
M M
X
L L
K K
J J
3 9.8-12.7 Nm F F
3 9.8-12.7 Nm
E E
Z
3 29.4-34.3 Nm
View Z 3 58.8-73.5 Nm
RKZ08311
40-18 WB93R-5
AE
C B A
C B A
AE
RKZ08321
View X
WB93R-5 40-19
3 49-58.8 Nm
3 39.2-49 Nm
3 39.2-49 Nm
3 39.2-49 Nm
3 39.2-49 Nm
3 39.2-49 Nm
5
8
3 137-157 Nm
A-A
3 117.6-161.8 Nm
3
117.6-161.8 Nm
4 9
1
6
7
B-B RKZ08330
40-20 WB93R-5
Unit: mm
Criteria Remedy
Standard size Repair limit
No. Check item
Free
Installed Installed Free Installed
installed x
length load installed load
Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.4N – 11.8N
control)
Spool return spring
2 (backhoe bucket 66.5x21.1 25.4 73.5N – 58.8N
boom control)
Spool return spring
3 (shovel control) 27.2x16.6 26.7 30.38N – 34.3N
Replace
Spool return spring spring
4
(boom swing control)
42x20 25.4 75.5N – 59.6N
Spool return spring

5
(arm control)
65.4x22.1 26.5 73.5N – 58.8N
Spool return spring

6 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
7 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
6 Priority valve spring 56.8x15.2 48.5 29.6N – 23.7N
9 Unloading valve spring 25.5x19.3 18 121.5N – 97.2N
WB93R-5 40-21
AD
2
7
3 117.6-161.8 Nm
8
3
1 4
8
8
1
8 5
3 19.6-24.5 Nm
1 3
5
3 14.7-19.6 Nm
AD
3 24.5-34.3 Nm
6 6
D-D C-C
3 14.7-19.6 Nm
3 24.5-34.3 Nm
AD - AD
RKZ08341
40-22 WB93R-5
Unit: mm
Free
installed
x Øe
Pressure compensation valve
spring
1
(Shovel arm, backhoe bucket,
15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing)
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB93R-5 40-23
3
3 65.7-82.3 Nm
2 2
1 1
1 2 E-E 2 1 K-K
F-F L-L
L-L M-M
RKZ03882
Unit: mm
Free
installed
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-24 WB93R-5
3 34-44 Nm
3 34.3-44.1 Nm
AC - AC
N-N
3 65.7-82.3 Nm
1
AA - AA
AB - AB AE - AE
RKZ08892
Unit: mm
Free
installed Installed Installed Free Installed
length Replace
x Øe load installed load
spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5 40-25
10-SPOOL VERSION (WITH MECHANICAL CONTROL)
D
3 9.8-12.7 Nm
AC
Komatsu Ltd.
AC
AB AB
AA AA
R R
X P P
N N
3 9.8-12.7 Nm
M M
L L
K K
J J
3 9.8-12.7 Nm F F
3 9.8-12.7 Nm
E E
D
3 29.4-34.3 Nm Z
3 58.8-73.5 Nm
RKZ08901
View Z
40-26 WB93R-5
AE
C B A
C B A RKZ09031
AE
View X
WB93R-5 40-27
3 49-58.8 Nm
3 3
3
137-157 Nm 39.2-49 Nm
117.6-161.8 Nm 3
117.6-161.8 Nm
9
4 3
39.2-49 Nm
3 3
39.2-49 Nm
2
3
1 39.2-49 Nm
3
10 3 39.2-49 Nm
39.2-49 Nm
11
6
7
B-B A-A
K-K J-J RKZ09041
40-28 WB93R-5
Unit: mm
Free
installed
x Øe
Spool return spring
control)
Spool return spring
boom control)
Spool return spring
3 (shovel control) 27.2x16.6 26.7 30.38N – 34.3N
Spool return spring

4
42x20 25.4 75.5N – 59.6N
Replace
5
(arm control)
65.4x22.1 26.5 73.5N – 58.8N
Spool return spring

6 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
7 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
10 Spool
return spring
29x17.5 28.5 22.5N – 18.0N
(Jig arm control)
11 Spool
return spring
(4 in 1 bucket control)
42.2x20 25.4 98.0N – 78.4N
WB93R-5 40-29
AD
7 2
3 24.5-34.3 Nm
8
3
1 4
8
1
8 5
8 3
1
3 19.6-24.5 Nm
5
AD
6 6 C-C
3 24.5-34.3 Nm
D-D
3 17.4-19.6 Nm
3 24.5-34.3 Nm
AD - AD RKZ09051
40-30 WB93R-5
Unit: mm
Free
installed
x Øe
spring
1
15.4x6 8 7.44N – 5.96N
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
WB93R-5 40-31
3
3 65.7-82.3 Nm
2 2
1 1
1 2 E-E 2 1 K-K
F-F L-L
L-L M-M
RKZ03882
Unit: mm
Free
installed
x Øe
1 18.0x18 17.5 39.2N – 31.4N
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-32 WB93R-5
3 34-44 Nm
3 34.3-44.1 Nm
AC - AC
N-N
3 65.7-82.3 Nm
1
AA - AA
AB - AB AE - AE
RKZ08892
Unit: mm
Free
installed Replace
x Øe spring
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5 40-33
8-SPOOL VERSION (WITH SERVOCONTROL)
3 9.8-12.7 Nm
AC
Komatsu Ltd.
AC
AB AB
AA AA
3 9.8-12.7 Nm N N
M M
X L L
K K
J J
3 9.8-12.7 Nm
F F
E E
3 9.8-12.7 Nm
D
3 58.8-73.5 Nm
3 29.4-34.3 Nm
RKZ09062
40-34 WB93R-5
AE
C B A
C B A RKZ09071
AE
View X
WB93R-5 40-35
3 49-58.8 Nm
3
3 39.2-49 Nm
39.2-49 Nm
3 39.2-49 Nm
3
39.2-49 Nm
3 39.2-49 Nm
5 6
A-A RKZ09080
10
3
4
3 2
2 2
1
7
8
B-B
40-36 WB93R-5
Unit: mm
Free
installed
x Øe
Spool return spring
control)
Spool return spring
2 (in arm control) 41.1x19.3 40.5 34.3N – 27.4N
Spool return spring

3
(out arm control)
42.3x19.2 40.5 54.9N – 43.9N
Spool return spring

4
29x17.5 28.5 22.5N – 18N
Replace
5
(shovel control)
27.2x16.6 26.7 30.38N – 24.3N
Spool return spring

boom control)
Spool return spring
7 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
8 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
WB93R-5 40-37
AD
2
7
3 117.6-161.8 Nm
8
3
1 4
8
8
1
8 5
3 19.6-24.5 Nm
1 3
5
3 14.7-19.6 Nm
AD
3 24.5-34.3 Nm
6 6
D-D C-C
3 14.7-19.6 Nm
3 24.5-34.3 Nm
AD - AD
RKZ08341
40-38 WB93R-5
Unit: mm
Free
installed
x Øe
spring
1
15.4x6 8 7.44N – 5.96N
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
WB93R-5 40-39
3
3 65.7-82.3 Nm
2 2
1 1 7
1 2 E-E 2 1 K-K
F-F L-L
J-J M-M RKZ09102
Unit: mm
Free
installed
x Øe
1 18.0x18 17.5 39.2N – 31.4N
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-40 WB93R-5
3 34-44 Nm
3 34.3-44.1 Nm
AC - AC
N-N
3 65.7-82.3 Nm
1
AA - AA
AB - AB AE - AE
RKZ08892
Unit: mm
Free
installed Replace
x Øe length load installed load
spring
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5 40-41
10-SPOOL VERSION (WITH SERVOCONTROL)
3 9.8-12.7 Nm
AC
Komatsu Ltd.
AC
AB AB
AA AA
3 9.8-12.7 Nm
R R
N N
M M
X
L L
K K
J J
3 9.8-12.7 Nm F F
E E
3 9.8-12.7 Nm
D
Z
3 29.4-34.3 Nm
3 58.8-73.5 Nm RKZ09121
ViewZ
40-42 WB93R-5
AE
C B A
C B A
RKZ09591
AE
ViewX
WB93R-5 40-43
3 49-58.8 Nm
5 6
9 3
3 39.2-49 Nm
10 39.2-49 Nm
4
3
3 3
3
2 39.2-49 Nm
2
39.2-49 Nm
3
39.2-49 Nm
11
7
8
B-B A-A
K-K J-J
RKZ09131
40-44 WB93R-5
Unit: mm
Free
installed
x Øe
Spool return spring
control)
Spool return spring
2 (in arm control) 41.1x19.3 40.5 34.3N – 27.4N
Spool return spring

3
(out arm control)
42.3x19.2 40.5 54.9N – 43.9N
Spool return spring

4
29x17.5 28.5 22.5N – 18N
Spool return spring

5
(shovel control)
27.2x16.6 26.7 30.38N – 24.3N Replace
spring
Spool return spring
boom control)
Spool return spring
7 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
8 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
Spool return spring
11 (jig arm control, 29x17.5 28.5 22.5N 18.0N
4 in 1 bucket control)
WB93R-5 40-45
AD
7 2
3 24.5-34.3 Nm
8
3
1 4
8
8 1 5
3 47-58.8 Nm
8 3
1
3 19.6-24.5 Nm
5
AD
6 6
3 24.5-34.3 Nm
D-D C-C RKZ09141
3 14.7-19.6 Nm
3 24.5-34.3 Nm
AD - AD
40-46 WB93R-5
Unit: mm
Free
installed
x Øe
spring
1 (Shovel arm, backhoe bucket, 15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing, jig
arm, 4 in 1 bucket)
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
spring.
5
(boom, shovel arm
20x8.4 15 4.32N – 3.45N
jig arm, 4 in 1 bucket)
WB93R-5 40-47
3
3 65.7-82.3 Nm
2 2
1 1 7
1 2 E-E 2 1 K-K
F-F L-L
J-J M-M RKZ09102
Unit: mm
Free
installed
x Øe
1 18.0x18 17.5 39.2N – 31.4N
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-48 WB93R-5
3 34-44 Nm
3 34.3-44.1 Nm
AC - AC
N-N
3 65.7-82.3 Nm
1
AA - AA
AB - AB AE - AE
RKZ08892
Unit: mm
Free
installed Replace
x Øe spring
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5 40-49
STANDARD MAINTENANCE PPC VALVES
PPC VALVES
SHOVEL CONTROL
1 2
3 3
RKZ10460
Unit: mm
Free
installed
x Øe
Return spring (outer) Replace
1
(for ports P1 and P2)
Return spring (outer)
2
3 Adjusting screw (inner)
40-50 WB93R-5
STANDARD MAINTENANCE PPC VALVES
1 2
3 3
RKZ10470
Unit: mm
Free
installed
x Øe
Return spring (outer) Replace
1
Return spring (outer)
2
3 Adjusting screw (inner)
WB93R-5 40-51
STANDARD MAINTENANCE SHOVEL CYLINDERS
SHOVEL CYLINDERS
DUMP CYLINDER
3 1250±130 Nm 3 539±54 Nm
1 3
2
707-00-0y920-1
RAISE CYLINDER
3 1670±170 Nm 3 677±67.5 Nm
1 3
2
707-00-0y891-1
Unit: mm
Criteria
No. Check item Cylinder Standard Tolerance Standard Clearance Remedy
size Shaft Hole clearance limit
Lifting 50
-- 0.030 + 0.162
0.035 0.238
Tolerance between -- 0.076 + 0.005
1 Replace
piston rod and head -- 0.025 + 0.141
Dump 45 -- 0.064 + 0.004
0.029 0.205
Lifting 60
-- 0.060 + 0.174
0.160 0.280
2 bushing and piston
head mounting pin Dump 45
-- 0.050 + 0.142
0.130 0.231
-- 0.089 + 0.080 Replace
pin and
T ole ra nc e be twe en Lifting 60
-- 0.060 + 0.174
0.160 0.280 bushing
bushing -- 0.106 + 0.100
3
and cylinder mounting -- 0.050 + 0.142
pin Dump 50 0.130 0.231
-- 0.089 + 0.080
40-52 WB93R-5
STANDARD MAINTENANCE SHOVEL CYLINDERS
4 IN 1 BUCKET
3 690±69 Nm 3 540±54 Nm
1
42N-6C-12800-1
Unit: mm
Free
installed
x Øe
Tolerance between -- 0.025 + 0.064 Replace
1 40 0.05 0.114
piston rod and head -- 0.050 + 0.025
Tolerance between
2 bushing and piston head 40 -- 0.150
0
mounting pin
WB93R-5 40-53
STANDARD MAINTENANCE BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
3 2740-2840 Nm
with Loctite 262
3 981±98 Nm 3
1
2
ARM
3 1670±170 Nm 3
3 961±96.1 Nm
1
2
707-00-0y871-1
BUCKET
31670±170 Nm
3 1176-1372 Nm
1 3
2
707-00-0y901-1
40-54 WB93R-5
BOOM SWING
3 44.1-53.9 Nm 3 785±78.5 Nm
3 297±29.4 Nm
1 2
707-02-07730-1
Unit: mm
Criteria
No. Check item Cylinder Tolerance Remedy

Standard Standard Clearance
size clearance limit
Shaft Hole
Boom 60
-- 0.030 + 0.051
0.035 0.227
-- 0.076 + 0.005
Arm 55 -- 0.030 + 0.046

0.030 0.132
Clearance between
-- 0.076 0
1
piston rod and head
Bucket 55
-- 0.030 + 0.051
0.035 0.227 Replace
-- 0.076 + 0.005
Boom swing 50
- 0.030 + 0.164
0.037 0.240
-- 0.076 + 0.007
Boom 60
-- 0.060 + 0.174
0.160 0.280
-- 0.106 + 0.100
Arm 50
-- 0.050 + 0.142
0.130 0.231
2 bushing and piston
head mounting pin -- 0.050 + 0.142
Bucket 45 -- 0.089 + 0.080
0.130 0.231
Boom swing 55
-- 0.060 + 0.174
0.160 0.280
-- 0.106 + 0.100 Replace
pin and
-- 0.060 + 0.174 bushing
Boom 60 0.160 0.280
-- 0.106 + 0.100
T ol e r an c e b et w e en
bushing -- 0.060 + 0.174
3 Arm 60 0.160 0.280
and cylinder mounting -- 0.106 + 0.100
pin
Bucket 45
-- 0.050 + 0.142
0.130 0.231
-- 0.089 + 0.080
WB93R-5 40-55
OUTRIGGERS
3 911±91.1 Nm
3 539±54 Nm with Loctite 262
1
707-00-0Y0910-1
JIG ARM
3 1080±100 Nm
3 539±54 Nm
1
42N-6C-13301-1
Unit: mm
Criteria
No. Check item Cylinder Tolerance Remedy

Shaft Hole
Outriggers 40 -- 0.025 + 0.132

0.031 0.196
-- 0.064 + 0.006
Clearance between
1 Replace
piston rod and head
Jig arm 40
-- 0.025 + 0.064
0.050 0.114
-- 0.050 + 0.025
40-56 WB93R-5
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
FRONT WORKING EQUIPMENT
E
C E
C
D
B
B D
A
A
1 3
2
A-A B-B
C-C
5
4
D-D E-E
RKZ10480
40-58 WB93R-5
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
Unit: mm
Criteria
No. Check item Tolerance Remedy

Shaft Hole
Clearance between
1 bushings and bucket 45 -- 0.050 + 0.080
0.130–0.329
mounting pin -- 0.089 + 0.240
Clearance between bushing -- 0.050 + 0.080

2 45 0.130–0.329
and link mounting pin -- 0.089 + 0.240
Clearance between -- 0.050

3 bushing and fulcrum link 45 + 0.080 Replace
0.130–0.208
mounting pin -- 0.089 + 0.119
Clearance between -- 0.060 + 0.137

4 60 0.143–0.303
bushing and link mounting pin -- 0.106 + 0.197
Clearance between bushing -- 0.050

5 50
and boom mounting pin -- 0.089
WB93R-5 40-59
STANDARD MAINTENANCE SWING BRACKET
SWING BRACKET
B
A
C
A C
1
3 4
B-B
2
1
A-A 5
C-C
RKZ10490
40-60 WB93R-5
STANDARD MAINTENANCE SWING BRACKET
Unit: mm
Criteria

Shaft Hole
Clearance between
1 rotating bushing and boom 60 -- 0.010 + 0.090
0.070–0.175
swing cylinder bushing -- 0.085 + 0.060
Clearance between
2 bushing and (lower) swing 65 -- 0.060 + 0.190
0.250–0.370
bracketrotating pin -- 0.106 + 0.264
Clearance between bushing Replace

3 and (upper) swing 65 -- 0.060 + 0.190
0.250–0.370 bushing
bracketrotating pin
-- 0.106 + 0.264 and
pin
Standard size Limit size
4 Upper shim thickness
2.50 --0 0.1
5 Central shim thickness 4.75 --0 0.1
6 Lower shim thickness 4.75 --0 0.1
WB93R-5 40-61
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
BACKHOE WORKING EQUIPMENT
C
C
D B
A
A
D
3
2
1
4
A-A
B-B
5
6 6
D-D
C-C RKZ10500
40-62 WB93R-5
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
Unit: mm
Criteria

Standard Minimum Clearance
Shaft Hole
Clearance between link

1 bushings and bucket 45 -- 0.050 --- 0.080 0.130–0.329
mounting pin -- 0.089 --- 0.240
Clearance between arm -- 0.050 --- 0.080

2 bushings 45 -- 0.089 --- 0.240 0.130–0.329
and bucket mounting pin
Clearance between arm

3 bushings 45 -- 0.050 --- 0.080 0.130–0.329
and lever mounting pin
-- 0.089 --- 0.240
Replace
Clearance between bushings -- 0.050 --- 0.080

4 45 0.130–0.329
and tilt lever mounting pin -- 0.089 --- 0.240
Clearance between -- 0.050 --- 0.080
5 bushings and arm mounting 50 -- 0.089 --- 0.119 0.130–0.208
pin
Clearance between bushings -- 0.060 --- 0.137

6 60 0.197–0.303
and boom mounting pin -- 0.106 --- 0.197
WB93R-5 40-63
90 OTHER
ELECTRICAL DIAGRAM (STANDARD VERSION) .. 3
WB93R-5 90-1
OTHER ELECTRICAL DIAGRAM (STANDARD VERSION)
ELECTRICAL DIAGRAM (STANDARD VERSION)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
42-N-06 42-N-06
15420 15420
Nome/Item Descrizione Description KUE P/N
P63 42-N-06-15110 42-N-06
A6 CENTRALINA FUNZIONI MACCHINA Function machine unit
11950 N1 N1 B13 Sensore return to dig Return to dig sensor
Z-B1
42-N-06 N1 B59 Livello olio freni Brake oil low level switch
M-B1.5
M-N1.5
L-N1.5
A 1 2 3 4
B97 AVVISATORE ACUSTICO POSTERIORE Rear horn switch
G-M1
A/B1
C-B1
G-L1
R-N1
H-V1
H1.5
M1
N1
11210
G-N1
Z-B1
L-R1
L-R1
B105 Sensore temperatura olio trasmissione Transmission oil temperature sender
R/N1
A/R1
H-V1
R/N1
C-L1
L/R1
V-N1
V-N1
B111 Galleggiante livello carburante Fuel level sender
A1
R1
N1
N1
N1
N1
4 2 8 4 1 9 10 12 8 7 2
7 1 3 4 6
V/N1
X57 X57 X57 X60 X60 X60 X60 X60 X60 1 B112 Termistore Thermistor
X169
X169
X169
X169
X169
X180
4 2 8 4 1 9 10 12 8 7 2
1 3 4 6 7
B113 Filtro aria Air filter switch
R N F Dx WASHER I 0 X89 X89 X89 X89 X89 7 1 3 7 1 3 7 1 3 4 6 B115 Sensore press. olio motore Engine oil pressure switch
LAVACRISTALLO
X80 X80 X80 X81 X81 X81 B121 Avvisatore acustico Horn
1 3 4 6 7 II I0
HORN
V180
7 1 3 7 1 3 42-N-06 42-N-06 E156 Fanale podteriore DX Rear right light
CLAXON 0
Sx 1 0 0 1 1 E154 Fanale posteriore SX Rear left light
H
S169 8 2 5 11880 11840
9
S60
5 3 11 6
8
8 2 5 E155 LUCE DIREZIONALE SX LEFT INDICATOR LIGHT
8 2 5 2 8 2
S57 9 5 3 11 6 S89 S80 S81 X169 X169 X169 E155 LUCE DIREZIONALE DX RIGHT INDICATOR LIGHT
G-N1.5
G-N1.5
X57 X60 X60 X60 X60 8 2 5 8 2 8 2 E136 Faro di lavoro posteriore DX laterale Lateral rear right working light
L-R1
L-R1
1 X89 X89 X89 X80 X80 X81 X81 E138 Faro di lavoro posteriore SX laterale Lateral rear left working light
A-G1
H-R1
H1
C1
V1
X181 E143 Faro lavoro ant. DX lat. Lateral front right working light
G-M1
A-G1
A-B1
A/R1
A/R1
C-L1
C-L1
G-N1
V/N1
L/R1
V-N1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 E146 Faro di lavoro anteriore SX laterale Lateral front left working light
X63 X64 C-L1 C-L1 E147 Luce di direzione SX Left indicator
L-B0.5
C-L0.5
G-M1
M-N1
M/B1
E148
B-V1
A-V1
A/V1
H-V1
R-V1
Z-B1
N1 N1 S-N1 A-B1 Presa girofaro Beacon lamp intake
V-N1
G1
N1
H1
V1
E151 Luce direzionale DX Right indicator
C-L1
C-L1
L-R1
L-R1
A1
S-N1
S-N1
Z-B1
Z-B1
N1
S-N1
A-G1 E152 Plafoniera Cabin lamp
1 1 1 1 1 1 1 1 1 1 E400 Faro di lavoro anteriore DX Front right working light

E401 Faro lavoro ant. SX centrale Front left working light
N1
A-B1
B-N1
A-N1
A-N1
R/N1
S-N1
7 1 3 4 6
X143
X151 X147 X146 X136 X138 X400 X401 X403 X402
N1
N1
N1
N1
X168
X168
X168
X168
X168
E402 Faro di lavoro posteriore SX centrale Rear left working light
R/N1
E151
E147
E146
E143
E136
E138
E400
E402
E401
E403
7 1 3 4 6
E403 Faro di lavoro posteriore DX centrale Rear right working light
7 1 3 7 1 3 7 1 3 F1 FUSIBILE FARI LAVORO ANTERIORI CENTRALI 15A Central front working light fuse 15A
X83 X83 X83 X85 X85 X85 X84 X84 II I0 F2 FUSIBILE FARI LAVORO POSTERIORI CENTRALI 15A Central rear working light fuse 15A
2 2 4 4 4 4
7 1 3 7 1 3 7 1 3 4 4 4 4 F3 FUSIBILE LUCE POSIZIONE DX 3A Right position light fuse 3A
X136
1 0 1 0 1 8 2 5
X151 X147 X146 X143 X138 X400 X401 X403 X402
0
S168 8 2 5 F4 FUSIBILE LUCE POSIZIONE SX 3A Left position light fuse 3A
F5 FUSIBILE AVVISATORE ACUSTICO 10A Horn fuse 10A
L/R1
X168 X168 X168
L-R1
N1.5
N1.5
8 2 8 2
S83 S85 S84
8 2
N1
N1
N1
N1
N1
N1
N1
N1
G-V1.5X166.s G-V1.5 F6 FUSIBILE FARI LAVORO POSTERIORI LATERALI 15A Lateral rear working light fuse 15A
A-G1.5
A-G1.5
X166.p
C-L1
8 2 8 2 8 2
X83 X83 X85 X85 X84 X84 C-L1 1 1
C-L1 F7 FUSIBILE TERGI POSTERIORE + AVVISATORE ACUSTICO POSTERIORE 7,5A Winshield wiper-washer + rear horn fuse 7,5A
C-L1 C-L1 2 2
C-L1 F8 FUSIBILE SWITCH LUCI STOP 7,5A Stop light swicth fuse 7,5A
S-N1 3 3
S-N1 X177.p F9 FUSIBILI FARI LAVORO ANTERIORI LATERALI 15A Lateral front working light fuse 15A
S-N1
R/N1
R/N1
A-G1 S-N1
A-N1
R/N1
R/N1
Z-N1
A-B1
A-B1
S-N1 4 4
S-N1 S-N1 1 X140 F10 FUSIBILE ALIM. TERGI ANTERIORE 10A Front windhield-wiper supply fuse 10A
L-R1 5 5
L-R1 Z-B1 F11 FUSIBILE OPTIONAL 7,5A Optional fuse 7,5A
F12 FUSIBILE BUZZER+STR.ANTERIORE+STR.LATERALE 5A Front and lateral instruments supply+ buzzer fuse 5A
A-G1
6
L-R1 6 L-R1 Z-B1 2 X142
N1
N1
L-N1
H1.5
7 F13 FUSIBILE ALIM. MANIPOLATORE10A Lever grip supply fuse 10A
A/B1
Z-B1 7 Z-B1
F14 FUSIBILE LAMPADE SWITCH + SWTCH OPTIONAL 10A Light switch + swicth optional fuse 10A
G-V1.5
A-G1
8
C-B1
Z-B1 8 Z-B1
B-G1
A-B1
A-B1
R-G1
F15
R-N1
G-V1
A/V1
H-L1
FUSIBILE CENTRALINA
M-N1
S/N1
Elettrostop + Safety starter fuse 10A
Z/N1
G-L1
N1
N1
N1
N1
G1
G1
N1
9 9
1
F16 FUSIBILE GIROFARO 10A Beacon light fuse 10A
1 1 1
2 4 3
X55
7 1 3 4 6
1 3
4 6 1 3 7 F17 FUSIBILE SWITCH EMERGENZA 10A Worning swicth fuse 10A
X167
X167
X167
X167
X167
7 1 1
X58 X58 X58 4 6 1 3 7
F18 FUSIBILE PLAFONIERA+ACCENDISIGARI 10A Cabin lamp + cigarette lighter fuse 10A
X86
X86
X86
X86
X86
X53.1 X54.1 X59.1 X88 X88 X88 X87 X87 X87 X87 X87 X148.1 X152.1
M58 M F19 FUSIBILE ANABBAGLIANTI 15A Low beam light fuse 15A
S53 S54 B59 7 1 3 4 6 7 1 3 0 1 4 6 1 3 7
0 1 4 6 1 3 7
53a
M 53b
0 F20 FUSIBILE ABBAGLIANTI 15A Main beam light fuse 15A
53
II I0 1 M
31b F21 FUSIBILE ALIM. SENSORE RETURN + DIG 10A Return to Dig sensor supply fuse 10A
N1
M55 S87 5 2 8
S167 5 2 8 F22 FUSIBILE EC POWER 7,5A EC POWER fuse 7,5A
1 1 1
31
2 A6 S86 8 2 5
S88 8 2
42N-06-15150 UNIT 5 2 8 5 2 8 F23 FUSIBILE +15 CENTRALINA STERZATURA 10A +15 Steering unit fuse 10A
X167
X167
G-V1 X167
X53.2 X54.2 X59.2 X55 8 2 5 8 2 X87 X87 X87
1 X86 X86 X86 X88 X88 1 E148 E152 Gnd F24 FUSIBILE ALIM. INTERMITTENZA 7,5A Flasher fuse 7,5A
M-N1
MULTIFUNCTION 01171074
X148.2 X152.2 F25 FUSIBILE SIRENA RETRO + ALIM. DEVIO 10A Steering column switch+reverse buzzer fuse 10A
G1
N1
N1
R-N1.5
R-G1
R-G1
B-R1
G1.5
G-V1
N1
A-B1
A-B1
F27 +30 rele candelette General fuse 175A
H/R1
H-L1
H-L1
Z/N1
Z/N1
G1 BATTERIA Battery
N1.5
G118 Motorino avviamento Starter motor
NEUTRAL POSITION STEERING COLUMN

G119 D+ alternatore Generator
N1.5
N1.5
N1.5
N1
N1
N1
N1
N1
H17 BUZZER Buzzer
+15 MULTIFUNCTION UNIT SUPPLY

FUNCTION MACHINE UNIT SUPPLY
SELF CONTROL SOLENOID VALVE

K1 CENTRALINA ANTIRIPETIZIONE AVVIAMENTO Antirepetition starting unit
S-N1
N1
REVERSE PPC SOLENOID VALVE

K2
MULTIFUNCTION UNIT SUPPLY

INTERMITTENZA Flasher
DIFFERENTIAL LOCK SWITCH

R/N1
EC POWER SOLENOID VALVE

M-B1.5
LIGHT PPC SOLENOID VALVE

CONSENT TOGETHER PEDAL
M-N1.5
L-B0.5
L-N1.5
C-L0.5
G-M1
M-N1
A-G1
B-V1
H-R1
R-N1
A-V1
Z-B1
H-V1
R-V1
R-G1
V-N1
K3 RELE' ANABBAGLIANTI Low beam light relay

M1
H1
N1
C1
V1
A-B1
LIGHTS AND SWITCH 4WD
A-G1.5
G-N1.5
R-N1.5
A1
R1
N1
G-M1
A-G1
A-G1
M-N1
B-G1
A-B1
A-B1
A-N1
B-N1
G/R1
G-V1
G-L1
A/R1
H-V1
R/N1
H/R1
C-L1
H-L1
S/N1
V/N1
V-N1
V-N1
G1.5
Z/N1
K4 RELE' ABBAGLIANTI Main beam light relay
PPC CONTROL SWITCH
A1
N1
4WD SOLENOID VALVE
X25.s Gnd7.2 Gnd7.1 K5 RELE' ANABBAGLIANTI Front horn relay
EC POWER SWITCH
X10.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
PPC SEAT SWITCH

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X26.s X44.s 1 2 3 4 5 6 Gnd8 Gnd7.3 K6 RELE' ELETTROVALVOLA RETURN TO DIG Return to DIG solenoid valve relay
K7 RELE' LUCI STOP Stop Light relay
SEAT SWITCH
OUT BUZZER
4WD SWITCH
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21
K8 RELE' CONSENSO AVVIAMENTO Start relay
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 A/R1
X10.p X9.p
X25.p
1 2 3 4 5 6 K9 RELE' MARCIA AVANTI Forward speed relay
X44.p
K10
GND
OFF ACC R1 ACC BR R2 C RELE' MARCIA INDIATRO Reverse speed relay
A-G1.5
A-G1.5
G-N1.5
86 87a 87
R-N1.5
X26.p
N2.5
G-M1
M-V1
B/G1
B-N1
G-V1
G-L1
A/R1
H-V1
R/N1
H/R1
S/N1
V/N1
V-N1
V-N1
Z/N1
V-Z1
M-N1.5
R1
L-B0.5
L-N1.5
C-L0.5
K11 RELE' STACCO TRASMISSIONE De-clutch relay

G1
ST
G-M1
M/B1
M-N1
A-B1
R-G1
B-R1
C-B1
G/R1
B-V1
H-R1
R-N1
A-V1
G-L1
X111
X111
X111
H-V1
R-V1
V-N1
V-N1
G1.5
N1.5
N1.5
A-B1
M1
R1.5
H1
C1
R1
N1
V1
K45
A1
B A C +30 rele preriscaldo Preheating relay
S24 B
X6 A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8 86 87a 87
X13
X13
X13
K56 30 rele preriscaldo Safety start relay
G1
K61 30 rele servizi Services relay
G-M1
X24.r1 X24.acc X24.b X24.br X24.c X24.gnd
M-N1
A-B1
A-B1
M-V1
M-V1
C-B1
B-N1
B/G1
B-R1
B-R1.5
C-N1
H-N1
85 30
H/R1
H/R1
H/N1
Z-B1
H-L1
S/N1
Z-N1
L/R1
K111
Z/N1
Rele detend retro Rele detend retro
M1
N1
M/N1
M/N1
N1.5
85 30
B1
K111
R6
L6
M42 Tergi posteriore Rear Windshield-Wiper
M/N1 X111 X111 B13
A-B1
M55 Pompetta Windshield-Washer pump
V/N1
S2 S3 S4 S5 S6 M58 Motore tergi anteriore Front windshield-wiper
H1.5 M116 Elettrofrezione compressore Compressor Electonic cluch
R114 Candelette Preheating
M1
R/N1 S2 INTERRUTTORE ELETTROVALVOLA EC. POWER SOLENOID VALVE E.C. POWER SWITCH
S3 BENNA CHIUDE CLOSED GRAB SWITCH
A1 S4 STACCO TRASMISSIONE DECLUCH SWITCH
C-B1
M-V1
M-N1
S5 BENNA APRE INTERRUTTORE OPEN GRAB SWITCH
A-B1
M-B1
C/B1
S-N1
Z-N1
N1
A-G1
C-L1
S6 BLOCCAGGIO DIFFERENZIALE DIFFERENTIAL LOCKING SWITCH
S24 Quadro avviamento pos. R1 Starting Switch
S40 Micro sedile Seat Switch
G-N1.5
M-N1 X47
M-B1.5
1
C-B1 X47
S41 PULSANTE POSTERIORE CLAXON Rear horn switch
2
S46 Freno di stazionamento Parking brake switch
C/B1 X47 3
M-N1 S53 INTERRUTTORE LUCI STOP Stop light Switch
M-B1 X47 4
S54 INTERRUTTORE STOP 4WD Stop 4WD Switch
A/R1
C-L1
L-N1.5
A1
X47 5
S57 Devio cambio Steering column gear shift
Z-N1 X47
CONNECT TO X15.s OF OPT. HARNESS
6
A-G1 S60 Devio luci Steering column light switch
A-B1 X47 7 S80 INTERRUTTORE RIDE CONTROL Ride control switch
42N-06-15840 42N-06-15810
42N-06-15940 42N-06-15190
N1 X47 8 S81 PULSANTE SBLOCCO BRACCIO Arm unlock switch

X47 9 S83 PULSANTE E/C POWER E/C Power Switch
M-V1 X47 10 S84 INTERRUTTORE VALVOLE EMPI EMPI solenoid valve switch
Z-N1 X47 11 S85 PULSANTE AVV. ACUSTICO POSTERIORE Rear horn switch
X47 12
42-N-06 S107 Stacco trasmissione Decluch switch
S86 INTERRUTTORE GENERALE LUCI General light switch
15710 S87 INTERRUTTORE 4WD 4WD Switch
L-N1.5
A-N1.5
C-B1
C-B1
C-B1
X15.p
N1.5
G-N1.5
1 S88 PULSANTE PPC PPC switch
A-R1
B-G1
M/N1
B-N1
C-L1
S/N1
N1
A-N1
M16
X15.p
S89
V6
INTERRUTTORE WARNING WARNING switch
B6
1 2 3
Z-N1
2
1 2
S40 86 87 X42 B97 AVVISATORE ACUSTICO POSTERIORE Rear horn switch
M-B1
86 87
1 1 X555 1 1 2 1
Y49 X49 Y48 M42 S104 Sw 4° marcia 4th speed switch
X17.1 X56 X56 X48 X23 X23 K61 X61 X61 K45 X45
S168 INTERRUTTORE FARO DI LAVORO ANTERIORE Front working light switch
V555 86 87 V23 86 87 86 87 M M
X15.p
H17 S167 INETTERRUTTORE GIROFARO Beacon light switch
85 30 85 30 85 30 S169 INTERRUTTORE FARI LAVORO POSTERIORI Rear working light switch
K56 85 X56.1 1 2 3 4 85 B X30 ACCENDISIGARI Cigarette lighter

1 2 2 X61.1 Y48 Ev flottante Float solenoid valve
X40
B-N1
Y49 Ev return to d.i.g. Return to DIG solenoid valve
R-G1
X17.2
R16
R6
N1
M-V1
H/N1
Y60 Valvole empi. EMPI Solenoid Valve
R6
N1
N1
N1
N1
Y90 Ev. PPC retro Rear PPC solenoid valve

X43 Y91 Ev EC power EC power Solenoid valve
1 R-G1
Y92 Back-up allarm Back-up alarm
15 2 G-N1
10 20 Y93 Ev. PPC PPC solenoid valve
3 R1
RPM x 100
Y94 Ev blocco differenziale Differential lock solenoid valve
5 25 4 B-N1 Arm unlock solenoid valve
V1 Y95 Ev sblocco braccio
A-G1
H-R1
G/R1
H-R1
5 H-N1
N1.5
Y96 Ev sblocco piastra Plate unlock solenoid valve

H-L1
0 30
R6
V6
L6
6 Z-N1 Grab close solenoid valve
7 6 5 4 3 2 1 Y98 Ev. chiusura benna
7 C-L0.5 Grab open solenoid valve
+15Key +15 +30
Y99 Ev apertura benna
8 C-B1
X3.s Y106 Ev 4WD 4WD Solenoid valve
9 A-V1 M-B1 1 42N-06-15140 UNIT (01171062) X4.s R1 Y108 Ev marcia avanti Forword solenoid valve
10 B-V1 2 1 Y117 Elettrostop Elettrostop
11 L-B0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 Y203 Ev marcia indietro Reverse speed solenoid valve
10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A
13 M/N1 H1
Z/N1
4 3 X12.s CONNETTORE A LINEA POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR

14 Z-B1 Z-N1 5 4 V1 X166.s CONNETTORE A LINEA CABINA TO CABIN HARNESS CONNECTOR
17 V1 B1 6 5 C1 X166.p CONNETTORE A LINEA INTTERRUTTORI TO SWITCH HARNESS CONNECTOR
18 V-B1 7 6 R1.5 X177.s CONNETTORE A LINEA FARI LAVORO TO WORKING LIGHT HARNESS CONNECTOR
X8.s
A-R1
19 8 7 R1.5 CONNETTORE A LINEA POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR

20 N1 9 8 A-G1.5 X128.s CONNETTORE A LINEA POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
H-R1 10 9 G-N1.5 X7.s CONNETTORE A LINEA POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
B-G1 11 X1.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
H-R1 12
K2 X10.p CONNETTORE A LINEA CRUSCOTTO ANTERIORE TO FRONT DASHBOARD HARNESS CONNECTOR
P43 K1
13 F8 F11 F10 F23 15 F15 15 F2 F9 F1 X11.p CONNETTORE A LINEA ELETTROVALVOLE TO SOLENOID VALVE HARNESS CONNECTOR
42N-06-15280 M-B1.5 14 15A 15A X12.p CONNETTORE A LINEA FANALI POSTERIORI TO CHASSIS HARNESS CONNECTOR
10A
15A
31 T 31 T
G1.5 15 7,5A 7,5A 10A 10A
53S 53M
X15.p CONNETTORE A LINEE OPTIONAL TO OPTIONAL HARNESSES CONNECTOR
53S 53M
A-N1 X30 X2.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
R/N1
R/N1 16 1
A-N1.5 17 X25.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
X27s
S46 X46 X26.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
A-R1 R-V1 18 2 1
1 X28.s CONNETTORE RISCALDAMENTO HEATING CONNECTOR
A/C X27s C-B2.5
R-G1 19 X41.s X41.s
X3.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
2 20
42N-07-11400 S41 2 X4.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
M-N1.5 21
X44.p CONNETTORE A LINEA CABINA TO CABIN HARNESS CONNECTOR
L/R1 X2.s
1 X5.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
R4 F5 K3
I _ 1
HEATING X28s 1
A-G1.5 2 K11 K5 K4 F6 F3 F4 F19F20 X30.1 X65.p CONNETTORE A LINEA MOTORE TO MOTOR HARNESS CONNECTOR
B-R1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 X7.p CONNETTORE A LINEA MOTORE TO MOTOR HARNESS CONNECTOR
R1.5
N1.5
3
42N-54-11300
G1
N1
X28s 2
R-N1 4 85 30 10A 85 30 85 30 85 30
X8.p CONNETTORE A LINEA CAMBIO SHUTTLE TO GEAR HARNESS CONNECTOR
15A 3A 3A 15A 15A
L-N1.5 5
X9.p CONNETTORE A LINEA CRUSCOTTO ANTERIORE TO FRONT DASHBOARD HARNESS CONNECTOR
N4
A-B1 6 X1.s 1 X25.s CONNETTORE A LINEA POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
7
X26.s CONNETTORE A LINEA POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
2
8 3 G1
A-N1.5 9 4 G-N1
L-N1.5 10 M-V1
K10 K6 K8 K9 K7 5 X11.s CONNETTORE A LINEA POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
D2 D3 D1
G-N1.5
11 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6

G1 X27s CONNETTORE ARIA CONDIZIONATA A/C HARNESS CONNECTOR
12 7 P43 PANNELLO STRUMENTI INSTRUMENTS PANEL
85 30 85 30 85 30 85 30 85 30
M1 13 8 P63 PANNELLO ANTERIORE FRONT CONTROL PANEL
14 9 X140 CONNETTORE A LINEA CABINA TO CABIN HARNESS CONNECTOR
R-G1 15 10 G-N1 X142 CONNETTORE A LINEA CABINA TO CABIN HARNESS CONNECTOR
16 11 G1
42-N-06 S/N1 17
11540 A-B1
42-N-06
11550
A-G1
C-L1
A-G1
42-N-06
R4
R6
R6
R6
12310
Gnd1.3
Gnd1.2
Gnd1.1
Gnd11
Gnd10
Gnd9
X68.1 X68.2
X68.3
Z-N1
H1.5
F27 S107
M-N1
A-B1
G-N1
C-B1
A-N1
B-R1
C/B1
Z-B1
Z-N1
V-N1
N1.5
N1.5
G1
A1
N1
C-B2.5
A-N1.5
R-N1.5
175A
G-M1
M-B1
B-N1
H-N1
H-N1
H-R1
S-N1
H/R1
Z-B1
H-L1
V-B1
V-N1
N1.5
M1
B6
V1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X11.p
X7.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X65.p 1 X12.p X8.p 1 2 3 4 5 6 7 8 9 10 11 12
1 2
X107 X107
X7.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X128.s 1 X126.4 X11.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.s 1 2 3 4 5 6 X8.s 1 2 3 4 5 6 7 8 9 10 11 12
N1.5
M-B1
M-N1
A-B1
G-N1
C-B1
A-N1
B-N1
C/B1
C-N1
H-N1
H-R1
H/R1
Z-B1
H-L1
Z-B1
H-L1
Z-N1
V/N1
V-N1
N1.5
N1.5
V-Z1
C-B2.5
A-N1.5
R-N1.5
G1
A1
B2
Gnd6
M-V1
H-N1
S-N1
Z-B1
V-B1
Z-N1
M16
M1
M1
B6
N6
V1
B-N1
B-V1
N1
A B C
X111
X111 X111
H-N1
H-R1
B-V1
Z-B1
H-L1
V-N1
B2
A-B1
G-N1
B-R1
B-R1
A1
A-N1.5
C-B2.5
R-N1.5
G1
M-V1
H-N1
S-N1
Z-B1
V-B1
Z-N1
M16
R25
R70
R70
R25
R25
B6
N1
V1
1 1 1
M-N1
C-B1
A-N1
C-N1
C/B1
Z-B1
H-L1
Z-N1
V/N1
N1.5
V-Z1
1 1 1 X109 X110.s
N1
N1
1 X105 Y106 Y203

1 1
1 1 3 1 1 1 3 B105 X106 Y108 X108 X203 B111
S104
X119.2
X119.1 A B C 1 1 X116 1 1 1 1 1 1 1 1 1 1 X154 X154 X155 X157 X156 X156 X104 CONNECT TO HARNESS
X118.1 X114 1 1 Y90 X90 Y91 X91 Y92 X92 Y93 X93 Y94 X94 Y95 X95 Y96 X96 Y98 X98 Y99 X99 X97
G118 R114
X117 X115 1 X112 X112 X112 X121
Y60 X60 M116 B97
G1 Y117 B115 B113
X113
42N-06-15960
H155
H157
30
M
50
G119 D+
B121 M E154 E156
12Vcc
30
G W
p p B112 t 2
t
57
59C
57
59C
3 2 2 2 2
U X104 X106 X108 X203
2 2 2 2 X109
31 t 2 2 2 2 2 2 2
H/R1
2 2
31
31
42-N-06 X113
X98 X99 X97
N70
X121 X60 X90 X91 X92 X93 X94 X95 X96

N1.5
N6
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
11230 4 4 4 4
N1.5
N1
N1
N1
N1
N1
N2
X154 X155 X157 X156
N1
N1
N1
N1
Gnd5 GND2.2 GND2.1 42-N-06

42-N-06 Gnd11 Gnd4
11190
11180 42-N-06
11890
42N-06-10140
WB93R-5 90-3
© 2006 KOMATSU UTILITY EUROPE S.p.A.
All Rights Reserved
Printed in Europe 02-06

Komatsu 5

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Komatsu 5

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REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS

SHOVEL LIFT CYLINDERS

2 -Take off the snap-ring (4) and the internal retaining

4 -Place a sling around the cylinder and connect it to a

7 -Lower cylinder (10) until it rests on blocks “B”.

8 -Start the engine to retract the piston.

k Stop the engine and eliminate residual pressure. 10

8 -Remove hoses (8) and (11), and remove hose clamp

9 -Remove the snap-ring (13) and the spacer (14).

10 -Remove cylinder (10).

k When aligning the positions between the hole and the

2 Internal bushing: ASL800050

SHOVEL DUMP CYLINDERS

the parking brake, and stop the engine.

1 -Remove the strap retaining the piston return hose (1).

For the right-hand cylinder only

a Do not engage the piston return hose with the sling.

6 -Start the engine to retract the piston(10).

7 -Remove hoses (1) and (11), and remove hose clamp

a Cap the hoses and holes to prevent contamination.

8 -Remove the snap-ring (13) and the spacer (14).

9 -Remove cylinder (3).

4 Tilt cylinder; approx 35 kg

k When aligning the positions between the hole and the

2 Internal bushing: ASL800050

1 -Stop the engine and release residual pressures.

k When aligning the positions between the hole and the

2 Internal bushing: ASL800050

FRONT WORKING EQUIPMENT

k Release all residual pressure in all circuits.

1 -Remove the tilt cylinders. (See "SHOVEL DUMP

2 -Disconnect the cylinders from the boom (1) and rest

4 -Put a sling round the boom (4) as shown in the figure,

5 -Using a puller, remove the oscillation pins (5) of the arm

4 Front equipment: approx. 1100 kg

k When aligning the positions between the hole and the

2 Internal bushing: ASL800050

BACKHOE PPC VALVES (Optional)

4 -Fully raise the boot (1).

5 -Loosen and remove the screws (2) retaining the PPC 1

9 -Disconnect the connector (9).

10 -Ensure that the hoses are marked (10), then disconnect

11 -Remove the PPC valve (11).

a Carefully inspect the hoses for the proper position

PPC VALVE SUPPORT RELEASE CABLES

2 -Remove the rear mat (1).

4 -Fully raise the boot (4).

10 -Remove the retaining screws (14) from the lock-

11 -Remove the entire lever assembly (15). 15

13 -Disconnect the cable (20) from the lower locking lever

14 -Loosen the nut (21) and unscrew the tensioner (22);

Installation and adjusting

1 -Using the tensioner (22), adjust cable tension to obtain

2 -Lock the nut while holding the tensioner into position

PPC VALVE SUPPORT RETURN GAS SPRING

2 -Remove the rear mat (1).

5 -Fully raise the boot (6).

SOLENOID VALVE GROUP (servocontrol and optional attachment)

k Release residual pressure from all circuits by moving all

2 -Disconnect the connector (1) and remove the seat (2).

Version with backhoe servocontrols

4 -Disconnect all connectors (6) from the solenoid valves .

a Check to ensure that all connectors have marks 6

6 -Loosen and remove two screws (8) and washers; 7