Fiat Kobelco W50/W60/W70 Wheel Loader Technical Handbook – 604.06.995.02

This Fiat Kobelco W50 / W60 / W70 Wheel Loader Technical Handbook (THB) has been written with the servicing mechanic in mind and contains important information required to carry out repair and servicing procedures.

APPLICABLE MODELS :

Fiat Kobelco W50 Wheel Loader
Fiat Kobelco W60 Wheel Loader
Fiat Kobelco W70 Wheel Loader

TABLE OF CONTENTS :

01 General
02 Service data
03 Engine
04 Travel drive
05 Axles
06 Steering
07 Brakes
08 Working hydraulic
09 Electrical system
10 Frame
11 Fittings, pipes and hoses
12 Sealing, protective, testing and cleaning agents

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication no. : 604.06.995.02
Total Pages : 594

Read through the Technical Handbook, but also the Operating Instructions for the FIAT HITACHI Wheel Loader before commencing any servicing or repair work. The Technical Handbook, as well as the Operating Instructions and Spare Parts List should be used as a source of reference and assistance – even when the user is well acquainted with the range of FIAT-HITACHI Wheel Loaders.

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W50 / W60 /W70 Wheel Loader
TECHNICAL HANDBOOK
FOREWORD
Using the Technical Handbook
Servicing and repair
FUNDAMENTAL SAFETY INSTRUCTIONS
Warnings and symbols
Danger in the event of non-observance of the safety instructions
Organizational measures
Selection and qualification of personnel
OPERATING, SAFETY INSTRUCTIONS
Standard operation
MAINTENANCE, SAFETY INSTRUCTIONS
WARNING OF SPECIAL DANGERS
Electric energy
Gas, dust, steam and smoke
Hydraulic and pneumatic equipment
Noise
Oil, grease and other chemical substances
TRANSPORTING AND TOWING – RECOMMISSIONING
REPAIR WORK – SAFETY INSTRUCTIONS
ACCUMULATORS
Safety instructions
ENGINE
Engine – repair instructions
Assisted starting (jump-starting) – Safety instructions
WELDING OPERATIONS
Welding operations – safety instructions
SERVICE DATEN
Allgemein General
VORWORT
FOREWORD
SI – UND WEITERE GR ¨ OSSEN
SI – AND ADDITIONAL UNITS
Raum – und Massegr¨oßen
Quantities of space and mass
Zeitgr ¨oßen
Time-related quantities
Kraft-, Energie- und Leistungsgr oßen
Quantities of force, energy and power
UMRECHNUNGSTABELLEN
CONVERSIONS TABLES
Umrechnung von L¨angen-Maßen
Conversion for units of length
Umrechnung von Fl ¨achenmaßen
Conversion for units of area
Umrechnung von foot (Fuss) und inch (Zoll) in Meter
Conversion from foot (Fuss) and inch (Zoll) to metric measures
Umrechnung von Newtonmeter “Nm” in Foot Pounds “ft.lb.”
Conversion from newtonmeter “Nm” into foot pounds “ft.lb.”
Umrechnungstabelle f ¨ ur Druckeinheiten von Gasen, D¨ampfen und Fl ¨ ussigkeiten
Conversion table for units of pressure in gases, steam and fluids
Umrechnungstabelle f ¨ ur Einheiten von Energie, Arbeit und W¨armemenge
Conversion table for units of power, ernergy and heat quantity
Umrechnungstabelle f ¨ ur Einheiten der mechanischen Spannung (Festigkeit)
Conversion table for units of mechanical stress (strength)
Praktisch gleichwertige Einheiten f ¨ ur Druck und mechanische Spannung (Festigkeit)
Practically equivalent units for pressure and mechanical stress (strength)
Temperatur – Einheiten und Umrechungsformeln
Units of temperature and conversion formulas
Leistung, Energiestrom, W¨armestrom
Power, energy and heat flow
Geschwindigkeiten
Speed
Masseeinheiten (Gewichte)
Units of mass (weight)
Volumeneinheiten, Durchflußmenge
Units of volume, flow rates
Kraftstoffverbrauch
Fuel consumption
BERECHNUNGSBEISPIELE
CALCULATION EXAMPLES
Steigungswinkel
Angles of slope
Fahrgeschwindigkeiten
Travel speeds
Hydraulische Leistungen (Pumpen/Motoren)
Hydraulic outputs (pumps/motors)
Zylinder-Hubzeiten
Stroking times of cylinders
Drehzahlen von Hydraulikmotoren
Speeds of hydraulic motors
ANZIEHDREHMOMENTE
Allgemeine Hinweise
TIGHTENING TORQUES
General information
Schrauben mit Regelgewinde nach DIN 13 – 13
Bolts with standard thread DIN 13 – 13
Schrauben mit metrischem Feingewinde DIN 13 – 13
Bolts with metric fine thread DIN 13 – 13
Anziehdrehmomente f ¨ ur SAE Flanschsystem
Tightening torques for SAE flange-system
Anzugswinkel
Tightening angles
SERVICE DATA W50
Foreword
Engine
Axles and transmission gears
Front axle
Rear axle with transfer box gearing
Travel speeds
Hydraulic system
Checking and setting data
Variable pump (PAG = Primary unit)
Triple hydraulic pump
Variable motor (SAG = Secondary unit)
Hydraulic cylinders
Service fluids
Tightening torques
Approx. weights
SERVICE DATA W60
Foreword
Engine
Axles and transmission gears
Front axle
Rear axle with transfer box gearing
Travel speeds
Hydraulic system
Checking and setting data
Variable pump (PAG = Primary unit)
Triple hydraulic pump
Variable motor (SAG = Secondary unit)
Hydraulic cylinders
Service fluids
Tightening torque
Approx. weights
SERVICE DATA W70
Foreword
Engine
Axles and transmission gears
Front axle
Rear axle with transfer box gearing
Travel speeds
Hydraulic system
Checking and setting data
Variable pump (PAG = Primary unit)
Triple hydraulic pump
Variable motor (SAG = Secondary unit)
Hydraulic cylinders
Service fluids
Tightening torque
Approx. weights
04 TRAVEL DRIVE
Hydraulic System, Safety Instructions
Explanations of circuit diagrams and illustrations
Depressurizing the hydraulic system
Principle: hydrostatic travel drive
Hydraulic circuit diagram – travel drive
Hydraulic circuit diagram, legend
Pressure measuring points
Functional description: hydrostatic travel drive of wheel loader W50 / W60 / W70
Travel drive installation
Pressure measuring points
Adjusting work at the hydrostatic travel drive
Mechanical zero position
Checking and adjusting high pressure at travelling
Adjusting cylinder (A13)
High-pressure relief valve (A4)
High-pressure relief valve (A4), deblockable
Pressure cutout (A8)
Switching valve (A11), electromagnetically activated
Feed pressure relief valve (A9)
Checking and adjusting feed pressure
Control valve (A7)
Checking and adjusting the regulation threshold (driving start)
Checking regulation end
Axial-piston oil motor (A15)
Checking and adjusting the regulation threshold of the hydraulic motor (displacement switch-over)
Inching valve (B10)
Adjusting the inching threshold
Repair instructions, hydraulic pump
Repair instructions, hydraulic motor
Reparaturanleitung
A4VG
A6VM

Technical Handbook
Axles
Preface
General
Design
Maintenance
General Working Instructions
Notes on working safety
Assembling Procedure
Weights
Survey
Front Axle Components, Screw Qualities, Tightening Torques, Screw Locking
Front Axle
Axle Drive Assembly
Wheel Hub Assembly
Rear Axle Components, Screw Qualities, Tightening Torques, Screw Locking
Rear Axle Assembly
Axle Drive Assembly
Brake Assembly
Wheel Hub Assembly
Front Axle Drawing
Rear Axle Drawing
Dismantling and Reassembling the Axles
Dismantling
Reassembling
Dismantling the Front Axle
Wheel Hub Assembly
Axle Drive Assembly
Differential Assembly
Dismantling the Rear Axle
Wheel Hub Assembly
Brake Assembly
Axle Drive Assembly
Differential Assembly
Assembling the Front Axle
Wheel Hub Assembly
Differential (Pre-assembling)
Complete Axle Drive and Axle Assemblies
Assembling the Rear Axle
Wheel Hub Assembly
Brake Assembly (Pre-Assembling)
Differential Assembly (Pre-Assembling)
Complete Axle Drive and Axle Assemblies
GLEASON Toothing Surface Appearances
GLEASON Toothing Surface Appearances
List of Special Tools
Screw Tightening Torques (DIN tables)
General information
Screw Tightening Torques
Bolts with standard thread
Bolts with metric fine thread DIN 13 – 13
06 STEERING
Hydraulic System, Safety Instructions
Explanations of circuit diagrams and illustrations
Depressurizing the hydraulic system
Hydraulic circuit diagram – steering hydraulics
Hydraulic circuit diagram, legend
Pressure measuring points
Overview of the steering system
Functional description
Triple pump (2) of the steering and working hydraulics and the brake system
Priority valve (L6)
Steering cylinder (L1)
Steering valve (L2)
Installing the steering system
Testing and adjusting the steering system
07 BRAKES
Safety instructions
Explanations of circuit diagrams and illustrations
Braking system, circuit diagram
Braking system, legend
Pressure measuring points
Functional description of the braking system
Service brake (pump-storage brake)
Auxiliary brake
Parking brake
Accumulator charging valve (B2)
Testing and adjusting the service brake
Accumulator charging valve (B2)
Accumulator (B4), Technical data
Accumulator (B4)
Accumulators, safety instructions
Pedal-type brake valve (B5)
Connecting valve (B8)
Inching valve (B10)
Manometric switches (B6, B7)
Checking the brake disks
Testing and adjusting operations on the auxilliary brake
Testing and adjusting operations on the parking brake
Bleeding the braking system
Bleeding
08 HYDRAULIC SYSTEM
Hydraulic System, Safety Instructions
Explanations of circuit diagrams and illustrations
Depressurizing the hydraulic system
Hydraulic circuit diagram – working hydraulics
Hydraulic circuit diagram, legend
Pressure measuring points
Functional description, working hydraulics
Control block (H6)
Triple pump (2) of the steering and working hydraulics and the brake system
Lifting cylinder (H1)
Dumping cylinder (H2)
Quick change locking cylinder (H3)
Hydraulic tank (T1) / Hydraulic filter (T3)
Hydraulic filter (T3), function
Hydraulic filter – application
Hydraulic filter functions
Hydraulic circuit diagram – cooling
Hydraulic circuit diagram, legend
Pressure measuring points
Functional description of hydraulic system cooling
Praktical checking
Combined cooler (T2)
Distributor (T5)
Distributor (T6)
Testing and adjustment work
Pressure testing and adjustment
Practical testing
Pipe-burst protection (optional)
Lifting cylinder load-holding valve (optional)
Dumping cylinder load-holding valve (optional)
09 ELECTRICAL SYSTEM

Technical Handbook
Fundamentals of electrical engineering
Preface
Important instructions
Electrical systems in general
The atom
Structure of atoms
Free electron
Electromagnetic field
Alternating current diagram
Power generation
Power generation in motor vehicles
Battery charging
Claw-pole alternator
Circuit with fault indication on interruption in the exciter circuit
Testing the charging system
Main components of automotive electrical systems
Battery
Types of batteries
Maintenance-free starter battery
Low-maintenance batteries
Checking the battery
Density values of diluted sulphuric acid
Mixing fresh battery acid
Mixing instructions
Maintenance
Troubleshooting
Function of the alternator
Alternator
Type designation
Alternator
Claw-pole alternator
Maintenance
Electric motors
Principle of the electric motor
Starting motor (starter)
Function of the starter
Engaging
Engaged
Checking the vehicle starter system
Starter
Maintenance
Lubrication
Fundamentals of automotive electrical systems
Current, voltage, resistance and power
Current (I)
Voltage (U)
Resistance (R)
Power (W)
Measurements with the multimeter
Adjustment of the multimeter
Measuring voltage
Measuring current
Measuring resistance
Ohmmeter
Series and parallel connection of electrical components
Batteries
Resistors
Series connection
Parallel connection
Capacitors
Series connection
Parallel connection
Electrolytic capacitors
Voltage losses and cables
Table 1 – Admissible loss of voltage
Remarks:
Calculation of lines
Quantities and units
Computation
Lines and wires in automotive electrical systems
Table 2 – Electrical copper wires for motor vehicles
Design example
Example:
Lighting
Headlamps adjustment hints
Floodlamps
Bulbs
Malfunctions of the lighting system and their causes
Transition resistance in electrical circuits
Special circuits in automotive electrical systems
The diode
The “free-wheeling” diode
Electrical circuit with a diode used as a “free-wheeling” diode.
Varistors
Voltage rectification in three-phase bridge circuits
Alternator regulator
Fuses in motor vehicles
Designation of individual components
Standardized designations of terminals
Terminal designation
Generator and generator regulator
Turn-signal indicator (flasher relay)
Symbols used in electrical engineering
Symbols for directions of motion

Technical Handbook
Automotive electrical systems in construction machinery Interpretation of wiring diagrams Troubleshooting
PREFACE
NOTES ON SAFETY
ELECTRICAL SYSTEM DOCUMENTATION
THE WIRING DIAGRAM
Explanation of the wiring diagram
Current paths
Main circuits
Branches
Relay contacts
Cross reference to other current paths
Contacts of plug-in connectors
Cable cross-section
Identification of contacts
Cable number
Electronic units
WIRING DIAGRAM LEGEND
Explanation of legend
Part
Quantity
Description and function
Current path
Location
Part number
CHECKING AND TESTING EQUIPMENT
Solenoid-valve tester
Test lamp
Multimeter
Testers
BASIC MEASURING AND TESTING PROCEDURES
Voltage checks
Checking the continuity
Checking the coil of a solenoid
PRACTICAL TROUBLESHOOTING
Notes on troubleshooting in automotive electrical systems
Example of systematic troubleshooting
Fault-finding diagram (example)
ANNEX
Identification of components
Schematic symbols
Electrical Connections
Switches, contacts
Indicators, measuring devices
Motors, alternators
Semiconductors
Miscellaneous
Symbols for directions of motion
Fuses
Fuse links
Fuse strips
10 FRAME
Repairing the loader frame
Exchanging the main pivot parts
Dismantling
Mounting

Technical Handbook
Fittings, pipes and hoses
INTRODUCTION
FUNDAMENTAL SAFETY INSTRUCTIONS
Warnings and symbols
Organizational measures
Selection and qualification of personnel
OPERATING SAFETY INSTRUCTIONS
Standard operation
MAINTENANCE SAFETY INSTRUCTIONS
WARNING OF SPECIAL DANGERS
Electric energy
Gas, dust, steam and smoke
Hydraulic and pneumatic equipment
Noise
Oil, grease and other chemical substances
TRANSPORTING AND TOWING – RECOMMISSIONING
WORKING EQUIPMENT
Assembling working equipment – safety instructions
Repair work – safety instructions
LINES FOR VARIOUS MEDIA
Materials for pipes and hoses
Conditions and deviations in the line system
Steel pipes
Hoses
Plastic pipes
CONNECTIONS
Pipe couplings
Sealing pipe couplings
Bulkhead couplings
Stud couplings and male nipples
Stircomatic seal rings
Swivel couplings
Swivel couplings
Swivel coupling with straight male thread acc. to DIN
Swivel coupling with long male adaptor
Fixed angle couplings
Banjo couplings
Banjo coupling
Banjo coupling with long male adaptor
FLANGE COUPLINGS WITH SAE BOLT PATTERN
Flanged pipe couplings – Flanit system
Flanged pipe couplings – Zako system
Flanged hose couplings
Sealing and connecting components
Flanges
Wedge rings
Seal rings
Double-hex bolts
Assembly aids for wedge rings
Pre-assembly device for F-rings
Inserter for Z-rings
Inserting the Z-ring
Assembling flange couplings
Flange coupling – pipe / connection surface, F-system
Zako-system
Flange coupling hose / connection surface
Flange coupling – pipe / hose
Flange coupling – hose / hose
Flange coupling – pipe / pipe
Appendix
Table 1: Seal rings for flange couplings
Table 2: Double – Hex. Bolts
Accessories
Pre-assembly aids for pipe flange couplings
Flanges-90°
Table 3: Parts Nos. for 90° flanges
Gauge connections
Table 4: Parts Nos. for gauge connections and accessories

Technical Handbook
Sealing, protective, testing and cleaning agents
INTRODUCTION
FUNDAMENTAL SAFETY INSTRUCTIONS
Warnings and symbols
Safety Instructions
PRESERVATION OF GEARBOXES
Rust inhibitor
Application to gearboxes and axles without oil filling
Preservation period
Gearboxes and axles with oil filling
Protective finishes
PRESERVATION OF CYLINDER PISTON RODS
Corrosion inhibitor
Consumption of inhibitor
Application of inhibitor
Removing the inhibitor
Renewing the inhibitor
Corrosion protection for pins and bearings (bushings and hubs)
Part nos. for Voler A.C.
Application of Voler A.C.
S0LUTION 1 CORROSION INHIBITOR FOR CYLINDER ROD THREADS
RIVOLTA W.S.X, NU CORROSION INHIBITOR FOR ELECTRICAL SYSTEMS
SURFACE SEALING AGENTS
WKT black – H
Loctite 573 (proprietary brand from Loctite Ltd.,)
HYLOMAR SQ 32/M SEALING AGENT (THREAD SEALER)
LIQUID THREAD ADHESIVES
METAL ADHESIVES
ADHESIVES FOR PLASTICS
Acrylic cyanide (Loctite IS 414)
ADHESIVE FOR O-RINGS
LUBRICANTS
Solid lubricating paste
Solid lubricant paste spray
Compound spray
Mineral-based lubricating paste
Lithium soap grease
SOLID LUBRICANT FOR MOLYCOTE-COATED BOLTS
SILICON-CORUNDUM POWDER (REDURIT)
P3 COLD CLEANER
SURFACE CRACK CHECKING AGENT (METAL-CHECK)

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