Fiat Kobelco W50/W60/W70 Wheel Loader Technical Handbook Manual - 604.06.995.02

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


APPLICABLE MODELS :

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


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

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

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

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W50 / W60 /W70 Wheel Loader
TECHNICAL HANDBOOK
    FOREWORD
        Using the Technical Handbook
        Servicing and repair
        FUNDAMENTAL SAFETY INSTRUCTIONS
        Warnings and symbols
        Danger in the event of non-observance of the safety instructions
        Organizational measures
        Selection and qualification of personnel
        OPERATING, SAFETY INSTRUCTIONS
        Standard operation
        MAINTENANCE, SAFETY INSTRUCTIONS
        WARNING OF SPECIAL DANGERS
        Electric energy
        Gas, dust, steam and smoke
        Hydraulic and pneumatic equipment
        Noise
        Oil, grease and other chemical substances
        TRANSPORTING AND TOWING - RECOMMISSIONING
        REPAIR WORK - SAFETY INSTRUCTIONS
        ACCUMULATORS
        Safety instructions
        ENGINE
        Engine - repair instructions
        Assisted starting (jump-starting) - Safety instructions
        WELDING OPERATIONS
        Welding operations - safety instructions
    SERVICE DATEN
    Allgemein General
        VORWORT
        FOREWORD
        SI - UND WEITERE GR ¨ OSSEN
        SI - AND ADDITIONAL UNITS
        Raum - und Massegr¨oßen
        Quantities of space and mass
        Zeitgr ¨oßen
        Time-related quantities
        Kraft-, Energie- und Leistungsgr oßen
        Quantities of force, energy and power
        UMRECHNUNGSTABELLEN
        CONVERSIONS TABLES
        Umrechnung von L¨angen-Maßen
        Conversion for units of length
        Umrechnung von Fl ¨achenmaßen
        Conversion for units of area
        Umrechnung von foot (Fuss) und inch (Zoll) in Meter
        Conversion from foot (Fuss) and inch (Zoll) to metric measures
        Umrechnung von Newtonmeter "Nm" in Foot Pounds "ft.lb."
        Conversion from newtonmeter "Nm" into foot pounds "ft.lb."
        Umrechnungstabelle f ¨ ur Druckeinheiten von Gasen, D¨ampfen und Fl ¨ ussigkeiten
        Conversion table for units of pressure in gases, steam and fluids
        Umrechnungstabelle f ¨ ur Einheiten von Energie, Arbeit und W¨armemenge
        Conversion table for units of power, ernergy and heat quantity
        Umrechnungstabelle f ¨ ur Einheiten der mechanischen Spannung (Festigkeit)
        Conversion table for units of mechanical stress (strength)
        Praktisch gleichwertige Einheiten f ¨ ur Druck und mechanische Spannung (Festigkeit)
        Practically equivalent units for pressure and mechanical stress (strength)
        Temperatur - Einheiten und Umrechungsformeln
        Units of temperature and conversion formulas
        Leistung, Energiestrom, W¨armestrom
        Power, energy and heat flow
        Geschwindigkeiten
        Speed
        Masseeinheiten (Gewichte)
        Units of mass (weight)
        Volumeneinheiten, Durchflußmenge
        Units of volume, flow rates
        Kraftstoffverbrauch
        Fuel consumption
        BERECHNUNGSBEISPIELE
        CALCULATION EXAMPLES
        Steigungswinkel
        Angles of slope
        Fahrgeschwindigkeiten
        Travel speeds
        Hydraulische Leistungen (Pumpen/Motoren) 
        Hydraulic outputs (pumps/motors)
        Zylinder-Hubzeiten
        Stroking times of cylinders
        Drehzahlen von Hydraulikmotoren
        Speeds of hydraulic motors
        ANZIEHDREHMOMENTE
        Allgemeine Hinweise
        TIGHTENING TORQUES
        General information
        Schrauben mit Regelgewinde nach DIN 13 - 13
        Bolts with standard thread DIN 13 - 13
        Schrauben mit metrischem Feingewinde DIN 13 - 13
        Bolts with metric fine thread DIN 13 - 13
        Anziehdrehmomente f ¨ ur SAE Flanschsystem
        Tightening torques for SAE flange-system
        Anzugswinkel
        Tightening angles
    SERVICE DATA W50
        Foreword
        Engine
        Axles and transmission gears
        Front axle
        Rear axle with transfer box gearing
        Travel speeds
        Hydraulic system
        Checking and setting data
        Variable pump (PAG = Primary unit)
        Triple hydraulic pump
        Variable motor (SAG = Secondary unit)
        Hydraulic cylinders
        Service fluids
        Tightening torques
        Approx. weights
    SERVICE DATA W60
        Foreword
        Engine
        Axles and transmission gears
        Front axle
        Rear axle with transfer box gearing
        Travel speeds
        Hydraulic system
        Checking and setting data
        Variable pump (PAG = Primary unit)
        Triple hydraulic pump
        Variable motor (SAG = Secondary unit)
        Hydraulic cylinders
        Service fluids
        Tightening torque
        Approx. weights
    SERVICE DATA W70
        Foreword
        Engine
        Axles and transmission gears
        Front axle
        Rear axle with transfer box gearing
        Travel speeds
        Hydraulic system
        Checking and setting data
        Variable pump (PAG = Primary unit)
        Triple hydraulic pump
        Variable motor (SAG = Secondary unit)
        Hydraulic cylinders
        Service fluids
        Tightening torque
        Approx. weights
    04 TRAVEL DRIVE
        Hydraulic System, Safety Instructions 
        Explanations of circuit diagrams and illustrations
        Depressurizing the hydraulic system
        Principle: hydrostatic travel drive
        Hydraulic circuit diagram - travel drive
        Hydraulic circuit diagram, legend
        Pressure measuring points
        Functional description: hydrostatic travel drive of wheel loader W50 / W60 / W70
        Travel drive installation
        Pressure measuring points
        Adjusting work at the hydrostatic travel drive
        Mechanical zero position
        Checking and adjusting high pressure at travelling
        Adjusting cylinder (A13)
        High-pressure relief valve (A4)
        High-pressure relief valve (A4), deblockable
        Pressure cutout (A8)
        Switching valve (A11), electromagnetically activated
        Feed pressure relief valve (A9)
        Checking and adjusting feed pressure
        Control valve (A7)
        Checking and adjusting the regulation threshold (driving start)
        Checking regulation end
        Axial-piston oil motor (A15)
        Checking and adjusting the regulation threshold of the hydraulic motor (displacement switch-over)
        Inching valve (B10)
        Adjusting the inching threshold
        Repair instructions, hydraulic pump
        Repair instructions, hydraulic motor
    Reparaturanleitung
    A4VG
    A6VM
    
    Technical Handbook
    Axles
        Preface
        General
        Design
        Maintenance
        General Working Instructions
        Notes on working safety
        Assembling Procedure
        Weights
        Survey
        Front Axle Components, Screw Qualities, Tightening Torques, Screw Locking
        Front Axle
        Axle Drive Assembly
        Wheel Hub Assembly
        Rear Axle Components, Screw Qualities, Tightening Torques, Screw Locking
        Rear Axle Assembly
        Axle Drive Assembly
        Brake Assembly
        Wheel Hub Assembly
        Front Axle Drawing
        Rear Axle Drawing
        Dismantling and Reassembling the Axles
        Dismantling
        Reassembling
        Dismantling the Front Axle
        Wheel Hub Assembly
        Axle Drive Assembly
        Differential Assembly
        Dismantling the Rear Axle
        Wheel Hub Assembly
        Brake Assembly
        Axle Drive Assembly
        Differential Assembly
        Assembling the Front Axle
        Wheel Hub Assembly
        Differential (Pre-assembling)
        Complete Axle Drive and Axle Assemblies
        Assembling the Rear Axle
        Wheel Hub Assembly
        Brake Assembly (Pre-Assembling)
        Differential Assembly (Pre-Assembling)
        Complete Axle Drive and Axle Assemblies
        GLEASON Toothing Surface Appearances
        GLEASON Toothing Surface Appearances
        List of Special Tools
        Screw Tightening Torques (DIN tables)
        General information
        Screw Tightening Torques
        Bolts with standard thread
        Bolts with metric fine thread DIN 13 - 13
    06 STEERING
        Hydraulic System, Safety Instructions 
        Explanations of circuit diagrams and illustrations
        Depressurizing the hydraulic system
        Hydraulic circuit diagram - steering hydraulics
        Hydraulic circuit diagram, legend
        Pressure measuring points
        Overview of the steering system
        Functional description
        Triple pump (2) of the steering and working hydraulics and the brake system
        Priority valve (L6)
        Steering cylinder (L1) 
        Steering valve (L2)
        Installing the steering system
        Testing and adjusting the steering system
    07 BRAKES
        Safety instructions
        Explanations of circuit diagrams and illustrations
        Braking system, circuit diagram
        Braking system, legend
        Pressure measuring points
        Functional description of the braking system
        Service brake (pump-storage brake)
        Auxiliary brake
        Parking brake
        Accumulator charging valve (B2)
        Testing and adjusting the service brake
        Accumulator charging valve (B2)
        Accumulator (B4), Technical data
        Accumulator (B4)
        Accumulators, safety instructions
        Pedal-type brake valve (B5)
        Connecting valve (B8)
        Inching valve (B10)
        Manometric switches (B6, B7)
        Checking the brake disks
        Testing and adjusting operations on the auxilliary brake
        Testing and adjusting operations on the parking brake
        Bleeding the braking system
        Bleeding
    08 HYDRAULIC SYSTEM
        Hydraulic System, Safety Instructions 
        Explanations of circuit diagrams and illustrations
        Depressurizing the hydraulic system
        Hydraulic circuit diagram - working hydraulics
        Hydraulic circuit diagram, legend
        Pressure measuring points
        Functional description, working hydraulics
        Control block (H6)
        Triple pump (2) of the steering and working hydraulics and the brake system
        Lifting cylinder (H1)
        Dumping cylinder (H2)
        Quick change locking cylinder (H3)
        Hydraulic tank (T1) / Hydraulic filter (T3)
        Hydraulic filter (T3), function
        Hydraulic filter - application
        Hydraulic filter functions
        Hydraulic circuit diagram - cooling
        Hydraulic circuit diagram, legend
        Pressure measuring points
        Functional description of hydraulic system cooling 
        Praktical checking
        Combined cooler (T2)
        Distributor (T5)
        Distributor (T6)
        Testing and adjustment work
        Pressure testing and adjustment
        Practical testing
        Pipe-burst protection (optional)
        Lifting cylinder load-holding valve (optional)
        Dumping cylinder load-holding valve (optional)
    09 ELECTRICAL SYSTEM
    
    Technical Handbook
    Fundamentals of electrical engineering
        Preface
        Important instructions
        Electrical systems in general
        The atom
        Structure of atoms
        Free electron
        Electromagnetic field
        Alternating current diagram
        Power generation
        Power generation in motor vehicles
        Battery charging
        Claw-pole alternator
        Circuit with fault indication on interruption in the exciter circuit
        Testing the charging system
        Main components of automotive electrical systems
        Battery
        Types of batteries
        Maintenance-free starter battery
        Low-maintenance batteries
        Checking the battery
        Density values of diluted sulphuric acid
        Mixing fresh battery acid
        Mixing instructions
        Maintenance
        Troubleshooting
        Function of the alternator
        Alternator
        Type designation
        Alternator
        Claw-pole alternator
        Maintenance
        Electric motors
        Principle of the electric motor
        Starting motor (starter)
        Function of the starter
        Engaging
        Engaged
        Checking the vehicle starter system
        Starter
        Maintenance
        Lubrication
        Fundamentals of automotive electrical systems
        Current, voltage, resistance and power
        Current (I)
        Voltage (U)
        Resistance (R)
        Power (W)
        Measurements with the multimeter
        Adjustment of the multimeter
        Measuring voltage
        Measuring current
        Measuring resistance
        Ohmmeter
        Series and parallel connection of electrical components
        Batteries
        Resistors
        Series connection
        Parallel connection
        Capacitors
        Series connection
        Parallel connection
        Electrolytic capacitors
        Voltage losses and cables
        Table 1 - Admissible loss of voltage
        Remarks:
        Calculation of lines
        Quantities and units
        Computation
        Lines and wires in automotive electrical systems
        Table 2 - Electrical copper wires for motor vehicles
        Design example
        Example:
        Lighting
        Headlamps adjustment hints
        Floodlamps
        Bulbs
        Malfunctions of the lighting system and their causes
        Transition resistance in electrical circuits
        Special circuits in automotive electrical systems
        The diode
        The "free-wheeling" diode
        Electrical circuit with a diode used as a "free-wheeling" diode.
        Varistors
        Voltage rectification in three-phase bridge circuits
        Alternator regulator
        Fuses in motor vehicles
        Designation of individual components
        Standardized designations of terminals
        Terminal designation
        Generator and generator regulator
        Turn-signal indicator (flasher relay)
        Symbols used in electrical engineering
        Symbols for directions of motion
        
    Technical Handbook
    Automotive electrical systems in construction machinery Interpretation of wiring diagrams Troubleshooting
        PREFACE
        NOTES ON SAFETY 
        ELECTRICAL SYSTEM DOCUMENTATION
        THE WIRING DIAGRAM
        Explanation of the wiring diagram
        Current paths
        Main circuits
        Branches
        Relay contacts
        Cross reference to other current paths
        Contacts of plug-in connectors
        Cable cross-section
        Identification of contacts
        Cable number
        Electronic units
        WIRING DIAGRAM LEGEND
        Explanation of legend
        Part
        Quantity
        Description and function
        Current path
        Location
        Part number
        CHECKING AND TESTING EQUIPMENT
        Solenoid-valve tester
        Test lamp
        Multimeter
        Testers
        BASIC MEASURING AND TESTING PROCEDURES
        Voltage checks
        Checking the continuity
        Checking the coil of a solenoid
        PRACTICAL TROUBLESHOOTING
        Notes on troubleshooting in automotive electrical systems
        Example of systematic troubleshooting
        Fault-finding diagram (example)
        ANNEX
        Identification of components
        Schematic symbols
        Electrical Connections
        Switches, contacts
        Indicators, measuring devices
        Motors, alternators
        Semiconductors
        Miscellaneous
        Symbols for directions of motion
        Fuses
        Fuse links
        Fuse strips
    10 FRAME
        Repairing the loader frame
        Exchanging the main pivot parts
        Dismantling
        Mounting
        
    Technical Handbook
    Fittings, pipes and hoses
        INTRODUCTION
        FUNDAMENTAL SAFETY INSTRUCTIONS
        Warnings and symbols
        Organizational measures
        Selection and qualification of personnel 
        OPERATING SAFETY INSTRUCTIONS
        Standard operation
        MAINTENANCE SAFETY INSTRUCTIONS
        WARNING OF SPECIAL DANGERS
        Electric energy
        Gas, dust, steam and smoke
        Hydraulic and pneumatic equipment
        Noise
        Oil, grease and other chemical substances
        TRANSPORTING AND TOWING - RECOMMISSIONING
        WORKING EQUIPMENT 
        Assembling working equipment - safety instructions
        Repair work - safety instructions
        LINES FOR VARIOUS MEDIA
        Materials for pipes and hoses
        Conditions and deviations in the line system
        Steel pipes
        Hoses
        Plastic pipes
        CONNECTIONS
        Pipe couplings
        Sealing pipe couplings
        Bulkhead couplings
        Stud couplings and male nipples
        Stircomatic seal rings
        Swivel couplings
        Swivel couplings
        Swivel coupling with straight male thread acc. to DIN 
        Swivel coupling with long male adaptor
        Fixed angle couplings
        Banjo couplings
        Banjo coupling
        Banjo coupling with long male adaptor
        FLANGE COUPLINGS WITH SAE BOLT PATTERN
        Flanged pipe couplings - Flanit system
        Flanged pipe couplings - Zako system
        Flanged hose couplings
        Sealing and connecting components
        Flanges
        Wedge rings
        Seal rings
        Double-hex bolts
        Assembly aids for wedge rings
        Pre-assembly device for F-rings
        Inserter for Z-rings
        Inserting the Z-ring
        Assembling flange couplings
        Flange coupling - pipe / connection surface, F-system  
        Zako-system
        Flange coupling hose / connection surface
        Flange coupling - pipe / hose
        Flange coupling - hose / hose
        Flange coupling - pipe / pipe
        Appendix
        Table 1: Seal rings for flange couplings
        Table 2: Double - Hex. Bolts
        Accessories
        Pre-assembly aids for pipe flange couplings
        Flanges-90°
        Table 3: Parts Nos. for 90° flanges
        Gauge connections
        Table 4: Parts Nos. for gauge connections and accessories
        
    Technical Handbook
    Sealing, protective, testing and cleaning agents
        INTRODUCTION
        FUNDAMENTAL SAFETY INSTRUCTIONS
        Warnings and symbols
        Safety Instructions
        PRESERVATION OF GEARBOXES
        Rust inhibitor
        Application to gearboxes and axles without oil filling
        Preservation period
        Gearboxes and axles with oil filling
        Protective finishes
        PRESERVATION OF CYLINDER PISTON RODS
        Corrosion inhibitor
        Consumption of inhibitor
        Application of inhibitor
        Removing the inhibitor
        Renewing the inhibitor
        Corrosion protection for pins and bearings (bushings and hubs)
        Part nos. for Voler A.C.
        Application of Voler A.C.
        S0LUTION 1 CORROSION INHIBITOR FOR CYLINDER ROD THREADS 
        RIVOLTA W.S.X, NU CORROSION INHIBITOR FOR ELECTRICAL SYSTEMS
        SURFACE SEALING AGENTS
        WKT black - H
        Loctite 573 (proprietary brand from Loctite Ltd.,)
        HYLOMAR SQ 32/M SEALING AGENT (THREAD SEALER) 
        LIQUID THREAD ADHESIVES
        METAL ADHESIVES
        ADHESIVES FOR PLASTICS
        Acrylic cyanide (Loctite IS 414)
        ADHESIVE FOR O-RINGS
        LUBRICANTS
        Solid lubricating paste
        Solid lubricant paste spray
        Compound spray
        Mineral-based lubricating paste
        Lithium soap grease
        SOLID LUBRICANT FOR MOLYCOTE-COATED BOLTS 
        SILICON-CORUNDUM POWDER (REDURIT)
        P3 COLD CLEANER
        SURFACE CRACK CHECKING AGENT (METAL-CHECK)

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