WEBM008500

WH609-1E0 WH613-1E0
WH713-1E0 WH714H-1E0
WH716-1E0
TELESCOPIC HANDLER
MODEL SERIAL NUMBER
WH609-1E0 395F61003 and up
WH613-1E0 395F61003 and up
WH713-1E0 395F71003 and up
WH714H-1E0 395F71003 and up
WH716-1E0 395F71003 and up
 CONTENTS

CONTENTS
Page
10. STRUCTURE AND FUNCTION ...................................................................................... 10-1

20. TESTING AND ADJUSTING ........................................................................................... 20-1

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

WH6-1E0 WH7-1E0 00-1

PAGE INTENTIONALLY
LEFT BLANK
 REVISED PAGES

REVISED PAGES
The affected pages are indicated by the use of the fol-
lowing marks. It is requested that necessary actions be
taken to these pages according to table below. Mark Indication Action required

Q Page to be newly Add

q Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised or

made additions.

Time of Time of Time of Time of Time of

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

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10-57 20-23 20-66 30-4
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WH6-1E0 WH7-1E0 00-3

 REVISED PAGES

Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
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30-78 30-140 30-202 30-264
30-79 30-141 30-203 30-265
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00-4 WH6-1E0 WH7-1E0

 k SAFETY

k IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu Utility and describe in this manual are both ef-
fective and safe methods of operation. Some of these operations require the use of tools specially designed
by Komatsu Utility for the purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be carefully followed. If any danger arises or may possibly arise,
first consider safety, and take necessary steps to face.

k SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual carefully chine on hard, level ground, and block the wheels to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not pos-
on the machine. sible, use blocks to prevent the work equipment from
2. When carrying out any operation, always wear safety falling down. In addition, be sure to lock all the control
shoes and helmet. Do not wear loose work clothes, or levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the ma-
• Always wear safety glasses when hitting parts chine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying machine.
out welding work, always wear welding gloves, apron, Never jump on or off the machine.
glasses, cap and other clothes suited for welding If it is impossible to use the handrails, ladders or steps,
work. use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure be-
fore starting. Always inform your fellow workers be- 11. When removing the oil filler cap, drain plug or hydrau-
fore starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to
work, hang UNDER REPAIR signs on the controls in prevent the oil from spurting out.
the operator’s compartment. Before disconnecting or removing components of the
hydraulic circuit and engine cooling circuit, first re-
5. Keep all tools in good condition and learn the correct
move the pressure completely from the circuit.
way to use them.
6. Decide a place in the repair workshop to keep tools 12. The water and oil in the circuits are not hot when the
and removed parts. Always keep the tools and parts in engine in stopped, so be careful not to get burned.
their correct places. Always keep the work area clean Wait for the oil water to cool before carrying out any
and make sure that there is no dirt or oil on the floor. work on the cooling water circuits.
Smoke only in the areas provided for smoking. Never
13. Before starting work, remove the leads from the bat-
smoke while working.
tery. Always remove the lead from the negative ( – )
terminal first.

WH6-1E0 WH7-1E0 00-5

 k SAFETY

14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places.
20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent
that they are not twisted. Damaged tubes are dan-
the component from hitting any other part.
gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or
tubes for high pressure circuits. Also, check that
crane.
connecting parts are correctly tightened.
15. When removing covers which are under internal
21. When assembling or installing parts, always use
pressure or under pressure from a spring, always
specified tightening torques.
leave two bolts in position on opposite sides. Slowly
When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to
rotate at high speed, be particulary careful to check
remove.
that they are correctly installed.
16. When removing components, be careful not to
22. When aligning two holes, never insert your fingers or
break or damage the wiring.
hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill-
measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up
any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.

18. As a general rule, do not use gasoline to wash parts.

In particular, use only the minimum of gasoline when
washing electrical parts.

00-6 WH6-1E0 WH7-1E0

 FOREWORD

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

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

STRUCTURE AND FUNCTION

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

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

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

NOTE

The specifications contained in this shop manual are subject to change at any time and without any no-
tice.
Contact your Komatsu Utility distributor for the latest information.

WH6-1E0 WH7-1E0 00-7

 HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

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

DISTRIBUTION AND UPDATING Symbol Item Remarks

Any additions, amendments or other changes will be
sent to Komatsu Utility distributors. Special safety precautions
Get the most up-to-date information before you start any are necessary when

k
work. performing the work.

Safety
FILING METHOD Extra special safety precautions
are necessary when performing
1. See the page number on the bottom of the page. the work because it is under in-
File the pages in correct order. ternal pressure.
2. Following examples show you how to read the page
Special technical precautions or
number.
other precautions for preserving
Example: a Caution
standards are necessary when
10 - 3 performing the work.

Weight of parts or systems.

4
Item number (10. Structure and Caution necessary when select-
Weight
Function) ing hoisting wire, or when work-
ing posture is important, etc.
Consecutive page number for each

3 Tightening
item Parts that require special atten-

3. Additional pages: additional pages are indicated by torque tion for the tightening torque dur-
ing assembly.
a hyphen (–) and number after the page number.
2
Fle as in the example. Parts to be coated with adhe-
Coat
Example: sives and lubricants etc.

5
10-4 Places where oil, water or fuel
Oil, water must be added, and their quan-
10-4-1 tity.
Added pages

6
10-4-2 Places where oil or water must
10-5 Drain be drained, and quantity to be
drained.

REVISED EDITION MARK

When a manual is revised, an edition mark is recorded
on the bottom outside corner of the pages.

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

00-8 WH6-1E0 WH7-1E0

 HOISTING INSTRUCTIONS

4
HOISTING INSTRUCTIONS

Hooks have maximum strength at the middle por-

k Heavy parts (25 kg or more) must be lifted with a

tion.

hoist etc. In the Disassembly and Assembly section,

every part weighing 25 kg or more is clearly indicated

with the symbol 4

1. If a part cannot be smoothly removed from the ma-

chine by hoisting, the following checks should be
made: 3) Do not sling a heavy load with one rope alone, but
sling with two or more ropes symmetrically wound
• Check for removal of all bolts fastening the part to
on to the load.
k Slinging with one rope may cause turning of the load
the relative parts.
• Check for any part causing interference with the
during hoisting, untwisting of the rope, or slipping of
part to be removed.
the rope from its original winding position on the
load, which can cause dangerous accidents.
2. Wire ropes
1) Use adequate ropes depending on the weight of 4) Do not sling a heavy load with ropes forming a wide
parts to be hoisted, referring to the table below: hanging angle from the hook.
When hoisting a load with two or more ropes, the
WIRE ROPES force subjected to each rope will increase with the
(Standard «S» or «Z» twist ropes hanging angles.
without galvanizing)
The table below shows the variation of allowable
Rope diameter (mm) Allowable load (tons) load (kg) when hoisting is made with two ropes,
each of which is allowed to sling up to 1000 kg ver-
10.0 1.0
tically, at various handing angles.
11.2 1.4 When two ropes sling a load vertically, up to 2000 kg
of total weight can be suspended.
12.5 1.6
This weight becomes 1000 kg when two ropes
14.0 2.2 make a 120° hanging angle.
On the other hand, two ropes are subjected to an ex-
16.0 2.8
cessive force as large as 4000 kg if they sling a 2000
18.0 3.6 kg load at a lifting angle of 150°.
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0

The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of the
rope used.
2) Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the
rope to slip off the hook during hoisting, and a se-
rious accident can result.

WH6-1E0 WH7-1E0 00-9

 STANDARD TIGHTENING TORQUE

3
STANDARD TIGHTENING TORQUE

The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

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

6 1 10 8 0.96±0.1 9.5±1 1.3±0.15 13.5±1.5

8 1.25 13 6 2.3±0.2 23±2 3.2±0.3 32.2±3.5

10 1.5 17 8 4.6±0.5 45±4.9 6.5±0.6 63±6.5

12 1.75 19 10 7.8±0.8 77±8 11±1 108±11

14 2 22 12 12.5±1 122±13 17.5±2 172±18

16 2 24 14 19.5±2 191±21 27±3 268±29

18 2.5 27 14 27±3 262±28 37±4 366±36

20 2.5 30 17 38±4 372±40 53±6 524±57

22 2.5 32 17 52±6 511±57 73±8 719±80

24 3 36 19 66±7 644±70 92±10 905±98

27 3 41 19 96±10 945±100 135±15 1329±140

30 3.5 46 22 131±14 1287±140 184±20 1810±190

33 3.5 50 24 177±20 1740±200 250±27 2455±270

36 4 55 27 230±25 2250±250 320±35 3150±350

39 4 60 ---- 295±33 2900±330 410±45 4050±450

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

00-10 WH6-1E0 WH7-1E0

 STANDARD TIGHTENING TORQUE

3
2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

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

1/2” - 20 17 2.6±0.5 25.5±4.9

9/16” - 18 17 4±0.5 39.2±4.9

3/4” - 16 22 6.7±2 65.7±19.6

7/8” - 14 27 8±2 78.5±19.6

1.1/16 - 12 32 9.7±3 95.15±29.4

1.5/16 - 12 38 17±3 166.7±29.4

1.5/8 - 12 50 20±5 196.2±49

22 27 8±2 78.5±19.6

33 41 20±5 196.2±49

Sealing surface

Thread diameter Width across flats TIGHTENING TORQUE

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

9/16” - 18 17 2.3–2.5 23–25

11/16” - 16 22 3.4–3.9 33–38

13/16” - 16 24 5.2–5.8 51–57

1” - 14 30 8.2–9.2 80–90

1.3/16 - 12 36 12.2–13.3 120–130

1.7/16 - 12 41 15.3–17.3 150–170

1.11/16 - 12 50 18.4–20.4 180–200

2” - 12 57 20.4–24.4 200–240

WH6-1E0 WH7-1E0 00-11

 COATING MATERIALS

2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:

Nomenclature Code Applications

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.

Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.

Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.

To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking
keys and bearings.

Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.

Loctite 542 Used for sealing the union threads for hydraulic tubes.

Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.

Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating

Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.

Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.

Used by itself on mounting flat surface

Gasket sealant Loctite 510
(Clearance between surfaces within 0.2 mm)

Used by itself on mounting flat surface

Loctite 518
(Clearance between surfaces within 0.5 mm

Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)

Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.

Vaseline ----- Used for protecting battery electrode terminals from corrosion

00-12 WH6-1E0 WH7-1E0

 ELECTRIC

ELECTRIC
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A–B A/B A–G – A–N A/N A–R A/R A–V A/V
Colour Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black Light Blue–Red Light Blue–Green
Code B B–G – B–N B/N B–R B/R – B/V – –
Colour White White–Yellow White–Black White–Red White–Green –
Code C C–B C/B C–L – C–N – – – – –
Colour Orange Orange–White Orange–Blue Orange–Black – –
Code G G–N G/N G–R – G–V – – – – –
Colour Yellow Yellow–Black Yellow–Red Yellow–Green – –
Code H H–L – H–N H/N – – – – – –
Colour Grey Grey–Blue Grey–Black – – –
Code L L–B L/B L–G – – L/N – – – –
Colour Blue Blue–White Blue–Yellow Blue–Black – –
Code M M–B – M–N M/N M–V – – – – –
Colour Brown Brown–White Brown–Black Brown–Green – –
Code N – – – – – – – – – –
Colour Black – – – – –
Code R R–G – R–N R/N R–V – – – – –
Colour Red Red–Yellow Red–Black Red–Green – –
Code S S–G – S–N – – – – – – –
Colour Pink Pink–Yellow Pink–Black – – –
Code V V–B – V–N V/N – – – – – –
Colour Green Green–White Green–Black – – –
Code Z Z–B Z/B Z–N Z/N – – – – – –
Colour Violet Violet–White Violet–Black – – –

COMPOSITION OF THE COLOURS

The coloration of two-colour wires is indicated by the composition of the symbol listed.
Example: G–V = Yellow-Green with longitudinal colouring
G/V = Yellow-Green with transversal colouring

WH6-1E0 WH7-1E0 00-13

 WEIGHT TABLE

WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model WH609 WH613 WH713 WH714H WH716

Engine assembly 390.0 390.0 390.0 390.0 390.0

Radiator - exchanger 36.0 36.0 36.0 36.0 36.0

Hydraulic oil tank (empty) 70.0 70.0 86.6 70.0 70.0

Fuel tank (empty) 10.0 10.0 10.0 10.0 10.0

Engine hood 45.0 45.0 45.0 45.0 45.0

Cabin (with seat) 476.0 476.0 476.0 476.0 476.0

Seat 34.0 34.0 34.0 34.0 34.0

Engine-gear box-pump group 672 672 672 672 672

Piston pump 21.6 21.6 21.6 21.6 21.6

Transmission 260.0 260.0 260.0 260.0 260.0

Front axle 436.5 436.5 436.5 436.5 436.5

Rear axle 435.0 435.0 435.0 435.0 435.0

Front wheel
140.0 140.0 140.0 140.0 140.0
Rear wheel

Control valve 30.0 30.0 30.0 30.0 30.0

Telescopic arm assembly (2-section boom) 1382.0 – – – –

• Basic boom 523.0 – – – –
• Top boom 510.0 – – – –

Telescopic arm assembly (3-section boom) – 2,112.0 2,288.0 2,318.0 2,588.0

• Basic boom – 627.0 690.0 690.0 762.0
• Intermediate boom – 400.0 430.0 430.0 494.0
• Top boom – 510.0 540.0 540.0 567.0

Outrigger 638.0 638.0 638.0 638.0 638.0

Boom lift cylinder 280.0 280.0 292.0 292.0 292.0

Boom extension cylinder 141.0 217.0 217.0 247.0 370.0

Frame levelling cylinder – 28.7 28.7 28.7 28.7

Outrigger cylinder 65.2 65.2 65.2 65.2 65.2

Locking axle cylinder – 35.0 35.0 35.0 35.0

Offset cylinder 32.0 32.0 32.0 32.0 32.0

Bucket cylinder 90.0 90.0 90.0 90.0 90.0

00-14 WH6-1E0 WH7-1E0

 TABLE OF OIL AND COOLANT QUANTITIES

TABLE OF OIL AND COOLANT QUANTITIES

AMBIENT TEMPERATURE CAPACITY (l)

TANK/
FLUID
RESERVOIR 1st filling Change
-30 -20 -10 0 10 20 30 40 50 °C

In cold climates
OIL SAE 5W-30
ACEA E5 - E4

Engine oil pan 12.8 12.5

OIL
API CH-4/CI-4, SAE 15W-40
ACEA E5 - E3.
JASO DH-1

Chains
ENGINE OIL SAE 15W-40 as required as required
lubrication

Hydraulic OIL WH6: 107 WH6: 95

SAE 10W-30
system CF - CF2 - CD WH7: 147 WH7: 120

Hydraulic WH6: 107 WH6: 95

system with
WH7: 147 WH7: 120
biodegradable oil

Front axle:
7.1 7.1
Differential

Final reduction
0.7 0.7
gear (ea.) OIL
Rear axle: UTTO FLUID
7.1 7.1
Differential

Final reduction
0.7 0.7
gear (ea.)

Hydraulic
12.2 10.4
transmission OIL ATF
GM DEXRON® II D
Transmission (DEXRON® is a
registered trade- 0.25 0.25
reduction gear mark of General
Motors Corpora-
Braking tion)
0.65 0.65
system

Fuel tank DIESEL OIL * 130 130

ASTM D975 N. 2

Engine
PERMANENT
cooling 20 –
COOLANT
system

✽ ASTM D975 N. 1

WH6-1E0 WH7-1E0 00-15

 TABLE OF OIL AND COOLANT QUANTITIES

ASTM: American Society of Testing and Materials

SAE: Society of Automotive Engineers
API: American Petroleum Institute
UTTO: Universal Tractor Transmission Oil
ACEA: Association Constructeurs Européens Automobiles
JASO: Japanese Standard Organization
a When the diesel oil sulphur content is less than 0.5%, change the engine oil according to the routine maintenance
intervals indicated in the operation and maintenance manual. If the diesel oil sulphur content exceeds 0.5%, change
the engine oil according to the following table:

Sulphur content Engine oil change interval

from 0.5 to 1.0% 1/2 of regular interval

over 1.0% 1/4 of regular interval

• It is advisable to use only engine oil with API CH-4/CI-4, ACEA E5 - E3, JASO DH-1 classification in order to
ensure the correct operation and constant reliability of the engine.
• Use Komatsu genuine products whose characteristics have been specifically formulated and approved for
use in the engine, in the work equipment hydraulic circuit, in the transmission, in the axles and in the brakes.
First filling quantity:total quantity of oil, including the oil for the components and pipes.
Oil change quantity:quantity of oil necessary to fill the system or unit during the normal inspection and
maintenance operations.

00-16 WH6-1E0 WH7-1E0

 CONVERSION TABLE

CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
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.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .

3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.

2. Convert 550 mm into inches

1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.

2 - Carry out the same procedure as above to convert 55 mm to 2.165 in.

3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.

From millimeters to inches

B
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

C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
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

WH6-1E0 WH7-1E0 00-17

 CONVERSION TABLE

From mm to in.
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

From kg to lb.
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

50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07

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 WH6-1E0 WH7-1E0

 CONVERSION TABLE

From liter to U.S. Gall.

1 ᐉ = 0.2642 U.S. Gall.

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

From liter to U.K. Gall.

1 ᐉ = 0.21997 U.K. Gall.

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 7.969 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 12.257 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

WH6-1E0 WH7-1E0 00-19

 CONVERSION TABLE

From Nm to lb.ft.
1 Nm = 0.737 lb.ft.

0 1 2 3 4 5 6 7 8 9

0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.633

10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003

20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373

30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743

40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113

50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483

60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853

70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223

80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593

90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963

100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333

110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703

120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073

130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443

140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813

150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183

160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553

170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923

180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293

190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663

00-20 WH6-1E0 WH7-1E0

 CONVERSION TABLE

From Nm to kgm
1 Nm = 0.102 kgm

0 1 2 3 4 5 6 7 8 9

0 0 0.102 0.204 0.306 0.408 0.510 0.612 0.714 0.816 0.918

10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938

20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958

30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978

40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998

50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018

60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038

70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058

80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078

90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098

100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118

110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138

120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158

130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178

140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198

150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218

160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238

170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258

180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278

190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298

WH6-1E0 WH7-1E0 00-21

 CONVERSION TABLE

From kgm to lb.ft.

1 kgm = 7.233 lb.ft.

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

90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1

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

130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 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 1352.6 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

00-22 WH6-1E0 WH7-1E0

 CONVERSION TABLE

From bar to psi (lb/in2)

1 bar = 14.503 psi

0 1 2 3 4 5 6 7 8 9

0 0 14.5 29.0 43.5 58.0 72.5 87.0 101.5 116.0 130.5

10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6

20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6

30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6

40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6

50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7

60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7

70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7

80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8

90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8

100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8

110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8

120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8

130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9

140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9

150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0

160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0

170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0

180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1

190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1

200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1

210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1

220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2

230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2

240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2

WH6-1E0 WH7-1E0 00-23

 CONVERSION TABLE

TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice 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 tem-
peratures 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 val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 144.8 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 72.4 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 0.0 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 2930
–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

00-24 WH6-1E0 WH7-1E0

 10 STRUCTURE AND FUNCTION

ENGINE-TRANSMISSION COUPLING .................... 2 HYDRAULIC PUMP .................................................46

POWER TRAIN ......................................................... 3 CONTROL VALVE ...................................................50
TRANSMISSION ....................................................... 5 PPC VALVE .............................................................51
FRONT AXLE .......................................................... 31 SOLENOID VALVES................................................54
REAR AXLE ............................................................ 35 SAFETY VALVES ....................................................60
BRAKE PUMPS....................................................... 39 CYLINDERS.............................................................67
STEERING SYSTEM (4WS) ................................... 40 AIR CONDITIONING SYSTEM ................................74
STEERING UNIT..................................................... 44 CLIMATE CONTROL SYSTEM OPERATION .........75
HYDRAULIC DIAGRAM .......................................... 45

WH6-1E0 WH7-1E0 10-1

STRUCTURE AND FUNCTION ENGINE-TRANSMISSION COUPLING

ENGINE-TRANSMISSION COUPLING

2
3

RKT00010

1. Engine
2. Flange
3. Screw
4. Transmission

10-2 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION POWER TRAIN

POWER TRAIN

9 4 3 2 1 9

7 8

RKT00020

9 9

DESCRIPTION • The driving power is transmitted from the transmis-

• The driving power generated by the engine (1) is sion flanges (3) to the front (5) and rear (6) axles
transmitted through the flywheel to the converter (2). through the cardan drive shafts (7 and 8).
The converter uses hydraulic oil to convert the torque • The driving power transmitted to the front (5) and rear
transmitted by the engine (1) into driving power. The (6) axles is reduced by the differentials and then trans-
converter (2) transmits motion to the drive shaft of the mitted to the final drives (9) through the drive shafts.
transmission (3) and to the drive shaft of the hydraulic
pump (4).
• The transmission (3) has two hydraulically-activated
clutches that can be selected by an electrically-con-
trolled gear selector.

WH6-1E0 WH7-1E0 10-3

STRUCTURE AND FUNCTION POWER TRAIN

5
Front of machine

7 3

4
10

9
8

RKT00030

1. Diesel engine 5. Front axle 9. Rear wheels

2. Converter 6. Rear axle 10. Front wheels
3. Transmission 7. Front cardan shaft
4. Hydraulic pump 8. Rear cardan shaft

10-4 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION
DIAGRAM OF THE POWER TRAIN

4
2

RKT00040

1. Engine
2. Converter
3. Transmission
4. Hydraulic pump
5. Rear flange
6. Front flange

WH6-1E0 WH7-1E0 10-5

STRUCTURE AND FUNCTION TRANSMISSION

3
4

8 2
5 a

c
7

RKT00060

a. Port 12 - from the oil cooler 1. Converter

b. Port 11 - to the oil cooler 2. Filter
c. Port 31 - from the brake pump (P Port) 3. Transmission oil drain plug
d. Port 71 - from the brake pump (S Port) 4. Drop box oil drain plug
5. Transmission plug vent
6. Drop box plug vent
7. Rotational speed sensor (YV)
8. Oil temperature sensor (X56)

10-6 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION

d
e

g
1
2
3
4
5

c
b
a

h
i

RKT00061

ELECTRICAL COMPONENTS CHECK POINTS

1. YR - Reverse clutch solenoid valve a. 31 Port - Clutch pressure
2. YF - Forward clutch solenoid valve b. 33 Port - Delivery pressure to intercooler
3. YS - Gear selector solenoid valve c. 32 Port - Pressione mandata all’intercooler
4. Y1 - 1st clutch solenoid valve d. 41 Port - 1st clutch pressure
5. Y2 - 2nd clutch solenoid valve e. 42 Port - 2nd clutch pressure
f. 43 Port - 3rd clutch pressure
g. 44 Port - 4th clutch pressure
h. 45 Port - Forward gear pressure
i. 46 Port - Reverse gear pressure

WH6-1E0 WH7-1E0 10-7

STRUCTURE AND FUNCTION TRANSMISSION

Forward gear
clutch

1 Reverse gear
clutch

3th clutch

4th clutch

2nd clutch

1st clutch
4

5 6

YR
YF RKT00070
YS
Y1
Y2

1. Direction selection clutch shaft

2. 3rd and 4th clutch shaft
3. 1st and 2nd clutch shaft
4. Transmission output shaft
5. Drop box output shaft
6. Front cardan flange
7. Rear flange

10-8 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION TRANSMISSION

FORWARD AND REVERSE GEAR DRIVE SHAFT

1
5
a b

4 3 RKT00080

a. Reverse gear port 1. Reverse gear gears

b. Forward gear port 2. Forward gear gears
3. Forward gear piston
4. Reverse gear piston
5. Drive shaft

3rd AND 4th GEAR DRIVE SHAFT

4
1 3

b
2 7

6 5 RKT00090

a. 3rd gear port 1. 4th gear driven gear

b. 4th gear port 2. Backing ring
3. 4th gear drive gear
4. 3rd gear drive gear
5. 3rd gear piston
6. 4th gear piston
7. Drive shaft

WH6-1E0 WH7-1E0 10-9

STRUCTURE AND FUNCTION TRANSMISSION

1st AND 2nd GEAR DRIVE SHAFT

1
2 3

a
4

6 5
RKT00100

st st
a. 1 gear port 1. 1 gear drive gear
b. 2nd gear port 2. 2nd gear drive gear
3. 3rd gear drive gear
4. Drive shaft
5. 2nd gear piston
6. 1st gear piston
DROP BOX INPUT SHAFT

1 2

1. Output drive gear

RKT00110 2. Input shaft

DROP BOX OUTPUT SHAFT

1
2

1. Output driven gear

RKT00120
2. Output shaft

10-10 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION TRANSMISSION

GEAR AND CLUTCH LAY-OUT

1 3
2
1 F
R2 4
1 3
4gh
Hi

INPUT
5

Forward OUTPUT
Reverse R
F
OUTPUT
RKT00880
2
4th - 3rd 1
clutch

1st - 2nd 4
clutch
3

RKTA7460

NOTE
1 - The following information describes the mechanic and hydraulic operation of the entire transmission, with-
out considering the electronic programme for machine operation.
2 - The diagrams refer to all combinations (i.e. speeds) that are possible for the type of transmission, even if the
solenoid valve energising programme does not cover the mechanical and hydraulic selection of all avail-
able gears.

TRANSMISSION GEAR ACTIVATED SOLENOID VALVES ACTIVATED CLUTCHES

5th forward YF - YS 4th – 3rd
4th forward YF Forward - 3rd
3rd forward YF - YS - Y2 4th – 2nd
2nd forward YF - Y2 Forward – 2nd
1st forward YF - Y1 - Y2 Forward – 1st
Neutral – 3rd
3rd reverse YR Reverse – 3rd
2nd reverse YR - Y2 Reverse – 2nd
1st reverse YR - Y1 - Y2 Reverse – 1st

WH6-1E0 WH7-1E0 10-11

STRUCTURE AND FUNCTION TRANSMISSION

1. OPERATION OF THE TRANSMISSION

The transmission is composed of 5 main assemblies:
1 - Converter, pump drive section and pressure regulating valve.
2 - Input shaft and directional clutches.
3 - Range clutches.
4 - Output section.
5 - Solenoid valve group.
A total of 5 forward speeds and 3 reverse speeds is achieved by combining the different clutches.

3
4

YR
YF
YS
Y1 RKT00900

Y2

10-12 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION TRANSMISSION

1.1 Converter, pump drive section and pressure regulating valve.

7 9 8

RKT00890
1 6

• Engine power is transmitted from the flywheel to the • The torque multiplication is function of the blading (im-
impeller (1), which coalesces with the housing (2) of peller, turbine and reaction member) and of the con-
the converter. verter output speed (turbine speed).
• This impeller (1) is the pump portion of the hydraulic The converter will multiply engine torque to its de-
torque converter and is the primary component which signed maximum multiplication ratio when the turbine
starts the oil flowing to the other components which shaft is at zero RPM (stall).
results in torque multiplication. • Therefore we can say that as the turbine shaft is de-
The impeller (1) can be compared to a centrifugal creasing in speed, the torque multiplication is increas-
pump that picks up fluid at its centre and discharges it ing.
at the outer diameter. • The hydraulic pump is connected with the pump drive
• The torque converter turbine (3) is mounted opposite gear. This pump drive gear is driven by the impeller
the impeller (1) and is connected to the converter hub gear (6). Since the impeller hub gear is connected
shaft (4). This element receives fluid at its outer di- with the impeller housing, the pump speed is in direct
ameter and discharges it at its centre. relation with the engine speed.
• The reaction member (5) of the torque converter is lo- NOTE
cated between and at the centre of the inner diame- The operating pressure regulator valve (7) is mounted
ters of the impeller (1) and turbine (3). behind the filter (8), in the filter adapter housing (9).
Its function is to take the fluid which is exhausting from
the inner portion of the impeller and change its direc-
tion to allow correct entry for recirculation into the tur-
bine element.

WH6-1E0 WH7-1E0 10-13

STRUCTURE AND FUNCTION TRANSMISSION

1.2 Input shaft and directional clutchesi

3 2 11

4 6 5 8 7 10 RKT00920

• The turbine shaft (1) driven by the turbine transmits • Pressure of the oil forces the piston (5) and discs (7
power to the forward clutch (2) (4th High) or to the re- and 8) against the back-up plate (10). The steel discs
verse clutches (3). clamping against friction discs enables the drum and
• These clutches consist of a drum with internal splines hub to be locked together and allows them to drive as
(4) and a bore to receive a hydraulic actuated piston one unit.
(5). • When the hydraulic pressure is released, some return
• The piston (5) is oil tight by the use of sealing rings springs (11) will push the piston (5) back and oil will
(6).The steel discs (7) with external splines, and fric- drain back into a return circuit and from here into the
tion discs (8) with internal splines, are alternated until transmission sump.
the required total is achieved. • The engagement of the directional clutches (forward
• The friction discs that are engaged on the hub are free and reverse) is modulated. This means that clutch
to increase in speed or rotate in the opposite direction pressure is built up gradually. This will enable the unit
as long as that specific clutch is not activated. to make forward, reverse shifts while the vehicle is still
• To engage the clutch, the solenoid will direct oil under moving and will allow smooth engagement of drive.
pressure through tubes and passages to the selected The modulation is done hydraulically.
clutch.
• Oil sealing rings (9) are located on the clutch shafts.
These rings delimit the drilled passage in the shaft to
the desired clutch.

10-14 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION TRANSMISSION

1.3 Clutches

• Once a directional clutch is engaged, power is transmitted to the range clutches (1st,2nd, 3rd or 4th High).
• Operation and actuation of the range clutches is similar to the directional clutches.
• The engagement of the range clutches is not modulated.

1.4 Output section

3rd clutch

4rd clutch

1st clutch 2nd clutch

RKT00950

• Once a range clutch is engaged, power is transmitted • The output shaft transmits motion to the drop box
to the output shaft. gears (1) and (2) which in turn transmit motion to the
Output rotation is the same as engine rotation. transmission shafts connected to the axles.

WH6-1E0 WH7-1E0 10-15

STRUCTURE AND FUNCTION TRANSMISSION

2. TRANSMISSION CONTROLS (also refer to hydraulic diagram)

Reverse gear control YR

Forward gear control YF
Gear selector control YS

1st clutch control Y1

2nd clutch control Y2

RKT00940

• The transmission is controlled by the direction and • Oil sealing rings are located on the clutch shafts.
range solenoid valves. These rings direct oil under pressure through a drilled
• The solenoid valves are mounted on the left side of passage way in the shaft to the desired clutch.
the transmission case.
• When selected direction and range solenoid valves
are energised, oil under pressure will flow through
tubes and passages to the selected clutch shafts.

10-16 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION TRANSMISSION

• TRANSMISSION IN NEUTRAL

YR
YF RKT00071
YS
Y1
Y2

WH6-1E0 WH7-1E0 10-17

 OPERATOR COMPARTMENT

10-18
PRESSURE TEMPERATURE : PRESSURE
X
GAUGE GAUGE CHECK PORT
bar

RKT00930
X : TEMPERATURE
C CHECK PORT

SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar C C bar C
STRUCTURE AND FUNCTION

LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE
LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar

1ST 2ND FORWARD SPLITTER REVERSE

SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID

BY-PASS FILTER
VALVE
2.1 - 3.5 bar

PUMP
41 42 43 44 45 46
bar bar bar bar bar bar

AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OIL SUMP

WH6-1E0 WH7-1E0
TRANSMISSION
STRUCTURE AND FUNCTION TRANSMISSION

• FORWARD 1st SPEED

YF

Y1
Y2

RKT00980

WH6-1E0 WH7-1E0 10-19

 OPERATOR COMPARTMENT

10-20
PRESSURE TEMPERATURE : PRESSURE
X
GAUGE GAUGE CHECK PORT
bar

RKT00970
X : TEMPERATURE
C CHECK PORT

SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar C C bar C
STRUCTURE AND FUNCTION

LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE
LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar

SPLITTER REVERSE
SOLENOID SOLENOID
1ST 2ND FORWARD
SOLENOID SOLENOID SOLENOID

BY-PASS FILTER
VALVE
2.1 - 3.5 bar

PUMP
41 42 43 44 45 46
bar bar bar bar bar bar

AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OIL SUMP

WH6-1E0 WH7-1E0
TRANSMISSION
STRUCTURE AND FUNCTION TRANSMISSION

• FORWARD 2nd SPEED

YF

Y2

RKT00990

WH6-1E0 WH7-1E0 10-21

 OPERATOR COMPARTMENT
PRESSURE TEMPERATURE

10-22
X : PRESSURE
GAUGE GAUGE CHECK PORT
bar

RKT01010
X : TEMPERATURE
C CHECK PORT

SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar C C bar C
STRUCTURE AND FUNCTION

LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE
LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar

1ST SPLITTER REVERSE

SOLENOID SOLENOID SOLENOID
2ND FORWARD
SOLENOID SOLENOID

BY-PASS FILTER
VALVE
2.1 - 3.5 bar

PUMP
41 42 43 44 45 46
bar bar bar bar bar bar

AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OIL SUMP

WH6-1E0 WH7-1E0
TRANSMISSION
STRUCTURE AND FUNCTION TRANSMISSION

• FORWARD 3rd SPEED

YF
YS

Y2

RKT01030

WH6-1E0 WH7-1E0 10-23

 OPERATOR COMPARTMENT

10-24
PRESSURE TEMPERATURE : PRESSURE
X
GAUGE GAUGE CHECK PORT
bar

RKT01020
X : TEMPERATURE
C CHECK PORT

SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar C C bar C
STRUCTURE AND FUNCTION

LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE
LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar

1ST REVERSE
SOLENOID SOLENOID
2ND FORWARD SPLITTER
SOLENOID SOLENOID SOLENOID

BY-PASS FILTER
VALVE
2.1 - 3.5 bar

PUMP
41 42 43 44 45 46
bar bar bar bar bar bar

AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OIL SUMP

WH6-1E0 WH7-1E0
TRANSMISSION
STRUCTURE AND FUNCTION TRANSMISSION

• FORWARD 4th SPEED

YF

RKT01040

WH6-1E0 WH7-1E0 10-25

 OPERATOR COMPARTMENT

10-26
PRESSURE TEMPERATURE : PRESSURE
X
GAUGE GAUGE CHECK PORT
bar

RKT01020
X : TEMPERATURE
C CHECK PORT

SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar C C bar C
STRUCTURE AND FUNCTION

LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE
LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar

2ND SPLITTER
1ST REVERSE
SOLENOID SOLENOID
SOLENOID SOLENOID
FORWARD
SOLENOID

BY-PASS FILTER
VALVE
2.1 - 3.5 bar

PUMP
41 42 43 44 45 46
bar bar bar bar bar bar

AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OIL SUMP

WH6-1E0 WH7-1E0
TRANSMISSION
STRUCTURE AND FUNCTION TRANSMISSION

• FORWARD 5th SPEED

YF
YS

RKT01060

WH6-1E0 WH7-1E0 10-27

 OPERATOR COMPARTMENT

10-28
PRESSURE TEMPERATURE : PRESSURE
X
GAUGE GAUGE CHECK PORT
bar

RKT01080
X : TEMPERATURE
C CHECK PORT

SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar C C bar C
STRUCTURE AND FUNCTION

LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE
LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar

2ND
1ST REVERSE
SOLENOID
SOLENOID SOLENOID
FORWARD SPLITTER
SOLENOID SOLENOID

BY-PASS FILTER
VALVE
2.1 - 3.5 bar

PUMP
41 42 43 44 45 46
bar bar bar bar bar bar

AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OIL SUMP

WH6-1E0 WH7-1E0
TRANSMISSION
STRUCTURE AND FUNCTION TRANSMISSION

• REVERSE 1st SPEED

YR

Y1
Y2

RKT01070

WH6-1E0 WH7-1E0 10-29

 OPERATOR COMPARTMENT

10-30
PRESSURE TEMPERATURE : PRESSURE
X
GAUGE GAUGE CHECK PORT
bar

RKT01090
X : TEMPERATURE
C CHECK PORT

SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar C C bar C
STRUCTURE AND FUNCTION

LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE
LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar

FORWARD SPLITTER
SOLENOID SOLENOID
2ND
1ST REVERSE
SOLENOID
SOLENOID SOLENOID

BY-PASS FILTER
VALVE
2.1 - 3.5 bar

PUMP
41 42 43 44 45 46
bar bar bar bar bar bar

AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OIL SUMP

WH6-1E0 WH7-1E0
TRANSMISSION
STRUCTURE AND FUNCTION FRONT AXLE

FRONT AXLE
CENTRE BODY
1 2 3 4 5

8
7 6

12 11

10 9

RKT00130
13 14 15 16
1. Ring nut 12. Plug
2. Differential housing 13. Bearing
3. Pin 14. Spacer
4. Ring gear 15. Ring nut
5. Bearing 16. Flange
6. Planetary gear CHARACTERISTICS:
7. Side gear • Version with aspirated engine
8. Drive shaft Amount of oil: 7.1 l
9. Nut Reduction ratio: 8:31
10. Bearing • Version with turbo engine
11. Pinion Amount of oil: 7.0 l
Reduction ratio: 9:31

WH6-1E0 WH7-1E0 10-31

STRUCTURE AND FUNCTION FRONT AXLE

BRAKES AND PARKING BRAKE

1 2 3

Section A - A

5
6
7

8 9
10
11
5

a 12
13 RKT00140

1. Pin 9. Intermediate braking disc

2. Nut 10. Screw
3. Dowel 11. Bushing
4. Brake bleed screw 12. Spring
5. Thrust lever 13. Braking disc
6. Push rod
a. From brake pump (B2 Port)
7. Pressure disc
8. Fulcrum lever

10-32 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION FRONT AXLE

FINAL REDUCTION

7 9

2 4 5 6 8 10
11
1 3
12

13

14

23 22
18 16 15

21 20 19 17

RKT00150

1. Bearing 15. Ring gear

2. Dowel 16. Ring gear carrier
3. Double cardan shaft 17. Screw
4. Bushing 18. Sealing ring
5. Pin 19. Sealing ring
6. Sealing ring 20. Ball bushing
7. Wheel hub 21. Housing
8. Bearing 22. Sealing ring
9. Nut 23. Bushing
10. Stud bolt
11. Planetary carrier CHARACTERISTICS
12. Planetary gears Amount of oil: 0.7 l
13. Bushing Reduction ratio: 1:6
14. Plug

WH6-1E0 WH7-1E0 10-33

STRUCTURE AND FUNCTION FRONT AXLE

STEERING CYLINDER

B
A A

a 2 b

3 Section B - B RKT00160

4
Section A - A

1. Steering cylinder
2. Centering sensor
3. Nut
4. Cotter pin

a. b Port - From ST1 solenoid valve group (T Port)

b. a Port - From steering unit (R Port )

10-34 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION REAR AXLE

REAR AXLE
CENTRE BODY

5 4 3 2 1

8
7 6

11 12

9 10

16 15 14 13 RKT00170

1 Ring nut 11. Pinion CHARACTERISTICS:

2. Differential housing 12. Plug • Version with aspirated engine
3. Pin 13. Bearing Amount of oil: 7.0 l
4. Ring gear 14. Spacer Reduction ratio: 8:31
5. Bearing 15. Ring nut • Version with turbo engine
Amount of oil: 7.1 l
6. Planetary gear 16. Flange
Reduction ratio: 9:31
7. Side gear
8. Drive shaft
9. Nut
10. Bearing

WH6-1E0 WH7-1E0 10-35

STRUCTURE AND FUNCTION REAR AXLE

BRAKES
A
1 2 3 a

A
Section A - A

4 5 6 7

RKT00180

1 Pin
2. Pressure disc
3. Brake bleed screw
4. Disc
5. Braking disc
6. Bushing
7. Screw
8. Spring

a. From brake pump (B2 Port)

10-36 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION REAR AXLE

FINAL REDUCTION

7 9

2 4 5 6 8 10
11
1 3
12

13

14

23 22
18 16 15

21 20 19 17

RKT00150

1. Bearing 15. Ring gear

2. Dowel 16. Ring gear carrier
3. Double cardan shaft 17. Screw
4. Bushing 18. Sealing ring
5. Pin 19. Sealing ring
6. Sealing ring 20. Ball bushing
7. Wheel hub 21. Housing
8. Bearing 22. Sealing ring
9. Nut 23. Bushing
10. Stud bolt
CHARACTERISTICS:
11. Planetary carrier
Amount of oil: 0.7 l
12. Planetary gears
Reduction ratio: 1:6
13. Bushing
14. Plug

WH6-1E0 WH7-1E0 10-37

STRUCTURE AND FUNCTION REAR AXLE

STEERING CYLINDER

B
A A

a 2 b

3 Section B - B
RKT00190

4
Section A - A

1. Steering cylinder
2. Centering sensor
3. Nut
4. Cotter pin

a. Port d - From ST1 solenoid valve group (A Port)

b. Port c - From ST1 solenoid valve assembly (B Port)

10-38 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION BRAKE PUMPS

BRAKE PUMPS

a b c d

RKT00200

e f

a. Port R1 - To oil brake tank

b. Port B1 - To rear axle
c. Port R2 - To oil brake tank
d. Port B2 - To front axle
e. Port P - From the transmission pump (31 Port)
f. Port S - To transmission (Port 71)

WH6-1E0 WH7-1E0 10-39

STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

STEERING SYSTEM (4WS)

5 3

9 2 10
T P
a d
6
1
A D

LS 7
B C

b c
L R Y15 Y17
T A

P B

Y16 Y18

8 RKT00210

1. Engine DESCRIPTION
2. Hydraulic pump • The steering system is completely hydraulic. The oil
3. Tank required, supplied by the pump (2) driven by the motor
4 Priority valve (1), is sent to the priority valve (4), which is incorpo-
rated in the control valve (5). The priority valve func-
5. Control valve
tions by Load Sensing, and sends the necessary
6. Steering unit quantity of oil to the steering system (6), even when
7. Steering wheel other oleodynamic components supplied by the same
8. ST1 solenoid valve group: circuit are in operation. The oil passes from this as-
– Y15: rear steering cut out sembly (6) into the steering cylinders (9 and 10). The
– Y16: front/rear steering solenoid valve group (8) can switch the oil flow to pro-
vide three types of steering:
– Y17: phase coincidence steering
1 - 2 wheels steering
– Y18: crab steering
Steering condition in which the rear axle is ex-
9. Front axle steering cylinder cluded.
10. Rear axle steering cylinder 2 - 2 wheels steering and 2 wheels counter-
steering (coordinated steering).
Steering condition in which rear steering is acti-
vated and the direction of the rear wheels is con-
trary to that of the front wheels.
3 - 4 wheels steering in the same direction (crab
steering).
Steering condition in which rear steering is acti-
vated and the direction of the rear wheels agrees
with that of the front wheels.
• The hydraulic power supplied by the pump (2) is
transferred to cylinders (9 and 10) and transformed
into mechanical steering power.

10-40 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

OPERATION

1 - Steering with front wheels only.

9 9
b a b a

B A B A

L T L T
e e
6 6
f R P f R P

g 3 g 3

P T P T
7 7
8 8

B A B A

C D C D

RKT00220

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (7) clockwise causes rotation Turning the steering wheel (7) anti-clockwise causes ro-
of the steering metering unit (6) and prepares the control tation of the steering metering group (6) and prepares the
valve (port R) to send oil through line e directly into cham- control valve (port L) to send oil through line g to the so-
ber a of the cylinder (9); the pressurized oil moves the pis- lenoid valve group (8) and thence through line f into cham-
ton which then steers the wheels. ber b of the cylinder (9); the pressurized oil moves the
The oil in chamber b of cylinder (9) is impelled through line piston which then steers the wheels.
f to the solenoid valve group (8) and thence into line g The oil in chamber a of cylinder (9) is impelled into line e
which is coupled to the control valve of the steering group which is coupled to the control valve of the steering as-
(6) (port L); from the oil control valve the oil passes out of sembly (port R); from the control valve, the oil passes out
Port T and drains into the tank (3). of Port T and drains into the tank (3).

WH6-1E0 WH7-1E0 10-41

STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

2 - Steering with 2 wheels steering and 2 wheels counter-steering (coordinated steering).

9 9
b a b a

B A B A

L T L T
e e
6 6
f P f P
R R

g 3 g 3

P T P T
7 7
8 8

B A h B A h
i
i
C D C D

c 10 d c 10 d

RKT00230

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (7) clockwise causes rotation of Turning the steering wheel (7) anti-clockwise causes ro-
the steering metering group (6) and prepares the control tation of the steering metering group (6) and prepares the
valve (port R) to send oil through line e directly into cham- control valve (port L) to send oil through line g to the so-
ber a of the cylinder (9). lenoid valve group (8) and thence through line i to cham-
The pressurized oil moves the piston of the cylinder (9) ber c of cylinder (10).
that steers the wheels while simultaneously impelling the The pressurized oil moves the piston of the cylinder (10)
oil in chamber c (at the same pressure as chamber a) that steers the wheels while simultaneously impelling the
through lines f and h into chamber d of the cylinder (10). oil in chamber d (at the same pressure as chamber c)
The oil in chamber c of cylinder (10) is sent through lines i through lines h and f into chamber b of the cylinder (9).
and g to the control valve of the steering assembly (port L) The oil in chamber a of cylinder (9) is sent through line e to
from which the oil passes out (port T) to drain into the tank the control valve of the steering group (port R) from which
(3). the oil passes out (port T) to drain into the tank (3).

10-42 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

3 - Steering with 4 wheels steering in the same direction (crab steering).

9 9
b a b a

B A B A

L T L T
e e
6 6
f g
R P R P

g 3 f 3
4 4
P T P T
7 Y16 Y15 7
5 5
8 8
Y18 Y17
B A h 2 B A h 2
i i

C D C D

c 10 d c 10 d

RKT00240

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (7) clockwise causes rotation Turning the steering wheel (7) anti-clockwise causes ro-
of the steering metering unit (6) and prepares the control tation of the steering metering group (6) and prepares the
valve (port R) to send oil (through line e) into chamber a of control valve (port L) to send oil (through line g) to the so-
the cylinder (9). lenoid valve group (8) and thence through line h to cham-
The pressurized oil moves the piston of the cylinder (9) ber d of cylinder (10).
that steers the wheels while simultaneously impelling the The pressurized oil moves the piston of the cylinder (10)
oil into chamber b (at the same pressure as chamber a) that steers the wheels while simultaneously impelling the
through lines f and i into chamber c of cylinder (10). oil in chamber c (at the same pressure as chamber d)
The oil in chamber d of cylinder (10) is sent through lines h through lines i and f into chamber b of steering cylinder (9).
and g to the control valve of the steering assembly (port L) The oil in chamber a of cylinder (9) is sent through line e to
from which the oil passes out (port T) to drain into the tank the control valve of the steering assembly (port R) from
(3). which the oil passes out (port T) to drain into the tank (3).

WH6-1E0 WH7-1E0 10-43

STRUCTURE AND FUNCTION STEERING UNIT

STEERING UNIT

a b d

e c

R L

240 bar 240 bar

LS

185
bar

T P
RKT00250

a. Port LS - From control valve (DLS port) OPERATION

b. Port T - To hydraulic oil tank • The steering unit consists of a control valve and a ro-
c. Port R - To front axle steering cylinder tating oil dispenser. These units function hydrostati-
(a Port) cally.
d. Port L - To ST2 solenoid valve group • When the steering wheel is moved, the control valve
(T Port) sends oil from the hydraulic pump (through the rotat-
e. Port P - From control valve (D Port) ing oil dispenser) to one or other end of the steering
cylinder.
SPECIFICATIONS The rotating oil dispenser ensures that the amount of
Steering unit type: LAGU 250/125-13LD240 oil supplied to the cylinder is proportional to the rota-
185M40-415S tion angle of the steering wheel.
Displacement with servocontrol: 250 cc/rev • If the steering unit pump malfunctions, the oil dispens-
Displacement in emergency: 125 cc/rev er functions automatically like a hand-pump to ensure
emergency steering.

10-44 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION HYDRAULIC DIAGRAM

HYDRAULIC DIAGRAM
C2
ASSALE ANTERIORE

ESTENSIONE
CILINDRO
DI SOLLEVAMENTO

BRACCIO
DI ROVESCIAMENTO
B A Y19

DI COMPENSAZIONE
C1
CILINDRO

(BRANDEGGIO)
A ATTACCO RAPIDO

430 bar
Ø2

430 bar
CILINDRO

CILINDRO ALLINEAMENTO
C1

BRACCIO

430 bar
C1

CILINDRO

STABILIZZATORE DX
STABILIZZATORE SX
CILINDRO
C1 C2

V1
C1
V1
V1

CILINDRO
CILINDRO
T

C1
C1
ASSALE POSTERIORE

TELAIO
C2 C1 C2 C1 C2
C1
B

C2

C2

C2
C D C2

V2

V2

V2
290 bar

430 bar
Ø2 Y11

430 bar
30 bar
350 bar
CILINDRO BLOCCAGGIO

430 bar
V1 V2

30 bar
R1 R2 ASSALE POSTERIORE

300 bar
V1 V2

Y18 Y17 V2 V1 V2 V1
F1

Y15 Y16
F2
P T

GRUPPO
ELETTROVALVOLE

L R
LS D PB1 B1 A1 PB2 B2 A2 Y pst B3 A3
150 l/min 110 l/min 150 l/min 110 l/min 150 l/min 150 l/min

3
240 bar 240 bar
DLS LS A1 B1 A2 B2 A3 B3 A4 B4

b b b
Ø1 A B A B A B A B

P P a
Y10 P T Y9
b a
Y6 P T Y5
b a
Y4 P T Y3
b
1.5
a
Y8 P T Y7
b

LS 1.5

P
2
P
T

T
1
21bar
GRUPPO
185 bar 260 bar ELETTROVALVOLE
a a

T
b
a
IDROGUIDA LS
T
P T

T T T T B T
A

4
A A A
275 bar
275 bar 200 bar 200 bar MANIPOLATORE
T PA1 PA2
DISTRIBUTORE

190 bar for WH716

X
P2
FR
T
18 bar

DR
280bar

PV
B

Y13A Y13
PR

TRASMISSIONE BV
Vmin 10cc GRUPPO ALIMENTAZIONE
M SERVOCOMANDI
MOTORE

S POMPA IDRULICA L2 L1 L

FILTRO IN SCARICO

FILTRO IN ASPIRAZIONE

SERBATOIO OLIO IDRAULICO

RKT02020

WH6-1E0 WH7-1E0 10-45

STRUCTURE AND FUNCTION HYDRAULIC PUMP

HYDRAULIC PUMP

1
B
3 d A

A
b
1
X
c 2
FR
18 bar

3
DR
28 bar
B

S L2 L1 L
a RKT00260

1. LS valve a. S Port - From hydraulic oil tank

2. PC valve b. B Port - To control valve (P Port)
3. TVC valves c. L1 Port - To hydraulic oil tank
d. X Port - To control valve (LS Port)

10-46 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION HYDRAULIC PUMP

HYDRAULIC PUMP

3 4 5

7
2 8
1

14
RKT00270

13 12 11 10 9

Section A - A

1. Drive shaft
2. Sealing ring
3. Swashplate return spring
4. Swashplate
5. Ball
6. TVC valve
7. Cylinder block
8. Spacer
9. Bearing
10. Valve plate
11. Piston (no. 9)
12. Flexplate
13. Guide shoe
14. Bearing

WH6-1E0 WH7-1E0 10-47

STRUCTURE AND FUNCTION HYDRAULIC PUMP

1 2 3 4 5

11 10 9 8 7 6 RKT00280

Section B - B

1. Load Sensing valve spool 7. Spring cover

2. Collar 8. Cut-off valve springs
3. Load Sensing valve springs 9. Collar
4. Spring cover 10. Restrictor
5. Adjusting nuts 11. Cut-off valve spool
6. Adjusting nuts

TVC VALVE

7 8
5 6
4
3
2
1

10
9

RKT00290

1. Piston 6. Swashplate
2. Stem 7. Spring
3. Bushing 8. Calibration screw
4. Spring 9. Spring
5. Ball 10. Adjusting nut

10-48 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION HYDRAULIC PUMP

PC VALVE, LS VALVE, POSITIONING PISTON

2
1

Control valve

3 4

to service
6

RKT00340

COMPONENTS
1. LS valve spool
2. LS valve spring
3. PC valve spool
4. PC valve springs
5. Swashplate return spring
6. TVC valve

WH6-1E0 WH7-1E0 10-49

STRUCTURE AND FUNCTION CONTROL VALVE

CONTROL VALVE

d e
b c f g

a
o

h
n
m A
l
k j i

q p

RKT00460

View “A”

a. P Port - From hydraulic pump (B Port) j. PA2 Port - From PPC valve (Port 4)
b. DLS Port - To steering unit (LS Port) k. PA1 Port - From PPC valve (Port 3)
c. B1 Port - To boom lift cylinder (V2 Port) l. A1 Port - From boom lift cylinder (V1 Port)
d. PB1 Port - From PPC valve (Port 1) m. LS Port - From hydraulic pump (X Port)
e. PB2 Port - From PPC valve (Port 2) n. T Port - To hydraulic oil tank
f. B2 Port - To swing cylinder (V2 Port) o. D Port - To steering unit (P Port)
and offset cylinder (B Port) p. PST Port - From supply unity (BV Port)
g. B3 Port - To boom extension cylinder (V1 Port) q. Y Port - To hydraulic oil tank
h. A3 Port - To boom extension cylinder (V2 Port)
i. A2 Port - To swing cylinder (V1 Port)
and offset cylinder (A Port)

10-50 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION PPC VALVE

PPC VALVE

a b
P T

g c

1 2 3 4
d RKT00450
f
View “A”

a. 1 Port - To control valve (PB1 Port)

b. T Port - To hydraulic oil tank
c. 4 Port - To control valve (PA2 Port)
d. P Port - From supply unity (PR Port)
f. 3 Port - To control valve (PA1 Port)
g. 2 Port - To control valve (PB2 Port)

WH6-1E0 WH7-1E0 10-51

STRUCTURE AND FUNCTION PPC VALVE

OPERATION OF THE PPC VALVES

1. Control lever in neutral position

Ports A and B of the control valve and lines P1 and
P2 of the PPC valve are connected to drain chamber
D through fine control hole f in stem (1). (Fig. 1 1).

D
T

P
f
2. Control lever moved to partial stroke (NEU-
TRAL to operation) 1
When push rod (4) starts to be pushed downwards
P1 P2
by lever (5), retainer (7) is pushed; stem (1) is also
pushed by the spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same time,
it is connected to pump pressure chamber PP, which A Control valve B
is directly linked to the servocontrol circuit.
Servocontrol circuit pressure passes through fine
control hole f, into the circuit and increases pressure Fig. 1 RKT01101

in line P1-A.
When pressure at P1 becomes higher, stem (1) is
pushed upwards and fine control hole f is re-con-
nected to chamber D, compressing spring (2).
The position of the stem (1) keeps changing until the
5
fine control hole f is at a point between drain cham-
ber D and pressure chamber PP, i.e. until pressure in 4
line P1 impacting the stem portion (1) counterbal-
ances the force applied by the spring (2).
The spring (2) is compressed proportionally to the
amount of movement of the lever (5), so the pres- 7
sure at P1 also rises in proportion to the travel of the
lever (5). 2 T
The balanced position remains until the position of
the push rod (4) changes, i.e.:
D
a) until pressures at A and P1 ports are perfectly
balanced; P
f
b) pressure in the A-P1 ‘arm’ impacting the stem
(1) reaches the value required to counter the 1
force of the spring (2).
This way the proportionality between travel of the P1 P2
PP
control lever, pressure in the A-P1 circuit, and dis-
placement of the main control valve stem is guar-
anteed (Fig. 2).
A Control valve B

Fig. 2 RKT01111

10-52 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION PPC VALVE

3. Control lever returned to neutral position

(Operation to NEUTRAL)
When control lever (5) is released and returned to
neutral position, push rod (4) is pushed up by spring 5
(3) which operates the retainer (7), and stem (1) is
pushed up by both the force of the spring (2) and the
force applied to the stem by pressure in the A-P1 4
‘arm’.
When this happens, fine control hole f of stem (1) is
connected to drain chamber D thus allowing pres-
7
sure in A-P1 to be released.
If the pressure at P1 drops too quickly, stem (1) is
pushed down by spring (2), and fine control hole f is 2 T
shut off from drain chamber D. At almost the same
time, fine control hole f is connected to pump pres- D
sure chamber PP, and the pump pressure is sup- P
plied to P1 ‘arm’ until the pressure at Port P1 f
recovers to a pressure that corresponds to the lever f'
position. 1
When the spool of the control valve returns, oil re-
turns to chamber D and flows from fine control hole f' P1 P2
PP
into chamber B of the control valve spool that is not
working.
The oil passes through Port P2 and enters chamber
B to fill the chamber with oil. (Fig. 3). A B
Control valve

RKT01121
4. Control lever at full stroke Fig. 3
(NEUTRAL to full stroke)
When lever (5) pushes down push rod (4), and re-
tainer (7) pushes down stem (1), fine control hole f is
connected to pump pressure chamber PP which is
connected with a constantly pressurized servocon- 5
trol circuit.
Therefore, the oil flows directly to the A-P1 ‘arm’,
and pushes the main control valve stem to the end of 4
its stroke. In turn, the stem sends the oil in chamber
B towards P2 input and through fine control hole f'
into drain chamber D. (Fig. 4). 7

2 T

D
P
f
f'
1
P1 P2
PP

A Control valve B

RKT01131
Fig. 4

WH6-1E0 WH7-1E0 10-53

STRUCTURE AND FUNCTION SOLENOID VALVES

SOLENOID VALVES
SERVOCONTROL SUPPLY UNIT

BV PR

PV
A

P2 T
P2

PV

Vista A PR BV

RKT02000

2. Y13 - Extension/retraction control supply solenoid valve

1. Y13A - PPC supply solenoid valve

a. PR Port - To PPC valve (P Port)

b. BV Port - To control valve (PST Port)
c. PV Port - Not used
d. T Port - To hydraulic oil tank
e. P2 Port - From hydraulic pump (B Port)

10-54 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION SOLENOID VALVES

ST1 STEERING SOLENOID VALVE GROUP (Y15 - Y16 - Y17 - Y18)

2 3

c
b
A D
d
a
B C

1 4 RKT02010

1. Y16 - Front/rear steering

2. Y15 - Rear steering cut out
3. Y17 - Phase coincidence steering
4. Y18 - Crab steering
5. Port block

a. F2 Port - To front axle steering cylinder (B Port)

b. F1 Port - From steering unit (L Port )
c. R1 Port - To rear axle steering cylinder (D Port)
d. R2 Port - To rear axle steering cylinder (C Port)

WH6-1E0 WH7-1E0 10-55

STRUCTURE AND FUNCTION SOLENOID VALVES

OP2 QUICK COUPLING SOLENOID VALVE GROUP (Y9 - Y10)

B1
LS
B

T
P

Made in Italy
A

A1

LS A1 B1

A B

a b
P Vista B Y10 P T Y9

1.5

RKT01980

1. Y9 - Quick-coupling solenoid valve

2. Y10 - Quick coupling solenoid valve

P Port - From hydraulic pump (B Port)

A1 Port - To quick coupling cylinder (V1 Port)
B1 Port - To quick coupling cylinder (V2 Port)
LS Port - From hydraulic pump (X Port)
T Port - To hydraulic oil tank

10-56 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION SOLENOID VALVES

FRAME LEVELLING AND OP2 QUICK COUPLING SOLENOID VALVE GROUP (Y7 - Y8 - Y9 - Y10)

1
3
B1
LS B4

B B

T
P

Made in Italy
A A

A1 A4

2 4

LS A1 B1 A2 B2

A B A B

a P T b a P T b
Y10 Y9 1.5 Y8 Y7
P
1.5

RKT01960

1. Y9 - Quick-coupling solenoid valve P Port - From hydraulic pump (B Port)

2. Y10 - Quick coupling solenoid valve A2 Port - To frame levelling cylinder (V1 Port)
3. Y7 - Left frame rotation solenoid valve B2 Port - To frame levelling cylinder (V2 Port)
4. Y8 - Right frame rotation solenoid valve A1 Port - To quick coupling cylinder (V1 Port)
B1 Port - To quick coupling cylinder (V2 Port)
LS Port - From hydraulic pump (X Port)
T Port - To hydraulic oil tank

WH6-1E0 WH7-1E0 10-57

STRUCTURE AND FUNCTION SOLENOID VALVES

STABILIZER AND OP3 QUICK COUPLING SOLENOID VALVE GROUP (Y3 - Y4 - Y5 - Y6 - Y9 - Y10)

B2 3

1
5
B1 B3
LS
B B B

T
P

Made in Italy
A A A

A1 A3

2 6

A2 4

LS A1 B1 A3 B3 A4 B4

A B A B A B

a P T b a P T b a P T b
Y10 Y9 Y6 Y5 Y4 Y3
1.5

RKT01970

1. Y3 - RH stabilizer up solenoid valve B3 Port - To RH stabilizer cylinder (V2 Port)

2. Y4 - RH stabilizer down solenoid valve A2 Port - To LH stabilizer cylinder (V1 Port)
3. Y5 - LH stabilizer up solenoid valve B2 Port - To LH stabilizer cylinder (V2 Port)
4. Y6 - LH stabilizer down solenoid valve A1 Port - To quick coupling cylinder (V1 Port)
5. Y9 - Quick coupling solenoid valve B1 Port - To quick coupling cylinder (V2 Port)
6. Y10 - Quick coupling solenoid valve LS Port - From hydraulic pump (X Port)
T Port - To hydraulic oil tank
P Port - From hydraulic pump (B Port)
A3 Port - To RH stabilizer cylinder (V1 Port)

10-58 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION SOLENOID VALVES

FRAME LEVELLING, STABILIZER, AND ST4 QUICK COUPLING SOLENOID VALVE GROUP
(Y3 - Y4 - Y5 - Y6 - Y7 - Y8 - Y9 - Y10)

B2 3 B3 5 7

B4
1

B1
T
LS B B B B

Made in Italy
A A A A

A1 A4

A2 4 6 8
LS A1 B1 A2 B2 A3 B3 A4 B4

A B A B A B A B

a P T b a P T b a P T b a P T b
Y10 Y9 Y6 Y5 Y4 Y3 1.5 Y8 Y7
P
1.5

T
RKT01990

1. Y3 - RH stabilizer up solenoid valve P Port - From hydraulic pump (B Port)

2. Y4 - RH stabilizer down solenoid valve A3 Port - To RH stabilizer cylinder (V1 Port)
3. Y5 - LH stabilizer up solenoid valve B3 Port - To RH stabilizer cylinder (V2 Port)
4. Y6 - LH stabilizer down solenoid valve A2 Port - To LH stabilizer cylinder (V1 Port)
5. Y7 - Left frame rotation solenoid valve B2 Port - To LH stabilizer cylinder (V2 Port)
6. Y8 - Right frame rotation solenoid valve A4 Port - To frame levelling cylinder (V1 Port)
7. Y9 - Boom equipment solenoid valve B4 Port - To frame levelling cylinder (V2 Port)
8. Y10 - Boom equipment solenoid valve A1 Port - To quick coupling cylinder (V1 Port)
B1 Port - To quick coupling cylinder (V2 Port)
LS Port - From hydraulic pump (X Port)
T Port - To hydraulic oil tank

WH6-1E0 WH7-1E0 10-59

STRUCTURE AND FUNCTION SAFETY VALVES

SAFETY VALVES
BOOM LIFT

d c
1
9 2

A A

3 4 5 6 7

RKT00530
Section A - A

1. Release screw a. V2 Port - From control valve (B1 Port)

2. Nut b. V1 Port - From control valve (A1 Port)
3. Nut c. C1 Port - To boom lift cylinder (head side)
4. Adjusting screw d. C2 Port - To boom lift cylinder (base side)
5. Spring
CHARACTERISTICS
6. Valve
Control ratio: 4:1
7. Spool
Control safety valve calibration: 30 bar
8. Control safety valve
Safety valve calibration: 350 bar
9. Safety valve

10-60 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION SAFETY VALVES

BOOM EXTENSION

a c b
A 1

A
d

2 3 4 5 6 7
8

Section A - A

RKT00540

1. Safety valve a. V2 Port - From control valve (A3 Port)

2. Nut b. V1 Port - From control valve (B3 Port)
3. Adjusting screw c. C2 Port - To extension cylinder (base side)
4. Spring d. C1 Port - To extension cylinder (head side)
5. Valve
CHARACTERISTICS
6. Spool
Safety valve calibration: 290 bar
7. Release screw
8. Nut

WH6-1E0 WH7-1E0 10-61

STRUCTURE AND FUNCTION SAFETY VALVES

SWINGING

b c

a d

A A

a d

2
3 4 5 6 7
9

Section A - A 8
RKT00520

1. Safety valve a. V2 Port - From control valve (B2 Port)

2. Control safety valve b. C2 Port - To swing cylinder (base side)
3. Nut c. C1 Port - Al cilindro brandeggio (lato testa)
4. Adjusting screw d. V1 Port - To control valve (A2 Port)
5. Spring
CHARACTERISTICS
6. Valve
Safety valve calibration: 300 bar
7. Spool
Control safety valve calibration: 30 bar
8. Release screw
Control ratio: 4:1
9. Nut

10-62 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION SAFETY VALVES

QUICK COUPLING

a d A

A
b c
1 2 3 2 1

Section A - A RKT00550

1. Spring CHARACTERISTICS
2. Valve Safety valve calibration: 350 bar
3. Spool Control ratio: 7:1

a. C1 Port - To quick coupling cylinder

(head side)
b. V2 Port - From solenoid valve group
OP2 - OP3 - OP4 (B1 Port)
c. V1 Port - From solenoid valve group
OP2 - OP3 - OP4 (A1 Port)
d. C2 Port - To quick coupling cylinder
(base side)

WH6-1E0 WH7-1E0 10-63

STRUCTURE AND FUNCTION SAFETY VALVES

REAR AXLE LOCKING

a c

A A

1 3 4

2 2
RKT00560

Section A - A

1. Y11 solenoid valve

2. Piston
3. Block
4. Y19 solenoid valve

a. C2 Port - To rear axle locking cylinder (head side)

b. T Port - To hydraulic oil tank
c. C1 Port - To rear axle locking cylinder (base side)

10-64 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION SAFETY VALVES

FRAME LEVELLING

a b
A
1

A
c d

2 3 4

Section A - A RKT00580

1. Safety valve CHARACTERISTICS

2. Adjusting screws Safety valve calibration: 430 bar
3. Spring
4. Valve

a. V2 Port - From OP2 OP4 solenoid valve

group (B2 Port)
b. V1 Port - From OP2 OP4 solenoid valve
group (A2 Port)
c. C2 Port - To frame levelling cylinder
(base side)
d. C1Port - To frame levelling cylinder
(head side)

WH6-1E0 WH7-1E0 10-65

STRUCTURE AND FUNCTION SAFETY VALVES

STABILIZERSI

a b
A
1

A
c d

2 3 4

Section A - A RKT00570

1. Safety valve CHARACTERISTICS

2. Adjusting screw Safety valve calibration: 430 bar
3. Spring
4. Valve

a. Port V2 - V2 Port-From OP3 solenoid valve

group (B2 Port) (B3 Port)
From OP4 solenoid valve group (B3
Port) (B4 Port)
b. V1 Port - From OP3 solenoid valve group (A2
Port) (A3 Port)
From OP4 solenoid valve group (A3
Port) (A4 Port)
c. C2 Port - To stabilizer cylinder (base side)
d. C1 Port - To stabilizer cylinder (head side)

10-66 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION CYLINDERS

CYLINDERS
BOOM LIFT

2 13 12 11 10 9

3 4 5 6 7 8
RKT00590

1. Safety valve 7. Cylinder head 13. Cylinder

2. Bushing base side 8. Cylinder head gasket
3. Dowel 9. Bushing head side
4. Guide ring 10. Scraper
5. Piston seal 11. Guide ring
6. Piston 12. Stem

OFFSET

1 2 3 4 5 6

12 11 10 9 8 7
RKT00600

1. Bushing base side 7. Scraper

2. Dowel 8. Guide ring
3. Piston seal 9. Cylinder head gasket
4. Guide ring 10. Stem
5. Cylinder head 11. Cylinder
6. Bushing head side 12. Piston

WH6-1E0 WH7-1E0 10-67

STRUCTURE AND FUNCTION CYLINDERS

BOOM EXTENSION (WH609)

1 2 3 4 13 5 6 7 14

RKT00610
12 11 10 9

1. Ring 6. Spacer 11. Cylinder head gasket

2. Ring 7. Stem 12. Cylinder
3. Piston seal 8. Safety valve 13. Dowel
4. Guide ring 9. Cylinder head 14. Scraper
5. Piston 10. Guide ring

BOOM EXTENSION (WH613 - WH713 - WH714H - WH716)

1 2 3 13 6 7 14

RKT00620

4 5 12 11 10 9

1. Ring 7. Stem 13. Dowel

2. Ring 8. Safety valve 14. Scraper
3. Piston seal 9. Cylinder head
4. Guide ring 10. Guide ring
5. Piston 11. Cylinder head gasket
6. Spacer 12. Cylinder

10-68 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION CYLINDERS

SWINGING

3
4
1 2 5
6

12 11 10 9 8 7 13

RKT00630

1. Bushing base side 6. Bushing stem side 11. Piston seal

2. Piston 7. Guide ring 12. Dowel
3. Safety valve 8. Cylinder head gasket 13. Scraper
4. Cylinder 9. Stem
5. Cylinder head 10. Guide ring

FRAME LEVELLING

3
2 5
1 6
13

RKT00660
12 11 10 9 8 7

1. Bushing base side 6. Bushing head side 11. Piston seal

2. Piston 7. Guide ring 12. Dowel
3. Guide ring 8. Cylinder head gasket 13. Scraper
4. Safety valve 9. Stem
5. Cylinder head 10. Cylinder

WH6-1E0 WH7-1E0 10-69

STRUCTURE AND FUNCTION CYLINDERS

STABILIZERS

3 4
2
6
1 7
13

12 11 10 9 8 RKT00670

1. Bushing base side 6. Cylinder head 11. Cylinder

2. Piston 7. Bushing stem side 12. Dowel
3. Guide ring 8. Guide ring 13. Scraper
4. Piston seal 9. Cylinder head gasket
5. Safety valve 10. Stem

QUICK COUPLING

1 2
8

7 6 5 4 3 RKT00640

1. Cylinder 6. Piston seal

2. Cylinder head 7. Nut
3. Cylinder head gasket 8. Scraper
4. Stem
5. Piston

10-70 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION CYLINDERS

REAR AXLE LOCKING (WH613 - WH713 - WH714H - WH716)

4
3
2
1 5
6
13

RKT00650
12 11 10 9 8 7

1. Bushing base side 6. Bushing head side 11. Piston seal

2. Piston 7. Guide ring 12. Dowel
3. Guide ring 8. Cylinder head gasket 13. Scraper
4. Safety valve 9. Stem
5. Cylinder head 10. Cylinder

WH6-1E0 WH7-1E0 10-71

STRUCTURE AND FUNCTION CYLINDERS

CHARACTERISTICS

WH609 WH613 WH713 WH714H WH716

Boom lift cylinder
Stem diameter 80 90 100 100 100
Cylinder inner diameter 150 160 180 180 180
Piston travel 1190 1190 1350 1350 1350
Cylinder max length 2730 2730 3050 3050 3050
Cylinder min length 1540 1540 1700 1700 1700
Offset cylinder
Stem diameter 40 40 40 40 40
Cylinder inner diameter 60 60 60 60 60
Piston travel 1223 1223 1383 1383 1383
Cylinder max length 2753 2753 3073 3073 3073
Cylinder min length 1530 1530 1690 1690 1690
Boom extension cylinder
Stem diameter 60 70 70 80 80
Cylinder inner diameter 80 110 110 120 120
Piston travel 3559 3500 3500 3978 3675
Cylinder max length 7548 7440 7440 8396 9790
Cylinder min length 3989 3940 3940 4418 5115
Frame levelling cylinder
Stem diameter – 50 50 50 50
Cylinder inner diameter – 100 100 100 100
Piston travel – 162 162 162 162
Cylinder max length – 561 561 561 561
Cylinder min length – 399 399 399 399
Stabilizer cylinder
Stem diameter 60 60 60 60 60
Cylinder inner diameter 130 130 130 130 130
Piston travel 394.5 394.5 394.5 394.5 394.5
Cylinder max length 1128.5 1128.5 1128.5 1128.5 1128.5
Cylinder min length 734 734 734 734 734
Swing cylinder
Stem diameter 100 100 100 100 100
Cylinder inner diameter 150 150 150 150 150
Piston travel 336 336 336 336 336
Cylinder max length 1025 1025 1025 1025 1025
Cylinder min length 689 689 689 689 689

10-72 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION CYLINDERS

WH609 WH613 WH713 WH714H WH716

Rear axle locking cylinder
Stem diameter 50 50 50 50 50
Cylinder inner diameter 100 100 100 100 100
Piston travel 162 162 162 162 162
Cylinder max length 561 561 561 561 561
Cylinder min length 399 399 399 399 399
Quick coupling cylinder
Stem diameter 20 20 20 20 20
Cylinder inner diameter 30 30 30 30 30
Piston travel 80 80 80 80 80
Cylinder max length 495 495 495 495 495
Cylinder min length 335 335 335 335 335
Key size for piston retaining nut 19 19 19 19 19

WH6-1E0 WH7-1E0 10-73

STRUCTURE AND FUNCTION AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM

2
Low pressure steam

Low pressure fluid/steam

High pressure steam

AMBIENT AIR High pressure fluid

10

1a

3 1

8
4 5

7
9
CAB INTERIOR
RKT00680

1. Compressor SPECIFICATIONS
2. Condenser Circuit operating pressure with engine
3. Filer – dehydrator reservoir at 2500 rpm and ambient temperature at 25/30°C:
4. Safety pressure switch Normal pressure: 15 – 17 bar
5. Expansion valve Low pressure: 1.6 – 1.8 bar
6. Evaporator Safety pressure values:
7. Thermostatic clutch control sensor High pressure: 26 bar
8. Air circulation blowers in cab Low pressure: 2.5 bar
9. Air cowl Coolant fluid: R134a
Amount of coolant: 110 +50/-30 g

10-74 WH6-1E0 WH7-1E0

STRUCTURE AND FUNCTION CLIMATE CONTROL SYSTEM OPERATION

CLIMATE CONTROL SYSTEM OPERATION

The compressor (1) is driven directly by the crankshaft On leaving the evaporator (6) the coolant is drawn once
by means of a belt, and is caused to rotate by a pulley fit- more into the compressor (1) and a new cycle commenc-
ted with an electromagnetically-engaged clutch (1a). es.
A thermostatic sensor (7) controls the engagement and The extraction of heat from the atmosphere in which the
disengagement of the clutch. It disengages the clutch evaporator is positioned leads to the condensation of the
when the evaporator reaches the lower temperature limit water suspended in the air, and hence to dehumidifica-
and engages the clutch when the evaporator reaches tion. The condensate is deposited on the evaporator fins
the upper temperature limit. where, if a temperature higher than 0°C is not main-
The coolant fluid (in gaseous phase) is drawn into the tained, it freezes and inhibits the functioning of the evap-
compressor where it is subjected to compression and an orator.
intense heating process. In these conditions the fluid is The task of keeping the temperature of the evaporator
then sent into the condenser (2) where, due to the heat above 0°C (and thus within the optimum limits for heat
extracted by ambient temperature air flowing over fins, it exchange) is entrusted to a thermostatic sensor (7).
reaches condensation temperature, and passes into a The condensate that forms on the evaporator fins (6)
high-pressure liquid state. also contains dust, pollens and particles suspended in
Subsequently the coolant passes into the drying-filter the air. Continual condensation therefore effectively pu-
assembly (3) which performs three functions: it filters out rifies the air, and the droplets of condensate are dis-
impurities, absorbs any moisture present in the circuit charged to the exterior.
and, finally, also functions as a reserve tank.
The coolant in its liquid state is then transferred to the A fixed quantity of anti-freeze oil is also introduced into
evaporator (6), first passing through an expansion valve the circuit, with the function of lubricating all the mechan-
(5). The task of this valve is the constant metering of the ical parts of the A/C system. A percentage of this oil cir-
quantity of fluid in order to maintain optimum evapora- culates constantly throughout the A/C system in
tion. atomised form, lubricating the compressor (pistons and
In the evaporator the coolant fluid is subjected to expan- bearings) and the expansion valve.
sion, bringing it up to the critical evaporation point at a A pressure switch (4) has been inserted in the electrical
temperature of approximately – 8°C. control circuit to protect the A/C system in the case of a
The flow of air generated by centrifugal fan (8), which lack of coolant fluid or if the quantity becomes insufficient
passes through the evaporator (6) at ambient tempera- due to leakages. This switch will inhibit the engagement
ture is considerably warmer than – 8°C. For this reason it of the electromagnetic clutch and hence the functioning
yields heat to the coolant fluid, bringing it up to boiling of the air-conditioning system.
point and complete evaporation.

WH6-1E0 WH7-1E0 10-75

PAGE INTENTIONALLY
LEFT BLANK
 20 TESTING AND ADJUSTMENTS

STANDARD SPECIFICATIONS.......................................... 3 TRANSMISSION (POWER SHIFT) CHECKS ................... 62

INTRODUCTION ............................................................... 33 TRANSMISSION ASSEMBLY PRESSURE CHECKS ...... 64
VALVE LASH ADJUSTMENT ........................................... 35 CHECKING THE SPEED OF THE TRANSMISSION
CHECKING ENGINE SPEED............................................ 36 SHAFTS RESPONSIBLE FOR
TRANSLATION (CARDAN SHAFTS) ................................ 67
TENSIONING THE AIR CONDITIONER COMPRESSOR
BELT.................................................................................. 39 LEVEL CALIBRATION....................................................... 68
ADJUSTING ACCELERATOR CABLE LENGTH.............. 40 CHECKING LOAD CELL CALIBRATION .......................... 69
ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING CALIBRATING THE OVERTURN PREVENTION SYSTEM
THE STOP LAMP MICROSWITCHES.............................. 41 (STANDARD)..................................................................... 70
ADJUSTING THE PARKING BRAKES ............................. 43 CALIBRATING THE OVERTURN PREVENTION (ASM)
CONTROL UNIT ................................................................ 75
BLEEDING AIR FROM CIRCUITS.................................... 45
CHECKING LED CALIBRATION (version with ASM)........ 77
PREPARING THE MACHINE READY FOR HYDRAULIC
PRESSURE CHECK AND CALIBRATION........................ 47 CHECKING SLIDING PADS CLEARANCE....................... 78
CHECKING AND CALIBRATING WORK EQUIPMENT HY- CHECKING BOOM SIDE ALIGNMENT............................. 80
DRAULIC PRESSURES.................................................... 48 BOOM CHAINS ................................................................. 82
CALIBRATING THE PRESSURE OF THE CHAIN TENSIONING ........................................................ 84
STEERING SYSTEM ........................................................ 54 CHECKING FOR BLOW-BY.............................................. 89
INSPECTING THE OPERATION OF THE UNLOADING ANALYSIS OF THE CAUSES RESPONSIBLE FOR
VALVE ............................................................................... 55 HYDRAULIC DRIFT........................................................... 92
CHECKING AND CALIBRATING THE DR VALVE EQUALIZING STABILIZER SPEED ................................ 101
(PUMP FLOW VARIATION) .............................................. 56
AIR CONDITIONING SYSTEM MAINTENANCE ............ 102
CHECKING THE DYNAMIC PUMP DP VALUE................ 57
CHECKING THE A/C SYSTEM’S OPERATING
CHECKING PUMP FLOW................................................. 58 TEMPERATURE.............................................................. 103
BRAKE SYSTEM CHECKS............................................... 59

WH6-1E0 WH7-1E0 20-1

20-2 WH6-1E0 WH7-1E0
TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

STANDARD SPECIFICATIONS
• FOR ENGINE

WH609 - WH613 - WH713

Machine model
WH714H - WH716

Standard Permissible
Check item Test conditions Unit
value value

Maximum speed rpm 2400±50 2400±50

Engine speed
Minimum speed rpm 1050±50 1050±50
(no load condition)
Operating speed rpm 2200±50 2200±50

Exhaust gas Abrupt acceleration Bosch

– –
colour At maximum speed index

Intake (20 °C) mm 0.25±0.05 0.25±0.05

Valve lash
Exhaust (20 °C) mm 0.50±0.05 0.50±0.05

Compression
Oil temperature 69–72°C bar
pressure – –
(Engine speed) (rpm)
(oil SAE30)

Pressure in
With recirculation
housing mm H2O – –
At maximum speed
(oil SAE30)

Engine At maximum speed bar (kPa) 3.1 (31.0)

–
oil pressure At minimum speed bar (kPa) 0.7 (70)

Engine oil
All speeds °C – –
temperature

Injection
B.T.D.C. mm 1.00 1.00±0.05
advance

WH6-1E0 WH7-1E0 20-3

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODELS WH609 - WH613

Machine model WH609 - WH613

Classifi Standard Permissible

Check item Test conditions Unit
cation value value

• Max. engine speed

• Hydraulic oil temperature: 45–55 °C
With stalled converter • Converter oil temperature: 80°C 2015 2015–2100
• Machine in 2nd gear
• Service brakes: applied
Engine speed (load condition)

• Max. engine speed

• Hydraulic oil temperature: 45–55 °C
With stalled converter • Converter oil temperature: 80°C
and hydraulic system • Machine in 2nd gear
rpm 1550 1550–2200
in load condition • Service brakes: applied
• Equipment crate curl at end of travel and steering
at end of travel

• Max. engine speed

• Hydraulic oil temperature: 45–55 °C
With hydraulic system in • Converter oil temperature: 80°C
2450 2450–2550
load condition • Parking brakes: applied
• Equipment crate curl at end of travel and steering
at end of travel

20-4 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODELS WH713 - WH714H - WH716

Machine model WH713 - WH714H - WH716

Classifi Standard Permissible

Check item Test conditions Unit
cation value value

• Max. engine speed

• Hydraulic oil temperature: 45–55 °C
With stalled converter • Converter oil temperature: 80°C 2015 2015–2100
• Machine in 2nd gear
• Service brakes: applied
Engine speed (load condition)

• Max. engine speed

• Hydraulic oil temperature: 45–55 °C
With stalled converter • Converter oil temperature: 80°C
and hydraulic system • Machine in 2nd gear
rpm 1610 1610–2200
in load condition • Service brakes: applied
• Equipment crate curl at end of travel and steering
at end of travel

• Max. engine speed

• Hydraulic oil temperature: 45–55 °C
With hydraulic system in • Converter oil temperature: 80°C
2450 2450–2550
load condition • Parking brakes: applied
• Equipment crate curl at end of travel and steering
at end of travel

WH6-1E0 WH7-1E0 20-5

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH609

Machine model WH609

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Engine speed: min.

General
• Hydraulic oil temperature: 45–55 °C 260 260±7
(cut-off) valve • Check one circuit at a time
Circuit pressure

• Engine speed: min.

Servocontrols 35 30 --0 3.5
• Equipment control in dump at end of travel

bar
LS differential pressure • Engine speed: max
20 20±1
(unloading valve) • Hydraulic oil temperature: 45–55 °C

• Engine speed: 1500 rpm

Steering 180 180±5
• Hydraulic oil temperature: 45–55 °C
Secondary valve pressure

Boom (up) 275 275 +0 5

• Engine speed: min.
• Hydraulic oil temperature: 45–55 °C
• General valve calibration: 290 bar
Boom • Check one circuit at a time
bar 275 275 +0 5
(extension)

• Engine speed: min.

Equipment control
• Hydraulic oil temperature: 45–55 °C 200 200 +0 5
(curl) • General valve calibration: 260±7 bar

• Engine speed: max

Engine

Engine speed • Hydraulic oil temperature: 45–55 °C

rpm
(with pump under load) • Engine oil pressure: within the acceptable range
• Total steering + equipment curl

l a b l a b
l
Control valve spool travel

a b
Boom

mm
45 6.5±0.3 6.5±0.3 45 6.5±0.3 6.5±0.3

Equipment RKT01630

20-6 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH609

Machine model WH609

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Pedal and lever travel

Boom up lever • Engine not running • Neutral o Up – 90±5
• At centre of lever knob
• Reading at end of travel
• Equipment down to the
ground
Boom down lever • Neutral o Down – 90±5
Pedal and lever travel

80mm
Equipment crate
• Neutral o Open mm – 90±5
opening lever

Equipment crate
• Neutral o Close – 90±5
closing lever

Accelerator control lever • Min. o Max. – 70±10

RKT01650

Boom up lever – 1.5±0.5

Force for lever ad pedal operation

Boom down lever – 1.5±0.5

• Engine speed: min.

• Oil temperature: 45–55 °C
Equipment crate
• For PPC valves: tool attachment 80 mm from kg – 1.5±0.5
opening lever handle base
• Accelerator pedal: from NEUTRAL to MAX

Equipment crate
– 1.5±0.5
closing lever

Accelerator control lever – 5.0±2.0

WH6-1E0 WH7-1E0 20-7

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH609

Machine model WH609

Classifi
Check item Test conditions Unit Standard value Permissible value
cation

Boom up
(from ground to max. 10.2 10.2±1

Up
height) • Check position: see Fig. A in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Boom down • Perform 3 tests and calculate the average

Down
(from ground to max. 8.8 8–10
height)

Extension

Boom extension
7.25 6.5–8.0
(full extension)
• Check position: see Fig. B in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
• Perform 3 tests and calculate the average
Retraction

Boom retraction
7.25 6.5–8.0
(full retraction)

Equipment crate curl

Work equipment speed

Curl

(from full dump to max. 3.3 3.7–4.5

curl) • Check position: see Fig. C in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Dump • Perform 3 tests and calculate the average
Dump

(from max. curl 3.0 2.5–3.5

to full dump)

Stabilizers up
(from fully extended 8.5 6.0–11.0
Up

to fully retracted) • Check position: see Fig. D in this chapter.

• Engine speed: MAX.
• Hydraulic oil temperature: 45–55 °C sec.
• Test one stabilizer at a time
Stabilizers down • Perform 3 tests and calculate the average
Down

(from fully retracted 9.0 7.0–11.0

to fully extended)

• Machine levelled
• Engine speed: MAX.
0.5 0.5
Up

• Hydraulic oil temperature: 45–55 °C

• Simultaneous stabilizer command
• Measure delay between the time one
Stabilizer synchronism
stabiliser touches the ground and the time sec.
(up-down movement) the other stabilizer touches the ground and
measure delay between the time one
Down

stabiliser reaches the fully retracted position 0.5 0.5

and the time the other stabilizer reaches the
fully-retracted position.

20-8 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH609

Machine model WH609

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

1 570 513–621

FORWARD GEAR
2 1243 1119–1355

• Wheels lifted with stabilizers and/or 3 1889 1700–2059

Translation speed

jack stands: see Figures E and F in

this chapter.
4 2550 2295–2780
Translation speed • Check engine at MAX rpm
m/1’
(no load) • Transmission oil temperature at
60-70 °C 5 3863 3477–4211
• Measure propeller shaft speed in all

REVERSE GEAR
gears. 1 570 513–621

2 1243 1119–1355

3 2550 2295–2780

WH6-1E0 WH7-1E0 20-9

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH609

Machine model WH609

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Inclination variation
Boom angle a° 1.1° 0–2.5°

• Machine control position:

see Figures G and H in this chapter.
• Machine levelled
Tips down

• Load P on forks: 3500 kg

Fork tip height • Stabilizers: fully lowered. 37.5 10–75
• Boom extension: letter E
• Boom inclination: 60° in relation to the
ground.
Hydraulic drift

• Forks: parallel to the ground.

a Carry out two tests:
a. with oil temperature at 40 °C
b. a. with oil temperature at 80 °C
a Measure any variations 10 minutes after
engine stop
a Measure inclination using a magnetic
RH

bubble placed on the boom mm Max. 2 0

a Measurement A at the tips of the forks
a Measurement B at the mark between
cylinder head and rod attachment
Stabilizer cylinder
(retraction)

Max. 2 0
LH

20-10 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH613

Machine model WH613

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Engine speed: min.

General
• Hydraulic oil temperature: 45–55 °C 260 260±7
(cut-off) valve • Check one circuit at a time
Circuit pressure

• Engine speed: min.

Servocontrols 35 30 --0 3.5
• Equipment control in dump at end of travel

bar
LS differential pressure • Engine speed: max
20 20±1
(unloading valve) • Hydraulic oil temperature: 45–55 °C

• Engine speed: 1500 rpm

Steering 180 180±5
• Hydraulic oil temperature: 45–55 °C
Secondary valve pressure

Boom (up) 275 275 +0 5

• Engine speed: min.
• Hydraulic oil temperature: 45–55 °C
• General valve calibration: 290 bar
Boom • Check one circuit at a time
bar 275 275 +0 5
(extension)

• Engine speed: min.

Equipment control
• Hydraulic oil temperature: 45–55 °C 200 200 +0 5
(curl) • General valve calibration: 260±7 bar

• Engine speed: max

Engine

Engine speed • Hydraulic oil temperature: 45–55 °C

rpm
(with pump under load) • Engine oil pressure: within the acceptable range
• Total steering + equipment curl

l a b l a b
l
Control valve spool travel

a b
Boom

mm
45 6.5±0.3 6.5±0.3 45 6.5±0.3 6.5±0.3

Equipment RKT01630

WH6-1E0 WH7-1E0 20-11

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH613

Machine model WH613

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Pedal and lever travel

Boom up lever • Engine not running • Neutral o Up – 90±5
• At centre of lever knob
• Reading at end of travel
• Equipment down to the
ground
Boom down lever • Neutral o Down – 90±5
Pedal and lever travel

80mm
Equipment crate
• Neutral o Open mm – 90±5
opening lever

Equipment crate
• Neutral o Close – 90±5
closing lever

Accelerator control lever • Min. o Max. – 70±10

RKT01650

Boom up lever – 1.5±0.5

Force for lever ad pedal operation

Boom down lever – 1.5±0.5

• Engine speed: min.

• Oil temperature: 45–55 °C
Equipment crate
• For PPC valves: tool attachment 80 mm from kg – 1.5±0.5
opening lever handle base
• Accelerator pedal: from NEUTRAL to MAX

Equipment crate
– 1.5±0.5
closing lever

Accelerator control lever – 5.0±2.0

20-12 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH613

Machine model WH613

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Boom up
(from ground to max. 10.2 10.2±1

Up
height) • Check position: see Fig. A in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Boom down • Perform 3 tests and calculate the average

Down
(from ground to max. 8.8 8–10
height)

Extension
Boom extension
7.25 6.5–8.0
(full extension)
• Check position: see Fig. B in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
• Perform 3 tests and calculate the average
Retraction

Boom retraction
7.25 6.5–8.0
(full retraction)

Equipment crate curl

Work equipment speed

Curl

(from full dump to max. 3.3 3.7–4.5

curl) • Check position: see Fig. C in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Dump • Perform 3 tests and calculate the average
Dump

(from max. curl 3.0 2.5–3.5

to full dump)

Stabilizers up
(from fully extended 8.5 6.0–11.0
Up

to fully retracted) • Check position: see Fig. D in this chapter.

• Engine speed: MAX.
• Hydraulic oil temperature: 45–55 °C sec.
• Test one stabilizer at a time
Stabilizers down • Perform 3 tests and calculate the average
Down

(from fully retracted 9.0 7.0–11.0

to fully extended)

• Machine levelled
• Engine speed: MAX.
0.5 0.5
Up

• Hydraulic oil temperature: 45–55 °C

• Simultaneous stabilizer command
• Measure delay between the time one
Stabilizer synchronism
stabiliser touches the ground and the time sec.
(up-down movement) the other stabilizer touches the ground and
measure delay between the time one
Down

stabiliser reaches the fully retracted position 0.5 0.5

and the time the other stabilizer reaches the
fully-retracted position.

WH6-1E0 WH7-1E0 20-13

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH613

Machine model WH613

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

1 570 513–621

FORWARD GEAR
2 1243 1119–1355

• Wheels lifted with stabilizers and/or 3 1889 1700–2059

Translation speed

jack stands: see Figures E and F in

this chapter.
4 2550 2295–2780
Translation speed • Check engine at MAX rpm
m/1’
(no load) • Transmission oil temperature at
60-70 °C 5 3863 3477–4211
• Measure propeller shaft speed in all
REVERSE GEAR

gears. 1 570 513–621

2 1243 1119–1355

3 2550 2295–2780

20-14 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH613

Machine model WH613

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Inclination variation
Boom angle a° 1.1° 0–2.5°

• Machine control position:

see Figures G and H in this chapter.
• Machine levelled Tips down
• Load P on forks: 3500 kg
Fork tip height • Stabilizers: fully lowered. 37.5 10–75
• Boom extension: letter E
• Boom inclination: 60° in relation to the
ground.
Hydraulic drift

• Forks: parallel to the ground.

a Carry out two tests:
a. with oil temperature at 40 °C
b. a. with oil temperature at 80 °C
a Measure any variations 10 minutes after
engine stop
a Measure inclination using a magnetic
RH

bubble placed on the boom mm Max. 2 0

a Measurement A at the tips of the forks
a Measurement B at the mark between
cylinder head and rod attachment
Stabilizer cylinder
(retraction)

Max. 2 0
LH

WH6-1E0 WH7-1E0 20-15

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH713

Machine model WH713

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Engine speed: min.

General
• Hydraulic oil temperature: 45–55 °C 260 260±7
(cut-off) valve • Check one circuit at a time
Circuit pressure

• Engine speed: min.

Servocontrols 35 30 --0 3.5
• Equipment control in dump at end of travel

bar
LS differential pressure • Engine speed: max
20 20±1
(unloading valve) • Hydraulic oil temperature: 45–55 °C

• Engine speed: 1500 rpm

Steering 180 180±5
• Hydraulic oil temperature: 45–55 °C
Secondary valve pressure

Boom (up) 275 275 +0 5

• Engine speed: min.
• Hydraulic oil temperature: 45–55 °C
• General valve calibration: 290 bar
Boom • Check one circuit at a time
bar 275 275 +0 5
(extension)

• Engine speed: min.

Equipment control
• Hydraulic oil temperature: 45–55 °C 200 200 +0 5
(curl) • General valve calibration: 260±7 bar

• Engine speed: max

Engine

Engine speed • Hydraulic oil temperature: 45–55 °C

rpm
(with pump under load) • Engine oil pressure: within the acceptable range
• Total steering + equipment curl

l a b l a b
l
Control valve spool travel

a b
Boom

mm
45 6.5±0.3 6.5±0.3 45 6.5±0.3 6.5±0.3

Equipment RKT01630

20-16 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH713

Machine model WH713

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Pedal and lever travel

Boom up lever • Engine not running • Neutral o Up – 90±5
• At centre of lever knob
• Reading at end of travel
• Equipment down to the
ground
Boom down lever • Neutral o Down – 90±5
Pedal and lever travel

80mm
Equipment crate
• Neutral o Open mm – 90±5
opening lever

Equipment crate
• Neutral o Close – 90±5
closing lever

Accelerator control lever • Min. o Max. – 70±10

RKT01650

Boom up lever – 1.5±0.5

Force for lever ad pedal operation

Boom down lever – 1.5±0.5

• Engine speed: min.

• Oil temperature: 45–55 °C
Equipment crate
• For PPC valves: tool attachment 80 mm from kg – 1.5±0.5
opening lever handle base
• Accelerator pedal: from NEUTRAL to MAX

Equipment crate
– 1.5±0.5
closing lever

Accelerator control lever – 5.0±2.0

WH6-1E0 WH7-1E0 20-17

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH713

Machine model WH713

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Boom up
(from ground to max. 10.2 10.2±1

Up
height) • Check position: see Fig. A in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Boom down • Perform 3 tests and calculate the average

Down
(from ground to max. 8.8 8–10
height)

Extension

Boom extension
7.25 6.5–8.0
(full extension)
• Check position: see Fig. B in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
• Perform 3 tests and calculate the average
Retraction

Boom retraction
7.25 6.5–8.0
(full retraction)

Equipment crate curl

Work equipment speed

Curl

(from full dump to max. 3.3 3.7–4.5

curl) • Check position: see Fig. C in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Dump • Perform 3 tests and calculate the average
Dump

(from max. curl 3.0 2.5–3.5

to full dump)

Stabilizers up
(from fully extended 8.5 6.0–11.0
Up

to fully retracted) • Check position: see Fig. D in this chapter.

• Engine speed: MAX.
• Hydraulic oil temperature: 45–55 °C sec.
• Test one stabilizer at a time
Stabilizers down • Perform 3 tests and calculate the average
Down

(from fully retracted 9.0 7.0–11.0

to fully extended)

• Machine levelled
• Engine speed: MAX.
0.5 0.5
Up

• Hydraulic oil temperature: 45–55 °C

• Simultaneous stabilizer command
• Measure delay between the time one
Stabilizer synchronism
stabiliser touches the ground and the time sec.
(up-down movement) the other stabilizer touches the ground and
measure delay between the time one
Down

stabiliser reaches the fully retracted position 0.5 0.5

and the time the other stabilizer reaches the
fully-retracted position.

20-18 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH713

Machine model WH713

Classifi
Check item Test conditions Unit Standard value Permissible value
cation

1 570 513–621

FORWARD GEAR
2 1243 1119–1355

• Wheels lifted with stabilizers and/or 3 1889 1700–2059

Translation speed

jack stands: see Figures E and F in

this chapter.
4 2550 2295–2780
Translation speed • Check engine at MAX rpm
m/1’
(no load) • Transmission oil temperature at
60-70 °C 5 3863 3477–4211
• Measure propeller shaft speed in all

REVERSE GEAR
gears. 1 570 513–621

2 1243 1119–1355

3 2550 2295–2780

WH6-1E0 WH7-1E0 20-19

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH713

Machine model WH713

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Inclination variation
Boom angle a° 1.1° 0–2.5°

• Machine control position:

see Figures G and H in this chapter.
• Machine levelled
Tips down

• Load P on forks: 3700 kg

Fork tip height • Stabilizers: fully lowered. 37.5 10–75
• Boom extension: letter E
• Boom inclination: 60° in relation to the
ground.
Hydraulic drift

• Forks: parallel to the ground.

a Carry out two tests:
a. with oil temperature at 40 °C
b. a. with oil temperature at 80 °C
a Measure any variations 10 minutes after
engine stop
a Measure inclination using a magnetic
RH

bubble placed on the boom mm Max. 2 0

a Measurement A at the tips of the forks
a Measurement B at the mark between
cylinder head and rod attachment
Stabilizer cylinder
(retraction)

Max. 2 0
LH

20-20 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH714H

Machine model WH714H

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Engine speed: min.

General
• Hydraulic oil temperature: 45–55 °C 260 260±7
(cut-off) valve • Check one circuit at a time
Circuit pressure

• Engine speed: min.

Servocontrols 35 30 --0 3.5
• Equipment control in dump at end of travel

bar
LS differential pressure • Engine speed: max
20 20±1
(unloading valve) • Hydraulic oil temperature: 45–55 °C

• Engine speed: 1500 rpm

Steering 180 180±5
• Hydraulic oil temperature: 45–55 °C
Secondary valve pressure

Boom (up) 275 275 +0 5

• Engine speed: min.
• Hydraulic oil temperature: 45–55 °C
• General valve calibration: 290 bar
Boom • Check one circuit at a time
bar 275 275 +0 5
(extension)

• Engine speed: min.

Equipment control
• Hydraulic oil temperature: 45–55 °C 200 200 +0 5
(curl) • General valve calibration: 260±7 bar

• Engine speed: max

Engine

Engine speed • Hydraulic oil temperature: 45–55 °C

rpm
(with pump under load) • Engine oil pressure: within the acceptable range
• Total steering + equipment curl

l a b l a b
l
Control valve spool travel

a b
Boom

mm
45 6.5±0.3 6.5±0.3 45 6.5±0.3 6.5±0.3

Equipment RKT01630

WH6-1E0 WH7-1E0 20-21

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH714H

Machine model WH714H

Classifi Standard Permissible
Check item Test conditions Unit
cation value value
• Pedal and lever travel
• Engine not running
Boom up lever • Neutral o Up – 90±5
• At centre of lever knob
• Reading at end of travel

• Equipment down to the

Boom down lever ground • Neutral o Down – 90±5
Pedal and lever travel

Equipment crate 80mm

• Neutral o Open mm – 90±5
opening lever

Equipment crate
• Neutral o Close – 90±5
closing lever

Accelerator control lever • Min. o Max. – 70±10

RKT01650

Boom up lever – 1.5±0.5

Force for lever ad pedal operation

Boom down lever – 1.5±0.5

• Engine speed: min.

• Oil temperature: 45–55 °C
Equipment crate
• For PPC valves: tool attachment 80 mm from kg – 1.5±0.5
opening lever handle base
• Accelerator pedal: from NEUTRAL to MAX

Equipment crate
– 1.5±0.5
closing lever

Accelerator control lever – 5.0±2.0

20-22 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH714H

Machine model WH714H

Classifi
Check item Test conditions Unit Standard value Permissible value
cation

Boom up
(from ground to max. 10.2 10.2±1

Up
height) • Check position: see Fig. A in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Boom down • Perform 3 tests and calculate the average

Down
(from ground to max. 8.8 8–10
height)

Extension
Boom extension
7.25 6.5–8.0
(full extension)
• Check position: see Fig. B in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
• Perform 3 tests and calculate the average
Retraction

Boom retraction
7.25 6.5–8.0
(full retraction)

Equipment crate curl

Work equipment speed

Curl

(from full dump to max. 3.3 3.7–4.5

curl) • Check position: see Fig. C in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Dump • Perform 3 tests and calculate the average
Dump

(from max. curl 3.0 2.5–3.5

to full dump)

Stabilizers up
(from fully extended 8.5 6.0–11.0
Up

to fully retracted) • Check position: see Fig. D in this chapter.

• Engine speed: MAX.
• Hydraulic oil temperature: 45–55 °C sec.
• Test one stabilizer at a time
Stabilizers down • Perform 3 tests and calculate the average
Down

(from fully retracted 9.0 7.0–11.0

to fully extended)

• Machine levelled
• Engine speed: MAX.
0.5 0.5
Up

• Hydraulic oil temperature: 45–55 °C

• Simultaneous stabilizer command
• Measure delay between the time one
Stabilizer synchronism
stabiliser touches the ground and the time sec.
(up-down movement) the other stabilizer touches the ground and
measure delay between the time one
Down

stabiliser reaches the fully retracted position 0.5 0.5

and the time the other stabilizer reaches the
fully-retracted position.

WH6-1E0 WH7-1E0 20-23

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH714H

Machine model WH714H

Classifi
Check item Test conditions Unit Standard value Permissible value
cation

1 570 513–621

FORWARD GEAR
2 1243 1119–1355

• Wheels lifted with stabilizers and/or 3 1889 1700–2059

Translation speed

jack stands: see Figures E and F in

this chapter.
4 2550 2295–2780
Translation speed • Check engine at MAX rpm
m/1’
(no load) • Transmission oil temperature at
60-70 °C 5 3863 3477–4211
• Measure propeller shaft speed in all
REVERSE GEAR

gears. 1 570 513–621

2 1243 1119–1355

3 2550 2295–2780

20-24 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH714H

Machine model WH714H

Classifi
Check item Test conditions Unit Standard value Permissible value
cation

Inclination variation
Boom angle a° 1.1° 0–2.5°

• Machine control position:

see Figures G and H in this chapter.
• Machine levelled Tips down
• Load P on forks: 4500 kg
Fork tip height • Stabilizers: fully lowered. 37.5 10–75
• Boom extension: letter E
• Boom inclination: 60° in relation to the
ground.
Hydraulic drift

• Forks: parallel to the ground.

a Carry out two tests:
a. with oil temperature at 40 °C
b. a. with oil temperature at 80 °C
a Measure any variations 10 minutes after
engine stop
a Measure inclination using a magnetic
RH

bubble placed on the boom mm Max. 2 0

a Measurement A at the tips of the forks
a Measurement B at the mark between
cylinder head and rod attachment
Stabilizer cylinder
(retraction)

Max. 2 0
LH

WH6-1E0 WH7-1E0 20-25

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH716

Machine model WH716

Classifi Permissible
Check item Test conditions Unit Standard value
cation value

• Engine speed: min.

General (cut-off)
• Hydraulic oil temperature: 45–55 °C 260 260±7
valve • Check one circuit at a time
Circuit pressure

• Engine speed: min.

Servocontrols 35 30 --0 3.5
• Equipment control in dump at end of travel

bar
LS differential pressure • Engine speed: max
20 20±1
(unloading valve) • Hydraulic oil temperature: 45–55 °C

• Engine speed: 1500 rpm

Steering 180 180±5
• Hydraulic oil temperature: 45–55 °C

Boom
Secondary valve pressure

275 275 +0 5
(up) • Engine speed: min.
• Hydraulic oil temperature: 45–55 °C
• General valve calibration: 290 bar
Boom • Check one circuit at a time
bar 275 275 +0 5
(extension)

• Engine speed: min.

Equipment control
• Hydraulic oil temperature: 45–55 °C 200 200 +0 5
(curl) • General valve calibration: 260±7 bar

• Engine speed: max

Engine

Engine speed • Hydraulic oil temperature: 45–55 °C

rpm
(with pump under load) • Engine oil pressure: within the acceptable range
• Total steering + equipment curl

l a b l a b
l
Control valve spool travel

a b
Boom

mm
45 6.5±0.3 6.5±0.3 45 6.5±0.3 6.5±0.3

Equipment RKT01630

20-26 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH716

Machine model WH716

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

• Pedal and lever travel

Boom up lever • Engine not running • Neutral o Up – 90±5
• At centre of lever knob
• Reading at end of travel
• Equipment down to the
ground
Boom down lever • Neutral o Down – 90±5
Pedal and lever travel

80mm
Equipment crate
• Neutral o Open mm – 90±5
opening lever

Equipment crate
• Neutral o Close – 90±5
closing lever

Accelerator control lever • Min. o Max. – 70±10

RKT01650

Boom up lever – 1.5±0.5

Force for lever ad pedal operation

Boom down lever – 1.5±0.5

• Engine speed: min.

• Oil temperature: 45–55 °C
Equipment crate
• For PPC valves: tool attachment 80 mm from kg – 1.5±0.5
opening lever handle base
• Accelerator pedal: from NEUTRAL to MAX

Equipment crate
– 1.5±0.5
closing lever

Accelerator control lever – 5.0±2.0

WH6-1E0 WH7-1E0 20-27

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH716

Machine model WH716

Classifi
Check item Test conditions Unit Standard value Permissible value
cation

Boom up
(from ground to max. 10.2 10.2±1

Up
height) • Check position: see Fig. A in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Boom down • Perform 3 tests and calculate the average

Down
(from ground to max. 8.8 8–10
height)

Extension

Boom extension
7.25 6.5–8.0
(full extension)
• Check position: see Fig. B in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
• Perform 3 tests and calculate the average
Retraction

Boom retraction
7.25 6.5–8.0
(full retraction)

Equipment crate curl

Work equipment speed

Curl

(from full dump to max. 3.3 3.7–4.5

curl) • Check position: see Fig. C in this chapter.
• Engine speed: MAX.
sec.
• Hydraulic oil temperature: 45–55 °C
Dump • Perform 3 tests and calculate the average
Dump

(from max. curl 3.0 2.5–3.5

to full dump)

Stabilizers up
(from fully extended 8.5 6.0–11.0
Up

to fully retracted) • Check position: see Fig. D in this chapter.

• Engine speed: MAX.
• Hydraulic oil temperature: 45–55 °C sec.
• Test one stabilizer at a time
Stabilizers down • Perform 3 tests and calculate the average
Down

(from fully retracted 9.0 7.0–11.0

to fully extended)

• Machine levelled
• Engine speed: MAX.
0.5 0.5
Up

• Hydraulic oil temperature: 45–55 °C

• Simultaneous stabilizer command
• Measure delay between the time one
Stabilizer synchronism
stabiliser touches the ground and the time sec.
(up-down movement) the other stabilizer touches the ground and
measure delay between the time one
Down

stabiliser reaches the fully retracted position 0.5 0.5

and the time the other stabilizer reaches the
fully-retracted position.

20-28 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH716

Machine model WH716

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

1 570 513–621

FORWARD GEAR
2 1243 1119–1355

• Wheels lifted with stabilizers and/or 3 1889 1700–2059

Translation speed

jack stands: see Figures E and F in

this chapter.
4 2550 2295–2780
Translation speed • Check engine at MAX rpm
m/1’
(no load) • Transmission oil temperature at
60-70 °C 5 3863 3477–4211
• Measure propeller shaft speed in all

REVERSE GEAR
gears. 1 570 513–621

2 1243 1119–1355

3 2550 2295–2780

WH6-1E0 WH7-1E0 20-29

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

• MACHINE MODEL WH716

Machine model WH716

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Inclination variation
Boom angle a° 1.1° 0–2.5°

• Machine control position:

see Figures G and H in this chapter.
• Machine levelled
Tips down

• Load P son forks: 4000 kg

Fork tip height • Stabilizers: fully lowered. 37.5 10–75
• Boom extension: letter E
• Boom inclination: 60° in relation to the
ground.
Hydraulic drift

• Forks: parallel to the ground.

a Carry out two tests:
a. with oil temperature at 40 °C
b. a. with oil temperature at 80 °C
a Measure any variations 10 minutes after
engine stop
a Measure inclination using a magnetic
RH

bubble placed on the boom mm Max. 2 0

a Measurement A at the tips of the forks
a Measurement B at the mark between
cylinder head and rod attachment
Stabilizer cylinder
(retraction)

Max. 2 0
LH

20-30 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

Fig. A Fig. B

RKT01660 RKT01670

Fig. C Fig. D

RKT01680 RKT01690

WH6-1E0 WH7-1E0 20-31

TESTING AND ADJUSTMENTS STANDARD SPECIFICATIONS

Fig. E Fig. F

10 cm 10 cm

RKT01700 RKT01710

Fig. G Fig. H
P

E
B B

RKT01730 RKT01720

20-32 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS INTRODUCTION

INTRODUCTION
IMPORTANT REMARKS
1 -Pressure checks should be performed with pressure gauges of appropriate scale.

2 -Analogue glycerine filled pressure gauges should be checked and, if necessary, calibrated before use. A
maximum deviation of 0.5% at full scale is allowed.

3 -It is advisable to check the pressures using dual channel digital instruments supporting DP (Dynamic
Pressure) measurement and controlled transducers, with error at full scale up to 0.5%.

4 -Temperatures should be checked using a digital probe thermometer; a maximum error of 1°C over 200°C is
allowed.

5 -For rotation speeds, use a stroboscopic tachometer capable of measuring speeds between 10 and 4.000
rpm.
Unless specified otherwise, rpm values should be measured at the engine pulley.

6 -When measuring time – for voltage and current – use a centesimal chronometer and a tester.

7 -For engine checks and adjustments, please refer to manual no. WEBMNEF001.

k DANGER
• Always park the equipment on flat, level ground before performing checks, adjustments or troubleshooting
operations.

• Unless otherwise stated, the machine’s safety devices (outriggers, blocks, parking brakes, etc.) should
always be used when carrying out checking procedures.

• When more than one person is involved in carrying out work on the equipment, use the standard signs to
indicate that the machine is undergoing maintenance. Do not allow unauthorised persons to stand in the
nearby areas.

• Before attempting to check the level of the coolant liquid, allow the liquid to cool. Removing the radiator cap
when the coolant liquid is still hot and under pressure may result in severe burns.

• Be extremely careful not to be caught in the moving parts of the equipment (generator belt, fan and rotating
parts).

WH6-1E0 WH7-1E0 20-33

PAGE INTENTIONALLY
LEFT BLANK
TESTING AND ADJUSTMENTS VALVE LASH ADJUSTMENT

VALVE LASH ADJUSTMENT

k Disconnect the cable from the negative (–) battery
terminal.
4
1 -Disconnect the wiring (1) connecting to the coolant
liquid temperature sensor (2) and disengage it from the 3
tie-straps.

2 -Disconnect the wiring (3) from the thermostart (4).

2 1

RKTA0700

3 -Disconnect the oil vapour bleed hose (6) from the valve
(5).

4 -Carry out the valve lash adjustment procedure by

following the instructions given in the engine workshop
5
manual (code no. WEBMNEF001).

6
RKTA8490

WH6-1E0 WH7-1E0 20-35

TESTING AND ADJUSTMENTS CHECKING ENGINE SPEED

CHECKING ENGINE SPEED

k When checking the engine rotation speeds, be
extremely careful not to touch any hot parts and be
aware that there is a danger of being caught in the 1
rotating members.

1 -Start the engine and heat the hydraulic oil and perform
the entire range of movements that are carried out in
normal working conditions, translations included.
A
a Check the hydraulic oil temperature by placing the
sensor of thermometer “A” to the pump suction pipe
(1).
Temperature should be 50±5°C. RKTA7640

2 -Position the machine on firm, level ground with the

transmission in NEUTRAL.

3 -Stop the engine and apply a measuring strip “B” to the

engine pulley (2) for use by the stroboscopic
tachometer.
B

RKTA7650

• CHECKING THE ENGINE WITH NO LOAD

1 -Start the engine and check the following:
• Minimum engine speed with no load (accelerator
pedal released).
• Maximum engine speed with no load (accelerator
pedal at maximum position).

Unit: rpm

MACHINE
MIN. MAX.
MODEL
WH609 1050±50 2400±50
WH613 1050±50 2400±50
WH713 1050±50 2400±50
WH714H 1050±50 2400±50
WH716 1050±50 2400±50

a If minimum and maximum engine speeds with no load

are not within specifications, check the accelerator pedal
position retainers and the accelerator cable conduit
before starting any other operation (See "ADJUSTING
ACCELERATOR CABLE LENGTH").

20-36 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING ENGINE SPEED

• CHECKING THE ENGINE UNDER LOAD

1. With stalled converter
1 -Run the engine at maximum speed and apply the
service brakes.
2 -With the brakes still applied, engage the 2nd gear; allow
the engine to stabilize, and then measure the rpm value.

k Keep the machine in a stalled condition for the minimum

time necessary (the interval should not to exceed 30
seconds) and wait at least 15 seconds between one
test and the next.

Unit: rpm

MACHINE TURBO ENGINE

MODEL MIN. MAX.
WH609 2015 2015–2100
WH613 2015 2015–2100
WH713 2015 2015–2100
WH714H 2015 2015–2100
WH716 2015 2015–2100

2. With stalled converter and hydraulic pump under

load
1 -Run the engine at maximum speed and apply the
service brakes.
2 -With the service brakes applied:
a - engage 2nd FORWARD gear;
b - perform a full equipment-crate curl and hold it in the
full position;
c - turn the wheels as far as they will go;
3 -Within the conditions described above, allow the engine
to stabilize, and then measure the rpm value.
4 -Repeat the checking procedure, this time with the 2nd
REVERSE gear applied.

k Keep the machine in a stalled condition for the minimum

time necessary (this should not exceed 30 seconds)
and wait at least 15 seconds between one test and the
next.

Unit: rpm

MACHINE TURBO ENGINE

MODEL MIN. MAX.
WH609 1550 1550–2200
WH613 1550 1550–2200
WH713 1610 1610–2200
WH714H 1610 1610–2200
WH716 1610 1610–2200

WH6-1E0 WH7-1E0 20-37

TESTING AND ADJUSTMENTS CHECKING ENGINE SPEED

3. With hydraulic pump under load

1 -Apply the parking brakes.
2 -Run the engine at maximum speed.
3 -Perform an equipment crate curl and hold it in the full curl
position.
4 -Turn the wheels as far as they will go and force steering.
5 -Within the conditions described above, allow the engine
to stabilize, and then measure the rpm value.
Unit: rpm

MACHINE TURBO ENGINE

MODEL MIN. MAX.
WH609 2450 2550
WH613 2450 2550
WH713 2450 2550
WH714H 2450 2550
WH716 2450 2550

• ANALYSIS
1 -If the readings are not within the prescribed values,
check the engine by following the instructions given in
the relevant manual, code no. WEBMNEF001.

20-38 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS TENSIONING THE AIR CONDITIONER COMPRESSOR BELT

TENSIONING THE AIR CONDITIONER COMPRESSOR BELT

1 -Loosen the screw (1) and nut (2).

2 -Turn the screw (3) clockwise to tension the belt (4).

3 2

1
4
RKTA1204

3 -Apply a 10 kg force at the centre of the segment from

compressor pulley (5) to engine pulley (6). 4
10 kg
4 -Check the resulting “F” arrow.

a F = 4-6 mm (normal tension)

F
F = 3 mm (new belt)

5
6
RKT01261

5 -Once proper tension is achieved, retain the position of

the adjusting screw (3) by tightening the nut (2).

3 2

RKTA1205

6 -Lock the adjusting bracket (7) with the screw (1).

7
1

RKTA1221

WH6-1E0 WH7-1E0 20-39

TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR CABLE LENGTH

ADJUSTING ACCELERATOR CABLE LENGTH

1 -Tighten the nut (1) until lash from the spring (2) is
eliminated and the spring is loaded by approximately 1
mm.
2
1

3
RKTA2253

2 -Press the accelerator pedal to the floor and make sure

the injection pump control lever (3) performs its full travel
when the accelerator pedal lever (4) contacts the elastic 5
pad (5).

RKTA2301

3 -Lock the check-nut (6).

3
RKTA2254

20-40 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING THE STOP

ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING THE STOP

LAMP MICROSWITCHES
1 -Position the machine on firm level ground with the boom
fully retracted and lowered; stop the engine and remove
the ignition key.

2 -Install wedges under the wheels.

RKTA8430

• Checking procedure
1 -Remove the mat.
A
2 -Place a square (A) to the cab floor and move the square
close to the edge of the brake pedal (1).
1
3 -Press the brake pedal by hand and check pre-travel.

a Normal pre-travel “G”: 7 +0 1 mm

G

RKTA0191

4 -Release the pedal (1) and check the position height

wise.

a Normal height “H”: 110 +0 2 mm 1

H
5 -If either value is not within specifications, adjust as
needed.

RKTA0200

• Pedal height adjustment

1 -Loosen the screws (2) and remove the covers (3 and 4).
3

2
2

4
RKTA0210

WH6-1E0 WH7-1E0 20-41

TESTING AND ADJUSTMENTS ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING THE STOP

2 -Loosen the nut (5) and adjust pedal height (1) using the
stop pad (6).
6
a Normal height: 110 +0 2 mm 5

3 -When adjustment is complete, lock the pad (6) with the

nut (5).

RKTA7660

• Sprag length adjustment

9 1
1 -Loosen the nut (7).

2 -Remove the pin (8) connecting the sprag to the pedal

(1).
7
3 -Tighten or loosen the fork (9) in relation to the sprag to
adjust pedal pre-travel to specification.
8
a Pre-travel “G”: 7 +0 1 mm G

4 -Install the pin (8) to its final position and lock the nut (7).
RKTA7670

• Microswitch adjustment
1 -Disconnect the connector (10), remove the nut (5) and 5
the connector support (11).

11

10
RKTA0230

2 -Loosen nuts (12 and 13) and adjust the position of the
lamp stop microswitch (14), which should be
abandoned by the pedal after travel “B”.

a Travel “B”: 11 +0 2 mm 12
13
14
B

RKTA0220

20-42 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS ADJUSTING THE PARKING BRAKES

ADJUSTING THE PARKING BRAKES

k These adjustments should be carried out with the axle
levers adjusted to the specified clearances. (For
details, see "30 REMOVAL AND INSTALLATION").

1 -Position the machine on firm, level ground with the boom

fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and remove the ignition key.

RKTA8440

• Brake cable length adjustment.

3 A
1 -With the lever in the full down position, rotate the parking
brake knob (1) clockwise to obtain a projection “A” of the
cable end (2) in relation to the brake lever gauge block
(3).

a A = 32±1 mm. 2
NOTE
Direction of rotation is as it would be for the Operator
sitting in the driver seat.
1
RKTA0270

2 -Install the washer (4) and two nuts (5); tighten the nuts
(5) until the washer (4) contacts the gauge block (3) of 3
lever (6). 6
Lock the nuts (5) into position.
4

RKTA0283

3 -Apply a force gauge to the centre of the handle (1) and

ensure that the lever back stop is triggered when a force F
“F” of 40 is applied. +0 2 kg.

RKTA0290

WH6-1E0 WH7-1E0 20-43

TESTING AND ADJUSTMENTS ADJUSTING THE PARKING BRAKES

• Functional check
a Check conditions:
• Tire pressures within specifications. 1
• Dry, solid road surface with a gradient of 20% ( N)
approx.
• Machine in operating conditions with no load.

1 -Start the engine and align the machine to drive on a

straight line, and then drive up the slope with 20%
gradient.

2 -Stop the machine by applying the service brake; move RKTA0300

the reversing control lever (1) to the neutral position (N).

3 -Apply the parking brake (2) (lock position), slowly

release the service brake and ensure the machine does
not move.

4 - If the machine shows signs of moving downwards, 2

press the service brake pedal, move the brake lever to
the unlock position and rotate the lever end (2) anti-
clockwise by 2 or 3 turns.

5 - Apply the parking brake and check again.

6 -Stop the engine and leave the machine in place for 3

minutes. The machine MUST NOT move for the entire
P
three-minute period. RKTA0310

20-44 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS

BLEEDING AIR FROM CIRCUITS

• Pump housing fill
a The pump housing must be filled:
a - Whenever the pump is removed.
b - Whenever the drain hose or suction pipe is removed
or replaced.
c - Whenever the hydraulic oil is changed or the tank
undergoes maintenance.

1 -Remove the cap (1) and introduce hydraulic oil into the
pump housing (2) until the level reaches the locating
hole. 1
2 -Reinstall the cap (1).

2
RKTA7690

• Bleeding air from cylinders

a The air bleeding procedure should be performed before
operating the machine in normal conditions whenever
the hydraulic cylinders or the pipes/hoses connected to
them are removed.

a Tackle one movement at a time, starting with the main

cylinders (boom extension and boom up).

1 -Start the engine and run the engine at high speed for
about 5 minutes to heat the oil.

2 -Return the engine to idle and cause the 1st piston you
want to bleed to extend and retract several times.

a Extend and retract the pistons to within 100 mm

approx. of the limit stops.

3 -Stop the engine, check and top up the oil level.

4 - Run the engine at maximum speed and repeat the

procedures described in step 2. Return the engine to idle
and allow the piston to travel its full stroke until the
hydraulic pump is under max. pressure.

5 - Repeat the procedures (starting from step 2) on all

cylinders and make sure you frequently check the oil
level.

WH6-1E0 WH7-1E0 20-45

TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS

• Bleeding air from brake circuits

a This procedure should be carried out whenever work is 1
performed on the brake circuit to remove or replace a
component, or when air enters the circuit.

a The machine should be stopped, with the equipment to

the ground.

1 -Make sure the oil in the brake system oil tank (1) is at
max level.

RKTA2731

2 -Remove the safety caps and apply a clear hose (3) to the
bleed screws (2) to collect the oil.

3 -Press the brake pedal to the floor and simultaneously

loosen the bleed screw (2) of the brake unit under 2
maintenance until the pedal reaches the end of its travel.

4 -Hold the pedals at the end of their travel while

simultaneously tightening the bleed screw (2).

5 -Release the brake pedal, wait a few seconds, and

repeat the steps described so far until there are no
bubbles in the oil coming out of the bleed screw.
RKTA7700

6 -Repeat the same steps on the other brake units.

a Frequently check the oil level in the oil tank and fill
whenever the level is near minimum.
3
a At the end of the bleeding procedure, apply the
safety caps to the screws (2). 2

RKTA7710

20-46 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS PREPARING THE MACHINE READY FOR HYDRAULIC PRESSURE

PREPARING THE MACHINE READY FOR HYDRAULIC PRESSURE

CHECK AND CALIBRATION
k NOTICE
Some checking procedures described here require
the provisional installation of mini-taps. These taps
should be removed at the end of the checks.

1 -Position the machine on firm, level ground with the

transmission in NEUTRAL and the parking brakes
applied.

RKTA8430

2 -Start the engine and heat the hydraulic oil, and perform
the entire range of movements that are carried out in
normal working conditions. 1

a Check the hydraulic oil temperature by placing the

sensor of thermometer “A” to the pump suction pipe
(1).
Unless specified otherwise, temperature should be
50±5°C. A

RKTA7640

WH6-1E0 WH7-1E0 20-47

TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC

CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC

PRESSURES
FOREWORD
• The machine is equipped with a control valve with two
servo-controlled elements (for boom lift and for IDROGUIDA
STEERING UNIT
equipment dump and curl) and is provided with an
element with proportional electric control for the
extension and retraction of the boom’s telescopic
elements.
• The control valve is protected against overpressure by a
maximum-pressure valve (or general valve, called cut-
off valve) with adjustable calibration.

1 2

FR
TRASMISSIONE
TRASMISSION 3
DR
MOTORE
ENGINE P

P1
RKT01740
S

POMPA IDRAULICA
HIDRAULIC PUMP

• The control valve is fed by the total capacity of pump P1.

• The capacity of pump P1 is partialized by the priority

valve (inside the control valve head) whenever the
power steering is engaged for a steering manoeuvre.

• The control valve contains spools which control the

following:
B
CONTROL USE 1 2 3

Boom cylinder A
A1 - B1
(Up/Down movement)

Equipment cylinder
A2 - B2
(Dump/Curl)

Telescopic cylinder
A3 - B3 RKT01750
(Extension/Retraction)

20-48 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC

1. CALIBRATION CHECK
GENERAL VALVE
(Cut-off valve)
a Check conditions:
• Engine: at operating temperature
• Hydraulic oil 50±5 °C
• Parking brakes: applied 1

1 -Connect a 600 bar pressure gauge to the pressure tap

(1) of the control valve (2).
2
2 -Start the engine and run it at IDLE and check the RKTA7720

calibration pressure of the cut-off (general) valve while

forcing the boom down to the end of its travel.

a Calibration pressure: 260±7 bar

3 -Using the same method as above, also check
calibration pressure with the engine running at 2000
rpm.

a Max allowable variation: 5 bar

a If general valve pressure does not match the
specified value, perform the calibration procedure.
(For details, please refer to "3. GENERAL AND
SECONDARY VALVE CALIBRATION").

2. SECONDARY VALVE
CALIBRATION CHECK
• Boom lift and extension
a Check conditions:
• Engine: at operating temperature
• Hydraulic oil: 50±5 °C
1
• Parking brake applied

a All pressure readings are taken at the same check point.

1 -Connect a 400 bar pressure gauge to the pressure tap 2
RKTA7720

(1) of the control valve (2).

2 -Remove the general valve seal (3), loosen the nut (4)
and tighten the pressure regulating screw (5) by 2 turns.
Lock the nut (4).
3
3 -Start the engine and run it at IDLE; perform a full boom
lift motion and measure max pressure.
a Normal pressure: 275±7 bar.

4
RKT01760

WH6-1E0 WH7-1E0 20-49

TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC

4 -Lower the boom and, with the engine at IDLE; extend

boom to end of travel and measure max pressure.
a Normal pressure:
WH609-WH613
WH713-WH714H: 275±7 bar
WH 716: 190±7 bar
a If valve calibration is not within specifications,
perform the calibration procedure. (For details, see
"3. GENERAL AND SECONDARY VALVE
CALIBRATION").

5 -Loosen the nut (3) and loosen the cut-off valve adjusting
screw (4) until normal pressure is restored. This should
be checked using the procedure described at step 2.

6 -Install a new seal (orange colour).

• Equipment dump and curl

NOTE
These checks require no change to the calibration of the
general valve.

a Check conditions:
• Engine: at operating temperature
• Hydraulic oil: 50±5 °C
• Parking brake applied

a All pressure readings are taken at the same check point.

1 -Connect a 600 bar pressure gauge to the pressure tap
(1) of the control valve (2).

2 -Start the engine and run it at IDLE; perform a full

equipment dump motion and measure the max pressure
value.

a Normal pressure: 200±7 bar

3 -Also check max pressure with a full equipment curl.

a Normal pressure: 200±7 bar

a If valve calibration is not within specification,

perform the valve calibration procedure. (For
details, refer to "3. GENERAL AND SECONDARY 1
VALVE CALIBRATION").

2
RKTA7720

20-50 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC

3. GENERAL AND SECONDARY

VALVE CALIBRATION
• General cut-off valve (1)

k Prepare the machine for calibration as described for the

pressure checking procedure.

1 -Remove the tamper seal (2) (yellow colour) 1

2 -Loosen the retaining nut (3).

3 -With the engine at IDLE, lower the boom to the end of its
2
travel. RKTA7720

4 -Adjust maximum pressure using the screw (4) provided.

• Turn the screw CLOCKWISE to INCREASE
pressure. 2 3
• Turn the screw COUNTER-CLOCKWISE to
DECREASE pressure.

5 -Tighten the nut (3) to retain the position.

3 Retaining nut: 20 Nm
6 -Install a new tamper seal (2) (orange colour).

4
RKT01610

• Secondary valves

k Prepare the machine for calibration as described for the

pressure checking procedure.

a This calibration applies to all secondary valves and can

be inspected by forcing the movement to the end of its
travel when checking.
1
1 -Loosen the retaining nut (1).

2 -Adjust pressure using the adjusting screw (3).

• Turn the screw CLOCKWISE to INCREASE 2
pressure. RKTA7720

• Turn the screw COUNTER-CLOCKWISE to

DECREASE pressure.

3 -Tighten the nut (2) to retain the position.

3 Retaining nut: 10±1 Nm

1
2
k At the end of adjustment, apply a protection (1) (orange
colour) against unauthorized tampering.

4 -Restore the general valve pressure.

3
RKT01620

WH6-1E0 WH7-1E0 20-51

TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC

4. SERVOCONTROL PRESSURE CHECK

1
a Check conditions
• Engine: stopped but at operating temperature
• Hydraulic oil: 50±5 °C
• Parking brake: applied

1 -Remove the PV cap from the servocontrol feed

assembly (1) and install a mini-tap (2). 2
2 -Connect a 60 bar pressure gauge.

a Version with Slow-Motion: check pressure on the RKTA7730

mini-tap (3) equipped.

3 -Start the engine and run it at IDLE; perform a full curl

motion and check max pressure.

a Normal pressure: 35 --0 3.5 bar

4 -Gradually run the engine to MAX speed, checking
pressure stability.

a Max allowable variation: 2 bar

RKTA7740

RKTA8450

5. CHECKING STEERING PRESSURE AND

PRIORITY VALVE OPERATION
a Check conditions:
• Engine stopped but at operating temperature.
• Hydraulic oil: 50±5 °C.
• Parking brakes applied.
1
1 -Connect a 60 bar pressure gauge to the pressure tap (1)
of the control valve (2).

2
RKTA7720

20-52 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC

2 -Start the engine, operate at 1500 rpm and start a light

steering manoeuvre, making sure that pressure
increases.

3 -Continue steering until full steering is obtained and

make sure that the pressure increases to normal value
when the steering wheel is forced.

a Normal pressure:
WH609 - WH613: 180±5 bar
WH713 - WH714H - WH716: 185±7 bar

4 -Ensure that no pressure variation exceeding 5 bar is

experienced when increasing to MAX speed.
3
a If pressure fails to reach normal value, perform the
steering system pressure calibration procedure.
(For details, see "CALIBRATING THE PRESSURE
OF THE STEERING SYSTEM").

a If the pressure displayed on the pressure gauge

shows no variation when turning the steering wheel,
and the effort needed to execute the steering
operation is high, inspect the operation of the
priority valve (3). RKTA1113

• Inspection of priority valve operation

1 -Remove the valve plug (4), spring (5), and stem (6) from
the priority valve (3).
a Note down the assembly sequence. 7
2 -Detach the plug (7) and remove the ball (8) of the inner
valve and remove the spring (9). 9
3 -Check the hole (10) and nozzle (11) for being clean.
4 -Reinstall the spring (9), ball (8) and plug (7). 8 10
2 Plug: Loctite 542
3 Plug: 20 Nm
a Do not allow Loctite to penetrate inside the hole
6
(10). 5
a Remove any excess Loctite from the valve stem (6). 11
5 -Lubricate the valve stem (6) and seat it, making sure it
slides freely.
6 -Introduce the valve spring (5) and install the valve plug 4
(4).

3 Plug: 100 Nm
7 -Start the engine, perform a few steering manoeuvres,
and if the malfunction is not eliminated, replace the RKT01770

complete valve stem.

WH6-1E0 WH7-1E0 20-53
TESTING AND ADJUSTMENTS CALIBRATING THE PRESSURE OF THE STEERING SYSTEM

CALIBRATING THE PRESSURE OF THE STEERING SYSTEM

a Check conditions:
• Engine stopped but at operating temperature
• Hydraulic oil: 50±5 °C.

• Checking procedure
1 -Connect a 600 bar pressure gauge to the pressure tap
(1) of the control valve (2).
1
2 -Start the engine and operate the engine at 1500±50 rpm
and perform a full steering motion.

3 -Force the steering wheel as far as it will go while 2

simultaneously checking the steering pressure. RKTA7720

a Normal pressure:
WH609 - WH613: 180±5 bar
WH713 - WH714H - WH716: 185±7 bar

4 -Perform an identical check on the opposite steering

direction.

• Calibration procedure
If pressure is not within specification, perform the calibration
procedure through the power steering maximum-pressure 6 5 4 7
valve (3).

1 -Remove the plug (4).

2 -Introduce a 4-mm hex wrench and loosen the screw (5).

3 -Adjust pressure using the adjusting screw (6).
• Turn the screw CLOCKWISE to INCREASE
pressure. 3
• Turn the screw COUNTER-CLOCKWISE to RKTA8420

DECREASE pressure.

4 -Stop the engine and retain the position of the adjusting

screw (6) by tightening the screw (5).

5 -Reinstall the plug (4), ensuring that the seal (7) is

correctly in place.

20-54 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS INSPECTING THE OPERATION OF THE UNLOADING VALVE

INSPECTING THE OPERATION OF THE UNLOADING VALVE

a Check conditions:
• Engine stopped but at operating temperature
1
• Hydraulic oil: 50±5 °C.
• Parking brakes: applied 2
1 -Connect the 600 bar digital pressure gauge for multiple
readings to feed pressure tap P (1), and to pressure tap
LS (2).

2 -Start the engine and operate it at MAX speed with no

load.

3 -When the speed is stabilized, check the DP on the RKTA7750

pressure gauge display.

a Normal difference: 21±1 bar

a If the difference in pressure is not within
specification, replace the unloading valve (3).

RKTA7760

WH6-1E0 WH7-1E0 20-55

TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING THE DR VALVE (PUMP FLOW

CHECKING AND CALIBRATING THE DR VALVE

(PUMP FLOW VARIATION)
• Checking procedure
a Check conditions:
• Engine stopped but at operating temperature.
• Hydraulic oil: 50±5 °C.
• Parking brakes applied.

1 -Connect a 600 bar pressure gauge to the pressure tap

(1) of the control valve (2).
1

2 -Remove the general valve seal (3), loosen the nut (4)
and tighten the pressure regulating screw (5) by 2 turns.
2
Lock the nut (4). RKTA7720

3 -Start the engine and run it at IDLE; lower the boom to its
maximum travel and check max pressure. 3 4
a Normal pressure: 280 + 5 bar
0

5
RKT01611

• Calibration procedure
If calibration does not match the specified value:

1 -Remove the cap (6). 9

2 -Loosen the nut (7).

3 -Adjust pressure using the adjusting screw (8).

• Turn the screw CLOCKWISE to INCREASE
pressure.
• Turn the screw COUNTER-CLOCKWISE to
DECREASE pressure. 7 8 6
RKT01780
7 -Tighten the nut (7) to retain the position.

3 Retaining nut: 21 Nm
8 -Check the grommet (9) and install the cap (6).

3 Cap: 21 Nm
9 -Loosen the nut (4) and loosen the cut-off valve adjusting
screw (5) until normal pressure is restored. (For details,
s e e " 3 . G E N ER A L A N D S E C O N D A R Y V A L V E
CALIBRATION").

10 -Install a new seal (3) (orange colour).

20-56 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING THE DYNAMIC PUMP DP VALUE

CHECKING THE DYNAMIC PUMP DP VALUE

a Check conditions:
• Engine stopped but at operating temperature.
2
• Hydraulic oil: 50±5 °C. 1
• Parking brakes applied.

1 -Remove the plug (P) from the pump flow regulating unit 4
(1) and install a pressure tap (2).

2 -Disconnect the LS (3) hose from the regulating unit, 3

install a pressure tap (4) and reconnect the hose.
3 -Connect two 600-bar pressure gauges or transducers to
the pressure taps. RKTA7770

4 -Disconnect the control valve feed hose (5) and

introduce a flow meter “F” between the pump feed hose F
(6) and hose (5).

5
RKTA8460

5 -Start the engine and start lifting the boom at increasing

speed until a steady flow of 45±3 l/min. is displayed on
the flowmeter (A).
6 -Once the value is reached, check the pressure on the P
and LS pressure gauges and perform a calculation to
obtain the difference in pressure, or check the DP.
a Repeat the measurements several times and
calculate the average.
a Normal DP: 17.5±1 bar
• If pressure is not within specifications:
7 -Remove the cap (7). RKTA7790

8 -Loosen the nut (8).

9 -Adjust pressure using the adjusting screw (9). 7 8

• Turn the screw CLOCKWISE to INCREASE
pressure.
• Turn the screw COUNTER-CLOCKWISE to
DECREASE pressure.
9
10 -Tighten the nut (8) to retain the position.

3 Retaining nut: 21 Nm
11 -Check the grommet and install the cap (7).

3 Cap: 21 Nm RKT01910

WH6-1E0 WH7-1E0 20-57

TESTING AND ADJUSTMENTS CHECKING PUMP FLOW

CHECKING PUMP FLOW

a Check conditions:
• Engine: stopped but at operating temperature 1
• Hydraulic oil: 50±5 °C.
• Parking brake: applied 2
1 -Disconnect the hoses (1) and (2) from the boom
extension and retraction cylinder lock valve (3) and
connect them to a two-way valve (4). 3
4

RKTA7800

2 -Disconnect the control valve feed hose (5) and

introduce a flow meter “F” between the pump feed hose F
(6) and hose (5).

3 -Connect a 600 bar pressure gauge to the pressure tap

(7) of the control valve (8).

5
RKTA8460

4 -Start the engine and operate it at 2000 rpm under load,

operating the boom retraction control and gradually
tightening the valve (4) until a pressure of 200±1 bar is
reached; then, check pump flow.

a Normal flow: MIN = 92 l/min

MAX = 98 l/min

5 -Repeat the same check at a pressure of 230±1 bar 7

a Normal flow: MIN = 77 l/min
MAX = 79 l/min

6 -If flow readings are different from the ones specified, 8

RKTA7721

recondition or replace the pump.

20-58 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS BRAKE SYSTEM CHECKS

BRAKE SYSTEM CHECKS

a Check conditions:
• Engine: stopped
• Machine: on firm level ground, with stabilizers fully
extended. If the machine is not equipped with
stabilizers, place wedges under the wheels.

The brake system checking procedure consists of two steps:

1 -Inspecting the circuit and brake pumps for leaks.
2 -Inspecting the brake units for leaks.
k If both inspections yield positive results, the
system lines should be checked for leaks. RKTA8440

• Inspecting the circuit and brake pumps for

leaks.

k Carry out the inspection on both front and rear brakes.

3
1 -Disconnect the relevant brake feed hose (2) from the
brake pump (1).
2 -Install a pressure tap (3) connected to a 250 bar 1
pressure gauge between the pump fitting (1) and the
feed hose (2).
2
3 -Start the engine and operate it at IDLE, press the brake
pedal and pressurize the circuit to 120 bar. RKTA7810

a Do not exceed the maximum pressure allowed,

which is 150 bar.
4 -Hold the pressure on the pedal for at least two minutes
and check that the pedal pressure and position remain
steady.

a 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 a blow-by condition inside the
pump.
Proof of this can be had by checking the oil in the
tank. If there is blow-by, the oil will be stirred.
5 -Repeat the same steps on the other brake pump.

• Inspecting the brake units for leaks

1
1 -Disconnect the feed hose (1) and remove the pipe (2).

RKTA7820

WH6-1E0 WH7-1E0 20-59

TESTING AND ADJUSTMENTS BRAKE SYSTEM CHECKS

2 -Connect the feed hose (1) to an apparatus consisting of

an isolator valve (3) a pressure tap (4) and an additional 3
hose (5) to be connected to the fitting of the unit to be
checked.

a The pressure tap (4) should be installed between

the hose (5) and the valve (3).

3 -Connect a 250 bar pressure gauge to the pressure tap

and open the isolator valve. 4
5
4 -Operate the brake pump and pressurize the circuit at a
maximum pressure of 150±5 bar.
RKTA7830

5 -Keep holding the pressure and close the isolator vale (3)
to keep the brake unit pressurized.

6 -Release the brake pedal and monitor the pressure

displayed on the pressure gauge for two minutes.

a If the pressure value shows a negative variation,

then the axle brake piston seals are faulty and
servicing is required on both brake units.

k Further proof of leakage is an increased oil level in

the axle causing the oil to be stirred. Replace all
seal rings in the axle and change the oil.

7 -Repeat the test on the other brake unit using the same
procedure described above.

k When checks and repairs, where applicable, are

completed, bleed the air from the brake units. (See
"BLEEDING AIR FROM CIRCUITS").

20-60 WH6-1E0 WH7-1E0

PAGE INTENTIONALLY
LEFT BLANK
TESTING AND ADJUSTMENTS TRANSMISSION (POWER SHIFT) CHECKS

TRANSMISSION (POWER SHIFT) CHECKS

The transmission can be affected by three kinds of
problems:
1 -Mechanical problems (worn clutches, bearings, etc.)
2 -Hydraulic problems (operating pressure, pump
conditions, etc.)
3 -Electrical problems (faulty solenoids and/or poor
electrical connections)
• All transmission checks should be carried out: with the
engine at IDLE and MAX rpm – controlled even under
load – with the pressures in the hydraulic circuits of the
machine and in the equipment perfectly calibrated and
with the transmission oil at MAX level.
• Before attempting to perform the inspections on the
clutches, make sure the all the shifts and the direction of
translation can be selected; also ensure that the service
and parking brakes are in perfect operating condition.
• Also check the exchanger for being clean, as the
exchanger is expected to keep the transmission oil
temperature within specifications.

a Allowable temperature: 70–120 °C

P41
P31
P42 P45

P43 P46

P44

RKT01930

P41 - 1st clutch pressure P31 - General clutch pressure

P42 - 2nd clutch pressure P45 - Forward gear clutch pressure
P43 - 3rd clutch pressure P46 - Reverse gear clutch pressure
P44 - 4th clutch pressure

20-62 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS TRANSMISSION (POWER SHIFT) CHECKS

TROUBLESHOOTING GUIDE

• Low clutch pressure

Cause Solution

1. Oil level is low. 1. Top up the oil level.

2. Pressure-control valve shows a blow-by condition. 2. Clean the valve spool and seat.

3. Feed pump is faulty 3. Replace the pump.

4. Piston seal rings or shaft segments are faulty. 4. Replace the rings and segments.

5. Clutch piston exhaust valve shows blow-by 5. Clean the valve.

condition.

• Low feed pressure

Cause Solution

1. Oil level is low. 1. Top up the oil level.

2. Suction filter is clogged. 2. Clean the filter.

3. Feed pump is faulty 3. Replace the pump.

• Overtemperature
Cause Solution

1. Seal rings are worn. 1. Remove and recondition the converter.

2. Pump is worn. 2. Replace the pump.

3. Oil level is low. 3. Top up the oil level.

4. Exchanger is dirty. 4. Clean the exchanger.

5. Exchanger feed and return hoses are obstructed or 5. Replace the hoses.
damaged.

• Noisy converter
Cause Solution

1. Pump is worn. 1. Replace the pump.

2. Bearings are damaged. 2. Fully remove the assembly to inspect the damaged
bearings.

• Poor power
Cause Solution

1. Engine speed is low when converter is stalled. 1. Check pump injection.

2. See OVERTEMPERATURE and carry out the 2. Solutions are illustrated in the
checks described there. OVERTEMPERATURE section.

WH6-1E0 WH7-1E0 20-63

TESTING AND ADJUSTMENTS TRANSMISSION ASSEMBLY PRESSURE CHECKS

TRANSMISSION ASSEMBLY PRESSURE CHECKS

Pressure checks can be carried out on the inner hydraulic
circuits of the transmission to find out any malfunctions.
These checks concern:
1 -General converter pressure.
2 -Engagement pressure for each individual clutch.
a Check conditions:
• Engine stopped but at operating temperature.
• Machine in neutral gear, on level ground, with
parking brakes applied.
• Transmission oil temperature: 82–93 °C.
• Transmission oil level: MAX.

1. General converter pressure

P31
1 -Remove the P31 plug and connect a 60 bar pressure
gauge.

2 -Start the engine, operate it at IDLE and check the

pressure.
a Normal pressure: 16.75 bar
3 -Gradually increase engine speed to 2000±30 rpm and
check pressure gauge reading.
a Normal pressure: 19.30 bar
a If the pressure values are lower than the specified
RKTA7840

values, the transmission pump needs replacing.

4 -Remove the pressure gauge and re-install the plug.

2. Engagement pressure for each individual

clutch
a Check conditions:
• Machine on firm level ground, with wheels raised by
outriggers and jack stands or resting on jack stands.
• Engine stopped but at operating temperature.
• Transmission oil temperature: 82–93 °C.
• Transmission oil level: MAX.
• Ports to be used for these checks:
P45 - FORWARD GEAR clutch pressure
P46 - REVERSE GEAR clutch pressure
P41 - 1st clutch pressure
P42 - 2nd clutch pressure
P43 - 3rd clutch pressure
P44 - 4th clutch pressure RKTA7850

20-64 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS TRANSMISSION ASSEMBLY PRESSURE CHECKS

3. Inspecting the 1st clutch - forward and

reverse gear
1 -Remove the P41 plug from the 1st clutch and connect a
P41
60 bar pressure gauge.
2 -Start the engine in NEUTRAL, operate it at 1800 rpm
and check the pressure on the pressure gauge.
a Normal pressure: 0–0.2 bar
3 -Engage the 1st FORWARD gear and operate the
engine at 1800 rpm.
4 -Check the pressure on the pressure gauge.
a Normal pressure: 16.5-19.3 bar RKTA7860

5 -Remove the pressure gauge and re-install the P41 plug.

6 -Remove the P45 FORWARD GEAR selection plug and
connect the pressure gauge (60 bar).
7 -Carry out steps from 3 to 5 to check the pressure values.
Readings should match the values specified in steps 2 P45
and 4.
8 -Repeat the same procedure for the P46 REVERSE
GEAR plug by engaging the 1st REVERSE gear.
Pressure readings should match the values stated in 2
and 4 above.

k If both forward and reverse pressures differ from

P46
the specified values, then there is a loss of
RKTA7870
pressure affecting the thrust piston of the clutch
with the lesser pressure.

4. Inspecting the 2nd – 3rd – 4th clutch

1 -Remove the P42 plug and connect a 60 bar pressure
gauge.
2 -Start the engine in NEUTRAL, operate it at 1800 rpm
and check the pressure on the pressure gauge.
a Normal pressure: 0-0.2 bar
3 -Select the 2nd FORWARD gear and operate the engine
at 1800 rpm.
P42
4 -Check the pressure on the pressure gauge.
RKTA7880

a Normal pressure: 16.5–19.3 bar.

5 -Stop the engine, remove the pressure gauge and re-
install the plug.

6 -Repeat the same checks on the lines of the P43 and P44 P43
plugs by engaging the 3rd FORWARD and 4th
FORWARD gears respectively. Pressures should be:
• with no gear engaged (NEUTRAL): 0–0.2 bar
• in gear: 16.5–19.3 bar

k If clutch pressures with the gears engaged are

lower than those specified, then there are leaks in
the seal segments. In this case, the transmission P44
needs reconditioning. RKTA7890

WH6-1E0 WH7-1E0 20-65

TESTING AND ADJUSTMENTS TRANSMISSION ASSEMBLY PRESSURE CHECKS

5. Transmission clutch wear inspection

This inspection is to be performed after completing the
inspection of the engine under load. The same procedures
apply. Transmission operating pressures must have been
checked before performing this inspection.
If rotation speeds differ from those specified for the
INSPECTION OF THE ENGINE UNDER LOAD, then the
clutches are worn and need to be replaced.

20-66 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING THE SPEED OF THE TRANSMISSION SHAFTS

CHECKING THE SPEED OF THE TRANSMISSION SHAFTS

RESPONSIBLE FOR TRANSLATION (CARDAN SHAFTS)
a Check conditions:
• Machine on firm, level ground with the boom fully
lowered and retracted.
• Frame perfectly levelled.
• Engine stopped but at operating temperature.
• Transmission oil: 50–70 °C (measured at the filter).

RKTA7850

1 -Fully extend the stabilizers to lift the front wheels.

k If the machine is not equipped with stabilizers,

apply two jack stands with anti-slip blocks under
the front frame in order to raise the machine by 10
cm approximately.

2 -Apply two jack stands “A” with anti-slip blocks under the
rear frame and raise the jack stands until the rear wheels
are lifted by 10 cm. approx.
A
3 -Apply a reflective strip “B” to the rear cardan shaft (1) in
order to be able to take rotation speed measurements
RKTA7900
with a stroboscopic tachometer.

4 -Start the engine and engage all the gears successively,

and, for each gear, check the number of cardan shaft
revolutions with the engine stabilized at the MAX rpm B 1
value.
Also check cardan shaft speed with the reverse gears.

a Speed to be checked:

NORMAL ALLOWABLE
SPEED SPEED

1 570 513 – 621

TRANSLATION DIRECTION

2 1243 1119 – 1355

FORWARD

RKTA7910

3 1889 1700 – 2059

4 2550 2295 – 2780

5 3863 3477 – 4211

1 570 513 – 621

REVERSE

2 1243 1119 – 1355

3 2550 2295 – 2780

a If shaft speeds are not within specifications, then the

clutches are worn.

WH6-1E0 WH7-1E0 20-67

TESTING AND ADJUSTMENTS LEVEL CALIBRATION

LEVEL CALIBRATION
1 -Position the machine on firm, perfectly level ground with
the boom fully lowered and retracted.

k Check that the forks are not resting on the ground,

and then stop the engine.

2 -Ensure that the tires are inflated to the proper pressure.

RKTA8430

3 -Level the frame crosswise using an electronic level or a

standard 40 cm level (“A”) placed on the front part of the
frame.

RKTA7920

4 -Tighten or loosen the screws (1) until the bubble (2) is

perfectly centred in relation to the centre ring. 1 3°
1°
0 5°
5° 0
1°
3°

RKTA8010

20-68 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING LOAD CELL CALIBRATION

CHECKING LOAD CELL CALIBRATION

a Check conditions:
1
• Frame perfectly levelled.
• Tires at prescribed pressure.
• Machine on firm level ground, with standard forks
installed.

1 -Disconnect the connector (1). Between the load cell and B

the wiring, place an extension lead A with two sockets A
for plugging the pins of tester B.

RKTA7930

1. Checking load signal with no load

1 -Using a level C, position the basic boom parallel to the
C
ground.

2 -Ensure the forks are raised but parallel to the ground.

3 -Check the signal emitted by the load cell.

a Normal signal: 30–35 mA

RKTA7940

2. Checking load signal in turnover

conditions
1 -Place the specified weight “P” on the forks and extend
the boom until the rear wheels lift off the ground by about
10 cm. P

MACHINE P

WH 609 2000 kg

WH613 - WH 713 - WH716 - WH714H 1000 kg

RKTA7950

2 -Check the signal emitted by the load cell.

a Normal signal: 35–45 mA.

k If the signal emitted by the load cell is not within

standard values, replace the load cell.

RKTA7960

WH6-1E0 WH7-1E0 20-69

TESTING AND ADJUSTMENTS CALIBRATING THE OVERTURN PREVENTION SYSTEM

CALIBRATING THE OVERTURN PREVENTION SYSTEM

(STANDARD)
• Calibration conditions
1 -Place the machine on a firm (concrete) platform that is
perfectly level. Do not apply the brakes and do not retain
the machine with outriggers or wedges.

2 -Ensure that calibration is performed in the absence of

wind, that the frame is levelled and that the wheels are
perfectly aligned.

3 -Make sure that the tire pressure is within specifications.

4 -The boom should be fully retracted and lowered to the
ground. Ensure that the forks are off the ground and in RKTA8430

their horizontal position.

k 1 - Calibrate the system using standard forks

only.

2 - Do not calibrate the system when optional

equipment is installed to the machine.

5 -After connecting the load cell connector (1) to the

machine wiring (2), start and operate the engine for at 2 1
least 15 minutes before starting the calibration
procedure.

6 -Stop the engine.

RKTA7970

• Calibration procedure
1 -Remove the dash front centre protective cover (3).
3

RKTA8020

20-70 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CALIBRATING THE OVERTURN PREVENTION SYSTEM

2 -Introduce a test jumper wire (4) into the female

connector (X30).

RKTA7980

3 -Crank the engine to start the procedure for calibrating

the overturn prevention unit. Calibration mode is
indicated by a green lamp (5) illuminating.

5
RKTA7990

4 -Press the “TEST” button (6) to save the first value in the
load range.
Now, the LED (5) will start blinking for 8 seconds to
indicate that the value of minimum load without
outriggers is being learnt.

5 -Learning ends when the green LED (5) turns off and is
6
confirmed by an audible tone which is emitted for 2
seconds. 5

RKTA8000

6 -When the tone stops, the red lamp (7) turns on. The red
lamp indicates maximum load. 7

RKTA7991

WH6-1E0 WH7-1E0 20-71

TESTING AND ADJUSTMENTS CALIBRATING THE OVERTURN PREVENTION SYSTEM

7 -Place a load "P" on the forks:

8
MACHINE P

WH 609 2000 kg

WH613 - WH 713 - WH716 - WH714H 1000 kg

P

NOTE
As load, you can use the same weight (one that is
suitable to the machine model) you have used for
checking the calibration of the load cell.
RKTA7951

8 -Gradually extend the boom (8), keeping the boom

parallel to the ground, until the rear wheels (9) lift off the
ground by approximately 10 cm.

9
RKTA7961

9 -Press the TEST button (6) to save the second value of

the load range.
Now, the LED (7) will start blinking for 8 seconds to 7
indicate that the value of the maximum load without
outriggers is being learnt.

10 -Learning ends when the red LED (7) turns off and is
6
confirmed by an audible tone which is emitted for 2
seconds.

RKTA8001

11 -Make sure that the procedure has been performed

correctly. If it has, the only LED still activated should be
the green LED (10) (POWER ON) while the horn (11)
should remain activated until the jumper wire (4) is
removed.

11
10

RKTA7992

20-72 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CALIBRATING THE OVERTURN PREVENTION SYSTEM

k IMPORTANT
a - If the jumper wire (4) in connector X30 loses a contact or
is removed before calibration is complete, calibration
will not be performed and the system will keep the
previous calibration as the applicable one. 4
b - In the event of a power cut (12V), calibration will be
cancelled. In this case, it is necessary to start a new
calibration procedure from the first step.
c - If, at the end of calibration, the overturn prevention
device blinks, this indicates that the following conditions
are occurring or have occurred:
• error during calibration; RKTA7980

• sensor malfunction;
• poor wiring continuity condition leading to non
repeatability of measurement.
d - In these conditions, all the LEDs will blink and the chime
(11) will emit a continuous sound. To know the type of
malfunction that is affecting the system, press the TEST 11
button (6). This will display the activation log for LED
coding.

k IMPORTANT 6
The only way to reset the system for normal operation is
by removing and re-introducing the ignition key.

RKTA7994

• Error coding
7
6
5
4

1. Errors at system start

1
0 = LED deactivated RKTA7993

1 = LED activated

Coding

Power LEDs are numbered from bottom to top

Likely cause LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7

Sensor is not connected or with current <

1 1 0 0 1 0 0
absolute Min.

Sensor is shorted or with current > absolute

1 1 0 0 0 1 0
Max.

System is not calibrated 1 0 1 0 1 0 1

Green Green Green Yellow Yellow Red Red

WH6-1E0 WH7-1E0 20-73

TESTING AND ADJUSTMENTS CALIBRATING THE OVERTURN PREVENTION SYSTEM

2. Errors during normal operation

0 = LED deactivated
1 = LED activated

Coding

Power LEDs are numbered from bottom to top

Likely cause LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7

Sensor is not connected 1 1 0 0 1 0 0

Sensor current is out of absolute range 1 1 0 0 0 1 0

Sensor is shorted 1 1 0 0 1 0 1

Green Green Green Yellow Yellow Red Red

3. Errors during calibration

0 = LED deactivated
1 = LED activated

Coding

Power LEDs are numbered from bottom to top

Likely cause LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7

Min. current acquisition < absolute Min. 1 0 1 0 1 0 0

Max. current acquisition > absolute Max. 1 0 1 0 0 0 1

Min. current acquisition XMax. current

1 1 0 1 0 1 0
acquisition

Green Green Green Yellow Yellow Red Red

20-74 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CALIBRATING THE OVERTURN PREVENTION (ASM) CONTROL

CALIBRATING THE OVERTURN PREVENTION (ASM) CONTROL UNIT

• INSTRUMENT CALIBRATION CONDITIONS
1 -The vehicle should be parked on flat, level ground. It
should be perfectly levelled, with no brakes applied and
no outriggers or wedges in place.
2 -The wheels should be perfectly aligned, the tires inflated
to the prescribed pressure.
3 -The boom should be fully retracted and parallel to the
ground. Ensure that the forks are off the ground and in

k1-
their horizontal position.
Calibrate using standard forks only.
2 - Do not calibrate the system when optional
equipment is installed to the machine.
RKTA8430

• INSTRUMENT CALIBRATION PROCEDURE

1 -Start the engine, place magnet (A) between PPC valve
LED (B) and horn LED (C).
Hold magnet in position while simultaneously pressing A
the TEST (D) button. This will activate all LEDs; hold the
button depressed for 20-30 seconds to enter calibration B
mode.

RKAA3680

2 -Release the TEST button and remove the magnet (A) as

LED 5 B
soon as LED 1 and LED 5 illuminate on the load scale
indicator (E). LED 3
C
3 -In this condition, press the TEST button (D) to save the E
first value in the load range (weight with no load).
4 -The storing of the first value in the load scale will cause LED 2
LEDs 3 and 5 to illuminate, indicating that the unit is
ready to learn the overturn weight. LED 1 D

RKAA3690

5 -Place a load "P" on the forks:

MACHINE P 1

WH 609 2000 kg

WH613 - WH 713 - WH714H- WH716 1000 kg P

RKAA3391

WH6-1E0 WH7-1E0 20-75

TESTING AND ADJUSTMENTS CALIBRATING THE OVERTURN PREVENTION (ASM) CONTROL

6 -Gradually extend the boom (1), keeping the boom

parallel to the ground, until the rear wheels (2) lift off the
ground by approximately 10 cm.

7 -Press the TEST button (D) to store overturn weight.

All LEDs on the panel should illuminate to indicate that
the value has been stored successfully.
In this condition, the ASM (Automatic Stop of
aggravating Movements) – AUTOSTOP – function is
enabled. This function inhibits all boom movements
except for boom retraction. 2
k In the even of a power cut during data acquisition, RKAA3401

calibration of the instrument will be cancelled.

The only way to restore the conditions required for
starting a new calibration procedure is to remove and
then reinsert the ignition key.

20-76 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING LED CALIBRATION (version with ASM)

CHECKING LED CALIBRATION (version with ASM)

• Check conditions
1 -The vehicle should be parked on flat, level ground. It
should be perfectly levelled, with no brakes applied and
no outriggers or wedges in place.

2 -The wheels should be perfectly aligned, the tires inflated

to the prescribed pressure.

3 -The boom should be fully retracted and perfectly parallel

to the ground. Ensure that the forks are off the ground
and in their horizontal position.

4 -The engine should be idling within the standard range of RKTA8430

values (1050±50 RPM).

k 1 - Perform checks using standard forks only.

2 - Do not perform checks when any optional
equipment is installed to the machine.
• CHECKING THE ACTIVATION OF THE 4TH
AND 5TH LED
1 -Place a 1000-kg weight “Q” onto the forks and repeat the 4 5
procedures described in the previous paragraph until the
4th LED (4) is activated.

2 -Extend boom gradually and slowly until the first LED

activates.

3 -Measure the size of gap "L" between basic boom and top
boom (2-stage machines) or between basic boom and
intermediate boom (3-stage machines).

4 -Fully retract the boom; take two more measurements RKAA3694

and calculate the average.

5 -Check to ensure that “L” is within the specified values.

6 -Carry out the same procedure for the 5th LED (5) and
check that the average of the “L” measurements is within
the specified values.

Unit: mm

LED 4
WH609
Machine: WH609 with WH613 WH713 WH714H WH716
stab.
“L” ±200 2860 2763 1290 1749 2033 1750

LED 5
WH609
Machine: WH609 with WH613 WH713 WH714H WH716
stab.
“L” ±200 3520 3420 1590 2124 2448 2050

WH6-1E0 WH7-1E0 20-77

TESTING AND ADJUSTMENTS CHECKING SLIDING PADS CLEARANCE

CHECKING SLIDING PADS CLEARANCE

a This inspection should be performed when servicing the
machine after 2000 hours of operation or after the boom
has suffered a severe side impact which makes it
necessary to check the alignment.

a Check conditions:
• Machine on firm, level ground, parking brakes
applied, or stabilizers fully extended, if equipped.
• Boom fully extended.
• Engine not running.

RKTA8070

1. Intermediate boom front sliding pads

clearance 1

1 -Remove the screws (1) and remove the front cover (2).

RKTA0025

2 -Using a feeler gauge (A), check clearance the between

upper side sliding pads (1) and top boom (2).

3 -Add up the readings to obtain the total clearance.

a Normal total clearance X : 1–1.5 mm

A
a Max. allowable total clearance: 2.25 mm 2
4 -Perform the same check on the lower sliding pads.

1
1 2
X RKTA8080

5 -Check clearance between RH and LH upper sliding

pads (3) and top boom (2).
3
a Normal clearance Y : 1.5 mm
a Max. allowable clearance: 3 mm
3

A 2
RKTA8090

20-78 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING SLIDING PADS CLEARANCE

6 -Using the same criteria, check clearances between front

sliding pads from the basic to the intermediate boom.

a Normal clearances are the same as specified in

steps 3 and 5.

7 -After the inspection, install any removed parts and

perform a full lubrication procedure.

RKTA8100

NOTES

1 -If total clearance exceeds the maximum

accepatable value, replace all the sliding pads.
(For details, refer to "30 REMOVAL AND
INSTALLATION").
2 -If total clearance exceeds the maximum allowable
value, a shim (1 mm) can be added to the lower
sliding pad.
Beyond this limit, replace the upper and lower
sliding pads.
(For details, please refer to "30 REMOVAL AND
INSTALLATION").

WH6-1E0 WH7-1E0 20-79

TESTING AND ADJUSTMENTS CHECKING BOOM SIDE ALIGNMENT

CHECKING BOOM SIDE ALIGNMENT

a Before attempting to perform this inspection, carry out
"CHECKING SLIDING PADS CLEARANCE".

1 -Position the machine on firm, level ground with the

frame levelled, the parking brakes applied and the
stabilizers, if equipped, down to the ground.

RKTA8440

2 -Fully extend the booms while keeping the forks parallel

to the ground and slightly raised.

3 -Stop the engine.

RKTA8070

4 -Using a ruler “A” placed against the sides of the basic

boom (1), mark the centre line on the end flange (2).
1
A

2
RKTA8110

5 -Repeat the procedure described in step 4 on the

intermediate boom (3). 3
A

RKTA8120

20-80 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING BOOM SIDE ALIGNMENT

6 -Tension a steel cable “B”, or a non-extensible rope with

approximately 2 mm diameter from the centre of the B B
basic boom (1) to the centre of the top boom (4).

1 4 RKTA8130

1a 1
3 B 1
4

T1 T2
2a 2

RKT01940

7 -Measure the distance between the axis of the basic

boom (1) and cable “B” (size T2) and the distance
between the axis of the intermediate boom (3) and cable
“B” (size T1).
Both values should be lower than the maximum
acceptable tolerance.

a Max tolerance: 5 mm
8 -If one or both values exceed the tolerance value, then
one or more shims should be moved from the outer side
of the arch to the inner side (in the example shown, from
sliding pads 1 – 1a to sliding pads 2 – 2a).

k Move one shim at a time and check again.

(For sliding pad and shim installation and removal,
refer to 30. "BOOM SLIDING PADS").
IMPORTANT
Move the side lower sliding pad shims and side
upper sliding pad shims simultaneously.

9 -At the end of the alignment, perform a full sliding pad

lubrication procedure.

WH6-1E0 WH7-1E0 20-81

TESTING AND ADJUSTMENTS BOOM CHAINS

BOOM CHAINS
• Oxidation inspection
1 -Position the machine on level ground with enough free
space at the front to be able to fully extend the boom.

2 -Move the boom to its horizontal position without load

and apply the parking brakes.

3 -Lower the outriggers, if equipped.

If the machine is not equipped with outriggers, place a
safety block under the centre portion of the front frame.

4 -Remove the screws (1) and remove the rear cover (2).

1
1

RKTA0013

5 -Remove the screws (3) and remove the extension chain

protective cover (4). 3
6 -While an assistant slowly extends the booms, another
assistant should visually check the links of the extension
chain for oxidation or oxide-contaminated lubricant.

RKTA0026

7 -With the boom fully extended, stop the engine, remove

5
the covers (5) and inspect the covered portion of the
extension chains (6) and the guide rollers (7).

RKTA0031

20-82 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS BOOM CHAINS

NOTES
1 - Before inspecting, check chain stretch.
2 - If chains are oxidised superficially and stretch is
within normal pasrameter values, remove the
chains and perform the full relubrication
operation.
3 - If chains are severely oxidised, you should
replace the chains even if stretch is within
normal parameter values.

• Chain re-lubrication procedure

1 -Thoroughly clean the chains with mild solvent (gas oil or
similar) and remove any trace of contaminated grease.

2 -Soak the chains in heated fluid engine oil (SAE 10) (kept
at a constant temperature of 70 °C) for at least 12 hours.

3 -Allow the oil to cool and drain the chains before re-
installing.
4 -After you have tensioned the chains, perform the
maintenance lubrication procedure.

WH6-1E0 WH7-1E0 20-83

TESTING AND ADJUSTMENTS CHAIN TENSIONING

CHAIN TENSIONING
• Preparation
1 -Before starting the chain tensioning procedure,
lubricate the sliding pads.
2 -Before starting the inspections and the tensioning
procedures, remove the front equipment.
3 -Place the machine on firm, level ground with enough
free space at the front to allow a full extension of the
boom.

4 -Lower the outriggers, if equipped.

If the machine is not equipped with outriggers, place a
safety block under the centre portion of the front frame. RKTA0040

5 -Move the boom to its horizontal position checking the 0°

angle on the pendulum goniometer (1).

RKTA0050

6 -Remove the extension chain front (3) rear (2) and upper
(4) protective covers. 2
3

RKTA8200

RKTA0032

20-84 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHAIN TENSIONING

1. Retraction chains:
• Checking procedure
5
1 -Retract the boom and check value “B” for being within
the 0-2 mm range when the intermediate boom (5)
contacts the basic boom (6) (A= 0 mm).

a If value “B” is not within this range, adjust.

B 6
A
RKTA0060

• Adjustment procedure
1 -Loosen the check-nut (7) by several turns. 7

RKTA0070

2 -Loosen the adjusting nut (3).

3 -Extend the booms by approximately 500 mm and then

retract.
8
4 -Ensure the intermediate boom (5) just contacts the
basic boom (6) (A= 0 mm); If necessary, repeat steps 3
and 4 of the adjustment procedure.
5

RKTA0080

5 -With the intermediate boom in contact with the basic

boom, measure value “B”, which must be smaller than 2
mm.

RKTA0061

WH6-1E0 WH7-1E0 20-85

TESTING AND ADJUSTMENTS CHAIN TENSIONING

6 -To adjust distance “B”, extend the boom by about 500

mm and gradually tighten the nut (8) without applying
any rotation to the tie rod.

7 -Repeat the inspection until an optimal “B” distance (1–2 8

mm) is obtained.

RKTA0081

8 -Tighten the check-nut (7) until snug.

RKTA0070

2. Extension chains 9
• Checking procedure
a This inspection should be carried out after the retraction
chain has been adjusted.

1 -Fully extend the boom and then retract by about 50 mm

to eliminate chain tension.

2 -Measure the distance “H” between the chains (9) and H

the surface of the boom (5) half way between the front
gear and the rear attachment, i.e. in the area where the
5
protective cover is joined. RKTA0090

a Adjustment values:

Model Normal “H” distance

WH613 14 mm
WH713 12 mm
WH714H 12 mm
WH716 8 mm

a Difference between the chains: 0-1 mm

20-86 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHAIN TENSIONING

• Adjustment procedure
1 -Remove the cotter pins and loosen the check nuts (10)
by several turns.

a Replace the cotter pins at each disassembly.

10

RKTA0100

2 -Tighten the tensioner nuts (12) while retaining the tie

rods (11) until the specified “H” distance is obtained.

k Tighten the tensioner nuts equally and in an

12 12
alternate manner without causing the tie rods to
rotate.

11

RKTA0110

3 -Lock the check-nuts (10).

10

RKTA0100

3. Checking chain stretch

a Perform this inspection before the final tension checks.
1 -Measure the 33-step length of the chains installed to the
machine; if the length is 646.7 +0 3.5 mm (which is
equivalent to 34 steps on a new chain) replace the
chains.
(For details, refer to REPLACEMENT CHAIN).

RKTA0130

WH6-1E0 WH7-1E0 20-87

TESTING AND ADJUSTMENTS CHAIN TENSIONING

4. Final checks
1 -Extend the boom by about 500 mm and retract the boom
slowly, making sure that “B” is 0-2 mm when the 5
intermediate boom (5) contacts the basic boom (6) (A=
0mm).

2 -If distance “B” exceeds 2 mm, adjust the boom retraction

chain.
(For details, please refer to "1. Retraction chains:").
B 6
A
RKTA0060

3 -Fully extend the boom and then retract by about 50 mm.

4 -Verify that the “H” distances between the extension

chains and the surface of the intermediate boom are
13
within the specified tolerances.
(For details, please refer to "2. Extension chains").

5 -Install the cotter pins (13).

6 -Lubricate the chains and reinstall the extension and 13
retraction chain protective covers as well as the rear
cover.

RKTA0140

20-88 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING FOR BLOW-BY

CHECKING FOR BLOW-BY

a Check conditions:
• No wind.
• Machine with standard forks attached, placed on
firm, level ground with the parking brakes applied
and the frame perfectly levelled.
• Boom fully lowered to the ground.
• Hydraulic oil temperature: 40 °C throughout the
system, measured at the pump suction pipe.
• Tires at prescribed pressure.

RKTA8430

1 -Place the specified weight “P” on the forks, and secure

the weight to the equipment crate (2) with the chains (1).
P
MACHINE P

WH 609 - WH613 3500 kg

WH 713 3700 kg

WH714H 4500 kg
1
WH 716 4000 kg

2 RKTA8140

2 -Start the engine and fully lower the stabilizers to the

ground.

3 -Place a fixed locator “A” to the stabilizer stem; note

down locator distance in relation to the cylinder head.

A
RKTA8150

4 -Secure a 20 m tape measure “B” to the end of the forks.

B
RKTA8160

WH6-1E0 WH7-1E0 20-89

TESTING AND ADJUSTMENTS CHECKING FOR BLOW-BY

5 -Lift the boom to 60°. The angle should be checked at the

basic boom using a magnetic level.

6 -Extend the boom until letter “E” of the intermediate boom

is visible.

a Move the locator until flush with the lower portion of

the basic boom.

60¡

RKTA8400

7 -Stop the engine and check the distance of the forks from
the ground while holding the tape measure
perpendicular to the ground. B
k To prevent any parallax errors leading to
measuring errors, place a fixed locator “C” to the
ground.
C

RKTA8170

8 -Wait for 10 minutes and then check:

a - fork end measurement;
b - inclination of the basic boom;
c - distances between the stabilizer cylinder heads and
the locator previously applied.

20-90 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING FOR BLOW-BY

9 -Check the values against the measurements taken in

steps 3, 5 and 7.

a Normal variation:

FORK END DOWN STABILIZER STEM

BOOM ANGLE VARIATION (°)
MODEL MOVEMENT (mm) RETRACTION (mm)

NORMAL MIN. MAX. NORMAL MIN. MAX. NORMAL MIN. MAX.

WH609 37.5 10 75 1.1 0 2.5 – – –

WH613 37.5 0 75 1.1 0 2.5 – – –

WH713 37.5 30 75 1.1 0 2.5 0.5 0 3.0

WH714H 37.5 10 75 1.1 0 2.5 0.5 0 3.0

WH716 37.5 0 75 1.1 0 2.5 0.5 0 3.0

10 -Start the engine, retract boom and stabilizers; perform

some standard manoeuvres until the hydraulic oil is
heated to a temperature of 80 °C (measured at the pump
suction pipe).

11 -Repeat the same procedures as above and measure the

same data.

a Normal variation:

FORK END DOWN STABILIZER STEM

BOOM ANGLE VARIATION (°)
MODEL MOVEMENT (mm) RETRACTION (mm)

NORMAL MIN. MAX. NORMAL MIN. MAX. NORMAL MIN. MAX.

WH609 37.5 10 75 1.1 0 2.5 – – –

WH613 37.5 0 75 1.1 0 2.5 – – –

WH713 37.5 30 75 1.1 0 2.5 0.5 0 3.0

WH714H 37.5 10 75 1.1 0 2.5 0.5 0 3.0

WH716 37.5 0 75 1.1 0 2.5 0.5 0 3.0

a If variation exceeds the acceptable tolerance

values, check for safety valve leakage and inner
cylinder blow-by.
(For details, please refer to "ANALYSIS OF THE
CAUSES RESPONSIBLE FOR HYDRAULIC
DRIFT").

WH6-1E0 WH7-1E0 20-91

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

a If the boom, equipment, stabilizer, axle-locking, and
frame levelling cylinders are affected by hydraulic drift, it
P
is necessary to check whether the cause lies with the
safety valves or with the cylinder gaskets.

a Check conditions applicable to all drift inspections:

• Engine: at operating temperature.
• Hydraulic oil: 45–55 °C.
• Test-weight “P” on the forks (secured with chains to
the equipment crate): 1

MACHINE P 2 RKTA8140

WH 609 - WH613 3500 kg

WH 713 3700 kg

WH714H 4500 kg

WH 716 4000 kg

1. Checking procedure for stabilizers

(if equipped)
a Test one stabilizer at a time.
a Check conditions:
• Boom fully retracted and lowered to the ground.

RKTA8430

1 -Remove the upper cover (1) to gain access to the safety

valve (2).

RKTA3180

20-92 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

2 -Start the engine, lower the stabilizer to be checked until

the corresponding front wheel lifts off the ground by
about 7 cm.

3 -Only if equipped: level the frame.

4 -Lower the forks (3) to the ground, and then stop the
engine. 3

RKTA8180

5 -Disconnect the front (4) and rear (5) lines from the valve
(2).

a Immediately cap the hoses to prevent contaminants

from entering the passages. 4 5

RKTA3191

6 -Start the engine and lift the forks (3) off the ground, and
then stop the engine.

RKTA8190

7 -Place a fixed locator “A” to the stabilizer stem; note

down locator distance in relation to the cylinder head.

8 -Monitor the position of the stem for 10 minutes.

• If the stem tends to retract and a leak is noticed at
the valve fittings, the valve is faulty and needs to be
replaced.
• If the stem tends to retract and no leak is noticed at
the valve, the drift is caused by blow-by inside the
cylinder.
A
RKTA8150

WH6-1E0 WH7-1E0 20-93

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

2. Checking procedure for equipment

cylinder
a Check conditions:
• Stabilizers down to the ground. P
• Frame levelled.
• Boom fully retracted.
• Test-weight “P” on the forks resting on the ground.
• Engine not running.

RKTA8240

1 -Remove the front cover (1) to gain access to the safety

valve (2).

RKTA3291

2 -Start the engine, lift the forks by about 70 cm keeping

them parallel to the ground and place them on a block or
on safety stands (“A”).

A
A
RKTA8210

3 -Stop the engine and disconnect the front lines (3) and
the rear lines (4) from the valve (2).
4
a Immediately cap the hoses to prevent contaminants
from entering the passages.
3 2

RKTA3301

20-94 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

4 -Start the engine and lift the forks off the block by about
10 cm; stop the engine. P
k Leave the block, or safety stands “A”, in place.

A
A
RKTA8220

5 -Measure and note down the distance of the tips of the

fork from the ground.
k To prevent any measurement errors, place a fixed
locator “C” to the ground.
6 -Monitor the position of the forks for 5 minutes:
• If the forks tend to overturn and a blow-by condition
is affecting the upper fitting (V2) of valve (2), then
drift is caused by the safety valve not being sealed
properly.
• If the forks tend to overturn and blow-by is at the A
lower fitting (V1), then drift is caused by blow-by
inside the cylinder. C RKTA8230

3. Checking procedure for the boom lift

cylinder
a Check conditions:
• Stabilizers fully extended.
P
• Frame levelled.
• Boom fully retracted.
• Test-weight “P” on the forks resting on the ground.
• Engine not running.

RKTA8240

1 -Start the engine and lift the boom (1) until it is possible for
a safety block “A” to be placed on the frame. 2
NOTES
1 - The purpose of the block (should the boom
accidentally fall) is to stop the boom before it
impacts the ground. 1
2 - Position the block towards the centre of the
machine, past the equipment pipes (2).
A

RKTA8250

WH6-1E0 WH7-1E0 20-95

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

2 -Continue lifting the boom (1) until the pendulum

goniometer (3) shows a 10° value, and the extend the 1
boom until letter B becomes visible. P

RKTA8260

RKTA8270

3 -Stop the engine and disconnect the hoses (4 and 5).

a Immediately cap the hoses to prevent contaminants

from entering the passages.
7
NOTE
Before proceeding further, allow the oil in the pipes (6
and 7) to flow out.

6
4 RKTA8280

4 -Go back five minutes later and verify which pipe is still
draining.
• If pipe (7) is still draining, the safety valve (8) is faulty
and needs to be replaced.
• If pipe (6) is still draining, then the hydraulic drift is
caused by blow-by inside the cylinder.
8

RKTA8290

20-96 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

4. Checking procedure for the boom

extension cylinder
a Check conditions:
• Stabilizers fully extended.
• Frame levelled.
• Boom fully retracted.
• Test-weight “P” on the forks resting on the ground.
• Engine not running.

1 -Start the engine and lift the boom to 60°. The angle
should be checked at the basic boom using a magnetic
level.

2 -Extend the boom until letter “E” of the intermediate boom

is visible.

60¡

RKTA8410

3 -Stop the engine and disconnect the hoses (1 and 2).

a Immediately cap the hoses to prevent contaminants

from entering the passages.

1 2

RKTA1761

4 -Check draining at the safety valve (3):

• If draining occurs at the right-hand fitting (4) the
valve is faulty and needs to be replaced.
• If draining occurs at the left fitting (5), then hydraulic 3
drift is caused by blow-by inside the cylinder.

5 4

RKTA8300

WH6-1E0 WH7-1E0 20-97

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

5. Checking procedure for the frame

levelling cylinder
a Check conditions:
• Machine on solid, level ground.
• Frame levelled.
• Boom fully retracted, with no load.
• Engine not running.

RKTA8430

1 -Install and lightly force a screw jack “A” between the rear
axle (left end) and the frame. This is required in order to
counteract axle swing in the next step of the procedure.
NOTE
The screw jack should be positioned on the flat surface A
of the axle.

RKTA8310

2 -Start the engine and drive the machine onto a raised

platform “B” with the sole right front wheel.

3 -Apply the parking brakes and stop the engine.

B RKTA8470

4 -Disconnect the hoses (2 and 3) from the safety valve

and cap them.

2
1

RKTA8330

20-98 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

5 -Apply some adhesive tape “C” and measure and note

down the length of the portion of the stem (4) between
the tape “C” and the cylinder head (5).
4
6 -Check draining behaviour. 5
• If draining is noticed at the safety valve (1), the valve
is faulty and needs to be replaced. C
• If no draining occurs at the valve and the stem tends
to retract in the following 10 minutes, then there is a
blow-by condition inside the cylinder.

k NOTICE!
Remove the adhesive tape previously applied RKTA8340

to the stem in step 5.

6. Checking procedure for axle

locking cylinder
a Check conditions:
• Machine on solid, level ground.
• Frame levelled.
• Boom fully retracted, raised above 50°, with no load.
• Engine not running.

RKTA8350

1 -Disconnect connectors (1 and 2) from the solenoid valve

group (3).
3

2
RKTA8360

2 -Start the engine and drive the machine onto a raised

platform “A” by about 8–10 cm with the sole rear left
wheel.
3 -Apply the parking brakes and stop the engine.

A RKTA8370

WH6-1E0 WH7-1E0 20-99

TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT

4 -Disconnect the feed hose (4) from the solenoid group (3)
and cap the hose. 4
5 -Monitor the draining behaviour of the solenoid valve
group for 5 minutes.
• If draining is continuous, then the solenoid valve
group (3) is faulty and needs to be changed. 3
• If no draining is noticed, proceed further with the
inspection.

RKTA8361

6 -Start the engine and drive the machine back on level

ground.

7 -Connect the C2 solenoid valve connector (2).

8 -Drive the machine back on the raised platform and stop

the engine.

C2
2

RKTA8380

9 -Apply some adhesive tape “B” and measure and note

down the length of the stem between the tape “B” and
the cylinder head (5).

10 -Repeat the measurement after 10 minutes.

• If the stem has retracted to any extent, the drift is
caused by blow-by inside the cylinder. B

RKTA8390

20-100 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS EQUALIZING STABILIZER SPEED

EQUALIZING STABILIZER SPEED

a After verifying that the individual stabilizer down and up
speeds are within standard specifications, it is 2
n ec es sar y to ch ec k th e sy nc hron is m bet we en B
stabilizers both in the down and up movements.
The adjustment reduces the speed of the faster A
movement in relation to the slower one.
Adjustment is carried out by using the screws below:
A - for down travel adjustment;
B - for up travel adjustment.

RKT01950

1 -Remove the protective cover (1) to gain access to the

valve (2).

RKTA3180

2 -With the engine stopped, remove the tamper seal (3)

from the screw you need to adjust. 4
3
3 -Loosen the nut (4), tighten the screw (5) by a few
degrees and tighten the nut again.

4 -Start the engine, check the synchronism and, if

necessary, repeat the adjustment steps until the values
are within specifications.
5
5 -Apply a new tamper seal (3) and place the protective
cover (1) back into place. 2
RKT01920

WH6-1E0 WH7-1E0 20-101

TESTING AND ADJUSTMENTS AIR CONDITIONING SYSTEM MAINTENANCE

AIR CONDITIONING SYSTEM MAINTENANCE

• Emptying and filling the air conditioning
system 1
2
1 -Connect the maintenance station to the service valves
(1 and 2) and follow the maintenance station
instructions for emptying the system.

2 -Carefully check the quantity of antifreeze oil that is

collected and/or contained in the parts that have been
removed because the same quantity shall have to be put
back into the system when filling.

3 -Once the necessary repairs have been performed on

RKTA1193
the A/C system (hose or other part replacement), fill the
system by introducing the previously recovered
antifreeze oil as well as the coolant gas.
For the filling procedure, follow the maintenance station
instructions relevant to A/C system fill.

20-102 WH6-1E0 WH7-1E0

TESTING AND ADJUSTMENTS CHECKING THE A/C SYSTEM’S OPERATING TEMPERATURE

CHECKING THE A/C SYSTEM’S OPERATING TEMPERATURE

a Check conditions:
• Machine on level ground with the boom fully
lowered and retracted.
• Parking brake applied

1 -Connect the maintenance station to the high pressure

valve (A.P.) and to the low pressure valve (B.P.).

2 -Start the engine and operate it at 1500 rpm.

3 -Activate the A/C system by the switch in the cab.

4 -Select an intermediate speed for cab ventilation.

RKTA8430

5 -Using a thermometer/hygrometer, check the cab inside

temperature for being equal to or under ambient
temperature.

a If cab temperature is higher than ambient

temperature, open the doors and windows and
allow the cab temperature to adjust and stabilize to
ambient temperature.

6 -Close the doors and windows and let the A/C system run
in these conditions for 5-10 minutes.

7 -Using a thermometer, check the air temperature at the

centre A/C outlets.

a Position the probe as close as possible to the point

where the air comes out.

8 -Compare the average values of the temperature

readings with the table to the side: Ambient
20 25 30 35
temperature (°C)
9 -If the average temperature value derived from the
Outgoing air
temperature readings is not within the range given in the 6– 8 8 –10 8 – 12 9 – 14
temperature (°C)
table, the system needs to be checked.

• Checking the A/C system

Check the A/C system once the procedures in steps 1, 2, 3,
Unit with R134a
4 and 6 above have been carried out. Outside
The system failure diagnostics is performed using a temperature B.P. (kg/cm²) A.P. (kg/cm²)
pressure-based method. (°C) Min. Max. Min. Max.
When the pressures are not within the acceptable range
given in the table below, look for the cause of malfunction by 20 1.2 2.5 6.0 9.0
checking the high pressure (A.P.) and the low pressure 25 1.0 2.5 7.5 10.5
(B.P.) pressure gauges.
30 1.1 2.4 9.5 13.0
35 1.3 2.4 12.0 15.5
40 1.5 1.8 18.0 18.8
45 1.8 1.9 21.5 22.0

WH6-1E0 WH7-1E0 20-103

TESTING AND ADJUSTMENTS CHECKING THE A/C SYSTEM’S OPERATING TEMPERATURE

The following conditions may exist:

Condition Cause - Malfunction

• Electromagnetic pulley slips or does not engage properly.
High B.P, normal or low A.P. • Expansion valve is stuck in the open position
• Compressor is damaged
• Expansion valve is stuck in the closed position or clogged
Low B.P, high or normal A.P. • Filter is saturated with dampness
• The B.P or A.P line is obstructed between the filter and the evaporator
• Hot air ingestion into the evaporator unit, into the lines or into the cab
Normal B.P, normal A.P. • Hot water circulating in the heating unit
• Ice has formed on the evaporator
• Normal condition with very high ambient temperature (higher than 43°C)
• Excess of coolant (30–35% more)
• Condenser overheating
High B.P, high A.P.
• Air in the system
• Obstruction of the A.P. line between the compressor and the condenser
hose, past the A.P. temperature reading point.
• Normal condition with very low temperature (lower than 5 °C)
• Coolant fluid level low (70–75% less) (leaks are likely)
Normal or low B.P, low A.P. • Obstruction of the A.P. line between the compressor and the condenser
hose, upstream from the A.P. temperature reading point.
• Compressor is damaged
• Compressor belt missing
B.P. is approximately equal to A.P. • The electromagnetic pulley slips or does not engage
• Compressor is damaged

20-104 WH6-1E0 WH7-1E0

30 REMOVAL AND INSTALLATION

HOW TO READ THE MANUAL .....................................5 HYDRAULIC PUMP ..................................................... 38

PRECAUTIONS TO BE TAKEN WHEN WORKING......6 • Removal.................................................................. 38
• Installation............................................................... 39
SPECIAL TOOLS ...........................................................7
COMPLETE ENGINE– SHIFT ASSEMBLY ................ 40
ENGINE HOOD.............................................................15
• Removal.................................................................. 40
• Removal ..................................................................15
• Installation............................................................... 49
• Installation ...............................................................16
ENGINE-TRANSMISSION ........................................... 50
RADIATOR HOOD .......................................................17
• Detachment ............................................................ 50
• Removal ..................................................................17
• Joining .................................................................... 51
• Installation ...............................................................17
CONTROL VALVE ASSEMBLY.................................. 52
AIR FILTER ..................................................................18
• Removal.................................................................. 52
• Removal ..................................................................18
• Installation............................................................... 55
• Installation ...............................................................18
BRACKET CONTROL, EQUIPMENT LOCK AND
TURBOCOMPRESSOR ...............................................19
FRAME LEVELLING SOLENOID VALVES ................ 56
• Removal ..................................................................19
• Removal.................................................................. 56
• Installation ...............................................................20
• Installation............................................................... 56
EXHAUST PIPE............................................................21
AIR CONDITIONER COMPRESSOR
• Removal ..................................................................21
(only if equipped) ....................................................... 57
• Installation ...............................................................22
• Removal.................................................................. 57
BELT, FAN ...................................................................23 • Installation............................................................... 58
• Removal ..................................................................23
COMPRESSOR BELT ................................................. 59
• Installation ...............................................................24
• Removal.................................................................. 59
RADIATOR-EXCHANGER ASSEMBLY ......................25 • Installation............................................................... 61
• Removal ..................................................................25
SERVO-CONTROL FEED VALVE .............................. 62
• Installation ...............................................................27
• Removal.................................................................. 62
INTERCOOLER ............................................................28 • Installation............................................................... 62
• Removal ..................................................................28
STEERING SELECTION SOLENOID VALVE
• Installation ...............................................................30
ASSEMBLY ................................................................. 63
MUFFLER .....................................................................31 • Removal.................................................................. 63
• Removal ..................................................................31 • Installation............................................................... 63
• Installation ...............................................................31
FRONT AXLE .............................................................. 64
BATTERY – BATTERY TRAY .....................................32 • Preparation ............................................................. 64
• Removal ..................................................................32 • Removal.................................................................. 64
• Installation ...............................................................33 • Installation............................................................... 66
CYLINDER HEAD.........................................................34 REAR AXLE................................................................. 67
• Removal ..................................................................34 • Preparation ............................................................. 67
• Installation ...............................................................35 • Removal.................................................................. 67
INJECTORS..................................................................36 • Installation............................................................... 69
• Removal ..................................................................36 TELESCOPIC BOOM .................................................. 70
• Installation ...............................................................36 • Removal.................................................................. 70
INJECTION PUMP........................................................37 • Installation............................................................... 73
• Removal ..................................................................37 LIFT AND OFFSET CYLINDERS ................................ 77
• Installation ...............................................................37 • Removal.................................................................. 77
• Installation............................................................... 78

WH6-1E0 WH7-1E0 30-1

INTERMEDIATE AND TOP BOOM ............................. 79 WIPER MOTORS .......................................................128
• Removal.................................................................. 79 • Removal ................................................................128
• Installation............................................................... 83 • Installation .............................................................130
EXTENSION CYLINDER ............................................. 84 PARKING BRAKE CABLE ........................................131
• Removal.................................................................. 84 • Removal ................................................................131
• Installation............................................................... 85 • Installation .............................................................132
BOOM SLIDING PADS................................................ 86 DASH / INSTRUMENT PANEL ..................................133
• Replacement........................................................... 86 • Removal ................................................................133
EXTENSION AND RETRACTION CHAINS • Installation .............................................................133
(Versions with 3-section boom) ................................ 95 CONTROL PANEL .....................................................134
• Removal.................................................................. 95 • Removal ................................................................134
• Installation............................................................... 97 • Installation .............................................................134
CHAIN RETURN PULLEY PINS AND BUSHINGS ..... 98 FUSE AND RELAY CENTRE.....................................135
• RETRACTION CHAIN PULLEY.............................. 98 • Removal ................................................................135
• Removal.................................................................. 98 • Installation .............................................................135
• Installation............................................................... 99 PROPELLER SHAFT .................................................136
• EXTENSION CHAIN PULLEYS............................ 100 • Removal ................................................................136
• Removal................................................................ 100 • Installation .............................................................137
• Installation............................................................. 101
FUEL TANK................................................................138
LOAD CELL ............................................................... 102 • Removal ................................................................138
• Installation............................................................. 102 • Installation .............................................................139
CONTROL UNIT ........................................................ 105 HYDRAULIC OIL TANK.............................................140
• Removal................................................................ 105 • Removal ................................................................140
• Installation............................................................. 105 • Installation .............................................................141
BALLAST................................................................... 106 FRAME LEVELLING CYLINDER...............................142
• Removal................................................................ 106 • Removal ................................................................142
• Installation............................................................. 106 • Installation .............................................................142
ENGINE LINE CENTRE............................................. 107 FRAME SWING LOCKING ROD
• Removal................................................................ 107 (WH609 and WH613 only).........................................143
• Installation............................................................. 107 • Removal ................................................................143
ACCELERATOR CABLE........................................... 108 • Installation .............................................................143
• Removal................................................................ 108 AXLE LOCKING CYLINDER .....................................144
• Installation............................................................. 109 • Removal ................................................................144
SHIFT-REVERSING GEAR LEVER ASSEMBLY ..... 110 • Installation .............................................................144
• Removal................................................................ 110 STABILIZER CYLINDERS (If equipped) ..................145
• Installation............................................................. 110 • Removal ................................................................145
STEERING COLUMN SWITCH UNIT - DIPSWITCH 111 • Installation .............................................................146
• Removal................................................................ 111 EQUIPMENT HOLDER ..............................................148
• Installation............................................................. 111 • Removal ................................................................148
STEERING UNIT........................................................ 112 • Installation .............................................................149
• Removal................................................................ 112 EQUIPMENT MOTION CYLINDER............................150
• Installation............................................................. 114 • Removal ................................................................150
• Disassembly.......................................................... 115 • Installation .............................................................151
• Assembly .............................................................. 118
CYLINDERS ...............................................................152
STEERING COLUMN ................................................ 122 • Disassembly ..........................................................152
• Removal................................................................ 122 • Assembly...............................................................153
• Installation............................................................. 122
EQUIPMENT QUICK-LOCK ASSEMBLY..................157
BRAKE PUMPS ......................................................... 123 • Removal ................................................................157
• Removal................................................................ 123 • Installation .............................................................157
• Installation............................................................. 124
AIR CONDITIONER FANS.........................................158
PPC VALVE ............................................................... 125 • Removal ................................................................158
• Removal................................................................ 125 • Installation .............................................................158
• Installation............................................................. 126
AIR CONDITIONER CONDENSER ASSEMBLY.......159
LEVEL ........................................................................ 127 • Removal ................................................................159
• Removal................................................................ 127 • Installation .............................................................160
• Installation............................................................. 127

30-2 WH6-1E0 WH7-1E0

DEHUMIDIFYING FILTER..........................................161 AXLES ....................................................................... 230
• Removal ................................................................161 • Disassembly ......................................................... 230
• Installation .............................................................162 • Planetary reduction............................................... 230
AIR CONDITIONING SYSTEM PRESSURE • Steering case........................................................ 234
SWITCH ......................................................................163 • Cardan shaft ......................................................... 237
• Removal ................................................................163 • Brakes................................................................... 239
• Installation .............................................................163 • Parking brake assembly (front axle) ..................... 241
• Removal of steering cylinder ................................ 243
CAB ............................................................................164
• Disassembly of steering cylinder .......................... 245
• Removal ................................................................164
• Differential............................................................. 246
• Installation .............................................................168
• Bevel pinion .......................................................... 251
TRANSMISSION.........................................................169 • Assembly .............................................................. 254
• TRANSMISSION ASSEMBLY...............................169 • Bevel pinion .......................................................... 254
• Disassembly ..........................................................169 • Differential............................................................. 262
• Assembly ...............................................................180 • Steering cylinder ................................................... 268
• 1st CLUTCH ..........................................................181 • Steering cylinder ................................................... 271
• Disassembly ..........................................................181 • Convergency adjustment ...................................... 274
• Assembly ...............................................................184 • Parking brake assembly (front axle) ..................... 274
• 2nd CLUTCH .........................................................185 • Brakes................................................................... 276
• Disassembly ..........................................................185 • Cardan shaft ......................................................... 279
• Assembly ...............................................................189 • Steering case........................................................ 280
• 4th CLUTCH ..........................................................190 • Planetary reduction............................................... 282
• Disassembly ..........................................................190
• Assembly ...............................................................193
• 3rd CLUTCH..........................................................194
• Disassembly ..........................................................194
• Assembly ...............................................................197
• REVERSE CLUTCH..............................................198
• Disassembly ..........................................................198
• Assembly ...............................................................200
• FORWARD CLUTCH ............................................202
• Disassembly ..........................................................202
• Assembly ...............................................................205
• PRESSURE REGULATOR VALVE.......................206
• Disassembly ..........................................................206
• Assembly ...............................................................206
• MODULATED VALVE ...........................................207
• Disassembly ..........................................................207
• Assembly ...............................................................208
• SPACER PLATE ...................................................211
• Disassembly ..........................................................211
• Assembly ...............................................................215
• CONVERTER HOUSING ......................................216
• Disassembly ..........................................................216
• Assembly ...............................................................218
• DROP BOX ASSEMBLY .......................................219
• Disassembly ..........................................................219
• Complete drop box assembly ................................219
• Input shaft..............................................................221
• Assembly ...............................................................221
• Input shaft..............................................................221
• Complete drop box assembly ................................221

WH6-1E0 WH7-1E0 30-3

REMOVAL AND INSTALLATION HOW TO READ THE MANUAL

HOW TO READ THE MANUAL

1. Removal and Installation of the groups
(1) The procedures and information needed to carry out the work of removing or Installing units or groups are given
in the removal procedure. The sequence of operations is not repeated in the installation procedure.

(2) Information needed for installation is marked with the symbol [*1]; The same symbol is repeated at the end of
each removal procedure for the same item, to indicate to which installation item it refers.

(Example)
REMOVAL GROUP ● ● ● : .......................................................Title of operation

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

out the operation.
1 - Remove XXXX (1): ..............................................................Step in removal procedure.
a: ........................................................................................Technique or important point to remember when
removing XXXX (1)
2 - eee (2): ...................................................................... [*1] This sign means that information is given for
the installation procedure
3 - Remove ttt (3):
6........... l: ....................................................................Recovery of oil or water, and the quantity to be re-
covered.

INSTALLATION GROUP qqq :................................................Title of operation.

q To install, reverse removal procedure.

[*1]: .............................................................................................Technique to be used for installation

a: ........................................................................................Technique or important point to remember when
removing eee (2)

q Addition of water or oil: ........................................................Step in removal procedure.

a: Point to remember when adding water or oil.

2. To the precautions to be taken during the removal or installation of the groups, must be added the specific "PRE-
CAUTIONS TO BE TAKEN WHEN WORKING".
Always make sure that these precautions are taken.

3. List of special tools.

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

4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks
and containers

(1) In the operating procedures, you will find the symbols 2,3 , 4, 5, 6; In the following or-
der, these represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS»,
«QUANTITIES OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS
AND LUBRICATION», «LUBRICATING GREASE».

NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this
manual.

WH6-1E0 WH7-1E0 30-5

REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHEN WORKING

PRECAUTIONS TO BE TAKEN WHEN WORKING

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

30-6 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION SPECIAL TOOLS

SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

Removal of telescopic boom A 1 ATR201501 Tool 1 –

1 00239496 Tool 1 Removal of inner gasket

2 00239497 Tool 1 Removal of dust seal

Disassembly/Assembly B
of steering unit
3 00239498 Tool 1 Mounting of inner gasket

4 00239499 Tool 1 Mounting of dust seal

Assembly of transmission C 1 Tool 1 Removal regolator group

1 Wrench 1 –

Removal/installation of
2 Tool 1 differential planetary
wheel pins

3 Bushing 1

Installation of differential
4 Tool 1 planetary wheel pins

Wrench 1
5 Flange locking
Wrench 1

6 Wrench 1 Flange ring nut locking

7 Wrench 1 Pinion locking

8 Block 1 –
Disassembly/Assembly D
axles 9 Spacer 1 –

1
Bearing inner
10 1 Installation pinion bearing
ringinstallation kit
1

Pinion dimension
11 Tool 1 measuring

Bearing inner
12 1 Installation pinion bearing
ringinstallation kit

13 Wrench 1 Installation pinion bearing

14 Plunger 1 –

15 Plunger 1 –

16 Tool 1 Arm alignment

WH6-1E0 WH7-1E0 30-7

REMOVAL AND INSTALLATION SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

17 Bush 1 –

18 Extension 1

19 Plunger 1

20 Plunger 1

21 Plunger 1

Disassembly/Assembly 22 Plunger 1
D
axles
23 Plunger 1

24 Plunger 1

Bearing inner Planetary bearing

25 1
ringinstallation kit installation

26 Plunger 1

27 Plunger 1

30-8 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION SPECIAL TOOLS

fl125
D2

10x15¡
D1 fl35.5 -- 0.1
-- 0.2
fl41
fl25
0.8

+ 0.2
fl20 0

1x45¡
fl15H7-n6 R1

0.8

fl5.5
100
fl14

5
2 x15¡

36
0.8

31

26

20
24
17
20
238
0
R1 fl25 0.8
fl10
fl35 M26X1.5
123

125
33
36

fl5.5
18

22.5
0.8

33
fl37H7-n6

6 9

10.5
fl47

1 x45¡
6

0.8
fl106 – 0.1 fl20 + 0.2
0
R30

25

fl25
fl41 RKT01280
RKT01270

D3 24.5 ⫾ 0.0.1
D4 3x30¡ 2x30¡
– 0.2

fl19.9 +-- 0.1

fl19.9 +-- 0.1

0

8.5

0
0.8

fl28.5

fl30

fl6
15¡ 10 46.45 – 0.1 – 0.5
10 19.6
56.6
+ 0.08
+ 0.12

29.6 0.5x45¡
-- 0.1
-- 0.2

fl23
fl30

fl27

fl20

0.8
fl19.9 +-- 0.1
0

RKT01290

1x30¡
175
RKT01300

135 –0.5
D5 fl185 – 0.2
97
73

– 0.2
120
61.5

80
fl105
61.5
85

126 12
fl32 fl105 – 0.2
25
10

150 125
10
15
15

125
25
100

fl34.5 --+ 00.2

fl45 fl50 RKT01310

WH6-1E0 WH7-1E0 30-9

REMOVAL AND INSTALLATION SPECIAL TOOLS

D6 fl85
fl66 D7 fl75
— 0.08
fl55 — 0.12
fl55H7

0.8
0.8

5 x15
Tornito fl

0.8
32,25
22
75

35
10

60
15

14
6

34
60
6 3/4"
fl15H7-n6

20
40
20

15¡

60
100
275 RKT01330

RKT01320

D8 99.5 D9 fl30.2 – 0.001

fl17

5x45¡
25

– 0.005

131
fl42

fl88.8
20

RKT01340
RKT01350

D10
fl19.55H7

A
21¡

0.8
R5

R2
23
B 3x15¡
fl83

fl40
fl88
R2

0.8
0.8
+ 0.1
-- 0

0.8
21¡
fl20

-- 0.08
-- 0.12
fl55
fl83
fl89

0.8

R2
23 40
0.8

R2 73
10 56 C B A
66
fl16.5 ---- 0.1
0.2

M18x1.5
M18x1.5

473.5
C 433.5
0.8 0.8 0.8
Ø40
fl35

15¡

5 5x15¡
-- 0.08
-- 0.12

11 30
fl19.5

45
RKT01360

30-10 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION SPECIAL TOOLS

D11 fl110 fl20

fl65 M14 x1
M14 x1

25 25
20

50
61---- 0.01
0.02
4 x45¡

R5

41
30
+0
fl41.2

15
fl20 -- 0.03

195
fl9

95
14

35
fl11
40 300

10
50
fl80
RKT01370

fl6.5

D12
ENERPAC Mod. RCH-123

23
3x15¡
64
R2

0.8

0.8
R3 0.8
21¡

-- 0.08
-- 0.12
fl40H8
fl70

fl54

fl55
fl83
fl40

fl89

0.8
R2
R2

10 56
66

312
M18X1.5

M18X1.5

267
50 5x15¡ 0.8
0.8
15¡

fl40H8

R3
-- 0.2
-- 0

17min.
fl19

30 RKT01380

WH6-1E0 WH7-1E0 30-11

REMOVAL AND INSTALLATION SPECIAL TOOLS

D13 fl75
-- 0.08
D14 fl50
fl55 -- 0.12

5x45¡
5x15
Tornito fl
0.8

32,25

fl10 35

63
60

87
74
R5

2 -- 0.2
15
14

12
48
59

12
0.8
R5
30

3x15¡
0.8
+ 0.08

0.8
fl37.75 + 0.12
M6
5

fl20
-- 0.2
fl40H7-n6 1/4 fl55 -- 0.3

fl44 fl89

fl99
RKT01400

D17 fl45 ---- 0.05

0.10
0.8

M8x1.25
RKT01390 R2 5¡
.5
15

D15
1.5x45¡

30

0.8
44
14
75

6
7
3
1

1
68

0.8
1x45

30¡
38

fl6.5
0.8

fl20.4 -- 00.05
-- 0.1
fl38.5 -- 0.2
+ 0.05
fl43.6 0
fl55 RKT01420

fl63
fl65 RKT01410

D16
50
20

120– 0.1
=

120– 0.1
200
=

90
= = 840
930
RKT01430

30-12 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION SPECIAL TOOLS

D18
R110
100

50

R1
5 5x45¡
27.5–0.2
55 500
555
17–0.1

fl23
125

RKT01440
125

fl30
D19 0
D20
fl54,5 -- 0.1

3x45¡
30
fl30

cementazione
R35 Proteggere da
0.8

46

130
70

155
14 10

0.8
1.5 x45¡

0.8
2,5 -- 00.2

0
0.8 R1
3 x15¡

7
0.8

0
fl54 + 0.1
10

fl79
R1 0.8
fl90 -- 0.15
RKT01450
0.8

49.5
89
RKT01460

D21 D22 D23 fl64

fl25
fl25
fl30
3 x45¡

3x15¡
2 x45¡
50

50
50

cementazione
cementazione

Proteggere da
Proteggere da

cementazione
150

Proteggere da

150

150
180

169

213
2 x45¡

R1
1.5x45¡

3-- 00.2
0
.5
R7
1.5
R5

13
0.4 10

.5

0.8
20 10

19 +-- 0.15

0.8
R1

0.8
52

50

0.8 R 29

fl67
0.8

3x15¡

-- 0.08
fl35 -- 0.12
RKT01480
5x15¡

fl50 fl35
RKT01470
-- 0.1
fl50 -- 0.2
RKT01490

WH6-1E0 WH7-1E0 30-13

REMOVAL AND INSTALLATION SPECIAL TOOLS

D24 fl75 D25

fl158.5
fl25 fl158.5

fl50 H7 20¡ fl35

3x45¡

fl30
50

0.8

16
0.8

R3
113
cementazione

-- 0.3
-- 0.5
Proteggere da

129
117
R3

148

102
fl132
150

R5 20¡

100
25

R3

8x15¡
fl40
233

fl140
fl50 ---- 0.08
0

0.12
R1

fl150
3-- 00.2

fl200 –0.03
13

0.8
0.8 fl95
75

70

fl35
5x15¡
0.8

-- 0.1
fl50 -- 0.2

fl56
fl64 RKT01500
RKT01510

fl35
D26 fl40 D27
2x45¡
2 x45¡
120

175
1x45¡

0.8
-- 0.2
-- 0.3
1
41

26
19

0.8
R3

0.8
5.5

0.8

5x15¡

0
fl139.5 -- 0.1
10 15
0.8

25

fl153
fl168
2x15¡

fl39 0.8
fl180 RKT01520 fl50 RKT01530

30-14 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION ENGINE HOOD

ENGINE HOOD
Removal
1
1 -Lift the engine hood (1).

RKTA8480

2 -While supporting the engine hood, loosen and remove

the screws (2) retaining the hinges (3).

RKTA0340

3 -Loosen and remove the self locking nut (4), the backing
washer and the screw (5) to disconnect the gas damper
(6) from its support (7). 6

4
5

RKTA8491

4 -Lower the hood and place an anti-slip block (A) between

lower edge of hood and body; then, strap the hood and
connect it a hoist.
5 -Remove the hood (1). [*1]

RKTA8500

WH6-1E0 WH7-1E0 30-15

REMOVAL AND INSTALLATION ENGINE HOOD

Installation
8
• To install, reverse the removal procedure.

[*1]

1 -Adjust the position of the hood, ensuring that the lock

assembly (8) is centred in relation to the retaining hook
(9).

9
RKTA8530

2 -Adjust the hinges vertically (3) to allow the closure

sealing strip (10) to evenly rest along the length of the
hood.
3

10

RKTA8540

3 -Adjust the hinges (3) horizontally until full contact

between the sealing strip (11) and the engine-
transmission mount (12) is achieved.
3
12

11

RKTA8550

30-16 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION RADIATOR HOOD

RADIATOR HOOD
Removal
1 -Loosen the nut (1), raise the hood and hold it securely in
position with the hood rod (2).
1
2

RKTA8510

2 -While supporting the hood (3), loosen and remove the

screws (4) retaining the hinge (5). 4
3
3 -Disengage the rod (6) and remove the hood (3).
5

RKTA8520

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-17

REMOVAL AND INSTALLATION AIR FILTER

AIR FILTER
Removal
3 2
1 -Unscrew and remove the cap (1) from the surge tank (2). 1
2 -Loosen and remove the screws (3), remove the surge
tank (2), and position the tank aside.

RKTA0400

3 -Loosen the clamps (4), (5) and disconnect the outside

air inlet hose (7) and engine intake hose (8) from the filter 7
(6).

8 4

RKTA0410

4 -Disconnect the air cleaner clogging sensor connector

(9).

RKTA0420

5 -Loosen and remove the screws (10) together with

washers and nuts and remove the filter (6). 6

10

Installation
• To install, reverse the removal procedure.

RKTA0430

30-18 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TURBOCOMPRESSOR

TURBOCOMPRESSOR
Removal
1 -Remove the engine hood.
(For details, see "ENGINE HOOD").

RKTA8501

2 -Disconnect the outside air inlet hose (2) from the air
cleaner (1). 2
3 -Remove the hose (3) connecting to the filter or
turbocompressor.

3
1

RKTA8560

4 -Disconnect the hose (4) from the oil vapour bleed valve
(5) and remove the air cleaner-to-turbocompressor
hose (6) and the clamp (7).
7
4

5
RKTA8492

5 -Loosen the clamps (8) and remove the hose (9).

8

8
9

RKTA8570

WH6-1E0 WH7-1E0 30-19

REMOVAL AND INSTALLATION TURBOCOMPRESSOR

6 -Loosen and remove the three screws (10) and remove

the support (11).
11

10

RKTA8580

7 -Loosen and remove the screws (12) retaining the

exhaust pipe (13).
13

12

RKTA0472

8 -Disconnect the exhaust pipe (13) and recover the

gasket (14).
14

13

RKTA0481

9 -Remove the turbocompressor following the instructions

given in the engine workshop manual (code
WEBMNEF001).

Installation
• To install, reverse the removal procedure.

30-20 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION EXHAUST PIPE

EXHAUST PIPE
Removal
• 1st Length 2
1 -Loosen and remove the screws (1) securing the pipe (2)
to the turbocompressor (3) (models with turbo engine), 1
or to the exhaust manifold (models with aspirated
engine). 3

a Models with aspirated engine:

replace the gasket between exhaust pipe and
manifold at each disassembly.
RKTA0471

2 -Loosen and remove the screws (4) together with their

respective washers, and remove the pipe (2).
2
a Replace the gasket between exhaust pipe and
muffler at each disassembly. 4 4
3 -Remove the pipe (2).

RKTA0490

• 2nd Length
1 -Loosen and remove the screws (5) and remove the tail
pipe (6). [*1]

RKTA0500

2 -Loosen and remove the screws (7) securing the 2nd

length of the pipe (8) to the muffler (9). 7
a Replace the gasket between exhaust pipe and
muffler at each disassembly.

9
RKTA0510

WH6-1E0 WH7-1E0 30-21

REMOVAL AND INSTALLATION EXHAUST PIPE

3 -Loosen the screw (10) remove the retaining screw (11),

and remove the clamp (12).

4 -Remove the pipe (8). 11

12

10

8
RKTA0520

Installation
• To install, reverse the removal procedure.

[*1]

a Before locking the tail pipe (6), adjust it until it is

centred in relation to the 2nd length of the exhaust.

30-22 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION BELT, FAN

BELT, FAN
Removal
1 -Remove the air intake hose (1).

RKTA8590

2 -Disconnect the coolant liquid outlet (2) hose (3)

connecting to the expansion tank from the cap.
3 5
3 -Remove the screw (4) and remove the clamp (5) that
2
supports the hose (3). Slide the hose (3) out towards the
engine compartment.

4
3

RKTA8600

4 -Remove the fan cover (6).

RKTA8610

5 -Loosen the screw (7) retaining the tensioner (8).

6 -Loosen the nut (9) and rotate the screw (10) to loosen
the belt. [*1]
10 9

7 8

RKTA8620

WH6-1E0 WH7-1E0 30-23

REMOVAL AND INSTALLATION BELT, FAN

7 -Loosen the compressor retaining screws (11).

8 -Disengage the belt (12) from the pulley (13). 12

11

11

13
14
RKTA8630

9 -Support the compressor (14) and simultaneously

disconnect the connector (15) and remove the fitting
screws (16). 15
16

16 16

RKTA8640

10 -Position the compressor (14) to the side and remove the

drive belt following the instructions in the engine
workshop manual (code WEBMNEF001).

a Slide the belt out through the openings between the

fan blades. 14

RKTA8650

Installation
• To install, reverse the removal procedure.

[*1]

a Tension the belt.

(For details, see "20 TESTING AND
ADJUSTMENTS").

30-24 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION RADIATOR-EXCHANGER ASSEMBLY

RADIATOR-EXCHANGER ASSEMBLY
Removal
1 -Unscrew the cap (1) and drain the coolant liquid. [*1]

6 Coolant liquid: 20 l approx.

1

RKTA8660

2 -Remove the radiators hood.

(For details, see "RADIATOR HOOD").
3 5
3 -Disconnect the hose (3) connecting to the expansion
tank from the radiator cap (2). Remove the screw (4); 2
remove the hose clamp (5), and slide the hose (3) out.

4
3

RKTA8601

4 -Disconnect the hose (6) from the radiator-intercooler

assembly and remove the hose. 7

5 -Remove the air inlet hose (7) and disconnect the

turbocompressor feed hose (8).

8
6

RKTA8670

6 -Remove the retaining screws and remove the fan guard

(9).
9

RKTA8611

WH6-1E0 WH7-1E0 30-25

REMOVAL AND INSTALLATION RADIATOR-EXCHANGER ASSEMBLY

7 -Disconnect the coolant liquid inlet hose (10) from the

radiator.

10

RKTA0581

8 -Disconnect the coolant liquid outlet hose (12) from the

radiator (11).
12

11

RKTA0592

9 -Disconnect the transmission oil inlet and outlet hoses

(13) from the exchanger. [*2]
13
a Mark the hoses to avoid mixing them up during
installation.

a Immediately cap the hoses and plug the holes to

prevent contaminants from entering the passages.

RKTA0601

10 -Loosen the screws (14), (15); remove the screws (14)

and disengage the radiator (10) from the brackets (16).

14
15

10
16

RKTA8680

30-26 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION RADIATOR-EXCHANGER ASSEMBLY

11 -Loosen and remove the lower nuts (17) retaining the

anti-vibration supports (18).

18

17

RKTA0554

12 -Remove four screws (19) retaining the fan shroud and

the middle screw (20) retaining the radiator assembly. 20

19

RKTA8690

13 -Shift the fan shroud towards the engine.

14 -Tilt the radiator towards the rear of the vehicle until the
hose sleeves become disconnected from the fan
shroud.

15 -Connect the complete assembly to a hoist and remove it

from the machine.

4 Assembly: 36 kg approx.

RKTA8700

Installation
• To install, reverse the removal procedure.

[*1]

a Carry out the coolant liquid filling procedure.

5 Coolant liquid: 20 l approx.

[*2]

a Top up the transmission oil.

WH6-1E0 WH7-1E0 30-27

REMOVAL AND INSTALLATION INTERCOOLER

INTERCOOLER
Removal
1 -Unscrew the cap (1) and drain the coolant liquid. [*1]

6 Coolant liquid: 20 l approx.

1

RKTA8660

2 -Remove the radiators hood.

(For details, see "RADIATOR HOOD").
3 5
3 -Disconnect the hose (3) connecting to the expansion
2
tank from the radiator cap (2). Remove the screw (4);
remove the hose clamp (5), and slide the hose (3) out.

4
3

RKTA8600

4 -Disconnect the hose (6) from the radiator-intercooler

assembly and remove the hose. 7

5 -Remove the air inlet hose (7) and disconnect the

turbocompressor feed hose (8).

8
6

RKTA8670

6 -Remove the retaining screws and remove the fan guard

(9).
9

RKTA8611

30-28 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION INTERCOOLER

7 -Disconnect the coolant liquid inlet hose (10) from the

radiator.

10

RKTA0581

8 -Disconnect the coolant liquid outlet hose (12) from the

radiator (11).
12

11

RKTA0592

9 -Disconnect the transmission oil inlet and outlet hoses

(13) from the exchanger. [*2]
13
a Mark the hoses to avoid mixing them up during
installation.

a Immediately cap the hoses and plug the holes to

prevent contaminants from entering the passages.

RKTA0601

10 -Loosen and remove the screws (14) retaining the fan.

14

RKTA8710

WH6-1E0 WH7-1E0 30-29

REMOVAL AND INSTALLATION INTERCOOLER

11 -Remove four screws (15) retaining the fan shroud and

the middle screw (16) retaining the radiator assembly. 16

15

RKTA8691

12 -Shift the fan shroud (17) towards the engine and pull out
the fan (18).

18
17

RKTA8720

13 -Remove the rear retaining screws (20).

19

14 -Remove the intercooler (20).

RKTA8740

Installation
• To install, reverse the removal procedure. 20
[*1]

a Carry out the coolant liquid filling procedure.

5 Coolant liquid: 20 l approx.

[*2]

a Check the transmission oil level.

RKTA8750

30-30 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION MUFFLER

MUFFLER
Removal
1 -Remove both lengths of the exhaust duct.
(For details, see "EXHAUST PIPE").
2
2 -Using a couple of belts, try to support the muffler (1)
temporarily.
3
3 -Disconnect the support (2) from the muffler support (3).

1
RKTA0620

4 -Loosen and remove the rear screws (4) along with their
respective washers.

5 -Loosen and remove the support’s front screws, remove

their respective washers and remove the muffler (1)
together with its support (2). 1
4

RKTA0630

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-31

REMOVAL AND INSTALLATION BATTERY – BATTERY TRAY

BATTERY – BATTERY TRAY

Removal
• Battery
3 1
1 -Lift the terminal shields (1) and disconnect the cables (2)
3
and (3). [*1]

k Disconnect the negative (–) cable first, and then

the positive (+) cable.
+
+
+
2
RKTA0640

2 -Loosen the nuts (4) until you are able to remove the
bracket (5) and the battery retaining rods.

4 5

RKTA0650

3 -Using the handles provided, remove the battery (6).

RKTA0660

• Battery tray
1 -Disconnect the washer pump connectors (7), (8). 11

a Record the positions for connection. 10

2 -Mark and then disconnect the feed pipes (9). 7
3 -Release the strap (10) and remove the tank (11).

9 8
RKTA0670

30-32 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION BATTERY – BATTERY TRAY

4 -Loosen and remove the screws (12), nuts and washers

retaining the surge tank (13). 12 13
5 -Remove the tank and position the tanks aside.

12

RKTA0401

6 -Loosen and remove the screw (14) and the nut retaining
the converter breather tube (15).

15

14

RKTA0680

7 -Loosen and remove the screws (16) together with their

respective washers and remove the battery tray (17).

16 17

RKTA0690

Installation
• To install, reverse the removal procedure.

[*1]

a Connect the positive (+) terminal first, and then the

negative (–) terminal.

WH6-1E0 WH7-1E0 30-33

REMOVAL AND INSTALLATION CYLINDER HEAD

CYLINDER HEAD
Removal
k Disconnect the cable from the negative (–) battery
2 1
terminal.

1 -Drain the coolant liquid.

6 Coolant liquid: 20 l approx.

4
3
2 -Disconnect the wiring (1) connecting to the coolant
liquid temperature sensor (2) and disengage it from the
tie-straps.

3 -Disconnect the wiring (3) from the thermostart (4). RKTA8760

4 -Disconnect the oil vapour bleed hose (6) from the valve
(5).

5 -Disconnect or remove:
a - the 1st length of the exhaust pipe. 5
b - the turbocompressor.
c - the coolant liquid surge tank.
d - The fan guard, the fan and the generator belt.
e - Only if equipped: the air conditioner compressor
with its support.
(For details, see the relevant section for each
6
component). RKTA8490

6 -Disconnect the feed hose (7) to the radiator from the

cylinder head.

RKTA0580

7 -Disconnect the cab heating feed hose (8) from the

cylinder head.

8 -Remove the cylinder head and/or replace the cylinder 8

head gasket by following the instructions given in the
engine workshop manuals (code WEBMNEF001).

RKTA0710

30-34 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CYLINDER HEAD

Installation
• Install the cylinder head by following the instructions
given in the engine workshop manuals (code
WEBMNEF001) and the reverse order for the parts
connected to it.

1 -Carry out the coolant liquid filling procedure.

5 Coolant liquid: 20 l approx.

WH6-1E0 WH7-1E0 30-35

REMOVAL AND INSTALLATION INJECTORS

INJECTORS
Removal
1 -Disengage the feed pipes (2) to the injectors from the
wire harness straps and from the retaining clamps (1).
1
2 -Perform all the preliminary valve adjusting procedures
described, without removing the valve covers.
1
2

2
RKTA8770

3 -Disconnect and remove the engine air intake hoses (3),

(4), and the centre support (5). 3
4 -Remove the injectors in accordance with the 5
instructions given in the engine workshop manual (code
WEBMNEF001).

RKTA8581

Installation
• To install, reverse the removal procedure.

30-36 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION INJECTION PUMP

INJECTION PUMP
Removal
1 -Disconnect the fuel temperature and heating control
1
connectors (1), (2) from the filter.

RKTA0730

2 -Disconnect the accelerator control cable (4) from the

injection pump (3) and remove the support bracket (5).
6
3 -Disconnect the fuel recovery hose (6) from the pump (3).

3
4

5
RKTA0740

4 -Disconnect the temperature sensor connector (7) and

the solenoid valve connector (8).

RKTA0750

5 -Remove the injection pump by following the instructions

given in the engine workshop manual (code
WEBMNEF001).

Installation
• To install, reverse the removal procedure.

1 -Bleed the system using the procedure described in the

engine workshop manual.

WH6-1E0 WH7-1E0 30-37

REMOVAL AND INSTALLATION HYDRAULIC PUMP

HYDRAULIC PUMP
Removal
k Lower and fully retract the boom and allow the
stabilizers (if equipped) to lower to the ground; apply the
parking brake, stop the engine, and remove the ignition
key.
1 -Open the engine hood.

k Disconnect the cable from the negative (–) battery

terminal.

2 -Drain the hydraulic oil.

6 Hydraulic oil: 1.5 l approx.

3 -Remove the air filter, the washer tank, the surge tank,
and the battery.
(For details, see the relevant removal procedure).

4 -Disconnect the feed pipe (1) and the servo-control hose 2

(2) from the pump assembly. [*1] 1

a Immediately cap the hoses and plug the holes to

prevent contaminants from entering the passages.

RKTA0760

5 -Disconnect the housing drain hose (4) and the suction

pipe (5) from the pump (3). [*1]
4

5
3

RKTA0770

6 -Loosen and remove the screws (6) and their respective

washers.
3
7 -Disengage the pump (3) and remove it.

4 Pump: 24 kg approx. 6

RKTA0780

30-38 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION HYDRAULIC PUMP

Installation
• To install, reverse the removal procedure.

[*1]

a Carefully check the condition of the O-rings on the

pump and on the suction and feed flanges.

a Coat the O-rings with grease to hold them in position

in their seats.

1 -Loosen the cap (7) and fill the pump housing with
hydraulic oil.

5 Oil: 1.5 l approx.

2 -Reinstall the cap (7).

3 -Fill the hydraulic oil reservoir to the maximum-fill level.

4 -Start the engine to allow the oil to circulate and check for 7
any leaks.

5 -Stop the engine, check the oil level and, if necessary, top
it up. RKTA0781

WH6-1E0 WH7-1E0 30-39

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

COMPLETE ENGINE– SHIFT ASSEMBLY

Removal
k Lower and fully retract the boom and allow the
stabilizers (if equipped) to lower to the ground; apply the
parking brake, stop the engine, and remove the ignition
key.
k Disconnect the negative (–)battery terminal.
1 - Drain the hydraulic oil. [*1]

6 Hydraulic oil: 95 l approx. +

2 -Drain the coolant liquid. [*1]

6 Coolant liquid: 20
RKTA0641

l approx.
3 -Only if equipped.
Drain the coolant fluid off the air conditioning system.
(For details, see "20 TESTING AND ADJUSTMENTS").
[*1]

4 -Remove:
a - The engine hood.
b - The battery and battery tray.
c - The air filter.
d - The exhaust piping
(For details, see the relevant section for each
component). RKTA8501

5 -Remove the engine air intake hoses (1), (2), and the
centre support (3). 1

RKTA8582

6 -Disconnect the accelerator control cable (5) from the

injection pump (4).
7 6 5
7 -Loosen the nut (6) and disengage the conduit (7) from
the support (8).

8
RKTA0790

30-40 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

8 -Disconnect the fuel return line (9) from the injection

pump.
9
9 -Disconnect the heating and fuel temperature sensor
connectors (11), (12) from the filter support (10). 10

12
11

RKTA0800

10 -Disconnect the connector (13) from the engine oil

pressure sensor.

11 -Disconnect the connector (14) from the engine stop

solenoid valve and disconnect the connector (15) from 15
the temperature sensor. 13

14
RKTA0810

12 -Disconnect the connector (16) from the coolant liquid

temperature sensor.
16
13 -Disconnect the wiring (17) from the thermostart.

17

RKTA0702

14 -Disconnect the fuel feed line (19) from the pump (18).

19

18

RKTA0820

WH6-1E0 WH7-1E0 30-41

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

15 -Disconnect the wirings (21), (22), (23) from the

generator (20). 20
21

22

23

RKTA0830

16 -Disconnect the wirings (24), (25) from the starter motor.

17 -Disconnect the ground cables (26) from the engine 26

block.

25

24

RKTA0840

18 -Only if equipped.
a - Disconnect the connector (27) connecting the air
conditioner compressor (28). 27
b - Drain the coolant fluid off the air conditioning
system.
(For details, see "20 TESTING AND
ADJUSTMENTS").

28

RKTA0850

c - Disconnect the coolant fluid feed and return lines

(29), (30) from the air conditioner compressor.
30

29

RKTA0860

30-42 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

19 -Remove the fan guard (31).

31

RKTA8612

20 -Loosen and remove the screws (32) retaining the

clamps (33). 34
33
21 -Disconnect the hose (34) connecting to the expansion
tank from the radiator cap.

32
34

RKTA8602

22 -Disconnect the upper coolant inlet hose (35) and the

lower coolant outlet hose (36) from the radiator.
36

35

RKTA0870

23 -Disconnect the transmission coolant inlet and outlet

hoses (37), (38) from the exchanger.
[*2]

a Mark the hoses to avoid mixing them up during

37
installation.

a Immediately cap the hoses and plug the holes to

prevent contaminants from entering the passages.

38
RKTA0591

WH6-1E0 WH7-1E0 30-43

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

24 -Loosen the screws (39), (40); remove the screws (39),

and disconnect the brackets (42) from the radiator (41).

39
40

41
42

RKTA8681

25 -Loosen by several turns the lower nuts (43) retaining the

anti-vibration supports (44) and tilt the radiator (41)
towards the rear of the machine.
41

44

43

RKTA0552

26 -Disengage from the clamps and disconnect the

temperature sensor and transmission input revolution
sensor connectors (45), (46). 45

46

RKTA0880

27 -Disconnect the gear select solenoid valve connectors

(47).
[*3]

k If the codes on the connectors appear damaged or 47

are illegible, mark all the connectors in order to
avoid mixing them up during installation.

RKTA0890

30-44 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

28 -Disconnect the feed hose (49) connecting to the control

valve, the servo-control feed assembly hose (50), and
the solenoid valve block feed hose (51) from the tube 49
(48).
51
a Immediately cap the hoses and tube to prevent
contaminants from entering the passages.
50

48

RKTA0900

29 -Disconnect the pump housing drain hose (52) and the

LS hose (53). [*4]
53 52

RKTA0771

30 -Disconnect the brake pump servo-control feed hose

(54) and the retaining clamp (55) from the transmission.

a Immediately cap the hose to prevent contaminants

from entering it.
54

55

RKTA0910

31 -Disconnect the brake pump servo-control drain hose

(56) from the transmission.

a Immediately cap the hose to prevent contaminants

from entering it.

56

RKTA0920

WH6-1E0 WH7-1E0 30-45

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

32 -Disconnect the cab heating hoses (57), (58) from the

cylinder head and engine thermostat.

57
58

RKTA0930

33 -Disconnect the hydraulic pump suction tube (59).

59

RKTA0940

34 -Remove the rear drive shaft protection bar (60).

60

RKTA0950

35 -Loosen and remove the screws (61) and the clevises

(62).

62

61
62

RKTA0960

30-46 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

36 -Loosen and remove the engine-to-shift screws (63) that

retain the hose supporting clamps (64).
64
64

63

RKTA0970

37 -Perform a visual check to ensure that all wiring and

hoses connected to the engine are totally free from
clamps or ties.

38 -Screw a pivot-type eye-bolt (A) to the transmission.

RKTA0980

39 -Connect the engine-shift assembly to a hoist using three

ropes or chains – one of the three should be adjustable
lengthwise.

a Connect the ropes or chains of equal length to the

engine lift brackets.

4 Complete assembly: 680 kg

RKTA0990

40 -Loosen and remove the self-locking nut (65) and the

engine’s left front retainer screw (66).
[*5]

65

66
RKTA1000

WH6-1E0 WH7-1E0 30-47

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

41 -Loosen the nuts (67) and remove the screws (68) from
the remaining engine mounts. [*6]
67

68

RKTA1010

42 -Tension the ropes or chains and start lifting to pull the

assembly out of the vehicle.

k Ensure that the assembly will be lifted starting from

the engine side and will remain tilted by approx. 20
cm.

RKTA1020

30-48 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION COMPLETE ENGINE– SHIFT ASSEMBLY

Installation
• To install, reverse the removal procedure.
[*1]
a Perform all the filling procedures.

5 Hydraulic oil: approx. 95 l

coolant liquid: approx. 20 l
Coolant fluid: (For details, see "20 TESTING
AND ADJUSTMENTS").
[*2]

a Check the transmission oil level before starting the

engine.
[*3]

a Thoroughly check to ensure that the connectors are

properly connected.
[*4]

a Fill the pump housing with hydraulic oil.

5 Oil: 1.5 l approx.

[*5]
3 Nut: 130±3 Nm
[*6]
a Tighten the screw (68) as far as it will go; then loosen
by 3 turns and lock the nut (67).
3 Nut: 130±3 Nm
1 -Start the engine and allow the engine to idle for a few
minutes.

2 -Stop the engine and check all levels.

3 -Start the engine again and bleed all hydraulic circuits.

WH6-1E0 WH7-1E0 30-49

REMOVAL AND INSTALLATION ENGINE-TRANSMISSION

ENGINE-TRANSMISSION
Detachment
1 -Remove the complete transmission assembly.
(For details, see "COMPLETE ENGINE– SHIFT
ASSEMBLY").

2 -Mount the assembly to a suitable stand.

RKTA1020

3 -Remove the hydraulic pump.

(For details, see "HYDRAULIC PUMP").

RKTA0782

4 -Screw an eye-bolt (1) and a pivot-type lift element (2) to

the transmission at the positions shown in the picture.

5 -Connect to a hoist using either end of the adjustable 1

rope or chain and put the assembly under slight tension.

RKTA1030

6 -Loosen and remove the screws (3) and remove the

cover (4).

4 3

RKTA1040

30-50 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION ENGINE-TRANSMISSION

7 -Slightly rotate the engine flywheel until you locate the

hydrodynamic coupling retaining screws (5).

8 -Remove the screws (5). [*1] 5

RKTA1050

9 -Loosen and remove the engine mounting screws (6)

and the transmission mounting screws (7) and detach 7
one assembly from the other. [*2]

6
RKTA1060

Joining
• To join the assemblies, reverse the detachment
procedure.
A

a Ensure that the coupling surfaces are clean and

dent-free.

[*1]

a To ease the joining of the flywheel to the

hydrodynamic coupling before attempting to join the
engine to the transmission, tighten a threaded stem
(A) to the coupling. The stem will serve as guide. RKTA1070

2 Screws: Loctite 262

3 Screws: 39 Nm
[*2]

3 Screws: 49 Nm
a Tighten in an alternate and criss-cross manner.

WH6-1E0 WH7-1E0 30-51

REMOVAL AND INSTALLATION CONTROL VALVE ASSEMBLY

CONTROL VALVE ASSEMBLY

Removal
k Lower and fully retract the boom and allow the
stabilizers (if equipped) to lower to the ground; apply the
parking brake, stop the engine, and remove the ignition
key.
1- Open the engine hood.

k Disconnect the cable from the negative (–) battery

terminal. +

2 - Drain the hydraulic oil. [*1]

6 Hydraulic oil: 95
RKTA0641

l approx.
3 -Disconnect the connector (1) of the boom extension/
retraction proportioning solenoid valve (2).

4 -Disconnect the lines (3), (4) from the valve (2).

NOTES 1
a - Immediately cap the hoses and plug the holes to
prevent contaminants from entering the
passages and to avoid oil drippings.
b - Before attempting to remove the control valve,
thoroughly clean the floor and any areas that are 3 2
soiled with oil in order to prevent slipping. 4
RKTA1080

5 -Remove the pump feed hose (5).

5

RKTA1090

6 -Disconnect the clamp (6) and remove the bracket (7).

7
RKTA1100

30-52 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CONTROL VALVE ASSEMBLY

7 -Mark and then disconnect the equipment curl/dump

control valve servo-control hose (8) and the boom lifting/
lowering control valve servo-control hose (9). 9 9

RKTA1110

8 -Mark and then disconnect the boom extension and

retraction control hoses (10).
9

8
10

RKTA1120

9 -Disconnect the hoses (11) connecting to the

compensator cylinder.
12 11
10 -Disconnect the hoses (12) connecting to the equipment
curl/dump cylinder.

11

RKTA1130

11 -Disconnect the boom lifting/lowering hoses (13).

13 13

RKTA1111

WH6-1E0 WH7-1E0 30-53

REMOVAL AND INSTALLATION CONTROL VALVE ASSEMBLY

12 -Disconnect the power steering feed hose (15) from the

head (14). 15

14

RKTA1140

13 -Disconnect the servo-control feed assembly LS signal

hose (16) from the head (14). 14

16

RKTA1150

14 -Disconnect and remove the pump feed tube (17) from

the head (14).

15 -Disconnect the solenoid valve block drain hose (19) 19 17

from the control valve drain line (18).

16 -Disconnect the control valve drain line (18) from the

20
head (14).
14

18

RKTA1160

17 -Loosen and remove the three screws shown (20) and

remove the complete control valve assembly (21). 20
4 control valve: without unions 30 kg 21
with unions 32 kg

20
RKTA7370

30-54 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CONTROL VALVE ASSEMBLY

Installation
• To install, reverse the removal procedure.

[*1]

a Fill the hydraulic oil reservoir to the maximum-fill

level.

5 Hydraulic oil: 95 l approx.

1 - Start the engine to allow the oil to circulate and check for
any leaks.
Perform several motions to bleed the air from the
system.
2 - Stop the engine, check the oil level and, if necessary,
top it up.

WH6-1E0 WH7-1E0 30-55

REMOVAL AND INSTALLATION BRACKET CONTROL, EQUIPMENT LOCK, AND FRAME LEVELLING

BRACKET CONTROL, EQUIPMENT LOCK, AND FRAME LEVELLING

SOLENOID VALVES
Removal
1 -Disconnect the connectors (1) of the solenoid valves
that need replacing.

k If the codes on the connectors appear damaged or

are illegible, mark all the connectors in order to
avoid mixing them up during installation.

1
1
RKTA1170

2 -Loosen and remove the 4 screws (2) and remove the

solenoid valve that needs replacing. [*1]

a Always recover the O-rings. 2

RKTA1180

Installation
• To install, reverse the removal procedure.

[*1]

a Apply a coat of grease to the seats of the O-rings to

hold the O-rings in position.

30-56 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AIR CONDITIONER COMPRESSOR (only if equipped)

AIR CONDITIONER COMPRESSOR (only if equipped)

Removal
1 -Connect the outlets (1) and (2) to the air conditioning 1
2
system maintenance station and draw the coolant fluid.
(For details, see "20 TESTING AND ADJUSTMENTS").

2 -Disengage the connector (3) from the clamp and

disconnect the connector.

3
RKTA1190

3 -Disconnect the coolant fluid feed and return pipes (5),

(6) from the air conditioner compressor (4). [*1]
6
a Always recover the O-rings.

4
RKTA0861

4 -Remove the fan guard (7).

RKTA0533

5 -Loosen the screw (8) retaining the tensioner (9).

6 -Loosen the nut (10) and rotate the screw (11) to loosen
the belt.
11 10

8 9

RKTA1200

WH6-1E0 WH7-1E0 30-57

REMOVAL AND INSTALLATION AIR CONDITIONER COMPRESSOR (only if equipped)

7 -Disengage the belt (12) from the pulley (13).

8 -Loosen the compressor retaining screws (14).

9 -Loosen the screws (15) and remove the compressor (4). 12

14
14

15
13

15 RKTA1210

Installation
• To install, reverse the removal procedure.

[*1]

a Ensure that the O-rings are undamaged.

2 Fittings and O-rings: refrigerant oil
1 -Tension the compressor belt.
(For details, see "COMPRESSOR BELT").

2 -Connect the maintenance station to the air conditioning

system and recharge the system.
(For details, see "20 TESTING AND ADJUSTMENTS").

30-58 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION COMPRESSOR BELT

COMPRESSOR BELT
Removal
1 -Disconnect the coolant liquid outlet hose (1) connecting 1 3
to the expansion tank from the cap.

2 -Remove the screw (2). Remove the clamp supporting

the hose (3); slide the hose out towards the engine
compartment.
2
1

RKTA8603

3 -Remove the fan cover (4).

RKTA8614

4 -Loosen the screw (5) retaining the tensioner (6).

5 -Loosen the nut (7) and rotate the screw (8) to loosen the
belt. [*1]
8 7

5 6

RKTA8621

6 -Loosen the compressor retaining screws (10).

7 -Disengage the belt (11) from the pulley (12). 11

12
10
RKTA8631

WH6-1E0 WH7-1E0 30-59

REMOVAL AND INSTALLATION COMPRESSOR BELT

8 -Disconnect the hose (14) from the radiator-intercooler

assembly (13) and remove the hose. 13 15

9 -Disconnect the air inlet hose (15) and the

turbocompressor feed hose (16).

16
14

RKTA8671

10 -Loosen and remove the screws (17) retaining the fan.

17

RKTA8711

11 -Loosen the screws (18) and remove the intercooler (13).

13

18

RKTA8780

12 -Remove the fitting screws (19) from the fan shroud (20).
19

20

19

RKTA8692

30-60 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION COMPRESSOR BELT

13 -Move away the fan shroud (20) and remove the fan (21).

14 -Remove the poor compressor belt and replace with a

new one.

21
20

RKTA8721

Installation
• To install, reverse the removal procedure.

[*1]

1 -Perform the belt tensioning procedure.

(For details, see "20 TESTING AND ADJUSTMENTS").

WH6-1E0 WH7-1E0 30-61

REMOVAL AND INSTALLATION SERVO-CONTROL FEED VALVE

SERVO-CONTROL FEED VALVE

Removal
k Lower and fully retract the boom and lower the 2
stabilizers (if equipped) to the ground; apply the parking
brake, stop the engine and remove the ignition key.

1 -Mark and then disconnect the connectors (1), (2).

RKTA1230

2 -Disconnect the lower hoses (3), (4).

a Immediately cap the hoses to prevent contaminants

from entering the passages. 3

RKTA1240

3 -Disconnect the upper lines (5) and (6).

a Immediately cap the hoses to prevent contaminants

from entering the passages. 5
6
4 -Loosen the screws (7), and remove the valve (8).

8
RKTA1250

Installation
• To install, reverse the removal procedure.

1 -Start the engine to allow the oil to circulate and check for
any leaks.
Perform several boom and equipment motions in order
to bleed the air from the system.

30-62 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STEERING SELECTION SOLENOID VALVE ASSEMBLY

STEERING SELECTION SOLENOID VALVE ASSEMBLY

Removal
k Lower and fully retract the boom and lower the
1

stabilizers (if equipped) to the ground; apply the parking

brake, stop the engine and remove the ignition key. 1
1 -Disconnect the 4 solenoid valve connectors (1).

k If the codes on the connectors appear damaged or

are illegible, mark all the connectors in order to
avoid mixing them up during installation. 1 1

RKTA1260

2 -Disconnect the feed (2) and drain (3) pipes and the
tubes (4), (5) connecting to the steering cylinders.
4
3 -Loosen the screws (6) and remove solenoid valve
assembly. 6

3
2

RKTA1270

Installation
• To install, reverse the removal procedure. A B
1 -Start the engine to allow the oil to circulate and check for
any leaks.
Perform several steering motions in all manners and in
both directions in order to bleed the air from the system.

k The steering unit allows the wheels to be realigned

even when the steering cylinders are being services or
the hydraulic pipes are being changed.
If after starting the engine it is difficult to realign the RKTA8810

wheels or a seizure in the steering system is found out,

stop the engine and, keeping the two centre buttons (A)
and (B) pressed, supply power for at least 5 seconds
with the ignition switch in position “I”, then start the en-
gine.
The steering mode is set to “2WS” and allows the front
wheels to be realigned.
It then changes over to the “4WS ROUND” steering
mode and allows the rear wheels to be realigned.

WH6-1E0 WH7-1E0 30-63

REMOVAL AND INSTALLATION FRONT AXLE

FRONT AXLE
Preparation
• Machine with outriggers
1 -Fully lower the boom, lower the outriggers and force
them down to the ground until they have reached the
end of their travel.

2 -Position and force two safety jacks “A” and anti-slip

blocks under the outrigger support and apply wedges
under both rear wheels.
A
RKTA1280

• Machine without outriggers

1 -Install two screw jacks “A”, together with safety blocks,
under the frame on the front of the machine.

2 -Raise the screw jacks until the front wheels have been
lifted off the ground by 2-3 cm. A
3 -Install wedges under the rear wheels.

RKTA1290

Removal
1 -Remove the front wheels (1). [*1]

RKTA1300

2 -Remove the fenders (2).

2

RKTA1310

30-64 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION FRONT AXLE

3 -Loosen and remove the screws (3) and clevises (4);

disconnect the front propeller shaft (5). [*2]
3

4
4

RKTA1320

4 -Disconnect the hoses (7),(8) from the steering cylinder

(6).

a Cap the hoses and plug the holes to prevent

contaminants from entering the passages.
6

7
RKTA1330

5 -Loosen and remove the parking brake adjustment nuts

(9) and disconnect the control cable (10).
9

10

RKTA0280

6 -Disconnect the service brake hose (11) and the wiring

(12) of the steering sensor (13). 13

11

12

RKTA1340

WH6-1E0 WH7-1E0 30-65

REMOVAL AND INSTALLATION FRONT AXLE

7 -Remove the pin (14) and disconnect the piston (15) of

the frame levelling cylinder (16) from the axle. 16
k If no frame levelling is provided, disconnect the
rod.
15

14

RKTA1350

8 -Install a wheel lift “B” under the axle and place anti-slip
blocks at the ends of the axle shafts.

9 -Raise the lift and ensure that the anti-slip blocks do

engage the axle while the raising of the lift takes place.

B
19

RKTA1360

10 -Loosen and remove the screws (17) retaining the

supports (18); lower the axle until disengaging the
centring pins; remove the complete axle (19). [*3]

17

17 18
RKTA1331

Installation
• To install, reverse the removal procedure.

[*1]

3 Front wheel nuts: 550±11 Nm

[*2]

3 Screws: 38±1 Nm
[*3]

3 Screws: 780±16 Nm

30-66 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION REAR AXLE

REAR AXLE
Preparation
• Machine with outriggers
1 -Fully lower the boom; lower and slightly force the
outriggers to the ground, and stop the engine.

• Machine without outriggers

1 -Fully lower the boom, apply the parking brakes, and stop
the engine.

RKTA0040

Removal
1 -Install two screw jacks “A” under the frame.

a If the machine is equipped with additional ballasts,

install the screw jacks under the rear ballast,
together with anti-slip blocks.

2 -Raise the “A” jacks equally, enough to lift and remove

the wheels (1). [*1]

A
1
RKTA1370

3 -Install a safety stand “B” under the ballast.

RKTA1380

4 -Loosen and remove the nuts and remove the fenders

(2).
2

RKTA1390

WH6-1E0 WH7-1E0 30-67

REMOVAL AND INSTALLATION REAR AXLE

5 -Disconnect the service brake hose (3) and the wiring (4)
of the steering sensor.

a Immediately cap the hoses to prevent contaminants 3

4
from entering the passages.

RKTA1400

6 -Disconnect the hoses (5), (6) from the steering cylinder.

a Immediately cap the hoses to prevent contaminants

from entering the passages.

6
5

RKTA1410

7 -Disconnect the load cell connector (7).

k If the load cell is changed, or if the axle is changed, 7

then you should test and calibrate the overturn
prevention control unit.
(For details, see "20 TESTING AND
ADJUSTMENTS").

RKTA0150

8 -Remove the pin (8) and disconnect the piston (9) of the
locking cylinder (10) from the axle.

9 10

RKTA1420

30-68 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION REAR AXLE

9 -Loosen and remove the screws (11) and clevises (12);

disconnect the rear propeller shaft (13).
12 11
[*2]

12
11
13

RKTA1430

10 -Install a wheel lift together with anti-slip blocks under the

axle, remove the axle by carrying out the procedures
described for the removal of the front axle.
(For details, see "FRONT AXLE").
[*3]

Installation
• To install, reverse the removal procedure.

[*1]

3 Wheel nuts: 550±11 Nm

[*2]

3 Screws: 38±1 Nm
[*3]

3 Screws: 780±16 Nm

WH6-1E0 WH7-1E0 30-69

REMOVAL AND INSTALLATION TELESCOPIC BOOM

TELESCOPIC BOOM
Removal
k Lower and fully retract the boom and lower the
stabilizers (if equipped) to the ground.
Remove the equipment in use from the telescopic
boom.
Apply the parking brake, stop the engine and remove
the ignition key.

k Disconnect the cable from the negative (–) battery +

terminal.

RKTA0641

1 -Disengage the wiring harnesses (1) from the straps.

2 -Remove the microswitch cover (2). 1

2

RKTA1440

3 -Remove the screws (3); remove the bracket (4) and the
microswitch (5) and position them aside.
5
4 -Disconnect the connector (6).
4
6

RKTA1450

5 -Disconnect the hoses (7).

a Immediately cap the hoses to prevent contaminants

from entering the passages.

7 7

RKTA1460

30-70 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TELESCOPIC BOOM

6 -Remove the engine and radiator hoods (8).

(For details, see "ENGINE HOOD" and "RADIATOR
HOOD").
8

RKTA8502

7 -Raise the telescopic boom (9) and install the

appropriate support tool A1 (code no. ATR201501)
under the lift cylinder head.

8 -Slowly lower the boom until the cylinder (10) rests on the
A1 tool (code no. ATR201501). 9
10

A1

RKTA1470

9 -Mark the radial position of the pin (11).

10 -Loosen the nut (12) and screw (13) and remove the nut 11
and the screw.

12

13

RKTA1480

11 -Connect a hoist to the complete boom (9), using three

ropes or chains – the one attached to the rear of the
boom should be adjustable lengthwise.

k Use the connections provided.

9

4 Boom: WH609: 1382 kg

WH613: 2112 kg
WH713: 2288 kg
WH714H: 2318 kg
WH716: 2588 kg

RKTA8790

WH6-1E0 WH7-1E0 30-71

REMOVAL AND INSTALLATION TELESCOPIC BOOM

12 -Slightly tension the ropes or chains and pull the fulcrum

pin (14) out.

a Recover the shoulders mounted between the boom

and the frame.
14

a Do not mix or invert the position of the shoulders.

RKTA1490

13 -Remove the pin (11) providing the attachment for the lift
cylinder (10) and offset cylinder (15).
11
a If necessary, use a push puller to remove the pin.

15
10

RKTA1500

14 -Remove the complete boom (9).

9

RKTA1510

30-72 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TELESCOPIC BOOM

Installation
1 -Install the A1 tool (code no. ATR201501) under the lift
cylinder (10).

10

A1

RKTA1520

2 -Connect the boom (9) to a hoist using three chains or

ropes – one of which should be adjustable lengthwise.

RKTA1530

3 -Using the attachment pin (11), align the rods of the lift
cylinder (10) and offset cylinder (15). 11

15
10

RKTA1540

4 -Position the boom in such a way as to centre the pistons

of cylinders (10) and (15) into the attachment eyelets.

15

10

RKTA1550

WH6-1E0 WH7-1E0 30-73

REMOVAL AND INSTALLATION TELESCOPIC BOOM

5 -Align the holes and introduce the pin (11).

11

RKTA1560

6 -Tighten a screw (B) into the centre hole on the pin (11)
and lock the screw with a nut (C). C
B
11

RKTA1570

7 -Orient the pin to the marks made during removal and

gradually tighten the screw (13) until it is fully locked.
11
Lock the position with the nut (12).

12

13

RKTA1480

8 -Install a block (D) approximately 12 cm thick under the

boom on the fulcrum side.

9 -Lower the boom until the fulcrum side rests on the

previously installed block.

RKTA1580

30-74 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TELESCOPIC BOOM

10 -Introduce a pin (E) into the equipment attachment hole.

11 -Place and a hydraulic jack (F) of min. 5 ton capacity

firmly in place under the pin (E).
E

RKTA1590

12 -Remove the boom lift ropes or chains, and then connect

to the hoist a standard chain fastened to the attachment
(G) of the boom (9) on the fulcrum side. Put under slight
tension.
G
9

RKTA1600

13 -Slightly lower the jack (F) and remove the block (D).

14 -As you work on the hydraulic jack (F) with the hoist,
9
swing the boom (9) and locate the fulcrum pin hole
centering position.

RKTA1610

15 -Introduce a shim (16) to the right between the frame (17)

and the boom (9); introduce the pin (14) and then
introduce the remaining shims on the left side. 16
17 14
a The quantity of shims used should be enough to
leave less than 1 mm clearance between the boom
and the frame.

a If more than two shims are needed, you should

install the larger amount of shims to the left side.

RKTA1491

WH6-1E0 WH7-1E0 30-75

REMOVAL AND INSTALLATION TELESCOPIC BOOM

16 -Lock the fulcrum pin (14) with the screw (18) and the
respective washer.

14

18

RKTA1620

17 -Connect the hoses (7).

7 7

RKTA1460

18 -Install the support (4) and the microswitch (5).

19 -Connect the connector (6). 5

4
6

RKTA1451

20 -Install the cover (2) and secure the wiring harness (1)
with the pull straps. 1
21 -Start the engine and perform some full arm lifting and 2
arm lowering movements.

22 -Install the equipment, and perform a few motions to

bleed the air from the circuits.

RKTA1440

30-76 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION LIFT AND OFFSET CYLINDERS

LIFT AND OFFSET CYLINDERS

Removal
1 -Remove the telescopic boom:
(For details, see "TELESCOPIC BOOM"). 1

2 -Install a screw jack (A) under the left side of the rear axle
and remove the left wheel and fender (1).

RKTA1630

3 -Connect a hoist and move the cylinders (2), (3) to their

upright position.

3 2

RKTA1640

4 -Mark and disconnect the hoses (4), (5) of the lift cylinder
(2).

a Immediately cap the hoses and plug the holes to

prevent contaminants from entering the passages.

5
4

RKTA1650

5 -Mark and disconnect the hoses (6), (7) of the offset

cylinder (3).

a Immediately cap the hoses and plug the holes to

prevent contaminants from entering the passages.

k The holes on the offset cylinder should be sealed

6
to prevent telescoping to take place during 7
removal.

RKTA1660

WH6-1E0 WH7-1E0 30-77

REMOVAL AND INSTALLATION LIFT AND OFFSET CYLINDERS

6 -Remove the screw, slide the pin (8) out and remove the
cylinders (2), (3).

RKTA1670

Installation
• To install, reverse the removal procedure.

1 -Perform a full lubrication procedure.

2 -Start the engine and perform several lifting and lowering

motions to bleed the air form the circuits.

30-78 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION INTERMEDIATE AND TOP BOOM

INTERMEDIATE AND TOP BOOM

Removal
a This procedure refers to machines with a 3-stage boom;
in the case of machines equipped with a 2-stage boom,
you should ignore the procedures described here for
chains and chain covers and housings.
a Definitions used in this section are as follows:
a - Basic boom (1)
b - Intermediate boom (2)
c - Top boom (3) 3
a In order to perform the extension cylinder’s retraction
and extension motions, it is necessary to have an
independent power unit (or a manual pump) available,
filled with the same type of hydraulic oil as the machine.
2

RKTA7450

1 -Place the machine on firm, level ground; apply the

parking brakes and remove the front equipment. 4
2 -Fully extend the boom and remove the chain housings
(4) and covers (5). [*1]

RKTA0020

RKTA0030

WH6-1E0 WH7-1E0 30-79

REMOVAL AND INSTALLATION INTERMEDIATE AND TOP BOOM

3 -Remove the rear cover (6)

RKTA0010

4 -Retract the boom until it is 40 cm away from the closure

of the intermediate boom.

5 -Only if equipped.
Remove the lower cover (7).

7
RKTA1680

6 -Disconnect and remove both left and right iron pipes (8).

RKTA1690

7 -Place a wheel support stand or a pallet truck (A) under

the top boom; rest the top boom on the stand or truck (3).

RKTA1700

30-80 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION INTERMEDIATE AND TOP BOOM

8 -Loosen and remove the screws securing the check

plates (9) along with the side guide sliding pads (10) of
the intermediate boom (2). 9
2

10

RKTA1710

9 -Remove the retraction chain cotter pin and retaining

nuts (11).

10 -Loosen the screws (12) and remove the support (13).

11

13
12
RKTA1720

11 -Remove the extension chain tensioner cotter pins and

nuts (14). [*2] 14

RKTA1730

12 -Start the engine and perform an extension motion until

the boom reaches the end of its travel; then stop the
engine.

k Make sure to guide and keep tensioned the

retraction chain (15) and the equipment rubber
hoses (16) while extending the boom. 16

15
RKTA7470

WH6-1E0 WH7-1E0 30-81

REMOVAL AND INSTALLATION INTERMEDIATE AND TOP BOOM

13 -Place a support block (B) under the cylinder head (17).

17

RKTA1740

14 -Remove the nuts (18) and screws (19) retaining the

extension cylinder rod attachment. [*3] 20 20
15 -Loosen and remove the nuts and screws (20) retaining
the extension cylinder rod attachment pin (21).

16 -Remove the pin (21) through the ballast holes. 21 19

19
18

RKTA1750

17 -Disconnect the hoses (23) from the safety valve (22).

23
22

23

RKTA1760

18 -Connect the intermediate boom (2) complete with top

boom (3) to a hoist and pull them out from the basic
boom. 3 2

RKTA1770

30-82 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION INTERMEDIATE AND TOP BOOM

19 -Slide the intermediate boom (2) and top boom (3) out
from the basic boom (1), and rest the entire assembly on
stands.

2 1

RKTA1780

Installation
4
• To install, reverse the removal procedure.
[*1]

a Before attempting to re-install the chain housings

(4) and covers (5):
a - Perform the extension chain tension adjustment
procedure.
b - Perform the extension travel adjustment procedure.
(For details, see "20 TESTING AND
ADJUSTMENTS").
RKTA0021
c - Perform a full chain and pin lubrication procedure.
[*2]

3 Check-nuts: 270 Nm
[*3]

3 Screws: 580 Nm
1 -Start the engine and perform full extension and
retraction motions in order to bleed the air from the
circuit.

2 -Stop the engine and check the hydraulic oil level.

WH6-1E0 WH7-1E0 30-83

REMOVAL AND INSTALLATION EXTENSION CYLINDER

EXTENSION CYLINDER
Removal
1 -Remove the intermediate and top boom from the
machine.
(For details, see "INTERMEDIATE AND TOP BOOM").

RKTA1781

2 -Using a separate power unit (or a manual pump) filled

with the same oil type as the machine, cause the piston
(1) to return until it is within 80 cm of the end of its travel.

RKTA1790

3 -Remove the guides (2) for the equipment hoses.

RKTA1800

4 -Loosen and remove the screws (3) together with their

respective washers and plates (4) retaining the cylinder
(5). [*1]
3
3

4 5

RKTA1810

30-84 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION EXTENSION CYLINDER

5 -Partially remove the cylinder (5).

Connect the cylinder to a hoist and then remove it
completely.
5

RKTA1820

Installation
• To install, reverse the removal procedure.

[*1]

3 Screws: 580±12 Nm
1 -Start the engine and perform full extension and
retraction motions in order to bleed the air from the
circuit.

2 -Stop the engine and check the hydraulic oil level.

WH6-1E0 WH7-1E0 30-85

REMOVAL AND INSTALLATION BOOM SLIDING PADS

BOOM SLIDING PADS

Replacement
k Lower and fully retract the boom and lower the
stabilizers (if equipped) to the ground; apply the parking
brake.
If the machine is not equipped with stabilizers, place
wedges under the wheels.
NOTES
3
1 -The operations described below regard 3-stage
booms; the same operations apply to 2-stage
booms, except for chain-related procedures.

2 -We recommend changing one sliding pad at a time

in order to avoid inverting or mixing up the shims 2
that are responsible for determining run clearance.

3 -Definitions used in this section are as follows:

a - Basic boom (1)
b - Intermediate boom (2)
1
c - Top boom (3)

RKTA7450

1. Lower sliding pads for intermediate and

top booms.
3
1 -Lift the complete boom and extend the intermediate
boom (2) by approximately 60-70 cm.

2 -Place a stand (A) under the top boom (3); lower the 2
complete boom again, slightly forcing it, and then
disengage the sliding pads.

A
RKTA1830

3 -Stop the engine, loosen and remove the retaining

screws (4) (2 screws for each sliding pad).

4 4

RKTA1840

30-86 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION BOOM SLIDING PADS

4 -Remove the worn sliding pads (5), install new sliding

pads and lock them in position with their respective
screws.
5

RKTA1850

2. Upper sliding pads for intermediate boom

1 -Start the engine and remove the stand (A) you have 3
installed in the previous step.

RKTA1860

2 -Loosen and remove the screws (5) (2 screws for each

sliding pad).
6

RKTA1870

3 -Remove the worn sliding pads (7) and their respective

shims (8); install new sliding pads and lock them in
position with their respective screws.
8
4 -Recover the shims, apply them to the new sliding pads
and re-install the complete sliding pads.

a To cause the shims to properly adhere the new

sliding pads, apply instant adhesive ASL800020 to
the shims in several points.
7

RKTA1880

WH6-1E0 WH7-1E0 30-87

REMOVAL AND INSTALLATION BOOM SLIDING PADS

3. Side sliding pads for intermediate and

top boom 9

1 -Loosen and remove the retaining screws (9) (n°6

screws for each sliding pad).

RKTA1890

2 -Remove the worn sliding pads (10) with their respective

shims.
10
3 -Recover the shims, apply them to the new sliding pads
and re-install the complete sliding pads.

a To cause the shims to properly adhere the new

sliding pads, apply instant adhesive ASL800020 to
the shims in several points.

RKTA1711

4. Upper sliding pads for top boom

12 11
1 -Fully extend the booms.
Stop the engine and remove the chain front housing (11)
and top cover (12).

RKTA0022

2 -Remove the lower cover (13) (only if equipped).

13
RKTA1681

30-88 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION BOOM SLIDING PADS

3 -Start the engine and retract the booms until the letter “A”
(for load diagram reference) is totally covered.

RKTA1900

4 -Remove the rear cover (14).

14

RKTA0011

5 -Remove the cotter pins (15) and check-nuts (16) while

holding the rods (17) in position; loosen the extension
16 18
chain tensioner rod nuts (18) in an alternate manner;
remove the nuts (18). 15
a Replace the cotter pins at each disassembly.
a Prevent rod rotation.
17

RKTA1910

6- Loosen and remove the upper screws and remove the

support (19) of the idler wheels guiding the chains.
19

RKTA1920

WH6-1E0 WH7-1E0 30-89

REMOVAL AND INSTALLATION BOOM SLIDING PADS

7 -Loosen the retaining screws (2 for each sliding pad) and

remove the worn upper sliding pads (20) together with
their respective shims (21). 21
8 -Recover the shims, apply them to the new sliding pad,
and re-install.

a To cause the shims to properly adhere the new

sliding pads, apply instant adhesive ASL800020 to
the shims in several points.
20

RKTA1930

9 -Install the chain guide idler wheel support (19) and

perform the tensioning procedure before installing the
housings and covers. 19

RKTA1940

5. Rear upper sliding pads for intermediate

boom
14
1 -With the boom fully lowered, remove the rear cover (14).

RKTA0011

2 -Disconnect the hose clamps (22) and connections (23);

move the hoses (24) towards the middle of the boom to
clear the work area.

22 22

24

24 23

RKTA1950

30-90 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION BOOM SLIDING PADS

3 -Loosen and remove the screws (25) and remove the

check plates (26); partially extract the sliding pad
lubrication ducts. 26 26

25

RKTA1960

4 -Tighten a threaded bar into the holes provided and

remove the worn sliding pads (27) complete with lower
(28) and side (29) shims. 29
27
5 -Recover the shims, apply them to the new sliding pads
and re-install the complete sliding pads.

a To cause the shims to properly adhere the new

sliding pads, apply instant adhesive ASL800020 to
the shims in several points.
28

RKTA1970

6. Rear upper sliding pads for top

boom
1 -With the boom fully lowered and with the rear cover
removed, disconnect the hoses (24).
24

24

RKTA1731

2 -Loosen and remove the screws (30).

30 30
3 -Remove the piston attachment pin (31).

4 -Loosen and remove the nuts (32) and washers and

remove the screws (33).

3 Nuts: 580±12 Nm
31 33

33
32

RKTA1751

WH6-1E0 WH7-1E0 30-91

REMOVAL AND INSTALLATION BOOM SLIDING PADS

5 -Connect an external power unit to the cylinder and let

the piston (34) slide out of the cylinder by approximately
70-80 cm.

a Make sure that the external power unit is filled with

the same type of hydraulic oil as the machine. 34

RKTA1791

6 -Remove the hose guides (35).

7 -Remove the screws and remove the upper guide rollers 36

(36).

8 -Remove the check plates and remove the sliding pads

complete with shims as described in paragraph "5. Rear
upper sliding pads for intermediate boom".
9 -Install by reversing the removal procedure. 35

RKTA1980

7. Rear lower sliding pads for intermediate

and top boom
NOTE
This procedure should only be carried out when
overhauling the boom or the machine, as the amount of
wear on these parts is virtually negligible.

1 -Remove the intermediate and top booms.

(For details, see "INTERMEDIATE AND TOP BOOM").

2 -Remove all side and front guide sliding pads.

(For details, please refer to paragraphs 1, 2, 3, and 4).

k Do not invert or change the position of the slip

clearance adjustment shims.

30-92 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION BOOM SLIDING PADS

3 -Disconnect the rods (17) from the extension chains (37).

37 17

RKTA1990

4 -Remove the clevises (38).

5 -Remove the retraction chain (39).

38

39

RKTA2000

6 -Place a pallet truck (B) under the top boom (3); partially
pull out the boom.

RKTA2010

7 -Connect the top boom (3) to a hoist; extract the top boom
and rest it on two stands or on a dolly.
3

RKTA2020

WH6-1E0 WH7-1E0 30-93

REMOVAL AND INSTALLATION BOOM SLIDING PADS

8 -Loosen and remove the screws retaining the lower

sliding pads (40) of the intermediate boom (2) and top 3
boom (3) and replace the sliding pads.

2
40 RKTA2030

9 -Remove the cylinder (41) from the top boom and replace
the worn sliding pads (42), (43).
42

41

43

RKTA2040

10 -Before attempting to reassemble, remove all

contaminated grease from the inside of the booms and
lubricate the sliding pad slip surfaces as well as the hose
surfaces in the cylinder covers.

RKTA2050

30-94 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION EXTENSION AND RETRACTION CHAINS (Versions with 3-section

EXTENSION AND RETRACTION CHAINS

(Versions with 3-section boom)
Removal
1 -Remove the intermediate boom complete with top 2
1
boom.
(For details, see "INTERMEDIATE AND TOP BOOM"
until point 19).

2 -Loosen the nuts (1) and disconnect the rods and guide
blocks (2). [*1]

RKTA1991

3 -Remove the screws (3) and remove the idler wheel

assembly (4) guiding the extension chain.

4 3

RKTA2060

4 -Loosen and remove the screws; remove the check

plates (5) along with the top boom side guide sliding
pads (6) and their respective shims. 5

RKTA1712

5 -Loosen and remove the screws; remove the top boom

vertical guide sliding pads (7) and their respective
shims.

RKTA1931

WH6-1E0 WH7-1E0 30-95

REMOVAL AND INSTALLATION EXTENSION AND RETRACTION CHAINS (Versions with 3-section

6 -Remove the screws and remove the clevises (8).

7 -Remove the retraction chain (9).

RKTA2001

8 -Loosen the screws (10), remove the pin (11) and

disconnect the retraction chain (9). 10

11

9
RKTA2070

9 -Connect the top boom (12) to a hoist and remove the top
boom.
12

RKTA2021

10 -Remove the cotter pins (13) and nuts (14). [*2]

11 -Remove the extension chains (15). 14

15 13

RKTA2080

30-96 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION EXTENSION AND RETRACTION CHAINS (Versions with 3-section

Installation
• To install, reverse the removal procedure.

[*1] L

a Tightening length for rods “L”: 115 mm

RKT01790

[*2]

a Tightening length for attachment:

Model Length “L1” L1

WH613 52.5 mm
WH713 54.0 mm
WH714
54.0 mm
WH714H
WH716 65.0 mm

RKT01800

WH6-1E0 WH7-1E0 30-97

REMOVAL AND INSTALLATION CHAIN RETURN PULLEY PINS AND BUSHINGS

CHAIN RETURN PULLEY PINS AND BUSHINGS

RETRACTION CHAIN PULLEY
Removal 1

1 -Remove the screws and remove the boom rear cover

(1).

RKTA0012

2 -Remove the cotter pin; loosen and remove the check-

nut. [*1]
2
3 -Loosen the nut (4) until it is flush with the rod head, being
careful not to cause any rotation of the rod (3). 4

RKTA2090

4 -Remove the clevises (5) retaining the chain.

6 6
5 -Loosen the nuts and retaining screws (6) until
disengaging the pin (7).

RKTA2002

6 -Remove the pin (7) and pulley (8).

6 6

RKTA2100

30-98 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CHAIN RETURN PULLEY PINS AND BUSHINGS

7 -Inspect pulley bushing (9) and pin (7) wear.

If the total of wear “A” plus wear “A1” is near or exceeds
1 mm, replace the bushing and pin.
A
A1
7

9 RKT01810

Installation
• To install, reverse the removal procedure.

1 -Perform the bushing lubrication procedure.

2 Bushings: NLGI 2EP grease

2 -Perform the chain tensioning procedure.
(For details, see "20 TESTING AND ADJUSTMENTS").

[*1]

3 Check-nuts: 270 Nm

WH6-1E0 WH7-1E0 30-99

REMOVAL AND INSTALLATION CHAIN RETURN PULLEY PINS AND BUSHINGS

EXTENSION CHAIN PULLEYS

Removal 1

1 -Remove the screws and remove the boom rear cover

(1).

RKTA0012

2 -Remove the screws (2) and the grease nipple and

remove the extension chain housing (3). 2
4

RKTA0024

3 -Remove the cotter pins (4); loosen and remove the

check-nuts (5).

RKTA2110

4 -Loosen the nuts (7) in an alternate manner until flush

with the rod heads, being careful not to cause any
rotation of the rods (6). 7

RKTA2120

30-100 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CHAIN RETURN PULLEY PINS AND BUSHINGS

5 -Loosen the nut and screw (8) until disengaging the pin
(9).

6 -Remove the pin (9) and pulleys (10).

8

10

9
RKTA2130

7 -Inspect pulley bushing (10) and pin (9) wear.

If the total of wear “A” plus wear “A1” (including for the
sole individual coupling) is near or exceeds 1 mm,
A
replace the bushings and the pin. A1
9

10
RKT01811

Installation
• To install, reverse the removal procedure.

1 -Perform the bushing lubrication procedure.

2 Bushings: NLGI 2EP grease

2 -Perform the chain tensioning procedure.

2 Chains: SAE 15W-40

3 -Perform the chain tensioning procedure.
(For details, see "20 TESTING AND ADJUSTMENTS").

WH6-1E0 WH7-1E0 30-101

REMOVAL AND INSTALLATION LOAD CELL

LOAD CELL
Installation
k Before attempting to install the load cell, ensure that the
sensor output signal (with the cell resting on a surface,
i.e. in a free condition) is about 50±1 mA with and
average power supply of 12 VDC.

1 -Remove all residues of pre-existing adhesive or

protective varnish from the seat provided in the right rear
axle shaft (1), and ensure that the surface is free of any 1
deformation due to dents.

2 -To complete the cleaning procedure, rub sandpaper No.

80-120 on the surface making circular movements.

RKTA2140

3 -Use compressed air at low pressure to blow out any

debris and cleaning residues from the holes provided for
the retaining screws.

RKTA2150

4 -Degrease the load cell seat using a paper rag previously

soaked in a dedicated degreasing agent.

2 Degreasant: Loctite 7063

k Do not use compressed air to dry. Allow the

degreasing agent to work until the seat is
completely dry.

RKTA2160

30-102 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION LOAD CELL

5 -Ensure that the base of the load cell (2) is free from
dents.

6 -Degrease the base plates of the load cell using a paper

rag previously soaked in a dedicated degreasing agent.

2 Degreasant: Loctite 7063

2

k Do not use compressed air to dry. Allow the

degreasing agent to work until the plates are
completely dry.

RKTA2170

7 -Apply a thin coat of anaerobic adhesive for coaxial part

assembly to the base plates of the load cell.

2 Adhesive: Loctite 638

2

RKTA2180

8 -Position the cell (2) by routing the cable (3) towards the
middle of the axle.
4 5
9 -Install the screws (4) and special washers (5) while
locking the position of the load cell by hand.

k Search for alignment between load cell (2) and

axle axis. 3

RKTA2190

10 -While holding the alignment position, tighten the screws

(4) using a torque wrench.

3 Screws: 70 Nm

k Note down the screw tightening sequence (4).

RKTA2200

WH6-1E0 WH7-1E0 30-103

REMOVAL AND INSTALLATION LOAD CELL

11 -Use a tester (A) capable of supplying an average of 12V

to check (within a couple of minutes) that the cell output
signal is between 48 and 55 mA.

k a -If current is not within the prescribed range,

loosen the screws you have tightened during A
step 10, and re-tighten, this time inverting the
tightening sequence.
b -If the current is still not within the prescribed
range after the operation above, remove the
load cell and check the surfaces for being level.
RKTA2210

12 -Allow the adhesive to polymerise for about 15 minutes

before attempting to install the axle on the machine.

13 -Wait about 12 hours for the adhesive to reach full 4

polymerisation, and then calibrate the overturn
prevention system.

14 -Touch up any painted parts that may have been

damaged (if any). 2
5

RKTA2220

30-104 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CONTROL UNIT

CONTROL UNIT
Removal
1 -Loosen and remove the four (1) screws and detach the 2
device (2). [*1]

RKTA7400

2 -Disconnect the connector (3). [*2]

RKTA7410

Installation
• To install, reverse the removal procedure.

[*1]

a Apply sealant to the notches provided for the

screwdriver.

2 Sealant: Black silicone

[*2]

a Before operating the machine, carry out the device

calibration procedure.
(For details, see "20 TESTING AND ADJUSTMENTS").

WH6-1E0 WH7-1E0 30-105

REMOVAL AND INSTALLATION BALLAST

BALLAST
Removal
1 -Remove the screws and remove the telescopic boom 1
rear cover (1).

RKTA0012

2 -Start the engine and lift the boom to 45°. Connect the
ballast (2) to a hoist and slightly tension the rope.

4 Ballast: 950 kg
2

RKTA7420

3 -Loosen and remove the screws (3); remove the ballast

(4). [*1]

2
3

RKTA7430

Installation
• To install, reverse the removal procedure.

[*1]

3 Screws: 585±12 Nm

30-106 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION ENGINE LINE CENTRE

ENGINE LINE CENTRE

Removal
k Disconnect the cable from the negative (–) battery
3

terminal. 2
1 -Loosen the knobs (1) (2 knobs) and remove the cover
(2).

1
RKTA2230

2 -Disconnect the fuse and relay connectors.

a Ensure that the wiring harnesses are marked; mark 3

them if necessary.

3 -Loosen and remove the screws (3) together with their

respective washers, and remove the complete centre
assembly (4).

4 3
RKTA2240

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-107

REMOVAL AND INSTALLATION ACCELERATOR CABLE

ACCELERATOR CABLE
Removal
k Remove the ignition key and apply the parking brakes.
2
1 -Loosen the check-nut, remove the nuts (1), and recover
the spring (2) and spring guides (3).
3

3 1

RKTA2250

2 -Loosen the nuts (4) and disengage the accelerator

cable conduit (5).
4

RKTA2260

3 -Remove the screws (6) and remove the front guard (7).
6

RKTA2270

4 -Loosen the nut (8) and disengage the conduit (9) from
the support (10).

10

RKTA2280

30-108 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION ACCELERATOR CABLE

5 -Remove the safety pin and disconnect the yoke (11)

connecting to the accelerator pedal.

6 -Remove the conduit (9).

11

RKTA2290

Installation
• Install the new conduit by inverting the removal
procedure.

1 -Perform the accelerator cable length adjustment

procedure.
(For details, see "20 TESTING AND ADJUSTMENTS").

WH6-1E0 WH7-1E0 30-109

REMOVAL AND INSTALLATION SHIFT-REVERSING GEAR LEVER ASSEMBLY

SHIFT-REVERSING GEAR LEVER ASSEMBLY

Removal
k Disconnect the cable from the negative (–) battery
terminal and apply the parking brake.

1 -Loosen and remove the screws (1), (2).

RKTA2310

2 -Disconnect and remove both covers (3), (4).

4
3

RKTA2320

3 -Loosen the screws and disconnect the connector (5).

RKTA2330

4 -Loosen and remove the screws (6) and remove the

assembly (7).

Installation
7
• To install, reverse the removal procedure. 6

RKTA2340

30-110 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STEERING COLUMN SWITCH UNIT - DIPSWITCH

STEERING COLUMN SWITCH UNIT - DIPSWITCH

Removal
k Disconnect the cable from the negative (–) battery
terminal and apply the parking brake.

1 -Loosen and remove the screws (1), (2).

RKTA2310

2 -Disconnect and remove both covers (3), (4).

4
3

RKTA2320

3 -Disconnect the connector (5).

4 -Loosen and remove the three screws (6) and remove

the steering column switch unit (7).
6 7

5
RKTA2350

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-111

REMOVAL AND INSTALLATION STEERING UNIT

STEERING UNIT
Removal
k Disconnect the cable from the negative (–) battery
1

terminal and apply the parking brake.

2
1 -Remove the screws (1) and remove the front guard (2).

RKTA2271

2 -Remove the steering column shield (3).

RKTA2360

3 -Disconnect the LS hose (4) from the steering unit.

4 -Disconnect the hose (5). 4

a Immediately cap the hoses and tube to prevent
contaminants from entering the passages.

RKTA2370

5 -Mark and then disconnect the hoses (6).

a Immediately cap the hoses and tube to prevent

contaminants from entering the passages.

6
6

RKTA2380

30-112 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STEERING UNIT

6 -Loosen the four fittings (7) connecting the pipes to the

steering unit.

RKTA2390

7 -Loosen the screw (8), remove the clamp (9) and the
distance piece (10).
9

10

RKTA2400

8 -Remove the pipes (11).

11

11

RKTA2391

9 -Loosen and remove the screws (12) and their respective

washers and remove the steering unit complete with the
pipes. [*1]

12 12

RKTA2410

WH6-1E0 WH7-1E0 30-113

REMOVAL AND INSTALLATION STEERING UNIT

Installation
a Before attempting to tighten the pipes to the power 9
steering fittings, engage the pipes into the clamps (9)
and distance piece (10). 10

RKTA2401

a First tighten the rear fittings (13) of the lines (6).

13

RKTA2381

a Fit the front pipes (11) and tighten the fittings.

• Continue with the installation procedure by reversing
the removal procedure.
11
1 -Start the engine and perform several steering motions in
both directions in the crab steering mode (i.e. steering
with 4 wheels turning in the same direction) in order to
bleed the system.

[*1]

3 Screws: 63 Nm
11

RKTA2391

30-114 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STEERING UNIT

Disassembly
1 -Clamp the complete power steering body (1) in a vice 1
with the screws facing upwards. Use a vice whose jaws
are lined with tender material (aluminium or soft steel).

a Do not tighten the vice excessively, or you will

damage the power steering body.

RKTA2420

2 -Mark the positions of the screws, cover (6) and metering

assembly (8). 3 2
Loosen the screws (2), (3), (4), and (5) in a criss-cross 4
5
manner and remove them.
8
6

RKTA2430

3 -Slide the cover (6) crosswise to remove it.

6

RKTA2440

4 -Using needle nose pliers, remove the bushing (7).

RKTA2450

WH6-1E0 WH7-1E0 30-115

REMOVAL AND INSTALLATION STEERING UNIT

5 -Mark the position between the rotor (9) and the driving
shaft (10).
9
Simultaneously remove the outer ring (8) and rotor (9).

a To remove, slide the assembly crosswise while 8

simultaneously lifting it.

RKTA2460

6 -Pull out the driving shaft (10).

10

RKTA2470

7 -Remove the stop disc (11) by sliding it crossways.

11

RKTA2480

8 -Remove the complete steering unit (1) from the vice and
place it in its horizontal position.
Rotate the drive pin (12) into the control valve (13) in its 1
horizontal position and remove the complete control
valve without removing the axial bearing (14).
13

RKTA2490

30-116 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STEERING UNIT

• Removing the seals

1 -When removing the inner seal (15), use tool B1 (code
no. 00239496). E
Install washer (C) into the power steering body (1) and
then install the expander tool (E) in its fully closed D
position.
B1
C
1

RKTA2500

2 -Open the expander tool (E) by rotating the upper knob

clock-wise while simultaneously holding the centre
check-nut (D).

RKTA2510

3 -Remove the washer (C) and push the expander tool (E)
towards the inside of the power steering body (1) until
the seal (15) has been removed.

4 -Loosen and remove the expander tool. C

E

RKTA2520

• Removing the wiper ring

B2
1 -To remove the wiper ring, use tool B2 (code no.
00239497).
Introduce a ring nut (G) into the power steering body (1)
and use a puller (H) and a hammer to remove the wiper
ring (16).
G H
a Be extremely careful not to damage the seat.

RKTA2530

WH6-1E0 WH7-1E0 30-117

REMOVAL AND INSTALLATION STEERING UNIT

Assembly
• Installing the inner seal (15) B3
1 -Before installing the inner seal, make sure you
S
thoroughly clean the seat surface, the inside of the
steering unit, and the cover from any trace of grease.
Install seal (15) to the driver part (S) of tool B3 (code no.
00239498) and introduce the driver into the bushing (B)
of the tool. B
15

RKTA2540

2 -Introduce bushing “B”, driver “S” and seal (15) into the
power steering body (1). 1
3 -Press the bushing and driver as far as they will go.

a After removing tool B3 (code no 00239498),

thoroughly check for the seal to be properly seated.

4 -Lubricate the grommet with mineral oil.

B3

RKTA2550

• Installing the control valve

1 -Slightly lubricate the control valve assembly (13) with
oil.
Check the bearing (14) for being mounted with the
thinner step against the outer bushing of the control
valve.

13
14
RKTA2560

2 -Introduce the control valve (13) into the power steering

body (1) starting from the top of the bearing (14) and 1
holding the drive pin (12) in its horizontal position. 13
a The control valve should slide into the housing
provided in the steering unit without forcing.

12

RKTA2570

30-118 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STEERING UNIT

• Completing the installation procedure

17
1 -Clamp the steering unit (1) in a vice as shown.
Check for proper positioning of the ball (17) (its function 1
is that of a cavitation-prevention valve).

RKTA2580

2 -Grease the O-ring (18) and position it on the power

steering body (1).
18

RKTA2590

3 -Install the stop disc (11) matching the holes in the disc
with those on the power steering body.
11

RKTA2600

4 -Introduce the driving shaft (10) and engage it to the pin

(12) of the control valve (13).

10

RKTA2610

WH6-1E0 WH7-1E0 30-119

REMOVAL AND INSTALLATION STEERING UNIT

5 -Grease the O-ring (19) and position it on the outer ring

(8).

19

RKTA2620

6 -Position the rotor (9) to the driving shaft (10), matching

the scribble marks you have made during disassembly.
9
7 -Position the outer ring (8) by locating the centring
position in relation to the power steering body (1) and
rotor (9).

8 10

RKTA2630

8 -Position the bushing (7).

RKTA2640

9 -Grease the 2nd O-ring (19) and seat it in the cover (6).

10 -Position the cover (6) to the metering assembly, making

sure to match the scribble marks you have made during
6
disassembly.

19

RKTA2650

30-120 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STEERING UNIT

11 -With the help of the exploded view diagram, install the

screws (2), (3), (4), and (5) to the correct positions.

a The screw (3) should be installed to the position 4

corresponding to the cavitation-prevention ball
valve (17). 3

5
2

RKTA2660

12 -Tighten the screws retaining the cover (6) and the

metering assembly (8) using the criss-cross method.

3 Screws: 30 +0 3 Nm

6
8

RKTA2670

13 -Turn the steering unit upside down; place the wiper ring
(16) to the power steering body (1) with the seal lip facing
upwards.
16

RKTA2680

14 -Using tool B4 (code No. 00239499), and a hammer,

introduce the wiper ring as far as it will go without forcing.

B4

RKTA2690

WH6-1E0 WH7-1E0 30-121

REMOVAL AND INSTALLATION STEERING COLUMN

STEERING COLUMN
Removal
k Disconnect the cable from the negative (–) battery
terminal and apply the parking brake. 2
1
1 -Remove the centre cap (1) and retaining screw (2) from
the steering wheel.

2 -Remove the steering wheel (3).

3
RKTA2700

3 -Remove the shift/reversing gear lever and the steering

column switch unit/dipswitch assembly.
(For details, see "SHIFT-REVERSING GEAR LEVER
ASSEMBLY" and "STEERING COLUMN SWITCH
UNIT - DIPSWITCH").

RKTA2710

4 -Remove the steering column shield (4).

5 -Remove the steering wheel position adjustment handle

(5).

RKTA2720

6 -Loosen and remove the screws (6) and their respective

washers and slide off the steering column (7) from the
top. [*1] 7

6
Installation
• To install, reverse the removal procedure.

[*1]

3 Screws: 63 Nm RKTA2411

30-122 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION BRAKE PUMPS

BRAKE PUMPS
Removal
k Disconnect the cable from the negative (–) battery
1

terminal and apply the parking brake.

2
1 -Loosen and remove the screws (1), and remove the
front guard (2).
1

RKTA2271

2 -Remove the cover (3) from the reservoir (4) and draw
out the oil in it.
4
3

RKTA2730

3 -Mark and disconnect the service brake feed hoses (5),

(6) from the pump. [*1]

4 -Disconnect the brake booster feed and discharge hoses

5
(7), (8).

a Immediately cap the hoses and tube to prevent 6

contaminants from entering the passages.
7

8
RKTA2740

5 -Disconnect the hoses (9), (10) connecting to the brake

oil reservoir.
10
a Immediately cap the hoses and tube to prevent
contaminants from entering the passages.

RKTA2750

WH6-1E0 WH7-1E0 30-123

REMOVAL AND INSTALLATION BRAKE PUMPS

6 -Loosen and remove the screws (11) and remove the

pump (12). [*2]

12

11

RKTA2760

Installation
• To install, reverse the removal procedure.

[*1]

a Perform the braking circuit bleed procedure.

(For details, see "20 TESTING AND
ADJUSTMENTS").

[*2]

a Ensure that the thrust arm centres the piston seat.

a When bleeding is complete, check the pedal pre-
travel and check the position of the microswitch.
(For details, see "20 TESTING AND
ADJUSTMENTS").

30-124 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION PPC VALVE

PPC VALVE
Removal
1 -Position the machine on level ground with the boom fully
lowered and retracted. 1
2 -Stop the engine, remove the ignition key and apply the
parking brakes. 2
3 -Raise the rubber boot (1) and remove the screws (2)
retaining the PPC valve (3).
3

RKTA2770

4 -Remove the screws and remove the fuse centre cover

(4).

RKTA2790

5 -Disconnect the connector (5) supplying the extension

potentiometer, the auxiliaries pushbuttons and
transmission release.
5

RKTA2800

6 -Loosen and remove the screws (6) securing the

feedthrough plate (7).

7
RKTA2780

WH6-1E0 WH7-1E0 30-125

REMOVAL AND INSTALLATION PPC VALVE

7 -Remove the PPC valve (3) and disconnect the hoses

(8).
[*1]

a Mark the hoses to avoid mixing them up during

installation.

a Immediately cap the hoses to prevent contaminants

from entering the passages.
8
k If slack is noticed at the control lever, make the
necessary adjustments to the assembly.
(For details, see "20 TESTING AND
RKTA2810
ADJUSTMENTS").

Installation
• To install, reverse the removal procedure.
1 T
[*1]

a Thoroughly check for proper hose connection:

P= Pressure 2 4
T= Discharge
1= Boom lift
2= Equipment curl
3= Boom lowering B 3
4= Equipment dump
RKT01820

1 -Start the engine to allow the oil to circulate and to check

the seals.

30-126 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION LEVEL

LEVEL
Removal
1 -Position the machine on firm, perfectly level ground with
the boom fully lowered and retracted.

k Check that the forks are not resting on the ground,

and then stop the engine.

2 -Ensure that the tires are inflated to the proper pressure.

RKTA8430

3 -Level the frame crosswise using an electronic level or a

40 cm. spirit level (A) placed on the front part of the frame
or on the outrigger support (if equipped).
A

RKTA0250

4 -Remove the level (1) to be replaced by loosening the

screws (2) in a gradual and alternate manner.
2 1

3
3

RKTA2820

Installation
• Install the new level by reversing the sequence of the
removal procedure and finish off by compressing the
springs (2) by 3 mm. approximately.
1 -Perform the calibration procedure.
(For details, see "20 TESTING AND ADJUSTMENTS").

WH6-1E0 WH7-1E0 30-127

REMOVAL AND INSTALLATION WIPER MOTORS

WIPER MOTORS
Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and remove the ignition key.

• Front wiper motor

1 -Remove the centre compartment cover (1).
1

RKTA2830

2 -Disconnect the wiper motor connector (2).

2

RKTA2840

3 -Disconnect the washer fluid hose (3).

4 -Remove the nuts (4) and the wiper arm complete with
washers and spacers.

a Note down the installation sequence. 3

RKTA2850

30-128 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION WIPER MOTORS

5 -Loosen and remove the screws (5) and remove the

motor (6).

RKTA2860

• Rear wiper motor

1 -Remove the screws (1) and remove the cab headliner 1
(2).

2
RKTA2870

2 -Disconnect the connector (3).

3 4
3 -Disconnect the washer fluid hose (4).

4 -Disconnect the ground cables (5).

5 8

RKTA2880

5 -Remove the nuts (6) and the wiper arm (7) complete with
washers and spacers.
6
a Note down the installation sequence.
6 -Remove the motor (8). 7
a Note down the seal assembly sequence.

RKTA2890

WH6-1E0 WH7-1E0 30-129

REMOVAL AND INSTALLATION WIPER MOTORS

• Upper wiper motor

1 -Remove the screws (1) and remove the cab headliner 1
(2).

2
RKTA2870

2 -Disconnect the connector (3).

3 -Disconnect the ground cables (4).

3

RKTA2900

4 -Disconnect the washer fluid hose (5).

5 -Remove the adhesive; remove the nuts (6) and the

5
wiper arm complete with washers and spacers. [*1]

a Note down the installation sequence.

RKTA2910

6 -Remove the motor (7).

a Note down the seal assembly sequence.

7

Installation
• To install, reverse the removal procedure.

[*1]

2 Sealant: Acetic silicone

RKTA2901

30-130 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION PARKING BRAKE CABLE

PARKING BRAKE CABLE

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and remove the ignition key.

4 -Remove the seat, remove the three screws (1), and

remove the cover (2).

1
2

1 RKTA2920

5 -Loosen and remove the nuts (3), disengage the cable

from the axle levers (4).
4
3

RKTA0281

6 -Disconnect the cable (5) from the brake apply lever.

5
RKTA2930

WH6-1E0 WH7-1E0 30-131

REMOVAL AND INSTALLATION PARKING BRAKE CABLE

7 -Disengage the conduit (6) from the axle lever (7) and
slide off the whole transmission.
7

RKTA2940

Installation
• To install, reverse the removal procedure.

1 -Adjust cable tension.

(For details, see "20 TESTING AND ADJUSTMENTS").

30-132 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION DASH / INSTRUMENT PANEL

DASH / INSTRUMENT PANEL

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted and the parking brakes
applied.

2 -Stop the engine and remove the ignition key.

3 -Remove the instrument panel top centre cover (1).

RKTA2830

4 -Disconnect the wiring harness (3) from the dash (2).

5 -Loosen and remove the four self-locking nuts (4), 6

remove the retaining brackets (5) and the complete
dash (6).
5

4
4
2
3
RKTA2950

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-133

REMOVAL AND INSTALLATION CONTROL PANEL

CONTROL PANEL
Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted and the parking brakes
applied.

2 -Stop the engine and remove the ignition key.

3 -Disconnect the cable from the negative (-) battery

terminal.
+

RKTA0641

4 -Loosen and remove the screws (1); remove the panel

(2).

RKTA2960

5 -Disconnect the connectors (3) from the switches,

pushbuttons and selector switches.

6 -Mark and then disconnect the cables from the ignition

lock cylinder (4); remove the complete panel.

4 3

RKTA2970

Installation
• To install, reverse the removal procedure.

30-134 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION FUSE AND RELAY CENTRE

FUSE AND RELAY CENTRE

Removal
1 -Position the machine on firm, level ground.

2 -Apply the parking brakes and remove the ignition key.

3 -Disconnect the cable from the negative (-) battery

terminal.

RKTA0641

4 -Loosen the screws and remove the panel (1).

RKTA2791

5 -Disconnect all wiring harnesses (2), ensuring that they

are all marked. 3 3
6 -Loosen and remove the four self-locking nuts (4) and
remove the complete circuit board.

2
RKTA2980

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-135

REMOVAL AND INSTALLATION PROPELLER SHAFT

PROPELLER SHAFT
Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine, apply the parking brakes and remove

the ignition key.

RKTA7440

• Front cardan shaft

1 -Loosen and remove the screws (1) together with their 1
respective washers, and remove the guard (2).

RKTA2990

2 -Remove the screws (3), remove the collars (4) from both
sides and remove the cardan shaft (5).
3

4
4

RKTA1320

• Rear cardan shaft

1 -Loosen the screws (6) and washers retaining the guard
(7).

a Leave the screws and guard in position to ease

removal. 6

RKTA0951

30-136 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION PROPELLER SHAFT

2 -Loosen and remove the self-locking nuts (8) and the

centre support screws (9).

8
8

RKTA3000

3 -Remove the screws (10) and remove the collars (11)

from both cardan shaft ends.
11
4 -Remove the guard (7) and slide off the cardan shaft (12).
7
10

12

RKTA3010

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-137

REMOVAL AND INSTALLATION FUEL TANK

FUEL TANK
Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine, apply the parking brakes and remove

the ignition key.

4 -Loosen and remove the screws (1) and remove the cab
assist step (2).

5 -Unscrew the drain cap (3) and recover the fuel.

6 Fuel: max 130 l

1
1

2 3
RKTA3020

6 -Disconnect the fuel level indicator connector (4) and

remove it from its support.

RKTA3030

7 -Remove the screws and remove the front cover (5).

RKTA2272

30-138 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION FUEL TANK

8 -Loosen the support band front and rear nuts (6) and
lower the tank (8) as much as possible.
6

7
8
RKTA3040

9 -Loosen the clamps and disconnect the fuel inlet and

return hoses (9), (10).

a Mark the hoses to avoid swapping during

9
installation.

10 -Remove the tank (8).

10

RKTA3050

Installation
• To install, reverse the removal procedure.

WH6-1E0 WH7-1E0 30-139

REMOVAL AND INSTALLATION HYDRAULIC OIL TANK

HYDRAULIC OIL TANK

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine, apply the parking brakes and remove

the ignition key.

4 -Loosen the cap (1) and completely drain the hydraulic

oil.

6 Hydraulic oil: max 95 l 1

RKTA3060

5 -Loosen and remove the four screws (2) and remove the
cover (3).
2

3
RKTA3070

6 -Loosen the clamps (4) and remove the inlet sleeve (5).

7 -Disconnect the steering unit discharge line (6). 6

7
8 -Disconnect the servocontrol discharge pipe (7).

a Cap the hoses and plug the holes to prevent 4

contaminants from entering the passages.

4 5
RKTA3080

30-140 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION HYDRAULIC OIL TANK

9 -Disconnect the main discharge line from the tank (8).

a Cap the line and plug the hole to prevent

contaminants from entering the passages.

RKTA3090

10 -Connect the tank (9) to a hoist and slightly tension the

ropes.

RKTA3100

11 -Loosen and remove the screws (10) securing the tank to

the frame.

10

RKTA3110

12 -Loosen and remove the screws (11); remove the tank

(9) complete with filters.
9

Installation 11
• To install, reverse the removal procedure.

RKTA3120

WH6-1E0 WH7-1E0 30-141

REMOVAL AND INSTALLATION FRAME LEVELLING CYLINDER

FRAME LEVELLING CYLINDER

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers (if equipped) to the ground in order

to prevent any rotation of the frame. A
3 -If the machine is not provided with outriggers, place
wedges under the rear wheels and force two stands (A)
under the sides of the front frame to prevent any rotation.
4 -Turn the front wheels all the way to the right; stop the
engine and remove the ignition key. RKTA1290

5 -Disconnect the hoses (2) from the cylinder (1).

a Cap the hoses and plug the holes to prevent

contaminants from entering the passages.
4 3
6 -Loosen and remove the screw (3) and remove the upper
pin (4). 2
1

RKTA3130

7 -Connect the cylinder (1) to a hoist, remove the screw

and remove the pin (5) and the cylinder.

4 Cylinder: 28.7 kg
1

RKTA3140

Installation
• To install, reverse the removal procedure.

1 -Perform the pin and bushing lubrication procedure.

2 -Start the engine and perform full frame-tilt manoeuvres

in both directions to bleed the circuit.

30-142 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION FRAME SWING LOCKING ROD (WH609 and WH613 only)

FRAME SWING LOCKING ROD

(WH609 and WH613 only)
Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers (if equipped) to the ground in order

to prevent any rotation of the frame.

3 -If the machine is not provided with outriggers, place

wedges under the rear wheels and force two stands (A)
under the sides of the front frame to prevent any rotation.
4 -Turn the front wheels all the way to the right; stop the
engine and remove the ignition key.

5 -Remove the screw (1) and then remove the upper pin (2)
and spacers (3). [*1]

2
1

RKTA7480

6 -Connect the rod to a hoist; remove the screw and the

lower pin (4). [*1]

4 Rod: 32.6 kg

RKTA7490

Installation
• To install, reverse the removal procedure.

[*1]

1 -Perform the coupling lubrication procedure.

2 Pins and bushings: NLGI 2 EP grease

WH6-1E0 WH7-1E0 30-143

REMOVAL AND INSTALLATION AXLE LOCKING CYLINDER

AXLE LOCKING CYLINDER

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers (if equipped) to the ground.

3 -Turn the rear wheels all the way to the left.

4 -Stop the engine and remove the ignition key.

5 -Disengage the wiring from the wire harness straps and

disconnect the connectors (1), (2) from the solenoid 6
valves. 4
6 -Disconnect the hose (4) from the valve (3).
5
a Cap the line and plug the hole to prevent 3
1
contaminants from entering the passages.
7 -Remove the screw (5) and remove the upper pin (6). 2

RKTA3150

8 -Start the engine and turn the rear wheels all the way to
the right; stop the engine and remove the ignition key.

9 -Connect the cylinder (7) to a hoist.

4 Cylinder: 35.0 kg
7

RKTA3160

10 -Remove the screw (8) and the pin (9).

11 -Remove the cylinder (7).

7

Installation
• To install, reverse the removal procedure.
8 9
1 -Perform the pin and bushing lubrication procedure.

2 -Lift the boom by more than 30° in order to activate and

bleed the circuit.
RKTA3170

30-144 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STABILIZER CYLINDERS (If equipped)

STABILIZER CYLINDERS (If equipped)

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers to the ground without forcing and

place wedges under the rear wheels.

3 -Stop the engine, apply the parking brakes and remove

the ignition key.

RKTA0240

4 -Remove the upper cover (1) giving access to the safety

valve.

RKTA3180

5 -Disconnect the lines (3), (4) from the valve (2).

a Cap the hoses and plug the holes to prevent

contaminants from entering the passages.
3
4

RKTA3190

6 -Place a support roller (A) under the cylinder (5).

RKTA3200

WH6-1E0 WH7-1E0 30-145

REMOVAL AND INSTALLATION STABILIZER CYLINDERS (If equipped)

7 -Remove the screw (6), and then remove the pin (7)
providing the attachment to the outrigger.

RKTA3210

8 -Remove the screw (8) and the pin (9) providing the
attachment for the cylinder.

9
8
RKTA3220

9 -Partially remove the cylinder (5) by sliding it on the

support roller (A).

10 -Connect the cylinder (5) to a hoist and remove it from the

frame. 5

RKTA3230

Installation
• To install, reverse the removal procedure.

1 -Introduce the cylinder into the frame and engage it with

the pin (9) previously locked with the screw (8).

k To move the cylinder, first place the support roller

8
(A) used for removal in position.

9
RKTA3201

30-146 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION STABILIZER CYLINDERS (If equipped)

2 -Connect the lines (3), (4) to the valve (2).

3
4

RKTA3190

3 -Start the engine and slowly extend the piston (5) until the
mating holes between the outrigger and rod are centred. 5
4 -Introduce the pin (7) and lock it with the screw (6).

5 -Perform the pin and bushing lubrication procedure.

6 -Perform several motions until the outriggers reach their 7

fully extended position in order to bleed the air from the
circuit.
6

RKTA3211

WH6-1E0 WH7-1E0 30-147

REMOVAL AND INSTALLATION EQUIPMENT HOLDER

EQUIPMENT HOLDER
Removal
1 -Remove the equipment (1) in use.

2 -Position the machine on firm, level ground with the boom

fully lowered and retracted and with the equipment
holder resting on the ground.
1
3 -Lower the outriggers, if equipped. If the machine is not
equipped with outriggers, place wedges under the rear
wheels.
4 -Stop the engine and remove the ignition key.
RKTA3240

5 -Hydraulic connection bucket and fork holders only

Disconnect the hoses (2), (3).
2

RKTA3250

6 -Remove the screw and then remove the pin (4)

providing the attachment for the piston (5). 4
a Recover the shims (6) and note down the
installation side.

6
RKTA3260

7 -Connect the equipment holder (7) to a hoist and slightly

tension the rope.
7

RKTA3270

30-148 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION EQUIPMENT HOLDER

8 -Remove the screw, and then remove the pin (8)

providing the attachment to the boom.

a Recover the shims (9) and note down the

installation side.
8

RKTA3280

Installation
• To install, reverse the removal procedure.

k Check the resulting side clearance between the boom

and the fork holder, and at the rod eye, for being less
than 1 mm.

1 -Lubricate the pins you have previously removed, before

attempting to start the machine.

WH6-1E0 WH7-1E0 30-149

REMOVAL AND INSTALLATION EQUIPMENT MOTION CYLINDER

EQUIPMENT MOTION CYLINDER

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and apply the parking brakes.

RKTA0240

4 -Remove the equipment holding assembly (1).

RKTA3271

5 -Loosen the screws and remove the front and top covers
(2), (3). 3
6 -Start the engine; lift the boom about 60 cm off the ground
and fully retract the piston of the cylinder responsible for
moving the equipment. 2
a Position a safety block between the boom and the
frame.

RKTA3290

7 -Stop the engine and remove the ignition key.

8 -Disconnect the hose (4) from the cylinder (5), (6).

5

6 4

RKTA3300

30-150 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION EQUIPMENT MOTION CYLINDER

9 -Connect a hoist to the cylinder (7) working through the

top compartment.

a Use a rope and the upper hose from the safety valve 8
to connect the cylinder to the hoist.

10 -Slightly tension the rope.

9
11 -Remove the screw (8) and the pin (9).

12 -Lower the hoist and slide off the cylinder (7) from the
7
boom lower side.

RKTA3310

Installation
• To install, reverse the removal procedure.

1 -Lubricate the pins you have previously removed, before

attempting to start the machine.

2 -Start the engine and perform some full travels in order to

bleed the air from the circuit.

WH6-1E0 WH7-1E0 30-151

REMOVAL AND INSTALLATION CYLINDERS

CYLINDERS
Disassembly
1
1 -Loosen and remove the screws (1), remove the safety
valve (2), and the O-rings (3). 2

a Note down the orientation of the valve prior to

removal.

a Replace the O-rings at each disassembly.

3

RKTA7500

2 -Clamp the cylinder in one or more vices with soft grips.

3 -Lift the caulking of the retainer ring (4). Using a spanner, 5 4

loosen and remove the cylinder head (4) and the
complete piston.

RKTA7510

4 -Clamp the piston in one or more vices with soft grips.

5 -Using a spanner, loosen the cylinder head (5) and the

braking bush, if installed.
Remove the complete piston rod (6).

6
5
RKTA7520

6 -Loosen and remove the retaining screw (7) from the

complete piston rod (6) 7
6
Remove the piston (8). 8

RKTA7530

30-152 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CYLINDERS

7 -Using a round-bladed screwdriver, remove the piston

(8), seals (9), guide rings (10) and the inner O-rings (11) 8 6
and (12). 11 12
a Be extremely careful not to damage the seal
grooves.

10

RKTA7540

8 -Using the same type of screwdriver previously used on

the piston, remove the seals (13), guide rings (14), 13 5
scraper ring (15), O-ring (16), anti-extrusion ring (17)
and O-ring (18) from the cylinder head (5).

a Be extremely careful not to damage the seal 15

grooves.

9 -Thoroughly clean all components with a mild solvent.

16 17
14

RKTA7550

Assembly
1 -Using a a pair of pliers, install the inner seal (13) to the
cylinder head (5).
13
a Thoroughly check for proper orientation.
2 -Install the guide rings (14).

RKTA7570

3 -Install the anti-extrusion ring (17) and O-ring (16).

16 17 13 18 15
a Check for proper orientation of the anti-extrusion
ring.

4 -Install the O-ring (18).

5 -Install the scraper ring (15).

14 RKTA7560

WH6-1E0 WH7-1E0 30-153

REMOVAL AND INSTALLATION CYLINDERS

6 -Install the O-rings (11) and ring (12) to the piston (8).
10 9 10 12

11

RKTA7580

7 -Install the seal (9) to the piston.

a The seal consists of two rings of rectangular cross- 9

section which require installation by means of a
rounded edge tool; pay attention to ensure that the
central line on the outer ring remains visible.

8 -Install the guide rings (10).

RKTA7590

9 -Check the parts for being thoroughly clean, and then

install the cylinder head (5) to the piston rod (6). 5
a Lightly lubricate the rod.
2 Rod: hydraulic oil
6

RKTA7630

10 -Clamp the piston rod (6) in one or more vices with soft
8 7
grips.

11 -If equipped, install the braking bush and ensure that

bush orientation matches that in the illustration.

12 -Install the piston (8) complete with seals.

a Tighten the piston to the rod.

2 Piston: hydraulic oil

RKTA7600

30-154 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CYLINDERS

13 -Tighten the piston to the rod. 3 Lift piston:

WH609: 1000±200 Nm
WH613: 950–1000 Nm
WH7: 1100±220 Nm
Offset piston: 385±75 Nm
Extension piston: 900±180 Nm
Equipment control piston: 1000±200 Nm
Outrigger piston: 900±180 Nm
Levelling piston: 700±140 Nm
Axle locking piston: 700±140 Nm

14 -Apply a coat of sealant to the retaining screw threads (7)

and install the screw to the piston (8).

2 Screw: Loctite 243

3 Screw: 20 Nm
15 -Caulk the edge of the screw to prevent screw rotation.

7 8

RKTA7610

16 -Check the cylinder, piston (6) and cylinder head (5) for
being thoroughly clean.

17 -Lubricate cylinder head and piston seals.

2 Seals: hydraulic oil

18 -With the cylinder in its horizontal position, introduce the
piston (6) and the cylinder head (5).

a Keep cylinder and piston perfectly aligned.

6
a Be extremely careful not to damage the seals. 5
RKTA7520

19 -Using a spanner, tighten and lock the cylinder head 3 Lift piston: 450–500 Nm
(5). Offset piston: 250–300 Nm
Extension piston: 450–500 Nm
Equipment control piston: 450–500 Nm
Outrigger piston: 450–500 Nm
Levelling piston: 450–500 Nm
Axle locking piston: 450 -500 Nm

WH6-1E0 WH7-1E0 30-155

REMOVAL AND INSTALLATION CYLINDERS

20 -Caulk the retainer ring (4) at one slot only.

RKTA7620

21 -Position the O-rings (3) to the valve seats (2); install the
valve to the cylinder and check for proper orientation. 1
22 -Lock the valve by tightening the screws (1) using the 2
criss-cross tightening method.

3 Screws: 20 Nm

RKTA7500

30-156 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION EQUIPMENT QUICK-LOCK ASSEMBLY

EQUIPMENT QUICK-LOCK ASSEMBLY

Removal
1 -Remove the equipment in use.

2 -Position the machine on firm, level ground with the boom

fully lowered and retracted and with the equipment
holder resting on the ground.

3 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.
4 -Stop the engine, remove the ignition key and apply the
parking brakes. RKTA3241

5 -Disconnect the pipes (2), (3) from the cylinder (1).

4
a Cap the hoses and plug the holes to prevent 2
contaminants from entering the passages. 3
a To ease removal, loosen the fittings (4) as well.

RKTA3320

6 -Loosen and remove the screws (5).

a Recover the shims (6) used for pin centring.

7 -Push the cylinder (1) to the left, tilt it outwards, and then
remove it.
1

6
RKTA3330

Installation
• To install, reverse the removal procedure.

1 -Start the engine and perform several motions in order to

bleed the circuit.

WH6-1E0 WH7-1E0 30-157

REMOVAL AND INSTALLATION AIR CONDITIONER FANS

AIR CONDITIONER FANS

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and apply the parking brakes.

RKTA0240

4 -Loosen and remove the four screws (1) retaining the fan
cover (2).
2

RKTA3340

5 -Remove the fan cover (2).

RKTA3350

6 -Disconnect the connector (4) of the fan to be replaced

from the wiring harness (3).
5
7 -Loosen the screws (5) and remove the fan (6).
6
6

Installation
• To install, reverse the removal procedure. 4

3
RKTA3360

30-158 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AIR CONDITIONER CONDENSER ASSEMBLY

AIR CONDITIONER CONDENSER ASSEMBLY

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and apply the parking brakes.

RKTA0240

4 -Loosen and remove the four retaining screws (1) and

remove the cover (2).
2

RKTA3340

5 -Connect the maintenance station to the connections (3),

(4) and drain the coolant fluid off the air conditioning 3
system. 4
(For details, see "20 TESTING AND ADJUSTMENTS").

RKTA1191

6 -Disconnect the lines (6), (7) from the condenser (5).

[*1]

a Immediately cap the lines and the condenser to 5

prevent contaminants from entering the air
conditioning circuit. 7
6

RKTA3370

WH6-1E0 WH7-1E0 30-159

REMOVAL AND INSTALLATION AIR CONDITIONER CONDENSER ASSEMBLY

7 -Disconnect the connectors (9), from the wiring (8).

8
RKTA3361

8 -Loosen and remove the four nuts (10) and remove the
complete assembly. 10

10

RKTA3380

Installation
• To install, reverse the removal procedure.

[*1]

a Ensure that the O-rings are undamaged.

2 Fittings and O-rings: antifreeze:
1 -Carry out the air conditioning system filling procedure.
(For details, see "20 TESTING AND ADJUSTMENTS".

30-160 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION DEHUMIDIFYING FILTER

DEHUMIDIFYING FILTER
Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and apply the parking brakes.

RKTA0240

4 -Loosen and remove the retaining screws (1) and

remove the cover (2).
2

RKTA3340

5 -Connect the maintenance station to the connections (3),

(4) and drain the coolant fluid off the air conditioning 3
system. 4
(For details, see "20 TESTING AND ADJUSTMENTS").

RKTA1191

6 -Disconnect the lines (6), (7) from the filter (5). [*1]

a Immediately cap the lines and plug the holes to 6

prevent humidity from entering the circuit.

7
RKTA3381

WH6-1E0 WH7-1E0 30-161

REMOVAL AND INSTALLATION DEHUMIDIFYING FILTER

7 -Remove the nuts (8) and washers; remove the screws

and spacers (9). 9
8 -Remove the filter (5).

RKTA3390

Installation
• To install, reverse the removal procedure.

[*1]

a Ensure that the O-rings are undamaged.

2 Fittings and O-rings: antifreeze:
1 -Carry out the system filling procedure.
(For details, see "20 TESTING AND ADJUSTMENTS").

30-162 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AIR CONDITIONING SYSTEM PRESSURE SWITCH

AIR CONDITIONING SYSTEM PRESSURE SWITCH

Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.

2 -Lower the outriggers, if equipped. If the machine is not

equipped with outriggers, place wedges under the rear
wheels.

3 -Stop the engine and apply the parking brakes.

RKTA0240

4 -Loosen and remove the retaining screws (1) and

remove the cover (2).
2

RKTA3340

5 -Connect the maintenance station to the connections (3),

(4) and drain the coolant fluid off the air conditioning 3
system. 4
(For details, see "20 TESTING AND ADJUSTMENTS").

RKTA1191

6 -Disconnect the connector (5) and remove the pressure

switch (6).
5

Installation 6
• To install, reverse the removal procedure.

1 -Carry out the system filling procedure.

(For details, see "20 TESTING AND ADJUSTMENTS").

RKTA3400

WH6-1E0 WH7-1E0 30-163

REMOVAL AND INSTALLATION CAB

CAB
Removal
1 -Position the machine on firm, level ground with the boom
fully lowered and retracted.
2 -Lower the outriggers, if equipped. If the machine is not
equipped with outriggers, place wedges under the rear
wheels.
3 -Stop the engine and apply the parking brakes.
4 -Disconnect the cable from the negative (-) battery
terminal.
5 -Drain the coolant liquid. [*1]

6 Coolant liquid: 20 l approx.

6 -Remove the screws and remove the front cover (1).

RKTA2273

7 -Only if equipped with air conditioning system.

Drain the coolant fluid and disconnect the hoses (2) and
2
(3) from the compressor.

a Immediately seal the hoses and holes to prevent

humidity from entering the passages.
(For details, see "20 TESTING AND
ADJUSTMENTS").
3

RKTA1192

8 -Remove the fuel tank (4).

(For details, see "FUEL TANK").
4

RKTA3051

30-164 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CAB

9 -Mark and disconnect the service brake feed hoses (5),

(6) from the brake pump. [*1]

10 -Disconnect the brake booster feed and discharge hoses

5
(7), (8) from the brake pump.

a Immediately cap the hoses and plug the holes to 6

prevent contaminants from entering the passages.
7

8
RKTA2740

11 -Disconnect the hoses (9), (10).

12 -Disconnect the Load Sensing hose (11) from the 11

steering unit.

a Immediately cap the hoses and plug the holes to

prevent contaminants from entering the passages.

10
9

RKTA2371

13 -Mark and disconnect the rear hoses (12), (13).

12

13

RKTA2402

14 -Disconnect the washer fluid hoses (15) from the check

valves (14).

a Disconnect the hoses at the check valve output.

14

15

RKTA7350

WH6-1E0 WH7-1E0 30-165

REMOVAL AND INSTALLATION CAB

15 -Disconnect connectors (16), (17), (18), (19), and the

horn wiring harness (20).
19
20
18

17

16

RKTA3410

16 -Remove the screw (21) and disconnect the ground

cable (22).
22

21

RKTA3420

17 -Mark and disconnect the hoses (23) connecting to the

PPC valve.

a Immediately cap the hoses and fittings to prevent

contaminants from entering the passages. 23

23

RKTA3430

18 -Remove the nuts (24) and disconnect the parking brake

control cable (25) from the front axle.
[*2] 24

25

RKTA0282

30-166 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION CAB

19 -Loosen and remove the nuts (26), the spring and spring
guide.
27
20 -Loosen the nut (27) and disengage the accelerator
cable and conduit.

26

RKTA0791

21 -Loosen and remove the cab mounting nuts (28) and

washers (29) along with the elastic pad (30).
[*3]

30
29

28
RKTA3440

22 -Connect the cab (31) to a hoist and lift it by 30 cm.

approximately.

4 Cab: 476.0 kg approx. 31

34
23 -Mark and disconnect the cab heating hoses (32), (33);
slide them off the clamp (34).

a Immediately cap the hoses to prevent contaminants

from entering the passages.
32
33
RKTA3450

WH6-1E0 WH7-1E0 30-167

REMOVAL AND INSTALLATION CAB

24 -Remove the cab (31).

a Place the cab on firm supports placed under the four

free corners of the cab floor.

31

Installation
RKTA3460

• To install, reverse the removal procedure.

[*1]

a Perform the braking circuit bleed procedure.

(For details, see "20 TESTING AND
ADJUSTMENTS").

a Carry out the coolant liquid filling procedure.

5 Coolant liquid: 20 l approx.

[*2]

3 Cab mounting nuts: 270±20 Nm

[*3]

a Adjust the parking brake cable length.

(For details, see "20 TESTING AND
ADJUSTMENTS").

1 -Start the engine and perform several lift and braking

manoeuvres in order to bleed the air from the control
circuits.

2 -Stop the engine and check the seals on the parts you
have previously removed.

30-168 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

TRANSMISSION
TRANSMISSION ASSEMBLY
Disassembly
1 -Front and rear view of transmission.

RKTA7440

2 -Remove the drive plate screws and washers. Remove

the backing ring (1) and drive plates (2). [*1]
2

1
RKTA3470

3 -Remove the plug retainer ring (3), the plug (4) and the O-
ring.

RKTA3480

RKTA3490

WH6-1E0 WH7-1E0 30-169

REMOVAL AND INSTALLATION TRANSMISSION

4 -Remove the ring (5) retaining the hydrodynamic

coupling (6) to the shaft.
6

RKTA3500

5 -Remove the hydrodynamic coupling (6).

RKTA3510

6 -Remove the coupling to turbine shaft backing ring (7).

RKTA3520

7 -Remove the filter (8). [*2]

RKTA3530

30-170 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

8 -Remove the pump mounting screws and washers.

Remove the pump (9) and gasket (10). [*3]
10

RKTA3540

9 -Using tool C1 remove the pressure regulator assembly

(11). [*4] C1 11

RKTA3550

10 -Remove the pressure sensor plug (12).

12

RKTA3560

11 -Remove the 18 screws and washers retaining the flange

(13) connecting to the engine. Remove the flange and
13
gasket.
[*5]

RKTA3570

WH6-1E0 WH7-1E0 30-171

REMOVAL AND INSTALLATION TRANSMISSION

12 -Remove the pump drive gear (14) from the hub.

14

RKTA3580

13 -Remove the backing washer (15), the intermediate gear

(16) and bearing (17).
15

RKTA3590

16

17

RKTA3600

14 -Remove the intermediate shaft (18) and backing washer

(19).
19

18

RKTA3610

30-172 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

15 -Remove the solenoid protection cover (20). [*6]

20

RKTA3620

20

RKTA3630

16 -Remove the solenoid coils (21) and O-rings. [*7]

21

RKTA3640

21

RKTA3650

WH6-1E0 WH7-1E0 30-173

REMOVAL AND INSTALLATION TRANSMISSION

17 -Remove the valve spools (22) and O-rings.

22

RKTA3660

18 -Remove the screws (23) retaining the transmission

spacer plate (24). 24

23

RKTA3670

19 -Remove the spacer plate (25) and gasket. [*8]

k To remove, pry the plate close to the dowel pins.

25

RKTA3680

20 -Remove the 1st and 2nd clutch assembly (26).

26

RKTA3690

30-174 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

21 -Remove the forward and reverse clutch assembly (27).

27

RKTA3700

22 -Remove the 3rd and 4th clutch assembly (28).

28

RKTA3710

23 -Remove clutch assembly rear bearings (29) and (30).

30

29

RKTA3720

24 -Remove the modulator valve housings (31).

31

RKTA3730

WH6-1E0 WH7-1E0 30-175

REMOVAL AND INSTALLATION TRANSMISSION

25 -Remove the spring assembly (32), stop pin (33), first

spool (34) and cartridge (35). 32 33

34

35

RKTA3740

26 -Using a pneumatic impact wrench, loosen and remove

the nuts (36) retaining the flanges (37), washers (38) 38
and O-rings (39). [*9]
36

37 39

RKTA3750

27 -Remove the screws and washers. Remove the rear

flange (40) of the drop box (41), O-ring (42) and O-ring
(43). [*8] 42
43
40

41

RKTA3760

28 -Remove the fill plug (44).

44

RKTA3770

30-176 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

29 -Loosen the screws (45) retaining the drop box (41).

[*10]

41

45

RKTA3780

30 -Connect the drop box (41) to a hoist. Tension the chain

or rope. Pry the drop box (41) from the transmission
housing.
41

RKTA3790

31 -Remove screws and washers; remove the flange (46)

and shim pack (47). [*8]

46

47

RKTA3800

32 -Using a suitable driver, disengage the drop box main

shaft (48) from the front bearing.

48

RKTA3810

WH6-1E0 WH7-1E0 30-177

REMOVAL AND INSTALLATION TRANSMISSION

33 -Remove the main shaft assembly (48).

48

RKTA3820

34 -Remove the dipstick (49), dipstick tube (50) and air

breather (51). 49
51

50

RKTA3830

35 -Remove the retainer (52), screw (53), O-ring seal and O-

ring (54) from the supply tube (55). 54
[*11]

53
52

RKTA3840

36 -Remove the supply tube (55).

55

RKTA3850

30-178 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

37 -Remove the forward and reverse clutch shaft bushing

retaining screw (56). [*12]
56

RKTA3860

38 -Using a hammer puller, remove the control valve sleeve

(57) and bearing (58).
57

58

RKTA3870

39 -Remove the front tapered bearing (59).

59

RKTA3880

40 -Remove the gear (60) and spacer (61).

61
60

RKTA3890

WH6-1E0 WH7-1E0 30-179

REMOVAL AND INSTALLATION TRANSMISSION

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

3 Screws: 35 -39 Nm
[*2]

3 Filter: 27 -34 Nm
[*3]

3 Screws: 35 -41 Nm
[*4]

3 Regulator assembly: 61 -68 Nm

[*5]

k Position two studs to ease the centring of clutch

shafts and sealing elements.
Do not use screws to force the installation.

3 Screws: 40 -50 Nm
[*6]

3 Screws: 5 -7 Nm
[*7]

3 Nuts: 22 -27 Nm
[*8]

3 Screws: 40 -50 Nm
[*9]

3 Nuts: 389 -407 Nm

[*10]

3 Screws: 170 -190 Nm

[*11]

2 Nut: (53): Loctite 270

[*12]

2 Screw: Loctite 243

53

RKT01830

30-180 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

1st CLUTCH
Disassembly 1
1 -Remove the sealing elements (1).

RKTA3900

2 -Remove the front bearing (2).

RKTA3910

3 -Remove the outer thrust bearing (3).

RKTA3920

4 -Remove the gear (4) and bearings (5).

5
4

RKTA3930

WH6-1E0 WH7-1E0 30-181

REMOVAL AND INSTALLATION TRANSMISSION

5 -Remove the inner thrust bearing (6).

RKTA3940

6 -Remove the clutch disc inner retainer ring (7).

RKTA3950

7 -Remove the end plate (8).

RKTA3960

8 -Remove the clutch discs (9) and (10). [*1]

10

RKTA3970

30-182 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

9 -Using a puller (A), compress the disc springs to

disengage the retainer ring. [*2]

RKTA3980

10 -Remove the retainer ring (11).

11

RKTA4000

11 -Remove the spring locating ring (12).

12

RKTA4010

12 -Remove the disc springs (13). [*3]

NOTE
Disc springs are specific for each clutch. Their
sequence of installation should never be inverted.
Spare springs are supplied as a pack and are already in 13
their sequence of installation.

RKTA4020

WH6-1E0 WH7-1E0 30-183

REMOVAL AND INSTALLATION TRANSMISSION

13 -Remove the inner spring locating ring (14).

14

RKTA3990

14 -Turn the clutch over and tap the clutch on a block of soft
material to remove the piston (15). [*4]
15
a Note down the seals assembly sequence.

RKTA4030

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

a Start clutch disc installation by placing a steel disc

(10) first.

a Install 10 + 10 clutch discs in total.

[*2]

a After installing the snap ring, turn the assembly over

and check clearance between piston and steel ring
for being between 2.03 and 3.43 mm.
If clearance is greater than 3.43 mm, remove the
snap ring (7) and end plate (8) and add a steel disc.
8 13
[*3]

a Orient the springs (13) as shown to the side.

7
[*4]

a The inner retainer ring should be extended to reach

the size of the shaft. This is done by rolling the seal
lip on a refaced piece of round steel.

RKT01840

30-184 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

2nd CLUTCH

Disassembly
1 -Remove the shaft bearing outer race (1).
1

RKTA4040

2 -Using a gear puller, remove the gear (2) and bearing

inner race (1).

1
2

RKTA4050

3 -Remove the ring (3) stopping the gear (2).

RKTA4060

4 -Remove the ring (4) retaining the thrust bearing (5).

RKTA4070

WH6-1E0 WH7-1E0 30-185

REMOVAL AND INSTALLATION TRANSMISSION

5 -Remove the outer thrust bearing (5).

RKTA4080

6 -Remove the gear (6) and bearings (7).

7

RKTA4090

7 -Remove the inner thrust bearing (8).

RKTA4100

8 -Remove the clutch disc inner retainer ring (9).

RKTA4110

30-186 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

9 -Remove the end plate (10).

10

RKTA4120

10 -Remove the clutch discs (11) and (12). [*1]

12

11

RKTA4130

11 -Using a puller (A), compress the disc springs to

disengage the retainer ring.

RKTA4140

12 -Remove the retainer ring (13).

13

RKTA4150

WH6-1E0 WH7-1E0 30-187

REMOVAL AND INSTALLATION TRANSMISSION

13 -Remove the spring locating ring (14).

14

RKTA4160

14 -Remove the disc springs (15). [*2]

NOTE
Disc springs are specific for each clutch. Their
sequence of installation should never be inverted. 15
Spare springs are supplied as a pack and are already in
their sequence of installation.

RKTA4170

15 -Remove the inner spring locating ring (16).

16

RKTA4180

16 -Turn the clutch over and tap the clutch on a block of soft
material to remove the piston (17). [*3]

a Note down the seals assembly sequence. 17

RKTA4190

30-188 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

a Start clutch disc installation by placing a steel disc

first.

a Install 5 +5 clutch discs in total.

[*2]

a Orient the springs (15) as shown to the side. 15

[*3]

a The inner retainer ring should be extended to reach

the size of the shaft. This is done by rolling the seal
lip on a refaced piece of round steel.

RKT01850

WH6-1E0 WH7-1E0 30-189

REMOVAL AND INSTALLATION TRANSMISSION

4th CLUTCH
Disassembly
1 -Remove the retainer ring (1).
1

RKTA4200

2 -Remove the outer thrust bearing (2).

RKTA4210

3 -Remove the gear (3), bearings (4), and spacer (5).

4
5
4

RKTA4220

4 -Remove the inner thrust bearing (6).

RKTA4230

30-190 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

5 -Remove the clutch disc inner retainer ring (7).

RKTA4240

6 -Remove the end plate (8).

8

RKTA4250

7 -Remove the clutch discs (9) and (10). [*1]

10

RKTA4260

8 -Using a puller (A), compress the disc springs to

disengage the retainer ring.
A
9 -Remove the retainer ring (11).

11

RKTA4270

WH6-1E0 WH7-1E0 30-191

REMOVAL AND INSTALLATION TRANSMISSION

10 -Remove the spring locating ring (12).

12

RKTA4280

11 -Remove the disc springs (13). [*2]

NOTE
Disc springs are specific for each clutch. Their
13
sequence of installation should never be inverted.
Spare springs are supplied as a pack and are already in
their sequence of installation.

RKTA4290

12 -Remove the inner spring locating ring (14).

14

RKTA4300

13 -Turn the clutch over and tap the clutch on a block of soft
material to remove the piston (15). [*3]

a Note down the seals assembly sequence.

15

RKTA4310

30-192 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

a Start clutch disc installation by placing a steel disc

first.

a Install 6 +6 clutch discs in total.

[*2]

a Orient the springs (13) as shown to the side. 13

[*3]

a The inner retainer ring should be extended to reach

the size of the shaft. This is done by rolling the seal
lip on a refaced piece of round steel.

RKT01851

WH6-1E0 WH7-1E0 30-193

REMOVAL AND INSTALLATION TRANSMISSION

3rd CLUTCH
Disassembly
1 -Remove the bearing outer race (1).

RKTA4320

2 -Using a gear puller, remove the gear (2) and bearing

inner race (1).

RKTA4330

3 -Remove the thrust bearing (3).

RKTA4340

4 -Remove the bearings (5) from the gear (4).

RKTA4350

30-194 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

5 -Remove the thrust bearing (6).

RKTA4360

6 -Remove the clutch disc inner retainer ring (7).

RKTA4370

7 -Remove the end plate (8).

RKTA4380

8 -Remove the clutch discs (9) and (10). [*1]

10

RKTA4390

WH6-1E0 WH7-1E0 30-195

REMOVAL AND INSTALLATION TRANSMISSION

9 -Using a puller (A), compress the disc springs to

disengage the retainer ring.

10 -Remove the retainer ring (11).

A

11

RKTA4400

11 -Remove the spring locating ring (12).

12

RKTA4410

12 -Remove the disc springs (13). [*2]

NOTE 13
Disc springs are specific for each clutch. Their
sequence of installation should never be inverted.
Spare springs are supplied as a pack and are already in
their sequence of installation.

RKTA4420

13 -Remove the inner spring locating ring (14).

14

RKTA4430

30-196 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

14 -Turn the clutch over and tap the clutch on a block of soft
material to remove the piston (15). [*3]

a Note down the seals assembly sequence. 15

RKTA4440

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

a Start clutch disc installation by placing a steel disc

first.

a Install 5 +5 clutch discs in total.

[*2]

a Orient the springs (13) as shown to the side. 13

[*3]

a The inner retainer ring should be extended to reach

the size of the shaft. This is done by rolling the seal
lip on a refaced piece of round steel.

RKT01851

WH6-1E0 WH7-1E0 30-197

REMOVAL AND INSTALLATION TRANSMISSION

REVERSE CLUTCH
Disassembly 1

1 -Remove the thrust bearing (1).

RKTA4450

2 -Remove the gear (2), bearings (3), and spacer (4).

3
4

RKTA4460

3 -Remove the thrust bearing (5).

RKTA4470

4 -Remove the clutch disc inner retainer ring (6). [*1]

RKTA4480

30-198 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

5 -Remove the end plate (7).

RKTA4490

6 -Remove the clutch discs (8) and (9). [*2]

RKTA4500

7 -Using a puller (A), compress the disc springs to

disengage the retainer ring.

8 -Remove the retainer ring (10).

7

10

RKTA4401

9 -Remove the spring locating ring (11).

11

RKTA4411

WH6-1E0 WH7-1E0 30-199

REMOVAL AND INSTALLATION TRANSMISSION

10 -Remove the disc springs (12). [*3]

NOTE
Disc springs are specific for each clutch. Their
12
sequence of installation should never be inverted.
Spare springs are supplied as a pack and are already in
their sequence of installation.

RKTA4530

10 -Remove the inner spring locating ring (13).

13

RKTA4540

11 -Turn the clutch over and tap the clutch on a block of soft
material to remove the piston (14). [*4]

a Note down the seals assembly sequence.

14

RKTA4550

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

a Start clutch disc installation by placing a steel disc

first.

a Install 6 +6 clutch discs in total.

30-200 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

[*2]

a After installing the snap ring, turn the assembly over

and check clearance between piston and steel ring
for being between 1.22 and 2.74 mm.
If clearance is greater than 2.74 mm, remove the
snap ring (6) and end plate (7) and add a steel disc.

[*3]

a Orient the springs (12) as shown to the side. 12

[*4]

a The inner retainer ring should be extended to reach

the size of the shaft. This is done by rolling the seal
lip on a refaced piece of round steel.

RKT01852

WH6-1E0 WH7-1E0 30-201

REMOVAL AND INSTALLATION TRANSMISSION

FORWARD CLUTCH
Disassembly
1
1 -Remove the sealing elements (1).

RKTA4560

2 -Remove the thrust bearing (2).

RKTA4570

3 -Remove the gear (3), bearings (4), and spacer (5).

5
4

RKTA4580

4 -Remove the thrust bearing (6).

RKTA4590

30-202 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

5 -Remove the clutch disc inner retainer ring (7).

[*1]
7

RKTA4600

6 -Remove the end plate (8).

8

RKTA4610

7 -Remove the clutch discs (9) and (10). [*2]

10

RKTA4620

8 -Using a puller (A), compress the disc springs to

disengage the retainer ring.
A
9 -Remove the retainer ring (11).
11

RKTA4630

WH6-1E0 WH7-1E0 30-203

REMOVAL AND INSTALLATION TRANSMISSION

9 -Remove the spring locating ring (12).

12

RKTA4640

10 -Remove the disc springs (13). [*3]

NOTE
Disc springs are specific for each clutch. Their
sequence of installation should never be inverted.
13
Spare springs are supplied as a pack and are already in
their sequence of installation.

RKTA4650

11 -Remove the inner spring locating ring (14).

14

RKTA4660

12 -Turn the clutch over and tap the clutch on a block of soft
material to remove the piston (15). [*4]

a Note down the seals assembly sequence.

15

RKTA4670

30-204 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

a Start clutch disc installation by placing a steel disc

first.

a Install 6 +6 clutch discs in total.

[*2]

a After installing the snap ring, turn the assembly over

and check clearance between piston and steel ring
for being between 1.22 and 2.74 mm.
If clearance is greater than 2.74 mm, remove the
snap ring (7) and end plate (8) and add a steel disc.

[*3]

a Orient the springs (13) as shown to the side. 13

[*4]

a The inner retainer ring should be extended to reach

the size of the shaft. This is done by rolling the seal
lip on a refaced piece of round steel.

RKT01853

WH6-1E0 WH7-1E0 30-205

REMOVAL AND INSTALLATION TRANSMISSION

PRESSURE REGULATOR VALVE

Disassembly
1 -Remove the pin from the valve (1).

a Use caution as valve spool is under spring pressure.

RKTA4680

2 -Remove piston (2) and spring (3) from the valve.

Perform a thorough cleaning procedure.

3 2

RKTA4690

Assembly
• To assemble, reverse the disassembly procedure.

30-206 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

MODULATED VALVE
Disassembly 2
1 -Remove the spring assembly (1) and pin (2) from the
housing sleeve.
1

RKTA4700

2 -Remove the second spool (3).

RKTA4710

3 -Remove the pins (4).

RKTA4720

4 -Remove the spool (6), spring (7), spring guide (8) and
shim (9) from the housing sleeve (5).

5 6
7

8 9
RKTA4730

WH6-1E0 WH7-1E0 30-207

REMOVAL AND INSTALLATION TRANSMISSION

Assembly
1 -Install the pin (4).
NOTE
On units with pins of different length, install the shortest
pin.

RKTA4750

2 -Introduce the shim (9) into the spring guide (8).

RKTA4740

3 -Install the spring (7).

7

RKTA4760

4 -Check the orifice in the spool (6) to be free and clear of

any foreign material.

RKTA4770

30-208 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

5 -Install the spool (6) and install the assembly with the
spring guide (8) facing the lower pin.
6

RKTA4780

6 -Introduce the spool (6) and complete assembly into the

sleeve (5).
5
6

RKTA4790

7 -Push the spool (6) inside and install the pin (4).
NOTE
On units with pins of different length, install the longest
pin.
5
4

RKTA4800

8 -Install the first spool (3).

RKTA4810

WH6-1E0 WH7-1E0 30-209

REMOVAL AND INSTALLATION TRANSMISSION

9 -Install the spring assembly (1).

RKTA4820

10 -Install the stop pin (2).

RKTA4830

30-210 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

SPACER PLATE
Disassembly 1
1 -Remove the screw (1) and the washer retaining the idler 2
gear (2).

RKTA4840

2 -Remove the end plate (3) and dowel pin (4).

RKTA4850

3 -Remove the idler gear (2).

RKTA4860

4 -Remove the bearing cage (5) and inner plate (6).

RKTA4870

WH6-1E0 WH7-1E0 30-211

REMOVAL AND INSTALLATION TRANSMISSION

5 -If you need to replace the shaft(7) of the idler gear (2),
turn the spacer plate (8) upside down and place it on
A
supports, and then pull out the shaft using a puller (A)
and a press.
7

RKTA4890

6 -Remove the snap ring (9) from the shaft (7).

RKTA4900

7 -Using a puller, remove the pump idler shaft (10) and

washer (11).

10

11

RKTA4910

8 -Remove the retainer ring (13) from the stator spline shaft
(12).
13

12

RKTA4920

30-212 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

9 -Push the spline shaft (12) far enough to expose the

retainer ring (14); remove the retainer ring.
14

12

RKTA4930

10 -Remove the shaft (12) and backing washer (15).

12

15

RKTA4940

11 -Remove the sealing ring (16). [*1]

16

RKTA4950

12 -Remove the expander ring (17).

17

12

RKTA4960

WH6-1E0 WH7-1E0 30-213

REMOVAL AND INSTALLATION TRANSMISSION

13 -If the shaft bearing (18) is to be replaced, remove

bearing from shaft (12).
18

12

RKTA4970

14 -Using a puller (B), compress the safety valve spring and

remove the retaining washer (19).
B

19

RKTA4980

15 -Remove the spring (20).

20

RKTA4990

16 -Turn the plate (8) upside down and remove the poppet
valve (21).

20

8
RKTA5000

30-214 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

Assembly
• To assemble, reverse the disassembly procedure.

[*1] 16

a Install the expander valve (17) and the segment (16)

as shown to the side.

17
RKT01860

WH6-1E0 WH7-1E0 30-215

REMOVAL AND INSTALLATION TRANSMISSION

CONVERTER HOUSING
2
Disassembly
1 -Remove the bearing (2) from the converter housing (1). 1

RKTA5010

2 -Remove the oil control valve ring (3).

RKTA5020

3 -Remove the oil seal (4). [*1]

a Note down direction of assembly. 4

RKTA5030

4 -Remove the plug (5).

RKTA5040

30-216 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

5 -Remove the screw (6) retaining the sleeve (7).

[*2]

RKTA5050

6 -Using a hammer puller, remove the sleeve (7). [*3]

RKTA5060

7 -Remove the plug (8).

RKTA5070

8 -Remove the screw (9) retaining the sleeve (10).

[*2]
9
10

RKTA5080

WH6-1E0 WH7-1E0 30-217

REMOVAL AND INSTALLATION TRANSMISSION

9 -Using a hammer puller, remove the sleeve (10). [*3]

10

RKTA5090

Assembly
• To assemble, reverse the disassembly procedure.

[*1]

a Apply a thin coat of sealant to the outer diameter of

the oil seal.

2 Oil seal: Loctite 641

[*2]

2 Retaining screw: Loctite 243

[*3]

a Install the sleeve with the chamfer facing up.

30-218 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

DROP BOX ASSEMBLY

1
Disassembly 2
• Complete drop box assembly
1 -Remove the retaining screws (1) and lockwashers from
the front flange (2).

RKTA5100

2 -Remove the flange (2) and shim pack (3).

RKTA5110

3 -Remove the retaining screws (4) and lockwashers from

the rear flange (5).

RKTA5120

4 -Remove the rear flange (5), O-rings (6) and seal rings
(7).
Also, remove the bearing outer race (9). 5
7
6

RKTA5130

WH6-1E0 WH7-1E0 30-219

REMOVAL AND INSTALLATION TRANSMISSION

5 -Using a soft hammer, disengage the output shaft (8)

from the rear bearing (9).

RKTA5140

6 -Remove the bearing inner race (9).

RKTA5150

7 -Remove the output shaft (8) complete with front bearing

inner race (10).

10

RKTA5160

8 -Remove the driven gear (11).

11

RKTA5170

30-220 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

• Input shaft
1 -Using a puller, remove the rear bearing outer race (9). 9

RKTA5180

2 -Remove the retainer ring (12).

12

RKTA5190

Assembly
• Input shaft
• To assemble, reverse the disassembly procedure.

• Complete drop box assembly

1 -Install the gear (11) into the drop box housing.

11

RKTA5200

WH6-1E0 WH7-1E0 30-221

REMOVAL AND INSTALLATION TRANSMISSION

2 -Install the output shaft (8) and front bearing inner race
(10).

k To assist installation, heat the bearing inner race

at 135±15 °C.
10 8

RKTA5210

3 -Turn the assembly upside down; place the shaft (8) on a

support block and install the inner race (9) to the rear
output of the shaft (8).

k The bearing can be best fit after heating it at

135±15 °C. 9
8

RKTA5220

4 -Install the bearing outer race (9) and tap it in place using
a plastic hammer.

RKTA5230

5 -Install the O-ring (14) to the drop box housing (13).

14
13

RKTA5240

30-222 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

6 -Coat the outside of the seal ring (7) with sealant and
install it to the flange (5). 7

2 Seal ring: Loctite 641 6

7 -Install the front output flange (5) and O-ring (6). 5

RKTA5250

8 -Lock the flange with screws (1) and washers.

3 Screws: 40 -50 Nm
1

RKTA5260

9 -Turn the assembly upside down and install the bearing

outer race (10).

10

10 -Using a centesimal microgauge, measure flange

thickness at worked areas “A” and “B”.
RKTA5270

a If necessary, remove all paint or dents (if any) from

the worked areas.

11 -Add the two thickness values to each other and then

divide by 2 to obtain the average base measurement
“D”.

Example:
A B
• Measurement in A = 6.990 mm

• Measurement in B = 7.000 mm
6.990+7.000 = 13.990 mm

13.990: 2 = 6.995 mm = Measure D

RKT01870

WH6-1E0 WH7-1E0 30-223

REMOVAL AND INSTALLATION TRANSMISSION

12 -Lubricate the front flange (2) and install it to the

assembly, ensuring that it slides freely in its seat. G 2 C
13 -Secure the flange (2) with screws (G) and tighten using
the criss-cross and alternate method to 9.5 – 13.6 Nm. D E F

a While tightening the screws, rotate the shaft several

times in both directions to set the bearings.

RKT01880

14 -Remove two screws leaving only the ones shown (G) in

place. G
15 -Using a torque wrench, increase screw tightening C
torque (for G screws) up to 1.13 Nm and perform some
shaft rotations in order to set the bearings.

16 -Increase the screw tightening torque by increments of

0.56 Nm until a final torque of 5.65 Nm is obtained. A
k At each torque increment, carry out
B

measurements in “A” and “B” and, if the difference

C
exceeds 0.127 mm, repeat steps from 12 on. G RKT01890

17 -Using a depth microgauge (C), measure “E” on surfaces

“A” and “B” and calculate the average. C
Example:
E = 7.457 mm D E F

18 -Detract base size “D” from “E” to obtain the “F” size, i.e.
the size of the shim pack to be mounted.
19 -Refer to the parts catalogue and choose among the
available shims. Make up the shim pack keeping
tolerance between 0 and –0.05 mm.

RKT01900

20 -Remove the flange (2).

RKTA5280

30-224 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

21 -Coat the outside of the seal ring (15) with sealant and
install it to the flange (2).

2 Seal ring: Loctite 641

22 -Install the O-ring (16) and the lubrication hole O-ring
(17). 17
23 -Position the shim pack and flange.

RKTA5290

24 -Install the screws (4) and washers and lock the flange.

3 Screws: 40 -50 Nm 4

RKTA5300

25 -Coat the outside of the oil seal (18) with sealant and
install it into the drop box body (19).

2 Seal ring: Loctite 641 18

k Push the oil seal far enough to obtain the “M” size
specified below:

a “M” size: 4 mm
18
19

4 mm RKTA5311

26 -Position the drive gear (11) into the transmission case

(20). 11
20

RKTA5320

WH6-1E0 WH7-1E0 30-225

REMOVAL AND INSTALLATION TRANSMISSION

27 -Install and engage the complete input shaft (21) into the
drive gear (11).

a Be extremely careful not to damage the seal ring

(18).
21
11
18

RKTA5330

28 -Coat the transmission case (20) with sealant and install

the drop box assembly (22).

2 Transmission case: Loctite 5205

22

21

20

RKTA5340

29 -Secure the drop box with screws (23) and self-locking

washers.

3 Screws: 275 -290 Nm

23

RKTA5350

30 -Install the fill plug (24) and O-ring.

24

RKTA5360

30-226 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

31 -Install the O-ring (25) retaining the flange (5).

25

RKTA5370

32 -Install the bearing outer cup (9).

RKTA5380

33 -Install the lubrication hole O-ring (26) into the flange (5).
5

26

RKTA5390

34 -Install the flange (5) and lock it with screws (1).

3 Screws: 40 -50 Nm

RKTA5400

WH6-1E0 WH7-1E0 30-227

REMOVAL AND INSTALLATION TRANSMISSION

35 -Ensure that the drive gear (27) is seated against the stop
ring of the main shaft (28), and then install the spacer
ring (29). 29
27

28 29

RKTA5411

36 -Heat the bearing inner race (30) to 135±14 °C and install

the race to the main shaft (28).

k Ensure that the bearing is well seated against the

spacer ring.

30

RKTA5420

37 -Install the bearing outer cup (31).

31

RKTA5430

38 -Using the procedure described in steps 10-20, calculate

the shim pack (32) to be mounted under the flange (2).

RKTA5440

30-228 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION TRANSMISSION

39 -Install the shim pack (32) and O-ring (33) to the flange
(2).

33

32

RKTA5451

40 -Install the flange (2) to the transmission and lock it with

screws and washers.

3 Screws: 40 -50 Nm

RKTA5460

41 -Install the attachment yokes (34), O-rings (35), washers

(36) and nuts (37) to the output shaft.

36
34

37 35
RKTA5470

42 -Tighten the nuts (37).

3 Nuts: 389 -407 Nm

RKTA5480

WH6-1E0 WH7-1E0 30-229

REMOVAL AND INSTALLATION AXLES

AXLES
NOTE: Some parts may be different in shape but procedures remain the same.
Disassembly 1
• Planetary reduction
1 -Remove the securing screws (1) from the planetary
carrier cover (2).

1
RKTA5490

2 -Disjoint the planetary carrier cover (2) from the steering

case (3) by alternatively forcing a screwdriver into the 3
appropriate slots.

2
RKTA5500

3 -Remove the complete planetary carrier cover (2).

RKTA5510

4 -Unloose and remove the tightening nuts (4) from the

crown flange (5).

RKTA5520

30-230 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

5 -Remove the safety flange (6).

RKTA5530

6 -Using a puller, remove the complete crown flange (5) by

acting on the stud bolts.
5

RKTA5540

7 -Partially extract the hub (7) using a plastic hammer.

a Alternately hammer on several equidistant points.

RKTA5550

8 -Remove the external bearing (8).

RKTA5560

WH6-1E0 WH7-1E0 30-231

REMOVAL AND INSTALLATION AXLES

9 -By hand remove the complete hub (7).

7

RKTA5570

10 -Remove the pins and remove the steering case (3).

(For details, see "Steering case").

RKTA5580

11 -Remove the snap rings (9).

RKTA5590

12 -With the help of a puller, remove the planet wheel gears

(10).

a Note down the assembly side of planet wheels.

10

RKTA5600

30-232 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

13 -Remove the snap ring (12) from the crown (13).

12 13

RKTA5610

14 -Remove the crown flange (5).

RKTA5620

15 -Remove the sealing ring (14) from the hub (7).

14

RKTA5630

16 -Remove the internal bearing (15).

15

RKTA5640

WH6-1E0 WH7-1E0 30-233

REMOVAL AND INSTALLATION AXLES

17 -Remove the external thrust blocks from the bearings (8)

and (15) forcing a pin-driver into the appropriate slots on
the hub (7).

a Hammer in an alternate way so as to avoid crawling

or deformation of the thrust blocks.

RKTA5650

18 -Use a puller to remove the centring ring (16), the sealing

ring (17) and the bearing (18) from the steering case (3). 16
a Note down the orientation of both centring ring (16)
and sealing ring (17). 17
16 17 18
18

3
RKTA5660

• Steering case
1
1 -Remove the guard (1) and disconnect the articulation
pin (2). (For details, see "Removal of steering cylinder").

RKTA5670

2 -Sling the entire unit (7) and connect it to the hoist, putting
the rod under light tension.
7

RKTA5680

30-234 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

3 -Unloose and remove the fitting screws (3) from the

bottom articulation pin (4).

a Screws cannot be re-used.

3
RKTA5690

4 -Remove the bottom articulation pin (4) complete with

front sealing ring (5). 5

4
RKTA5700

5 -Unloose and remove the fittin screws (3) from the top
articulation pin (6).

RKTA5710

6 -Using two levers, remove the top articulation pin (6)

complete with front seal (5).
Pay attention not to damage the surfaces.

6
5

RKTA5720

WH6-1E0 WH7-1E0 30-235

REMOVAL AND INSTALLATION AXLES

7 -Remove the complete steering case (7).

RKTA5730

8 -Using a puller for inner parts, remove the top bush (8)
and the bottom ball-bush (9).

RKTA5740

9 -Remove the articulation pins (4) and (6) and the front
sealing rings (5).
5
a Note down direction of assembly.

4 6

RKTA5750

10 -If the ball cover (11) needs replacing, remove it from the
bottom articulation pin (4).

11

RKTA5760

30-236 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

• Cardan shaft
1 -Remove the steering case.
(For details, see "Steering case").

a For front axle: introduce compressed air (approx. 7 3

bar) in the braking circuit.
2
2 -Unloose and remove the top and bottom check nuts (2)
from the dowels (3).

RKTA5770

3 -Remove top and bottom check dowels (3) from the

bushing unit (6).

RKTA5780

4 -Remove the u-joint (4).

a To remove the u-joint use, if necessary, a plastic

hammer or a lever.

4
RKTA5790

5 -Remove the snap ring (5) from the bushing unit (6).

RKTA5800

WH6-1E0 WH7-1E0 30-237

REMOVAL AND INSTALLATION AXLES

6 -Position the entire u-joint (4) under a press and remove

the complete bush (6).
4

RKTA5810

7 -Remove the snap ring (7) from the bearing (8).

8 -Use a puller to remove the bearing (8), the sealing ring

(9) and the O-ring (10).

a Note down the assembly side of the ring (9).

7
8 8 9

10

RKTA5820

30-238 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

• Brakes
1 -Remove the swinging support (1) on the side opposite
the drive.
1
a If the bushing (2) is worn and needs replacing, note 2
down the assembly side of the connection notch
"A".
A

RKTA5830

2 -Disconnect the pins of the steering bars from the

steering case. (For details, see "Removal of steering
cylinder").

3 -Sling the arm (3) to be removed and put the rod under 3
slight tension.

RKTA5840

4 -Unloose and remove the screws (4) and the washers (5)
that fix the arm (3) to the central body (6).
4 5
6

3 RKTA5850

5 -Remove the arm (3) together with the pack of the

braking disks (7). Place the arm on a bench.

RKTA5860

WH6-1E0 WH7-1E0 30-239

REMOVAL AND INSTALLATION AXLES

6 -Remove the braking disks (7) and note down their order
of assembly.

a If the disks do not need replacing, avoid switching

their position.

7 -Extract the u-joint (17). (For details, see "Cardan shaft").

17
7
RKTA5870

8 -Remove the reversal springs (8) from the piston (9).

8
a If the springs (8) are weak or deformed they must be 9
replaced.

8
RKTA5880

9 -Remove the pin screws (10) guiding the piston (9).

k If the screws are to be replaced, note down the

9
different colours for the different brake gap.
(For details, see "Brakes").

10

RKTA5890

10 -Slowly introduce compressed air through the

connection of the braking circuit in order to extract the
entire piston.

k Hold on to the piston as it may be suddenly ejected

and damaged.

9
RKTA5900

30-240 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

• Parking brake assembly

(front axle)
1 -Disconnect the steering rod from the housing and
remove the axle shafts.
(For details, see "Removal of steering cylinder").

RKTA5920

2 -Remove the screw (1) retaining the washer (2) retaining

the lever (3).
1

RKTA5940

3 -Remove the washer (2), lever (3) and O-rings (4).

a Mark the positions of the levers (3) in relation to the 2

thrust levers (12 and 13).
3

12 13
4

RKTA5910

4 -Loosen and remove the screws (5); remove the bushing

(6) together with the O-ring seal (7).
6

7
5
RKTA5930

WH6-1E0 WH7-1E0 30-241

REMOVAL AND INSTALLATION AXLES

5 -Connect the complete axle shaft (8) to a hoist and

slightly tension the rope.
Remove the complete axle shaft.
(For details, see "Brakes").

8
RKTA5960

6 -Remove the brake rotors (9) and the complete piston

(10).
(For details, see "Brakes").
10

9
RKTA5950

7 -If the points (11) are to be replaced, clamp the piston

(10) in a vice with soft grips and remove the points.
10

11

RKTA5970

8 -If the thrust levers (12 and 13) are to be replaced,

remove the U-joint (14) before removing the axle shafts
(8).

8
12 13
14
RKTA5980

30-242 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

• Removal of steering cylinder

1 -Remove the centring sensor (1) of the steering piston 1
(2), if supplied. 2

RKTA5990

2 -Remove the safety cotter pins (3) from the articulation

pins (4) of the steering bars (5).

k Dispose of used cotter pins.

5
6
3

4
RKTA6000

3 -Remove the castellated nuts (6) that lock the articulation

pins (4).
4

RKTA6010

4 -Disconnect the tapered pins of the articulation (4) from

the steering case (7) by means of a puller.
7

4
5

RKTA6020

WH6-1E0 WH7-1E0 30-243

REMOVAL AND INSTALLATION AXLES

5 -If the connection of the steering bars includes a safety

collar (13), raise the border.
13

RKTA6030

6 -Disconnect left and right steering bars (5) from the

piston (2).
2

RKTA6040

7 -Remove the securing screws (8) from the steering

cylinder (9). 9

RKTA6050

8 -Extract the cylinder (9) using a plastic hammer.

RKTA6060

30-244 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

• Disassembly of steering cylinder

2
1 -Remove the snap ring (1) from the cylinder head (2).

RKTA6070

2 -With the help of a plastic hammer, push the head (2)

inside the cylinder (3).

a The head should line up with the edge of the 3

cylinder.

RKTA6080

3 -With the help of a drift, apply pressure to the stop ring (4)
that is placed inside the cylinder (3) and extract the ring
using a screwdriver.
3

RKTA6090

4 -Hammer the piston (5) on the rear of the head (2) using
a plastic hammer. Continue hammering until the head
(2) is ejected from the cylinder (3).

5
3
2
RKTA6100

WH6-1E0 WH7-1E0 30-245

REMOVAL AND INSTALLATION AXLES

5 -Disassemble the cylinder unit (3) by extracting first the

head (2), then the piston (5).

k Note down the assembly side of the piston. The

5

bevelled part "A" of the piston is oriented towards

the head (2).

A
RKTA6110

6 -Remove all seals, anti-extrusion rings and scraper rings

from head (2), cylinder (3) and piston (5).

a All seals must be replaced every time the unit is

disassembled.

a Particular attention must be paid not to damage the

seats of both seals and piston slide.

• Differential
1 -Remove the complete arms.
(For details, see "Brakes").

RKTA5841

2 -Mark the position of the ring nuts (1). Remove the fittin
screws (3) from the ring nuts (1).
3

1
RKTA6120

30-246 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

3 -Uniformly heat the ring nuts (1) up to a temperature of

80°C.

RKTA6130

4 -Apply tool D1 and remove the ring nuts.

a Accurately clean the threaded portions on ring nuts

of body and cover.
D1

RKTA6140

5 -Remove the fittin screws (4) from the middle cover (5).
4 5

4
RKTA6150

6 -Insert a screw-driver in the opposing slots then force and

remove the middle cover (5) and the complete 6
differential unit (6). 5
a Support the pieces using a rod.

RKTA6160

WH6-1E0 WH7-1E0 30-247

REMOVAL AND INSTALLATION AXLES

7 -If the bearings need replacing, extract the external

thrust blocks of the bearings (7) and (8) from middle 2
cover (5) and central body (2). 8
a Accurately check the O-ring (9).

7 9
5

RKTA6170

8 -Remove the top plug (10).

10
a Top plug cannot be re-used.

RKTA6180

9 -Remove the fittin screws (11) from the crown (12).

11
12

RKTA6190

10 -If the bearing need replacing, extract the bearing (7) and
remove the crown (12).

7
12

RKTA6200

30-248 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

11 -Remove the shim washer (13) and the planetary gear

(14). 13

14

RKTA6210

12 -If the bearing need replacing, extract the bearing (8)

from the differential carrier (15).

15
RKTA6220

13 -Remove the snap rings (16) from the two pins (17) of the
planet wheel gears (18).

16 17

RKTA6230

14 -Insert tool D2 between the planet wheel gears (18).

D2

18 18

RKTA6240

WH6-1E0 WH7-1E0 30-249

REMOVAL AND INSTALLATION AXLES

15 -Force tool D2 in-between the planet wheel gears (18)

using two pin-drivers.

k Make sure that tool D2 is perfectly lined up with the

pins (17) when locked.

15

17
RKTA6250

16 -Place the differential carrier (15) under a press, position

bush D3 and insert gudgeon D4A. Press D4A pin to limit D4A D3
position.
D4A

17
15

RKTA6260

17 -Remove gudgeon D4A and bush D3.

a In this condition the tool D2 contains pin (17). D4A D3

RKTA6270

18 -Remove tool D2 together with the pin (17) of the planet

wheel.

15

17
RKTA6250

30-250 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

19 -Leave the released planetary gear in position and again

lock tool D2. D2
20 -Repeat the operations for the extraction of the pin of the
2nd planet wheel (17).

21 -Repeat the operations for all other pins.

18 18

RKTA6240

2 - Remove tool D2 and remove the last two planet wheel

gears (18), the 2nd differential unit gear (14) and the
relative shim washer (13) from the differential carrier. 14

13

15

RKTA6280

• Bevel pinion
1 -Remove the complete arms and the differential unit.
(For details, see "Brakes" and "Differential").

RKTA5841

2 -If disassembly is awkward, heat the check nut (1) of the

flange (2) at 80 °C.
2
a Heating is meant to unloose the setting of Loctite on
the nut (1). 1

RKTA6290

WH6-1E0 WH7-1E0 30-251

REMOVAL AND INSTALLATION AXLES

3 -Position tool D5A (or D5B), so as to avoid pinion

rotation.
Unloose and remove the nut (1); also remove the O-ring
(3). D5A

RKTA6300

4 -Remove the flange (2) complete with guard (4) by

means of a puller.

RKTA6310

5 -Remove the swinging support (5)

5

RKTA6320

6 -Remove the sealing ring (6).

RKTA6330

30-252 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

7 -Position wrench D6 onto the ring nut (9) and apply bar
hold D6 to the pinion (10).
Stop wrench D6 and rotate the pinion so as to release
and remove the ring nut (9).

a If disassembly proves awkward, weld the ring nut at 9

approx. 80 °C. D7

D6

RKTA6340

8 -Apply blocks D8 and, with the help of a puller, extract the

pinion (10) complete with the internal bearing (11), the 14
distance piece (12) and shims (13).

a The thrust blocks of the bearings remain in the

central body (14).
10

D8 RKTA6350

9 -Remove the pinion (10), shims (13) and distance piece

(12). 14
12
10

13

RKTA6360

10 -Using a puller and a press, remove the inner bearing

(11) from the pinion (10).

10

11

RKTA6370

WH6-1E0 WH7-1E0 30-253

REMOVAL AND INSTALLATION AXLES

11 -Remove the thrust block of the external bearing (15).

15

RKTA6380

12 -Insert a drift in the appropriate holes and remove the

thrust block of the internal bearing (11) as well as the
shim washers (16).

16
11
RKTA6390

Assembly
• Bevel pinion
1 -Using a surface plate, reset a centesimal comparator
and place it on the measurement ring D9 (with a D9
thickness of 30.2 mm).
Preset the comparator to approx. 2 mm.

RKTA6400

2 -Bring the internal bearing (11), complete with its thrust

block, under the comparator.
Determine overall thickness "D" of the bearing checking
the discrepancy between this size and the size of the
measurement ring.

k Press the thrust block in the centre and take

several measurements while rotating the thrust
block.
11

RKTA6410

30-254 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

3 -Partially insert the thrust block of the external bearing

(15).
14
15

D10C

D10A
RKTA6420

4 -Install tension rod D10C, measurement ring D9 and

front guide tool D10A on the thrust block of the external
bearing (15).
D9 D10C 15

D10A
D10B
RKTA6430

5 -Connect the tension rod to the press and move the thrust
block of the external bearing (15) into its seat.
Disconnect the press and remove the tension rod.

k Before starting the next stage, make sure that the

thrust block has been completely inserted into its
seat.

15

RKTA6440

6 -Insert tool D11B complete with external bearing (15),

measurement ring D9 and gauged ring nut
D11C.Manually tighten.
D11C D9 D11B
15

RKTA6450

WH6-1E0 WH7-1E0 30-255

REMOVAL AND INSTALLATION AXLES

7 -Fit a centesimal comparator with long stem into bar

D11A; when the bar rests on two size- blocks of 57 mm,
reset the comparator.
D11A
8 -Preset the comparator to approx. 2 mm and reset.

RKTA6460

9 -Lay bar D11A on gauged nut D11C and take the size "A"
at about 57 mm corresponding to the maximum
diameter of arms centring.
D11C

A
D11A
RKTA6470

10 -Calculate size "B" which will be the first useful value for
calculating the size of the shims (16) that are to be D9
inserted under the thrust block of the internal bearing D11C
(11).
R115

D11B

A
30.2 61
(61-A)+115+30.2=B B RKT01540

11 -Check the nominal size (X) marked on the pinion and

add or subtract the indicated variation Y) so as to obtain 10
size "Z".e.g.:
X
Es: Z=118 + 0.1= 118.1
Z=118 – 0.2= 117.8

RKTA6480

30-256 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

12 -Calculate size "C" which represents the second value

for calculating the size of the shims "S" that are to be
placed under the thrust block of the internal bearing (11).

(16) S
D Z
C=Z+D C RKT01550

13 -Calculate the difference between sizes "B" and "C" so B-C=S

as to obtain the size "S" of the shim (16) that will go under
the thrust block of the internal bearing (11). 16 S

RKTA6490

14 -Insert shim "S" (16) and the thrust block of the internal
bearing (11) in the central body.

a To hold shim "S" (16) in position, apply grease.

16
11
RKTA6500

15 -Position tool D10A and tension rod D10C.

Connect the tension rod to the press, fasten the thrust
block and then remove the tools.

a Before starting the next stage, make sure that the

thrust block has been completely inserted into its
seat.

D10A
D10C
RKTA6510

WH6-1E0 WH7-1E0 30-257

REMOVAL AND INSTALLATION AXLES

16 -Position tools D11C and D11B complete with tapered

bearings (11) and (15); manually tighten until a rolling
torque has been obtained.
D11C
11 15

D11B
RKTA6520

17 -Insert the stem of a depth comparator in either side hole

of tool D11C; reset the comparator with a presetting of
approx. 3 mm. D11C

RKTA6530

18 -Remove the comparator and release tools and bearings

from the central body.
D11C
19 -Re-install all and insert the distance piece (12) between 11
bearings (11) and (15); manually tighten the whole pack. 12 15
D11B

RKTA6540

20 -Insert depth comparator into tool D11B-D11C and

measure variation "H" in relation to the zero setting H
performed back at point 18.
D11C
11

15
D11B

RKTA6550

30-258 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

21 -The variation is to be added to a set value of 0.12–0.13 H+0,12 0,13=S1

mm, so as to obtain the size of shim "S1" (13) which will
be inserted between the external bearing (15) and the 13 S1
distance piece (12) and subsequently, to determine the
preload for the bearings.

RKTA6491

22 -Position the internal bearing (11) and the pinion (10)

under a press; force the bearing onto the pinion.

10
11

RKTA6560

23 -Fit the pinion (10), shim "S1" (13) and distance piece
(12) in the main body (14). 14
12
a The finer shims must be placed in- between the
10
thicker ones.

13

RKTA6360

24 -Insert the external bearing (15) in the central body in

order to complete the pack arranged as in the figure.
11 13
12 15

RKTA6570

WH6-1E0 WH7-1E0 30-259

REMOVAL AND INSTALLATION AXLES

25 -Connect the pinion (10) to the tie rod D12A and D12B;
connect the tie rod D12C to the press and block.
10

RKTA6580

26 -Apply Loctite 242 (for the front axle) or Loctite 270 (for
rear axle) to the thread of the ring nut (9) and screw the
nut onto the pinion (10).

10
9

RKTA6590

27 -Apply special wrench D6 to the ring nut (9) and bar-hold

D7 to the pinion (10).
28 -Lock the wrench D6 and rotate the pinion using a
dynamometric wrench, up to a minimum required torque
setting of:
3 front axle: 500 Nm. D7
3 rear axle: 900 Nm
29 -Apply onto the pinion (10) the bar-hold "D13" and with
the help of a torque metre, check the torque of the pinion
(8).

3 Torque: 120–170 Ncm

k If torque exceeds the maximum value, then the size of
D6
RKTA6600

shim "S1" (13) between the bearing (15) and the

distance piece (12) needs to be increased.If torque
does not reach the set value, increase the torque
setting of the ring nut (9) in different stages to obtain a
maximum value of:
3 front axle: 570 Nm
3 rear axle: 1000 Nm
D13

k If torque does not reach the minimum value, then the

size of shim "S1" (13) needs to be reduced.
k When calculating the increase or decrease in size of
shim "S1", bear in mind that a variation of shim (13) of
0.01 mm corresponds to a variation of 60 Ncm in the
torque of the pinion (10). RKTA6610

30-260 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

30 -Remove blocks D8 (used for extracting the pinion) and

re-install the arms.
(For details, see "Bevel pinion").

D8

RKTA6620

31 -Lubricate the outer surface of the new sealing ring (6)

and fit it onto the central body (14) using tool D14.
5
32 -Install the swinging support (5).

a Check that it is properly oriented.

RKTA6320

33 -Fit the flange (2) complete with the guard (4) and fasten
it. For keying the flange (2), use a plastic hammer if
necessary.

a Make sure that the guard (4) is securely fastened

onto the flange and that it is not deformed.

2 4

RKTA6630

34 -Apply Loctite 242 to the threaded part of the pinion (10).

Position tool D5A (or D5B) and fasten it in order to avoid
rotation. Insert O-ring (3) the nut (1) and tighten it using
a dynamometric wrench.

3 Torque wrench setting: 280 -310 Nm

D5A

RKTA6640

WH6-1E0 WH7-1E0 30-261

REMOVAL AND INSTALLATION AXLES

• Differential
1 -Insert the shim washer (13) and the planetary gear (14) 14
in the differential carrier (15).

13

15

RKTA6280

2 -Position the shim washer (19) and the first planet wheel
gear (18). 18
Hold them in position using bar D4C.
19

D4C

RKTA6650

3 -With the help of gudgeon D4A, position the second

planet wheel gear (18) and the relative shim washer 18
(19).
D4A

19

D4C

15

RKTA6660

4 -Insert tool D2 between the two planetary gears (18).

Line up the entire unit by pushing bar D4C all the way
down until gudgeon D4A is ejected. D2

D4C

RKTA6670

30-262 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

5 -Lock tool D2 behind the planet wheel gears (18).

After locking, remove bar D4C. D2

18 18

RKTA6240

6 -Fit the snap rings (20) onto the pins (17).

20
17

RKTA6680

7 -Place the differential carrier (15) under the press,

position bush D3 and insert the planet wheel pin (17).
17
D3

RKTA6690

8 -Put gudgeon D4B on top of the planet wheel pin (17).

D4B
17

D4B D3

17

RKTA6700

WH6-1E0 WH7-1E0 30-263

REMOVAL AND INSTALLATION AXLES

9 -Press D4B pin all the way down.

D4B
D3

D4B
17

15

RKTA6710

10 -Remove gudgeon M4B, bush M3 and fit the snap ring

(16) on the pin (17).

k Make sure that the snap ring centres the seat and
that it rests on the surface of the differential carrier. 16
Repeat the operations on the other planet wheel
pin or planet wheel axle. 17

RKTA6720

11 -Position the second planetary gear (14) in the

differential carrier (15). 13

14

RKTA6210

12 -Position the shim washer (13) on the crown (12).

a In order to hold the shim washer (13) in position,

apply grease to it. 13
12

RKTA6730

30-264 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

13 -Position the crown (12) on the differential carrier (15)

and lock it with screws (11) applied with Loctite 242.

3 Torque wrench setting for screw: 128 -142 Nm 12

11
a Secure the screws using the cross-tightening
method.

15

RKTA6740

14 -Install the bearings (7) and (8) using tool D15.

D15 8
D15 7

RKTA6750

15 -If the bearings are replaced, insert the external thrust

blocks in the middle cover (5) and in the central body (2). 2

RKTA6760

16 -Position the differential unit (6) in the central body (2)

with the help of a bar and fit the middle cover (5). 6

a Thoroughly check the state of the O-ring (9) and 5

make sure that the cover is fitted with the oil
discharge in the lower position.

RKTA6160

WH6-1E0 WH7-1E0 30-265

REMOVAL AND INSTALLATION AXLES

17 -Lock the middle cover (5) with screws (4).

3 Torque wrench setting for screw: 23.8 -26.2 Nm 4

5
a If the ring nuts (1) are removed, spread them with
Loctite 242.
4
4

RKTA6770

18 -Tighten ring nuts on the crown side until clearance

between pinion and crown is zero, then lock the crown;
go back 1/4–1/2 turn

D1

RKTA6780

19 -Pre-set the bearings by means of the ring nut situated on

the opposite side of the crown, so as to increase pinion
torque up to 140–210 Ncm.

k If bearings are not new, check the static torque; if

D13
bearings are new, check the continuous torque.

RKTA6610

20 -Introduce a comparator with rotary key "A" through the

top plug hole (10).
Position the comparator on the centre of one of the teeth A
of the crown (12), pre-set it to 1mm and reset it. 12

RKTA6790

30-266 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

21 -Manually move the crown (12) in both directions in order

to check the existing backlash between the pinion and
the crown. A

RKTA6800

22 -Adjust the backlash between the pinion and the crown

by unloosing one of the ring nuts (1) and tightening the
opposite to compensate.

a Normal backlash: 0.18–0.23

D1
a Difference between MIN. and Max. clearance for
whole circumference should not exceed 0.09 mm.

RKTA6780

23 -Apply Loctite 242 to the screws (3), fit them into one of
the two holes and tighten. 10
3 Torque wrench setting: 23.8 -26.2 Nm
3
24 -Fit the top plug (10) after applying repositionable jointing
compound for seals to the rims.

RKTA6810

25 -Re-install the complete arms.

(For details, see "Brakes").

RKTA5841

WH6-1E0 WH7-1E0 30-267

REMOVAL AND INSTALLATION AXLES

• Steering cylinder
1 -After applying grease, install the sealing ring (6) of the 3 6 7 8
shaft, the anti-extrusion ring (7) and the scraper ring (8)
inside the cylinder (3).

k Thoroughly check that positioning of the anti-

extrusion ring (7) is correct.

RKT01560

2 -After applying grease, install the sealing ring (6) of the

shaft, the anti-extrusion ring (7) and the scraper ring (8)
in the head (2). 8 7 6 2

k Thoroughly check that positioning of the anti-

extrusion ring (7) is correct.

RKT01570

3 -Fit the seal (9) onto the outside of the head (2).

k 1 - In order to facilitate assembly, apply grease to 2 9

the outer surface of the piston.
2 - Do not roll the seal (9) up.

RKT01580

4 -Prepare the piston (5) by fitting it with the guide ring (10),
the magnetic ring (11), the O-ring (12) and the seal (13). 11
k 1 - In order to facilitate assembly, apply grease.
13 10

2 - If a centring sensor is not fitted, then the

magnetic ring (11) should be replaced by
another guide ring (10).
12 5

RKT01590

30-268 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

5 -Apply tool D17 to the shaft on the opposite side of the

head (2) and centre it on the cylinder (3) so that it fits into D17
the piston (5).
5
a Apply a little grease to seals and cylinder.

RKTA6820

6 -Push the piston (5) into the cylinder for 100 mm using a
plastic hammer.

3
RKTA6830

7 -Remove tool D17 and apply it to the opposite side of the

piston (5).
D17

5
2
RKTA6840

8 -Apply grease to head (2) seals, fit the head onto the
piston (5) and push it into the cylinder (3) using a plastic
hammer.
3
2
D17
a The head should line up with the edge of the
cylinder.

5
RKTA6850

WH6-1E0 WH7-1E0 30-269

REMOVAL AND INSTALLATION AXLES

9 -Insert the stop ring (4) ensuring that it fits into the seat of
the cylinder (3). 4

3
RKTA6860

10 -Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring (4).

RKTA6870

11 -Fit the snap ring (1) on the head (2).

k Make sure that the snap ring (1) is securely

2

fastened in its seat.If necessary, force it into its

seat using a drift and a hammer.

RKTA6070

30-270 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

• Steering cylinder
1 -Check that the O-rings (15) of the axle unit are in good 9
condition; lubricate the seats of the seals (15) and fit the
steering cylinder (9) into its seat.

RKTA6880

2 -Lock the cylinder by cross- tightening the screws (8).

3 Torque wrench setting: 116 -128 Nm

9 8

RKTA6890

3 -Apply Loctite 242 to the thread and connect the steering

bars by screwing the terminals onto the piston stem. 13

3 Torque wrench setting: 240 -270 Nm

a Versions with coupling require that the rim of the
articulation (13) is riveted onto the surfaces of the
piston stem.

RKTA6900

4 -Insert the pins (4) in the steering case (7) and lock into
position using a torque wrench setting of 260–290 Nm.
Find the position of the notching in relation to the hole of 4
the cotter pins and tighten the nut (6) further.

k Check that rubber guards (A) are intact.

7

RKTA6910

WH6-1E0 WH7-1E0 30-271

REMOVAL AND INSTALLATION AXLES

5 -Insert the cotter pins (3) and bend the safety stems.

k Use new cotter pins.

6
3

RKTA6920

6 Install the proximity (1) for checking piston (2) centring -

if applicable - and tighten the screws (10).

3 Torque wrench setting: 5 -6 Nm

1
2

10

RKTA5991

Eliminate the action of the negative brake, if fitted.

Apply tools D18 to the hubs and lock them. D18
Using a level "B", check that tools are perfectly flat and
parallel to each other.
D18

7 -Connect the sensor (1) to the inspection device

according to diagram.
RKTA6930

I max=0,80 A
1
NERO
BLACK
CONNETTORE
CONNECTOR

2 BLU
1 3
BLUE
--
4

BATTERIA
BATTERY

MARRONE
BROWN
+
2A
RKT01600

RKTA6940

30-272 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

8 -Centre the piston by slowly moving it first in one direction

then in the other and position it half way on the stroke, = =
which is determined by the switching on and off of the
signal lamp of the inspection device in the reversal
stage.

RKTA6950

9 -Inspect jut "C" on one side of the piston and note down
the size for checking later adjustments.
C
a If cylinders come without a sensor, the centring of
the piston must be carried out on the basis of the
maximum stroke.

RKTA6960

10 -Without moving the piston, check front and rear size at

the edge of tools D18.
Max. difference: 0.6–0.7 mm

a In order to check the rear size, rotate the bevel

pinion and check that tools D18 are flat.

D18

D18
RKTA6970

11 -If necessary, adjust convergency without moving the

centring of the piston and adjust the length of the
steering bars (5) or (14).
5 14
a With a half turn of screw, the front size is reduced by
about 3 mm, whereas the rear one is increased by
about 3 mm.

RKTA6980

WH6-1E0 WH7-1E0 30-273

REMOVAL AND INSTALLATION AXLES

• Convergency adjustment
1 -Unloose the nuts (11) and screw them onto the ball-and-
15
socket joints (15).
11

RKTA6990

2 -Hold the articulations still and rotate the ball-and-socket

joints (15). 15
Once the convergency has been adjusted, lock the nuts 11
(11).

3 Torque wrench setting for nuts: 298 -328 Nm

RKTA7000

• Parking brake assembly

(front axle)
1 -Install the thrust levers (12 and 13) first, and then the
double offset joint (14).

12 13
14
RKTA5981

2 -Apply a coat of Loctite 270 to the point threads (11) and

then install the points to the piston (10). 10
3 Point tightening torque: 30 -35 Nm

11

RKTA7010

30-274 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

3 -Re-install piston (10) and brake rotors (9).

(For details, see "Brakes").
10

9
RKTA5950

4 -Install the axle shafts (8) to the main body; check for
proper axle shaft levelling and then lock the axle shafts.
(For details, see "Brakes").

8
RKTA5960

5 -Install the bushing (6) together with the O-ring seal (7)
and lock it into position with screws (5).

3 Torque wrench setting for screw: 23.8 -26.2 Nm

6
RKTA7020

6 -Install the following parts in the sequence given: lower

O-ring seal (4), lever (3) washer (2) and associated O-
ring seal (4), and then lock into position with a screw (1).

a Do not change the positions previously marked

during disassembly.

2
3
RKTA7030

WH6-1E0 WH7-1E0 30-275

REMOVAL AND INSTALLATION AXLES

7 -Connect the braking circuit and apply maximum

operating pressure to allow the rotors to set.
Release the pressure, loosen the nut (15) and unscrew
the dowel (16) by a few turns. 15

16

RKTA7040

8 -Apply an 8-10 N (0.8–1 kg) force to the lever (3). The 8 10 N

force should be directed in the braking direction to
eliminate pre-travel.
Hold the force and simultaneously tighten the nut (16)
6
until contact with the bushing (6) is achieved.

3
16

RKTA7050

9 -Lock the dowel (16) in this position with the nut (15).

3 Nut tightening torque: 20 -25 Nm

15
a Pre-travel should be eliminated without loading the
thrust levers (12 and 13). 16
a After connecting the control cable, you should
check that both dowels (16) will contact the bushing
when the brakes are released.

RKTA7060

• Brakes
14
1 -Thoroughly clean the piston (9) and the seal channels. 12
2 -Replace the O-rings (11 and 12) and anti-extrusion rings 11
(13 and 14) and make sure not to alter the direction of
installation. 13

k Thoroughly check for proper positioning of the

anti-extrusion rings (13 and 14).

3
9
RKTA7070

30-276 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

3 -Introduce the springs (15) for stroke self-regulation and

make them flush with the piston (9).

15

15 9
RKTA7080

4 -Lubricate the seals (11 and 12) and install the piston (9)
to the axle-shaft (3).

k Ensure that the piston seat connects to the stop pin A

(A) inside the axle-shaft.

RKTA7090

5 -Assist the installation of the piston (9) by lightly tapping

with a plastic hammer along the contour.

RKTA7100

6 -Install the pin screws (10). Be sure that they are all the
same colour.
White: clearance 1 mm 9
Yellow: clearance 0.75 mm
Blue: clearance 0.5 mm

7 -Apply Loctite 270 to the threads.

3 Torque wrench setting: 5 -7 Nm

10

RKTA5890

WH6-1E0 WH7-1E0 30-277

REMOVAL AND INSTALLATION AXLES

8 -Install the return springs (8) of piston (9).

Use utmost care not to deform the spring connections. 8
9

8
RKTA5880

9 -Lightly lubricate the braking rotors (7) and install them to

the axle shaft in the proper sequence, orientated in such
a way that the oil holes and the “B” marks are perfectly
aligned.
B
a Steel rotors should be installed in such a way as to
expose the slot corresponding to the oil level plug.

7
RKTA7110

10 -Check the axle shaft retainer ring (16) for being

undamaged and properly positioned. Install the
complete axle shaft. Lock it into position with two
opposing screws (4) and washers (5).

16

RKTA5861

11 -Use tool D16 to check for axle shaft planarity and finally
lock the axle shafts with the screws (4) and washers (5) D16
using the criss-cross tightening method.

3 Torque wrench setting: 298 Nm

RKTA7120

30-278 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

• Cardan shaft
1 -Using tools D19 and D20, insert the sealing ring (9) and
the bearing (8) in the bush (6).

a Carefully check the assembly side of the seal (12). D19 D20

9 8

6 6
RKTA7130

2 -Fit the snap ring (7) on the bearing (8).

7
11

RKTA7140

3 -Heat the bearing in oil at an approx. temperature of

100°C and fit the entire bush (6) on the u-joint (4).

RKTA7150

4 -Fit the check ring (5) on the bushing unit (6); also put the
O-ring (10) into position.
10
6

RKTA5801

WH6-1E0 WH7-1E0 30-279

REMOVAL AND INSTALLATION AXLES

5 -Insert the u-joint and tighten the top and bottom dowels
(3).

3 Torque wrench setting: Max. 15 Nm 3

a For u-joint coming with a bush, centre the point of

the check dowels in the slot.

RKTA7160

6 -Apply Loctite 242 to the jutting parts of the dowels (3).

3

RKTA7170

7 -Screw the check nuts (2) of the dowels (3) and lock them
using a dynamometric wrench.

3 Torque wrench setting: 122 Nm

2

RKTA7320

• Steering case
1 -If the bottom articulation pin (4) has been extracted,
position the pin under a press and fit the ball cover (11).

11
4

RKTA7330

30-280 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

2 -Fit the front sealing rings (5) onto the articulation pins (4)
and (6).
5
a Carefully check that the rings are properly oriented
(5).
4 6

RKTA5750

3 -Lubricate the top bush (8) or the bottom ball bush (9) and
fit them into the fulcrum holes of the arm.
Use tools D21 and D22.
D21

8 D22

RKTA7340

4 -Lubricate the terminal of the u-joint (10) and install the

steering case (7).
Pay due attention not to damage the dust cover rings
and the sealing rings. 7

RKTA5730

5 -Fit a new seal (5) onto the top articulation pin (6).
Lubricate and install the unit in the steering case.
Position the screws (3) and lightly tighten.
6 -Check the correct assembly side of the seal (5). 6
5

RKTA5720

WH6-1E0 WH7-1E0 30-281

REMOVAL AND INSTALLATION AXLES

7 -Fit a new seal (5) onto the bottom articulation pin (4).
Lubricate and fit the unit in the steering case. Position 5
the screws (3) and lightly tighten.

4
RKTA5700

8 -Check the correct assembly side of the seal (5).

3
9 -Tighten the new fittin screws (3) of top and bottom
articulation pins in sequence using the cross tightening
method.

3 Torque wrench setting: 128 -142 Nm

3
RKTA7180

10 -Connect the articulation pin (2).

(For details, see "Steering cylinder"). 1
11 -Lubricate articulations with Molikote and fit the dust
cover (1).

RKTA5670

• Planetary reduction
1 -Lubricate the bushing (18) and the seat of the steering 3
D23
case (3).

2 -Install the bushing (18), using tool D23.

18

RKTA7190

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REMOVAL AND INSTALLATION AXLES

3 -Lubricate the outer surface of the sealing ring (17) and

centring ring (16); fit them into their seat using tool D24.

16 17
D24

RKTA7200

4 -Position the lower part of tool D25A and the thrust block
of the external bearing (8) under the press.

D25A

RKTA7210

5 -Lubricate the seats of the bearings and position the hub

(7) on tool D25A; position the thrust block of the internal
bearing (15).

a Check that the thrust block is correctly oriented.

15

D25A

RKTA7220

6 -Position the upper part of tool D25B and press the thrust
blocks into the hub (7) all the way down.

7 D25B

RKTA7230

WH6-1E0 WH7-1E0 30-283

REMOVAL AND INSTALLATION AXLES

7 -Apply a repositionable jointing compound for seals to

the outer surface of the sealing ring (14).

15

RKTA7240

8 -Apply a repositionable jointing compound for seals to

the outer surface of the sealing ring (14).

9 -Position the sealing ring (14) in the hub (7). 14

a Check that the ring (14) is correctly oriented.
7

RKTA7250

10 -Position tool D26 and press the sealing ring (14) into its
seat.
D26

14

RKTA7260

11 -Insert the flange (5) in the crown (13).

13

RKTA5621

30-284 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

12 -Insert the snap ring (12) in order to fix the flange (5) in the
crown (13).

a Carefully check that ring (12) is properly inserted in

the slot of the crown (13). 13
12

RKTA7270

13 -With the help of tool D27, insert the planet wheel gears
(10) into the cover (2).
Accurately check the orientation.
D27

10
RKTA7280

14 -Lock the gears (10) into position by fitting the snap rings
(9).

RKTA5590

15 -Fit the steering case (3) onto the U-joint (19) and install
the articulation pins.
(For details, see "Steering case").
3

RKTA5580

WH6-1E0 WH7-1E0 30-285

REMOVAL AND INSTALLATION AXLES

16 -Connect the steering bars.

(For details, see "Steering cylinder").

RKTA5671

17 -Install the hub (7).

7

RKTA5570

18 -Install the external bearing (8).

a Using a plastic hammer, drive the bearing to the limit

stop by lightly hammering around the edge. 8

RKTA5560

19 -Fit the complete crown flange (5).

a In order to fasten the flange (5), use a plastic

hammer and alternately hammer on several 5
equidistant points.

RKTA7290

30-286 WH6-1E0 WH7-1E0

REMOVAL AND INSTALLATION AXLES

20 -Apply Tecnolube Seal 101 grease to the surface of the

safety flange (6) which touches the crown flange (5).

21 -Fit the safety flange (6). 6

RKTA5530

22 -Apply Loctite 242 to the studs and fit in the nuts (4).

RKTA7300

23 -Cross tighten the nuts (4) in two stages.

3 Initial torque wrench setting: 120 Nm

3 Final torque wrench setting: 255–285 Nm
4

RKTA7360

24 -Fit the planetary carrier cover (2) onto the hub (3).

a Check that the O-ring (20) is in good condition and in 2

position.

RKTA5510

WH6-1E0 WH7-1E0 30-287

REMOVAL AND INSTALLATION AXLES

25 -Lock the planetary carrier cover (2) by tightening the

screws (1). 1
3 Torque wrench setting for screw: 40 -50 Nm

2
RKTA7310

30-288 WH6-1E0 WH7-1E0

© 2008 KOMATSU UTILITY EUROPE S.p.A.
All Rights Reserved
Printed in Europe 04-08