CK25-1 Webm007000 PDF

WEBM007000
CK25-1
CRAWLER SKID-STEER LOADER
SERIAL NUMBER
CK25-1 F00003 and up
CONTENTS
CONTENTS
Page
10. STRUCTURE AND FUNCTION ....................................................................................... 10-1
20. TESTING AND ADJUSTING ........................................................................................... 20-1
30. REMOVAL AND INSTALLATION ................................................................................... 30-1
40. MAINTENANCE STANDARD .......................................................................................... 40-1
90. OTHER .....................................................................................................................90-1
00-2 CK25-1
REVISED PAGES
REVISED PAGES
The affected pages are indicated by the use of the
following marks. It is requested that necessary actions
be taken to these pages according to table below. Symbol 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

Symbol Page Symbol Page Symbol Page Symbol Page Symbol Page
revision revision revision revision revision
00-1 10-16 10-59 10-102 20-36

00-2 10-17 10-60 10-103 20-37
00-3 10-18 10-61 10-104 20-38
00-4 10-19 10-62 10-105
00-5 10-20 10-63 10-106 30-1
10-21 10-64 10-107 30-2
00-6
10-22 10-65 10-108 30-3
00-7 10-23 10-66 30-4
00-8 10-24 10-67 20-1 30-5
00-9 10-25 10-68 20-2 30-6
00-10 10-26 10-69 20-3 30-7
00-11 10-27 10-70 20-4 30-8
00-12 10-28 10-71 20-5 30-9
00-13 10-29 10-72 20-6 30-10
00-14 10-30 10-73 20-7 30-11
00-15 10-31 10-74 20-8 30-12
10-32 10-75 20-9 30-13
00-16
10-33 10-76 20-10 30-14
00-17 10-34 10-77 20-11 30-15
00-18 10-35 10-78 20-12 30-16
00-19 10-36 10-79 20-13 30-17
00-20 10-37 10-80 20-14 30-18
00-21 10-38 10-81 20-15 30-19
00-22 10-39 10-82 20-16 30-20
00-23 10-40 10-83 20-17 30-21
00-24 10-41 10-84 20-18 30-22
10-42 10-85 20-19 30-23
10-43 10-86 20-20 30-24
10-1 10-44 10-87
10-2 20-21 30-25
10-45 10-88 20-22 30-26
10-3 10-46 10-89
10-4 20-23 30-27
10-47 10-90 20-24 30-28
10-5 10-48 10-91
10-6 20-25 30-29
10-49 10-92 20-26 30-30
10-7 10-50 10-93
10-8 20-27 30-31
10-51 10-94 20-28 30-32
10-9 10-52 10-95
10-10 20-29 30-33
10-53 10-96 20-30 30-34
10-11 10-54 10-97
10-12 20-31 30-35
10-55 10-98 20-32 30-36
10-13 10-56 10-99
10-14 20-33 30-37
10-57 10-100 20-34 30-38
10-15 10-58 10-101 20-35 30-39
CK25-1 00-3
REVISED PAGES
Time of Time of Time of Time of Time of

Symbol Page Symbol Page Symbol Page Symbol Page Symbol Page
revision revision revision revision revision
30-40 40-1
30-41 40-2
30-42 40-3
30-43 40-4
30-44 40-5
30-45 40-6
30-46 40-7
30-47 40-8
30-48 40-9
30-49 40-10
30-50 40-11
30-51 40-12
30-52 40-13
30-53 40-14
30-54 40-15
30-55 40-16
30-56 40-17
30-57 40-18
30-58 40-19
30-59 40-20
30-60 40-21
30-61 40-22
30-62 40-23
30-63 40-24
30-64
40-25
30-65
40-26
30-66
40-27
30-67
30-68 40-28
30-69 40-29
30-70 40-30
30-71
30-72 90-1
30-73 90-2
30-74 90-3
30-75 90-4
30-76 90-5
30-77 90-6
30-78
30-79
30-80
30-81
30-82
30-83
30-84
30-85
30-86
30-87
30-88
30-89
30-90
30-91
30-92
30-93
30-94
30-95
30-96
00-4 CK25-1
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
effective 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. Read all the 7. Before adding or making any repairs, park the
Operation and Maintenance Manual carefully BEFORE machine on hard, level ground, and block the wheels
operating the machine. to 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
on the machine. possible, use blocks to prevent the work equipment
2. When carrying out any operation, always wear safety from falling down. In addition, be sure to lock all the
shoes and helmet. Do not wear loose work clothes, or control levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the
• Always wear safety glasses when hitting parts machine 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. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron, impossible to use the handrails, ladders or steps, use
glasses, cap and other clothes suited for welding a stand to provide safe footing.
work.
PRECAUTIONS DURING WORK
4. When carrying out any operation with two or more
workers, always agree on the operating procedure 11. When removing the oil filler cap, drain plug or
before starting. Always inform your fellow workers hydraulic pressure measuring plugs, loosen them
before starting any step of the operation. Before slowly to prevent the oil from spurting out.
starting work, hang UNDER REPAIR signs on the Before disconnecting or removing components of the
controls in the operator’s compartment. hydraulic circuit and engine cooling circuit, first
remove the pressure completely from the circuit.
5. Keep all tools in good condition and learn the correct
way to use them. 12. The water and oil in the circuits are not hot when the
engine in stopped, so be careful not to get burned.
6. Decide a place in the repair workshop to keep tools
Wait for the oil water to cool before carrying out any
and removed parts. Always keep the tools and parts in
work on the cooling water circuits.
their correct places. Always keep the work area clean
and make sure that there is no dirt or oil on the floor. 13. Before starting work, remove the leads from the
Smoke only in the areas provided for smoking. Never battery. Always remove the lead from the negative ( –
smoke while working. ) terminal first.
CK25-1 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 will not be damaged by contact with other parts
capacity. Install the lifting equipment at the correct when the machine is being operated.
places. Use a hoist or crane and operate slowly to
20. When installing high pressure hoses, make sure
prevent the component from hitting any other part.
that they are not twisted. Damaged tubes are
Do not work with any part still raised by the hoist or
dangerous, so be extremely careful when installing
crane.
tubes for high pressure circuits. Also, check that
15. When removing covers which are under internal connecting parts are correctly tightened.
pressure or under pressure from a spring, always
21. When assembling or installing parts, always use
leave two bolts in position on opposite sides. Slowly
specified tightening torques. When installing the
release the pressure, then slowly loosen the bolts to
parts which vibrate violently or rotate at high speed,
remove.
be particulary careful to check that they are correctly
16. When removing components, be careful not to installed.
break or damage the wiring.
22. When aligning two holes, never insert your fingers or
Damage wiring may cause electrical fires.
hand.
17. When removing piping, stop the fuel or oil from
23. When measuring hydraulic pressure, check that the
spilling out. If any fuel or oil drips on to the floor, wipe
measuring tool is correctly assembled before taking
it up immediately.
any measurement.
Fuel or oil on the floor can cause you to slip, or can
even start fires. 24. Take sure when removing or installing tracks. When
removing the track, the track separates suddenly, so
18. As a general rule, do not use gasoline to wash parts.
never let anyone stand at either end of the track.
In particular, use only the minimum of gasoline when
washing electrical parts.
00-6 CK25-1
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
workshop.
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 ADJUSTMENTS

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.
REMOVAL AND INSTALLATION

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.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your Komatsu Utility distributor for the latest information.
CK25-1 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,
These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.
Symbol Item Remarks
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be Special safety precautionsare
sent to Komatsu Utility distributors. Get the most up-to- necessary whenperforming the
k
date information before you start any work. work.
Safety Extra special safety precautions

FILING METHOD
are necessary when performing
1. See the page number on the bottom of the page. File the work because it is under
the pages in correct order. internal 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 selecting
Weight
Function) hoisting wire, or when working
posture is important, etc.
Consecutive page number for each
3
item Parts that require special attention
Tightening
for the tightening torque during
3. Additional pages: additional pages are indicated by torque
assembly.
a hyphen (–) and number after the page number. Fle
2
as in the example. Parts to be coated with adhesives
Coat
Example: and lubricants etc.
5
10-4 Places where oil, water or fuel
Oil, water
must be added, and their quantity.
10-4-1
Added pages
6
10-4-2 Places where oil or water must be
Drain drained, and quantity to be
10-5
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 CK25-1
HOISTING INSTRUCTIONS
4
HOISTING INSTRUCTIONS
serious accident can result. Hooks have maximum
k Heavy parts (25 kg or more) must be lifted with a

strength at the middle portion.
hoist etc. In the Removal and Installation 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

machine by hoisting, the following checks should be
made:
3) Do not sling a heavy load with one rope alone, but
• Check for removal of all bolts fastening the part to
sling with two or more ropes symmetrically wound
the relative parts.
on to the load.
k Slinging with one rope may cause turning of the load
• Check for any part causing interference with the
part to be removed.
during hoisting, untwisting of the rope, or slipping of
2. Wire ropes the rope from its original winding position on the
load, which can cause dangerous accidents.
1) Use adequate ropes depending on the weight of
parts to be hoisted, referring to the table below:
4) Do not sling a heavy load with ropes forming a wide
WIRE ROPES
hanging angle from the hook.
(Standard «S» or «Z» twist ropes
When hoisting a load with two or more ropes, the
without galvanizing)
force subjected to each rope will increase with the
Rope diameter (mm) Allowable load (tons) hanging angles. The table below shows the
10.0 1.0 variation of allowable load (kg) when hoisting is
made with two ropes, each of which is allowed to
11.2 1.4 sling up to 1000 kg vertically, at various handing
12.5 1.6 angles. When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
14.0 2.2 This weight becomes 1000 kg when two ropes make
16.0 2.8 a 120° hanging angle. On the other hand, two ropes
are subjected to an excessive force as large as 4000
18.0 3.6 kg if they sling a 2000 kg load at a lifting angle of
20.0 4.4 150°.
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
CK25-1 00-9
STANDARD TIGHTENING TORQUE
3
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 CK25-1
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
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
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
CK25-1 00-11
COATING MATERIALS
2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
Function 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 seal
ASL800020
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
Loctite 270 Used for high resistant locking and for sealing threaded parts, bolts and stud 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 only
Loctite 601
after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675
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

Loctite 510
Gasket sealant (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 sticking,
(Lubricant including ASL800040
burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
ASL800050
(Lithium grease) facilitation of assembling work.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
00-12 CK25-1
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 Cross (mm) (A)
Numberstrands Ø of strands(mm)
section(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
CLASSIFICATION BY COLOUR AND CODE

Primary Auxiliary
Code A A-B A/B A-G A-N A/N 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
Colour White White–Yellow White–Black White–Red
Code C C-B C/B C-L C-N C/N
Colour Orange Orange–White Orange–Blue Orange–Black
Code G G-N G/N G/R
Colour Yellow Yellow–Black Yellow–Red
Code H H-G H-L H-N H-R H/R
Colour Grey Grey–Yellow Grey–Blue Grey–Black Grey–Red
Code L L/B L-G L/G L-N L/N L-R L/R
Colour Blue Blue–White Blue–Yellow Blue–Black Blue–Red
Code M M-B M/B 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 S/N
Colour Pink Pink–Yellow Pink–Black
Code V V-B V/B V-N
Colour Green Green–White Green–Black
Code Z 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
CK25-1 00-13
WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model CK25-1
Engine assembly - Muffler - Exhaust pipe 235
Radiator-oil cooler group 32
Hydraulic oil tank (empty) 25
Engine hood 18.5
Cabin (without seat) 215
Seat:
• Standard 10
• with suspension 16
Engine-pump group 330–332
Piston pump:
• Standard 80
• High-Flow 82
Control valve
• 3-spool (standard) 21
• 4-spool (High-Flow) 24
Work equipment (without shovel) 400

• Arm 365
• Work equipment support 57
• Bucket 190
• Tilt cylinder 17
• Dump cylinder 12
• Lifting lever (n. 1) 23
• Lever fulcrum (n. 1) 14
Final drive 65
Drive wheel 19
Lower idler roller (2 lips) 19

Lower idler roller (3 lips) 25
Rubber shoe (320 mm) 167
Front idler wheel (3 lips) 48
Rear idler wheel (1 lip) 32
Track tensioner cylinder 31
00-14 CK25-1
TABLE OF OIL AND COOLANT QUANTITIES
KIND OF AMBIENT TEMPERATURE CAPACITIES (l)

RESERVOIR
FLUID -30 -20 -10 0 10 20 30 40 50°C 1st filling Refill
SAE 10W
SAE 30
OIL
Engine oil pan SAE 40 10.2 10.2
API CD
SAE 10W-30
SAE 5W-30
Hydraulic system SAE 10W

OIL
and hydrostatic 40 27
API CD
transmission SAE 5W-30
Hydraulic circuit
with
40 27
biodegradable oil
OIL SAE 10W-30

Final drive (each) 1.17 1.17
API CD
a
Fuel
DIESEL OIL 50 —
tank
ASTM D975 N. 2
PERMANENT
Engine cooling
LIQUID 15 —
system
(aa)
a ASTM D975 N. 1
aa Special red permanent antifreeze compatible with aluminium radiators. If pure, dilute with water
(50%).
ASTM: American Society of Testing and Materials

SAE: Society of Automotive Engineers
API: American Petroleum Institute
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.
CK25-1 00-15
IMPORTANT:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. In 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
(2) When starting the engine at temperatures below 0ºC, use engine oil SAE 10W, 10W-30, 5W-30, even if during the
day the temperature increases by 10ºC.
(3) Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a
half.
(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic
circuit of equipment and for reductions.
00-16 CK25-1
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
CK25-1 00-17
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 CK25-1
From liter to U.S. Gall.

1 = 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 = 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
CK25-1 00-19
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 CK25-1
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
CK25-1 00-21
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 CK25-1
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
CK25-1 00-23
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 CK25-1
10 STRUCTURE AND FUNCTION
P.T.O. ........................................................................................ 2 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (4/7) ...100

POWER TRAIN ......................................................................... 3 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (5/7) ...101
FRAME ...................................................................................... 4 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (6/7) ...102
TRACK TENSIONER IDLER WHEEL ....................................... 5 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7) ...103
TRACK TENSIONER CYLINDER AND BUMPER SPRING ..... 6 ELECTRICAL DIAGRAM
LOWER IDLER ROLLER .......................................................... 7 (TOP-CABIN LIGHT LINE STANDARD) (1/2) ......................104
REAR IDLER ROLLER.............................................................. 8 ELECTRICAL DIAGRAM
HYDRAULIC CIRCUIT (STANDARD) ....................................... 9 (TOP-CABIN LIGHT LINE STANDARD) (2/2) ......................105
HYDRAULIC CIRCUIT (FLOAT) ............................................. 10 ELECTRICAL DIAGRAM
(TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2) .............106
HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE) ........ 11
ELECTRICAL DIAGRAM
HYDRAULIC CIRCUIT (HIGH-FLOW) .................................... 12
(TOP-CABIN LIGHT LINE HOMOLOGATION) (2/2) .............107
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW) ....................... 13
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN
CHANGE) ................................................................................ 14
HYDRAULIC PUMP ................................................................ 15
CONTROL VALVE (3-SPOOL) ............................................... 33
CONTROL VALVE (4-SPOOL) ............................................... 43
CLSS ....................................................................................... 47
SOLENOID VALVE ................................................................. 55
ACCUMULATOR..................................................................... 58
PATTERN CHANGE VALVE (OPTIONAL) ............................. 59
OPERATION ........................................................................... 61
R.H. PPC VALVE (STANDARD) ............................................. 62
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL) .......... 66
L.H. PPC VALVE (STANDARD) .............................................. 70
L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL) ........... 74
EQUIPMENT CONTROL PPC VALVE.................................... 78
CYLINDERS ............................................................................ 81
ELECTRICAL DIAGRAM (ENGINE LINE) (1/3) ...................... 83
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3) . 86
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3) ... 89
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5) .... 92
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7)..... 97
CK25-1 10-1
STRUCTURE AND FUNCTION P.T.O.
P.T.O.
5
4
1 2
RKS02070
1. Drive plate
2. Flywheel
3 Insert (4 pcs.)
4. Half sleeve
5. Pump
6. Flywheel cover
10-2 CK25-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
8 8
7
4
1
3 A BC 2
8 6 8
RKS05080
1. Endothermic engine 5. High-flow solenoid valve

2. Hydraulic pump 6. L.H. final drive
3. Control valve 7. R.H. final drive
4. Solenoid valve 8. Idler wheel
4a. Speed increment
4b. Servocontrol
4c. Parking brake
CK25-1 10-3
STRUCTURE AND FUNCTION FRAME
FRAME
3
2 4
7 8 6 7 6 5
RKS04100
1. Track tensioner idler wheel 5. Rear idler wheel

2. Track 6. Lower idler roller (3 lips)
3. Final drive 7. Lower idler roller (2 lips)
4. Drive wheel 8. Track tensioner cylinder and bumper spring
10-4 CK25-1
STRUCTURE AND FUNCTION TRACK TENSIONER IDLER WHEEL
TRACK TENSIONER IDLER WHEEL
6 4 3
5
RKS04160
1. Roller
2. Shoulder
3. Bushing
4. Shaft
5. Gasket
6. Snap ring
CK25-1 10-5
STRUCTURE AND FUNCTION TRACK TENSIONER CYLINDER AND BUMPER SPRING
TRACK TENSIONER CYLINDER AND BUMPER SPRING
1 2 B 3 4
B
5
Section A - A
C
A A
6
7
9 8
Detail C
RKS04160
1. Piston 6. Valve
2. Cylinder 7. Grease fitting
3. Pin 8. Sealing ring
4. Spring retainer plate 9. Guard ring
5. Bumper spring
10-6 CK25-1
STRUCTURE AND FUNCTION LOWER IDLER ROLLER
LOWER IDLER ROLLER

2-LIP TYPE
2
6
5 4 3 RKS04180
1. Roller 4. Shaft
2. Shoulder 5. Gasket
3. Bushing 6. Snap ring
3-LIP TYPE
2
6
5 4 3 RKS04190
1. Roller 4. Shaft
2. Shoulder 5. Gasket
3. Bushing 6. Snap ring
CK25-1 10-7
STRUCTURE AND FUNCTION REAR IDLER ROLLER
REAR IDLER ROLLER
3
5 4
RKS04200
1. Roller
2. Shoulder
3. Bushing
4. Shaft
5. Gasket
6. Snap ring
10-8 CK25-1
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (STANDARD)
HYDRAULIC CIRCUIT (STANDARD)

female 1/2" P1 P2 P4 P3
ø16 t=2 ø12.7 l=3700 (13/16-16 ORFS)
LEFT PPC L.H. PPC R.H.
T
SIDE ø16 t=2 ø12.7 l=3700 (13/16-16 ORFS)
ARM P
male 1/2" 100
P1 P2 100
P3 P4
ø6.5 l=400 (1/2-20 JIC) MESH MESH
ARM CYL. L.H. Pout1 Pout3 Pout2 Pout4
ø9.5 l=1100 (13/16-16 ORFS) ø10 l=520 ø10 l=520

ø10 l=520 ø10 l=520 (9/16-18 JIC) (9/16-18 JIC)
ø9.5 l=1750 (13/16-16 ORFS) A3 (9/16-18 JIC) (9/16-18 JIC)
ø6.5 l=600 (9/16-18 JIC)
ø6.5 l=680 (9/16-18 JIC)
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
B3
Pb3 ø6.5 l=400 (1/2-20 JIC)
ARM CYL. R.H. Pa3
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ø9.5 l=1100 (13/16-16 ORFS)
A2
ø9.5 l=1750 (13/16-16 ORFS)
Pb2 B2
Pa2 ø6.4 l=1500 (1/2-20 JIC)
BUCKET CYL. L.H. ø10 l=1050 ø10 l=1050

(9/16-18 JIC) (9/16-18 JIC)
ø9.5 l=530 (13/16-16 ORFS) Pb1 A1
B1
ø9.5 l=530 (13/16-16 ORFS) ø6.4 l=1500 (1/2-20 JIC)
Pa1 ø6.4 l=950 (1/2-20 JIC)
ø6.4 l=950 (1/2-20 JIC)

BUCKET CYL. R.H.
ø9.5 l=530 (13/16-16 ORFS)
ø9.5 l=530 (13/16-16 ORFS)
P 206 bar
ø0.5 Ts
T
ø6.4 l=650 (1/2-20 JIC)

ø6.4 l=950 (1/2-20 JIC)
ø6.4 l=850 (1/2-20 JIC)
ø6.4 l=650 (1/2-20 JIC)

R/G
ø12.7 l=1950 (13/16-16 ORFS)
ø12.7 l=1950 (13/16-16 ORFS)

Dr
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
Ps
TRAVEL MOTOR R.H. ø19.1 l=1100 (1"3/16-12 ORFS)
ø6.5 l=1300 (9/16-18 JIC)
P2 P1 Pp (brake) ø6.5 l=1300 (9/16-18 JIC)
B A A
ø1,4
steel pipe ø25 t=3 L=855 ø15.9 l=1000 (1"13/16-12 ORFS) ø1,4
Db1 B A B A
A B C
steel pipe ø25 t=3 L=910 ø15.9 l=1000 (1"13/16-12 ORFS) ø1,4 ø1,4
Da1
B
Pa1
Db2 Da2 Pa2 P4 SV1 SV2 SV3
P
steel pipe ø25 t=3 L=870

T SPEED PPC BRAKE
ø15.9 l=1000 (1"13/16-12 ORFS)
steel pipe ø25 t=3 L=903 ø15.9 l=1000 (1"13/16-12 ORFS)
ø7.9
E
ø9.5 l=1000 (9/16-18 JIC)

P2 P1 Pp (brake)
ø6.4 l=1550
(9/16-18 JIC) Pb1 T5 Pb2 S3 S4
E2
Ps
ø19.1 l=945
ø6.5 l=1700 (9/16-18JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1700 (9/16-18JIC)
ø24.6~26.2 l=1000
TRAVEL MOTOR L.H.
R/G
ø9.5 l=1150 (9/16-18 JIC)
RKS04011
ø9.5 l=2380 (9/16-18 JIC)
ø19 l=1500 ø16 ø19 l=1600
ø9.5 l=2380 (9/16-18 JIC) t2 (1"5/16-12 JIC) ø25.4 l=500 ø25.4 l=620
(1"1/16-12 JIC) (1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=1100
(1"1/16-12 JIC) ø25
CK25-1 10-9
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (FLOAT)
HYDRAULIC CIRCUIT (FLOAT)

female 1/2" P1 P2 P4 P3
ø16 t=2 ø12.7 l=3700 (13/16-16 ORFS)
LEFT PPC L.H. PPC R.H.
T
SIDE ø16 t=2 ø12.7 l=3700 (13/16-16 ORFS)
ARM P
male 1/2" 100
P1 P2 100
P3 P4
ø6.5 l=400 (1/2-20 JIC) MESH MESH
ø9.5 l=1100 (13/16-16 ORFS) ø10 l=520 ø10 l=520

ø10 l=520 ø10 l=520 (9/16-18 JIC) (9/16-18 JIC)
P (9/16-18 JIC)
A3 (9/16-18 JIC)
ø6.5 l=600 (9/16-18 JIC)
ø6.5 l=680 (9/16-18 JIC)

ø9.5 l=1750 (13/16-16 ORFS)
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
B3
ø6.5 l=400 (1/2-20 JIC)
ARM CYL. R.H. Pa3
Pb3
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ø9.5 l=1100 (13/16-16 ORFS)
A2
ø9.5 l=1750 (13/16-16 ORFS)
Pb2 B2
Pa2 ø6.4 l=1500 (1/2-20 JIC)

(9/16-18 JIC) (9/16-18 JIC)
ø9.5 l=530 (13/16-16 ORFS) Pb1 A1
B1
ø9.5 l=530 (13/16-16 ORFS) ø6.4 l=1500 (1/2-20 JIC)
BUCKET CYL. R.H.
ø6.4 l=950 (1/2-20 JIC)
ø6.4 l=950 (1/2-20 JIC)

ø9.5 l=530 (13/16-16 ORFS)
ø9.5 l=530 (13/16-16 ORFS) Pa1
P 206 bar
ø0.5 Ts
ø6.4 l=650 (1/2-20 JIC)

ø6.4 l=950 (1/2-20 JIC)
T
ø6.4 l=850 (1/2-20 JIC)
ø6.4 l=650 (1/2-20 JIC)

R/G
ø12.7 l=1950 (13/16-16 ORFS)
ø12.7 l=1950 (13/16-16 ORFS)

Dr
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
Ps
ø6.5 l=1300 (9/16-18 JIC)
P2 P1 Pp (brake) ø6.5 l=1300 (9/16-18 JIC)
B A A
ø1,4
Db1 B A B A
A B C
Da1
B
Pa1
Db2 Da2 Pa2 P4 SV2 SV3
P SV1

T SPEED PPC BRAKE
ø15.9 l=1000 (1"13/16-12 ORFS)
ø7.9
E
ø9.5 l=1000 (9/16-18 JIC)

P2 P1 Pp (brake)
ø6.4 l=1550
(9/16-18 JIC) Pb1 T5 Pb2 S3 S4
E2
Ps
ø19.1 l=945
ø6.5 l=1700 (9/16-18JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1700 (9/16-18JIC)
ø24.6~26.2 l=1000
TRAVEL MOTOR L.H.
R/G
ø9.5 l=1150 (9/16-18 JIC)
RKS04021
ø9.5 l=2380 (9/16-18 JIC)
ø19 l=1500 ø16 ø19 l=1600
ø9.5 l=2380 (9/16-18 JIC) t2 (1"5/16-12 JIC) ø25.4 l=500 ø25.4 l=620
(1"1/16-12 JIC) (1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=1100
(1"1/16-12 JIC) ø25
10-10 CK25-1
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE)
HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE)
female 1/2" PPC L.H. PPC R.H.

ø16 t=2 ø12.7 l=3700 (13/16-16 ORFS) T
LEFT
SIDE ø12.7 l=3700 (13/16-16 ORFS)
P
ø16 t=2
ARM P1 P2 P3 P4
100
P1 P2 P3 P4 100
male 1/2" MESH MESH
ø6.5 l=400 (1/2-20 JIC)

ARM CYL. L.H.
ø10 l=520 (9/16-18 JIC)
ø10 l=520 (9/16-18 JIC)

ø10 l=520 (9/16-18 JIC)
ø10 l=520 (9/16-18 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)

ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)

ø9.5 l=1100 (13/16-16 ORFS)
ø6.5 l=600 (9/16-18 JIC)
ø6.5 l=680 (9/16-18 JIC)

P
ø9.5 l=1750 (13/16-16 ORFS) A3
B3
ø6.5 l=400 (1/2-20 JIC)
ARM CYL. R.H. Pb3 Pa3
ø9.5 l=1100 (13/16-16 ORFS)
A2
ø9.5 l=1750 (13/16-16 ORFS)
Pb2 B2
Pa2
ø6.4 l=1500 (1/2-20 JIC)

BUCKET CYL. L.H.
ø6.4 l=950 (1/2-20 JIC)
ø9.5 l=530 (13/16-16 ORFS) Pb1 A1

B1
ø9.5 l=530 (13/16-16 ORFS)
BUCKET CYL. R.H.
ø9.5 l=530 (13/16-16 ORFS)
ø9.5 l=530 (13/16-16 ORFS) Pa1
206 bar
P
ø0.5 Ts
OUTPUT ISO PATTERN (KOMATSU) INPUT
HYDRAULIC CIRCUIT DIAGRAM T
ø6.4 l=650 (1/2-20 JIC) P4 OUT P4 IN
ø6.4 l=850 (1/2-20 JIC) P3 OUT P2 IN
ø6.4 l=650 (1/2-20 JIC) P2 OUT P1 IN
ø6.4 l=950 (1/2-20 JIC) P1 OUT P3 IN
ø6.4 l=1500 (1/2-20 JIC) P5 OUT P5 IN
R/G
ø12.7 l=1950 (13/16-16 ORFS)

ø6.4 l=950 (1/2-20 JIC) P6 OUT P6 IN
ø12.7 l=1950 (13/16-16 ORFS)
Dr ø12.7 l=3850 (13/16-16 ORFS)
ø16 t=2
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS) P4 OUT P4 IN

P3 OUT P2 IN
Ps
P2 OUT P1 IN
ø10 l=1050 (9/16-18 JIC)

P1 OUT P3 IN
ø6.5 l=1300 (9/16-18 JIC)
P5 OUT P5 IN
P2 P1 Pp (brake) ø6.5 l=1300 (9/16-18 JIC)
P6 OUT P6 IN
A OPTION PATTERN (CASE)

B A
ø1,4
B A B A
Db1
Da1
B
Pa1
Db2 Da2 Pa2 P4
ø10 l=1050 (9/16-18 JIC)

ø7.9
E
A B C
P2 P1 Pp (brake)
ø9.5 l=1000
ø6.4 l=1550 (9/16-18 JIC)
Pb1 T5 S4 P SV1 SV2 SV3
(9/16-18 JIC) PB2 S3
E2
T SPEED PPC BRAKE
Ps
ø19.1 l=945
(1"1/16-12 JIC) ø6.5 l=1700 (9/16-18 JIC)
Dr ø6.5 l=1700 (9/16-18 JIC)
TRAVEL MOTOR L.H. ø24.6~26.2 l=1000

R/G
ø9.5 l=1150 (9/16-18 JIC)
ø9.5 l=2380 (9/16-18 JIC)

ø19 l=1500 ø16 ø19 l=1600
ø9.5 l=2380 (9/16-18 JIC) (1"1/16-12 JIC) t2 (1"5/16-12 JIC) ø25.4 l=500 ø25.4 l=620
(1"5/16-12 JIC) (1"5/16-12 JIC)
RKS04051
ø19.1 l=1100
(1"1/16-12 JIC) ø25
CK25-1 10-11
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (HIGH-FLOW)
HYDRAULIC CIRCUIT (HIGH-FLOW)

male 3/4
ø20 t=2 ø16 l=3750 (1"14 ORFS) ø4.7 l=450 (1/2-20 JIC)
PPC L.H. PPC R.H.
LEFT female 3/4
S ø6.5 l=670 (9/16-18 JIC)
SIDE ø20 t=2 ø16 l=3750 (1"14 ORFS)
P1 P2 P4 P3
ARM T
female 1/2
T
ø16 t=2 ø12.7 l=2650 (1"1/16-12 JIC - 13/16-16 ORFS)
P1 P2
P
100 100
P1 P2 P3 P4
P2 MESH MESH
ø4.7 l=450 (1/2-20 JIC)
Pi2 ø4.7 l=570
ø9.5 l=1000 (13/16-16 ORFS) (1/2-20 JIC) ø10 l=520 ø10 l=520
ø10 l=520 ø10 l=520 (9/16-18 JIC) (9/16-18 JIC)
ø9.5 l=1750 (13/16-16 ORFS) A3 (9/16-18 JIC) (9/16-18 JIC)
ø6.5 l=600 (9/16-18 JIC)
ø6.5 l=680 (9/16-18 JIC)

ø6.5 l=400 (1/2-20 JIC)
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
B3
ø6.5 l=400 (1/2-20 JIC)
ARM CYL. R.H. Pb3 Pa3
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ø9.5 l=1000 (13/16-16 ORFS)
A2
ø9.5 l=1750 (13/16-16 ORFS)
Pb2 B2
ø6.4 l=1500 (1/2-20JIC)
Pa2

(9/16-18 JIC) (9/16-18 JIC)
ø9.5 l=530 (13/16-16 ORFS) Pb1 A1
B1
ø9.5 l=530 (13/16-16 ORFS) ø6.4 l=1500 (1/2-20 JIC)
BUCKET CYL. R.H.
ø6.4 l=950 (1/2-20 JIC)
ø6.4 l=950 (1/2-20 JIC)

ø9.5 l=530 (13/16-16 ORFS)
ø9.5 l=530 (13/16-16 ORFS) Pa1
P (206 bar)
ø0.5
Ts
T
ø6.4 l=650 (1/2-20 JIC)

ø6.4 l=950 (1/2-20 JIC)
ø6.4 l=850 (1/2-20 JIC)
ø6.4 l=650 (1/2-20 JIC)

TRAVEL MOTOR R.H.
ø12.7 l=1950 (13/16-16 ORFS)
R/G
ø12.7 l=1950 (13/16-16 ORFS)
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)

Dr ø12.7 l=3850 (13/16-16 ORFS)
ø16 t=2
Ps
ø19.1 l=1100 (1"3/16-12 ORFS)
ø12.7 l=1350 (1"-14 ORFS)
ø6.5 l=1300 (9/16-18 JIC)
P2 P1 Pp (brake) ø6.5 l=1300 (9/16-18 JIC)
B A A
ø1,4
B A B A
Db1 A B C
Da1
B
Pa1
Db2 Da2 Pa2 P4 P5 SV1 SV2 SV3
P

T SPEED PPC BRAKE
ø7.9
E
ø9.5 l=1000 (9/16-18 JIC)

P2 P1 Pp (brake)
ø6.4 l=1550
(9/16-18 JIC) Pb1 T5 Pb2 S3 S4
E2
Ps
ø19.1 l=945
(1"1/16-12 JIC) ø6.5 l=1700 (9/16-18JIC)
Dr ø6.5 l=1700 (9/16-18JIC)
ø24.6~26.2 l=1000
R/G
ø9.5 l=1150 (9/16-18 JIC)
TRAVEL MOTOR L.H. ø19 l=1500 ø16 ø19 l=1600 RKS04031

(1"1/16-12 JIC) t2 (1"5/16-12 JIC)
ø25.4 l=500 ø25.4 l=620
(1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=1100
(1"1/16-12 JIC)
ø9.5 l=2380 (9/16-18 JIC)

ø25
ø9.5 l=2380 (9/16-18 JIC)
10-12 CK25-1
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (SUPER HIGH-FLOW)
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW)
female 1/2
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
RIGHT
SIDE male 1/2
ARM ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)

P1 P2 P4 P3
P2 PPC L.H. PPC R.H.
T
male 3/4
ø20 t=2 ø16 l=3750 (1"14 ORFS) P
100 100
LEFT MESH
P1 P2 P3 P4
female 3/4 MESH
ø0.5
SIDE ø20 t=2 ø16 l=3750 (1"14 ORFS)
A4 Pout1 Pout3 Pout2 Pout4
ARM
female 1/2 B4
ø10 l=520 (9/16-18 JIC)
ø10 l=520 (9/16-18 JIC)
ø6.4 l=950 (9/16-18 JIC)

ø12.7 l=2650 (1"1/16-12 JIC - 13/16-16 ORFS) ø10 l=520 ø10 l=520
ø16 t=2
Pi (9/16-18 JIC) (9/16-18 JIC)
ø6.5 l=600 (9/16-18 JIC)
ø6.5 l=680 (9/16-18 JIC)
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
A3
ARM CYL. L.H.
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
(1/2-20 JIC)
ø6.4 l=435
ø6.5 l=400 (1/2-20 JIC)
B3
ø6.5 l=400 (1/2-20 JIC)
ø9.5 l=1000 (13/16-16 ORFS)
Pb3
ø9.5 l=1750 (13/16-16 ORFS)
A2
ARM CYL. R.H. Pb2 B2
ø6.4 l=1500 (1/2-20 JIC) ø10 l=1050 ø10 l=1050
ø9.5 l=1000 (13/16-16 ORFS) (9/16-18 JIC) (9/16-18 JIC)
Pa2
ø9.5 l=1750 (13/16-16 ORFS)

ø6.4 l=1500 (1/2-20 JIC)
Pb1 A1
BUCKET CYL. L.H. B1
ø9.5 l=530 (13/16-16 ORFS)
ø9.5 l=530 (13/16-16 ORFS)
ø6.4 l=950 (1/2-20 JIC)
ø6.4 l=950 (1/2-20 JIC)

BUCKET CYL. R.H.
ø9.5 l=530 (13/16-16 ORFS) Pa1
ø6.4 l=650 (1/2-20 JIC)

ø6.4 l=950 (1/2-20 JIC)
ø6.4 l=850 (1/2-20 JIC)
ø6.4 l=650 (1/2-20 JIC)

ø9.5 l=530 (13/16-16 ORFS)
P 206 bar
ø0.5 Ts
T
TRAVEL MOTOR R.H.

R/G
ø12.7 l=1950 (13/16-16 ORFS)
Dr ø12.7 l=1950 (13/16-16 ORFS)
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)

Ps
ø19.1 l=1100 (1"3/16-12 ORFS)
ø12.7 l=1350 (1"-14 ORFS)
ø6.5 l=1300 (9/16-18 JIC)
P2 P1 Pp (brake) ø6.5 l=1300 (9/16-18 JIC)
B A A
ø1,4
B A B A
Db1 A B C
Da1
B
Pa1
Sb2 Db2 Da2 Pa2 P4 P5
P SV1 SV2 SV3

T SPEED PPC BRAKE
ø15.9 l=1000 (1"13/16-12 ORFS)
ø7.9
E
ø9.5 l=1000 (9/16-18 JIC)

P2 P1 Pp (brake)
ø6.4 l=1550
(9/16-18 JIC) Pb1 T5 Pb2 S3 S4
E2
Ps
ø19.1 l=945
(1"1/16-12 JIC) ø6.5 l=1700 (9/16-18JIC)
Dr ø6.5 l=1700 (9/16-18JIC)
ø24.6~26.2 l=1000
R/G
ø9.5 l=1150 (9/16-18 JIC)
TRAVEL MOTOR L.H. ø19 l=1500 ø16 ø19 l=1600

(1"1/16-12 JIC) t2 (1"5/16-12 JIC)
ø25.4 l=500 ø25.4 l=620 RKS04041
(1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=1100
(1"1/16-12 JIC)
ø9.5 l=2380 (9/16-18 JIC)

ø25
ø9.5 l=2380 (9/16-18 JIC)
CK25-1 10-13
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN CHANGE)
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN CHANGE)

female 1/2
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
RIGHT
SIDE male 1/2
ARM ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
P2 PPC L.H. PPC R.H.

T
male 3/4
ø20 t=2 ø16 l=3750 (1"14 ORFS) P
100 100
LEFT P1 P2 P3 P4 MESH P1 P2 P3 P4 MESH
female 3/4 ø0.5
SIDE ø20 t=2 ø16 l=3750 (1"14 ORFS)
A4
ARM
female 1/2 B4
ø10 l=520 (9/16-18 JIC)
ø10 l=520 (9/16-18 JIC)
ø6.4 l=950 (9/16-18 JIC)

ø12.7 l=2650 (1"1/16-12 JIC - 13/16-16 ORFS)
ø10 l=520 (9/16-18 JIC)
ø10 l=520 (9/16-18 JIC)

ø16 t=2
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)

ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)
ø6.4 l=435 (1/2-20 JIC)

Pi
ø6.4 l=435 (1/2-20 JIC)

ø6.5 l=600 (9/16-18 JIC)
ø6.5 l=680 (9/16-18 JIC)

A3
ARM CYL. L.H. ø6.5 l=400 (1/2-20 JIC)
B3
ø6.5 l=400 (1/2-20 JIC)
ø9.5 l=1000 (13/16-16 ORFS)
Pb3
ø9.5 l=1750 (13/16-16 ORFS)
A2
ARM CYL. R.H. Pb2 B2
ø6.4 l=1500 (1/2-20 JIC)
ø9.5 l=1000 (13/16-16 ORFS) Pa2
ø6.4 l=950 (1/2-20 JIC)
ø9.5 l=1750 (13/16-16 ORFS)
Pb1 A1
BUCKET CYL. L.H.
B1
ø9.5 l=530 (13/16-16 ORFS)
ø9.5 l=530 (13/16-16 ORFS)
BUCKET CYL. R.H.
ø9.5 l=530 (13/16-16 ORFS)

Pa1
ø9.5 l=530 (13/16-16 ORFS) OUTPUT ISO PATTERN (KOMATSU) INPUT

P 206 bar
ø0.5 Ts ø6.4 l=650 (1/2-20 JIC) P4 OUT P4 IN
T P2 IN
ø6.4 l=850 (1/2-20 JIC) P3 OUT
ø6.4 l=650 (1/2-20 JIC) P2 OUT P1 IN
TRAVEL MOTOR R.H.
ø6.4 l=950 (1/2-20 JIC) P1 OUT P3 IN
ø6.4 l=1500 (1/2-20 JIC) P5 OUT P5 IN
R/G
ø12.7 l=1950 (13/16-16 ORFS) ø6.4 l=950 (1/2-20 JIC) P6 OUT P6 IN

Dr ø12.7 l=1950 (13/16-16 ORFS)
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)

P4 OUT P4 IN
ø16 t=2 ø12.7 l=3850 (13/16-16 ORFS)
P3 OUT P2 IN
Ps
ø19.1 l=1100 (1"3/16-12 ORFS)
P2 OUT P1 IN
ø10 l=1050 (9/16-18 JIC)

ø12.7 l=1350 (1"-14 ORFS)
P1 OUT P3 IN
ø6.5 l=1300 (9/16-18 JIC)
P5 OUT P5 IN
P2 P1 Pp (brake) ø6.5 l=1300 (9/16-18 JIC)
P6 OUT P6 IN
A OPTION PATTERN (CASE)

B A
ø1,4
B A B A
Db1 ø1,4
Da1 B
Pa1
Db2 Da2 Pa2 P4 P5
ø10 l=1050 (9/16-18 JIC)

ø7.9
E
A B C
P2 P1 Pp (brake)
ø6.4 l=1550
P SV1 SV2 SV3
(9/16-18 JIC) Pb1 E2 T5 PB2 S3 S4
T SPEED PPC BRAKE

Ps
ø19.1 l=945
ø9.5 l=1000 (9/16-18JIC) ø6.5 l=1700 (9/16-18 JIC)
(1"1/16-12 JIC)
Dr ø6.5 l=1700 (9/16-18 JIC)
ø24.6~26.2 l=1000
R/G
ø9.5 l=1150 (9/16-18 JIC)
TRAVEL MOTOR L.H. ø19 l=1500 ø16 ø19 l=1600

(1"1/16-12 JIC) t2 (1"5/16-12 JIC)
ø25.4 l=500 ø25.4 l=620 RKS04061
(1"5/16-12 JIC) (1"5/16-12 JIC)
ø19.1 l=1100
(1"1/16-12 JIC)
ø9.5 l=2380 (9/16-18 JIC)

ø25
ø9.5 l=2380 (9/16-18 JIC)
10-14 CK25-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
HST PUMP LPV40 +45 (STANDARD FLOW)
10 1 8 7 2 8 7 5
6
JAPAN
Komatsu.Ltd.
11 12 3 11
8 9 9 8 RKS04520
1. Piston pump STRUCTURE

2. Control piston This pump is composed of variable swash plate type
3. Suction safety valve tandem piston pumps (1), control pistons (2), suction
safety valves (3), charge safety valve (4), charge pump (5),
4. Charge safety valve
work equipment gear pumps (6), and adjustment screws
5. Charge pump (7), (8), (9), AS valve (10), shuttle valve (11) and
6. Work equipment pump synchronization valve (12).
7. Adjustment screw (Neutral position)
8. Adjustment screw (Max. displacement)
9. Adjustment screw (Pump power control)
10. AS valve
11. Shuttle valve
12. Synchronization valve
CK25-1 10-15
HST PUMP LPV40 +45 (HIGH FLOW)
10 1 8 7 2 8 7 5
6
JAPAN
Komatsu.Ltd.
11 12 3 11
8 9 9 8 RKS04510
1. Piston pump STRUCTURE

2. Control piston This pump is composed of variable swash plate type
3. Suction safety valve tandem piston pumps (1), control pistons (2), suction
safety valves (3), charge safety valve (4), charge pump
(5), work equipment gear pumps (6), and adjustment
5. Charge pump screws (7), (8), (9), AS valve (10), shuttle valve (11) and
6. Work equipment pump synchronization valve (12).
7. Adjustment screw (Neutral position)
8. Adjustment screw (Max. displacement)
9. Adjustment screw (Pump power control)
10. AS valve
11. Shuttle valve
10-16 CK25-1
HST PUMP LPV45 +45 (STANDARD FLOW AND HIGH FLOW)

FUNCTION
• The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurised oil is
discharged according to the load.
• It is possible to change the discharge amount by changing the swash plate angle (plus, zero and minus)
4 2 5 6 14
3
15 (Standard version)
11
A 7 12 8 9 10 13 15 (High-flow version)
RKS04530
1. Shaft 6. Slider 11. Main bearing

2. Case 7. Shoe 12. Spline
3. Cradle bearing 8. Piston 13. Sub bearing
4. Rocker cam 9. Cylinder block 14. Charge pump
5. Control piston 10. Valve plate 15. Work equipment pump
STRUCTURE • Piston (8) carries out relative movement in the axial

• Cylinder block (9) is supported to shaft (1) by a spline direction inside each cylinder chamber of cylinder
(12), and shaft (1) is supported by the front and rear block (9).
bearings (11), (13). • The cylinder block seals the pressurised oil to valve
• The tip of piston (8) is a concave ball, and shoe (7) is plate (10) and carries out relative rotation.
caulked to it to form one unit. Piston (8) and shoe (7) This surface is designed so that the oil pressure
form a spherical bearing. balance is maintained at a suitable level.
• Rocker cam (4) has flat surface A, and shoe (7) is The oil inside each cylinder chamber of cylinder block
always pressed against this surface while sliding in a (9) is sucked in and discharged through valve plate
circular movement. There is a cradle bearing (3) (10).
between cradle and rocker cam (4) which is secured
to the case.Rocker cam (4) sways on cradle bearing.
CK25-1 10-17
OPERATION
1. Operation of pump
• Cylinder block (9) rotates together with shaft (1),
and shoe (7) slides on flat surface "A".
When this happens, rocker cam (4) moves along
cylindrical surface “B”, so angle “α” between the
centre line of shaft (1) and centre line X of rocker
cam (4) changes, thereby varying the axial direction
of pistons in relation to the cylinder block.
Angle “k”is called "swash plate angle".
i) Central line X of rocker cam (4) maintains
swash plate angle “k” in relation to the axial 4 7 8 9 E PA PB
direction of cylinder block (9), and flat surface
“A” moves as a cam in relation to shoe (7).
In this way, piston (8) slides on the inside of X
cylinder block (9), so a difference between k PA
volumes E and F is created inside cylinder
block (9). The suction and delivery is carried
out by this difference F – E . PB
In other words, when cylinder block (7) rotates
and the volume of chamber F becomes 1 RKS00271
smaller, the oil is discharged during that stroke. B A F

On the other hand, the volume of chamber E Fig. 1
becomes larger, and as the volume becomes
bigger, the oil is sucked in (Fig. 1).
ii) If centre lineX of rocker cam (4) is in line with
the axial direction of cylinder block (9) (swash 9 E'
4 PA PB
plate angle “k”= 0), the difference between
volumes E' and F' inside cylinder block (9)
becomes 0, so the pump does not carry out any 0
suction or delivery of oil (Fig. 2).
iii) Central line X of rocker cam (4) maintains
swash plate angle “k”in relation to the axial
direction of cylinder block (9), and flat surface
“A” moves as a cam in relation to shoe (7). RKS00220
In this way, piston (8) slides on the inside of Fig. 2 F'

cylinder block (9), so a difference between
volumes E’’ and F’’ is created inside cylinder
block (9).
The suction and delivery is carried out by this E" PA PB
7 8 9
difference E’’–F’’. 4
In other words, when cylinder block (9) rotates
and the volume of chamber E becomes
smaller, the oil is discharged during that stroke. PA
On the other hand, the volume of chamber F
becomes larger, and as the volume becomes
bigger, the oil is sucked in. k PB
If the direction of swash plate angle is changed, X
the relation between discharge and suction of
ports PA and PBreverses (Fig. 3). Fig. 3 F" RKS00101
10-18 CK25-1
2. Control of discharge amount

• If swash plate angle “k” becomes larger, the difference between volumes E and F becomes larger and discharge
amount Q increases. Swash plate angle is changed by control piston (5).
• Control piston (5) moves in a reciprocal movement according to the signal pressure from pilot line (PPC and AS
valves).
This straight line movement is transmitted through slider (6) to rocker cam (4), which is supported by the cylindrical
surface to cradle, slides in a rotating movement in direction.
• On this pump, maximum swash plate angle is ±17.7°.
5
6
4
4
RKS00280
RKS00360
• Screw A restricts to the maximum stroke of control piston (i.e. maximum displacement of each pump). When screw
A is tightened, maximum displacement decreases, and when screw A is loosened, maximum displacement
increase. This screw should be adjusted when the machine doesn’t travel straight or machine maximum speed is
little bit wrong.
• Screw B is the fine adjuster of neutral position of control piston (5). That adjust prevent machine from creep.
A 5
A
6
RKS04500
Function of the control piston (on non-induction of pilot signal)
CK25-1 10-19
• There are no pressure, so control piston (5) doesn’t move and main pump is on neutral condition.
PPA =0 5 PPB=0
RKS04540
Function of the control piston (on induction of pilot signal)
PPA > 5 PPB
RKS04550
• When pressurised oil which has the pressure PPA>PPB is led from pilot line (PPC or AS valve), control piston (5)
moves to the right (o).
Control piston (5) moves the balanced position by spring force and pressure PPA.
• If the relation of pressure dimension of PPA, PPB is reversed, control piston moves to the left (i).
• The lowest between AS valve output pressure and PPC output pressure is selected by shuttle valve and sent to
control piston (5). (For details, see "SHUTTLE VALVE").
10-20 CK25-1
SUCTION SAFETY VALVE (HST Circuit)
RKS00110
3
1
1. Charge pump
2. Charge safety valve 3A 3B 3C 3D 3E 3F
3. Suction safety valve
3A. Valve
3B. Rod
3C. Sleeve
3D. Spring
3E. Spring
3F. Plug
4. Piston pump
5. Travel motor RKS00090
FUNCTION
There are two suction safety valves installed to each HST pump, and they have the following functions:
1) High pressure safety valve

The valve restricts the maximum pressure inside the HST circuit in order to protect the HST circuit.
2) Suction safety valve

The valve ensures the flow of the charge oil to the closed HST circuit and prevents the charge oil from flowing into
the pump high pressure side (delivery side).
CK25-1 10-21
Actuation when acting as high pressure relief valve (Valve at piston pump delivery side)
• Port A is connected to the piston pump circuit and port B is connected to the charge circuit. The pressurised oil fills
port C through drill hole a of piston (3A). The pressurised oil at high pressure port A fills port D through groove b
between body and valve.
Poppet (3A) is in tight contact with valve seat (3C).
B 3A 3B 3C 3D 3E
a A b C D RKS00050
• If abnormal pressure is generated in the circuit and the oil pressure at ports A and D reaches the pressure set by
spring (3D), poppet (3A) is pushed to (o) direction, and oil at port A is relieved to port B to reduce the oil pressure
at port A.
B 3A
a A b 3D D
RKS00060
10-22 CK25-1
Operation when acting as suction safety valve
1. When HST pump delivery is 0.

The HST circuit is closed, and the charge oil does not flow into the HST circuit.
Therefore the charge pressurised oil from the charge pump (1) all passes the charge safety valve (2) and is drained
to the pump case.
Travel motor
Pump
PB PA
RKS00120
3
1
CK25-1 10-23
2. When HST pump discharges from port PA.

1) Valve at the piston pump delivery side.
When the pressure oil is discharged from port PA of the HST pump (4), port PA becomes the high pressure
side.
This pressure oil at port PA flows into port D through the groove b.
When this happen, sleeve (3C) is pushed to left direction (i), because of the difference in area (A1>A2).
Therefore the pressure oil from charge pump is prevented from flowing into HST pump.
3C b D
PA
PB PA
A2 A1
4
RKS00070
PB PA
RKS00130
1
2) Valve at piston pump suction side

Port PB is at low pressure because port PB is suction side. Sleeve (3C) is pushed to right direction (o) to open
body seat portion because of the difference in area (A1>A2).
In this way, the charge pressure oil at port B flows into port PB through this clearance to charge to the HST
circuit.
3C PB
A1 A2 B
RKS00080
10-24 CK25-1
CHARGE SAFETY VALVE (Charge circuit)
RKS00140
3
1
1. Charge pump
2. Charge safety valve 2A 2B 2G 2C 2D 2E 2F
2A. Valve
2B. Spring
2C. Valve seat
2D. Poppet
2E. Spring
2F. Adjustment screw
2G. Filter
3. Suction safety valve RKS0004
FUNCTION
There is the charge safety valve installed to the HST pump.The charge safety valve restricts the maximum pressure
inside the charge circuit in order to protect the charge circuit.
CK25-1 10-25
FUNCTION
Port A is connected to the charge circuit.
Port B is connected to the tank drain circuit.
The pressurised oil fills port C through orifice a in valve (2A).
Poppet (2D) is in tight contact with valve seat (2C)
2A C 2C 2D 2E
1
a B RKS00010
• If abnormal pressure is generated in the circuit or the shuttle valve of HST motor is at neutral and the oil pressure at
ports A and C reaches the pressure set by spring (2E), poppet (2D) is pushed to right direction (o), and oil at C is
relieved to port B and pressure of the oil at C reduces.
2A C 2D 2E
RKS00020
B
• When pressure at port C reduces due to the shifting of poppet (2D), pressure at port A exceeds pressure at port B
due to the hole a in valve (2A).
This pressure gap shifts valve (2A) to right direction (o) and lets the pressurised oil at port A move to port B, thus
allowing charge circuit pressure to be adjusted.
2A C
RKS00030
a B
10-26 CK25-1
CHARGE PUMP
7
4
RKS00150
1. Slide plate FUNCTION

2. Coupling • HST charge pump is built-in the HST pump and driven
3. Shaft with HST pump at the same time.
4. Outer ring • The pressurised oil generated by the charge pump is
5. Case sent to safety valve in the charge circuit and to AS
valve.
6. Inner roter
• Charge pump sucks oil from hydraulic tank.
7. Outer roter
SPECIFICATIONS
• Type: trochoid pump
• Theoretical delivery: 32 cm³/rev
CK25-1 10-27
OPERATION
Delivery
7 6 B
A
2
Delivery side
A
Suction side
A RKS00160
Suction
• Charge pump is connected to HST pump shaft by coupling (2), so inner roter (6) and outer roter (7) rotate.
• During bucket (6) and impeller (7) rotation, oil is sucked in as quantity A increases and is discharged as quantity B
decreases.
• During rotation of inner roter (6) and outer roter (7), port A increases in volume as it performs oil suction, whereas
port B decreases in volume as it performs delivery.
10-28 CK25-1
ANTI ENGINE-STALL CONTROL VALVE (AS VALVE)
2 5
1A 1B 1C 1F 1D 1E
1G 1L 1H
RKS00170
1. AS valve FUNCTION
1A. Nut • The AS valve is attached on the main piston pump. It
1B. Screw reduces pressure for pump swash plate control from
1C. Spring charge circuit.
1D. Spring • The AS valve outputs pressure correspond with
engine revolution.
1E. Spring
1F. Valve
1G. Valve
1H. Nut
1L. Screw
2. Charge pump
3. Orifice
5. Engine
CK25-1 10-29
OPERATION
2 5
B A
1C 1D 1G
E
D
G
C RKS00180
• The oil from the charge pump (2) that rotates with the engine flows through a orifice (3) that is installed in the main
piston pump. And the oil always flows to pump charge circuit.
• Charge pump (2) is fixed capacity pump, so that discharge flow is proportionate to engine rotation speed. With the
oil from the charge pump (2) passed through the orifice, differential pressure is generated at port A and port B. This
differential pressure actuates the differential pressure sensing valve (1G) and makes hydraulic force F.
• By the hydraulic force F, the differential pressure sensing valve (1G) is moved direction.
That makes a change of spring (1D) load.
In port C, the AS valve output pressure that is balanced with spring (1C) and (1D) load is generated by reducing from
charge pressure of port G.
So the AS valve output pressure corresponds with charge flow (2) that is changed by engine (5) revolution.
10-30 CK25-1
SHUTTLE VALVE
1 3 2 RKS00200
1. Spool
2. Plug
3. Cover
FUNCTION
• The shuttle valves are installed in covers of pump swash plate control pistons. They select lower pressure either
travel PPC pressure or AS valve pressure, and output to pump swash plate control pressure.
D B A C
F2 F1
E RKS00210
Operation
• Port C is connected to port A (Travel PPC pressure inlet port). And hydraulic force F1 by travel PPC pressure
actuates the valve (1).
• And port D is connected to port B (AS pressure inlet port). Hydraulic force F2 by AS valve pressure actuates the
valve (1).
• By the hydraulic force F1 and F2, the shuttle valve selects lower pressure either PPC pressure or AS valve pressure.
It outputs lower pressure of them from port E to control pump swash plate.
CK25-1 10-31
TRAVEL SYNCHRONIZATION VALVE
1A
1B
P1 1C
P2
3 2 2 3
Left travel Right travel

RKS04660
1A. Spool
1B. Body
1C. Spring
2. Travel pump
3. Drive motor
FUNCTION
• Synchronization valve is mounted to main pump.
• Its purpose is to compensate for the difference in flow rate between right and left travel circuits in forward travel.
This way, the amount of oil circulating through the right and left circuits is almost equal and no deviation occurs
during travel.
• Synchronization is not dependent on differential pressure between P1 and P2 or flow rates.
• The difference in flow rate is compensated in forward travel, and the vehicle travels straight.
• On steering, the difference in flow rate rather than flow rate compensation is controlled, and then steering can be
performed.
OPERATION
• When pressure P1 is greater than pressure P2, oil flows through spools (1), (2).
• When a preset flow rate is reached, spool (2) shifts due to differential pressure between port a and b and passage
c reduces, thereby reducing the oil flow.
10-32 CK25-1
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
CONTROL VALVE (3-SPOOL)

STANDARD VERSION
B
D A
B3 A3
B2 A2
PB3
PA3
G G
F F
PA2 PB2
E E
PA1 B1 A1
PB1
C C
T P
TS
B A
D
RKS00254
P. from hydraulic pump A3: to attachment port

T: to tank B1: to lift arm cylinder (bottom side)
TS. to tank B2: to bucket cylinder (bottom side)
A1: to lift arm cylinder (head side) B3: to attachment port
A2: to bucket cylinder (head side)
CK25-1 10-33
4 9
4
8
3
7
2
1
Section A - A Section B- B
AA
BB 10 12
13
AA 11
BB Section BB-BB
Section C - C Section AA-AA
RKS00520
1. Main relief valve 8. Spool (bucket)

2. Plug 9. Spool (attachment)
3. Suction valve (bucket bottom side) 10. Flow-divider
4. Plug 11. Check valve (circulating circuit)
5. Plug 12. Combination circulating valve
6. Series - parallel circuit switching valve 13. Leveling circulating valve
7. Spool (lift arm)
10-34 CK25-1
9 8 9
4 5
3 7
2 1 2 7
Section E - E
1 Section D - D
1 1
1 1 1
1 3 6 4 5 RKS00670
Section F - F Section G - G
1. Unload valve 9. Plug

2. Pressure compensation valve (lift arm) 10. Shuttle valve
3. Pressure compensation valve (bucket) 11. Spool (bucket)
4. Pressure compensation valve (attachment) 12. Suction valve
5. Pressure compensation valve (attachment) 13. Shuttle valve
6 Pressure compensation valve (bucket) 14. Spool (attachment)
7. Pressure compensation valve (lift arm) 15. Plug
8. Spool (lift arm)
CK25-1 10-35
FLOAT VERSION
B
D A
B3 A3
B2 A2 PB3
PA3
G G
F F
PA2
E E PB2
PA1 B1 A1
PB1
C C
T P
TS
B A
D
RKS04390
P. from hydraulic pump A3: to attachment port

A1: to lift arm cylinder (head side) B3: to attachment port
10-36 CK25-1
3 8
3
2 7
1
Section A - A Section B- B
AA
BB 9 11
12
AA 10
BB
Section C - C Section AA-AA Section BB-BB
RKS04400
1. Main relief valve 7. Spool (bucket)

2. Suction valve (bucket bottom side) 8. Spool (attachment)
3. Plug 9. Flow divider
4. Plug 10. Check valve (circulating circuit)
5. Series - parallel circuit switching valve 11. Combination circulating valve
6. Spool (lift arm) 12. Leveling circulating valve
CK25-1 10-37
4 5
10 11
6 2 12
3 7
2
8 2 7 13
Section E - E
1 Section D - D
15 14
18 17 18
16 3 6 4 5
Section F - F Section G - G RKS04410
1. Unload valve 10. Spool (lift arm)

2. Pressure compensation valve (lift arm) 11. Float valve
3. Pressure compensation valve (bucket) 12. Solenoid
4. Pressure compensation valve (attachment) 13. Spool (float)
5. Pressure compensation valve (attachment) 14. Spool (bucket)
6 Pressure compensation valve (bucket) 15. Suction valve
7. Pressure compensation valve (lift arm) 16. Shuttle valve
8. Shuttle valve 17. Spool (attachment)
9. Plug 18. Plug
10-38 CK25-1
HIGH-FLOW VERSION
B C A
Pi2
B3 A3
PA3
H H
PB3
G G
F F
PA2 E PB2
B2 A2 E
B1 A1 PB1
PA1
D D
T P
TS
B A
C
RKS04420
P. from gear pump (P4 port) A2: to bucket cylinder (head side)
P2. from gear pump (P5 port) A3: to attachment port
Pi2. From solenoid valve group (B port) B3: to attachment port
A1: to lift arm cylinder (head side)
CK25-1 10-39
Section B- B
3 3
Section A - A
RKS04430
1. Main relief valve 5. Series - parallel circuit switching valve

2. Suction valve (bucket bottom side) 6. Spool (lift arm)
3. Plug 7. Spool (bucket)
4. Float valve 8. Spool (attachment)
10-40 CK25-1
AA
BB
AA
BB
6 Section D - D
7 9
4 8
11 10
1 Section BB-BB
Section C - C
12
Section AA-AA RKS04450
1. Unload valve 7 Pressure compensation valve (bucket)

2. Pressure compensation valve (lift arm) 8. Pressure compensation valve (lift arm)
3. Pressure compensation valve (bucket) 9. Combination circulating valve
4. Pressure compensation valve (attachment) 10. Leveling circulating valve
5. Check valve (HIGH FLOW) 11. Flow-divider
6. Pressure compensation valve (attachment) 12. Check valve (circulating circuit)
CK25-1 10-41
2 4
3 5
11 10
8 1 7 6
Section E - E
13 9 12
Section F - F
19
16 15 16
18
Section H - H
14 17
Section G - G
RKS04440
1. Pressure compensation valve (lift arm) 11. Suction valve

2. Spool (lift arm) 12. Pressure compensation valve (bucket)
3. Plug 13. Shuttle valve
4. Float valve 14. Pressure compensation valve (attachment)
5. On - off solenoid 15. Spool (attachment)
6. Spool (float) 16. Plug
7. Pressure compensation valve (lift arm) 17. Pressure compensation valve (attachment)
8. Shuttle valve 18. Check valve (High - Flow)
9 Pressure compensation valve (bucket) 19. High - Flow joining spool
10. Spool (bucket)
10-42 CK25-1
CONTROL VALVE (4-SPOOL)

SUPER HIGH-FLOW VERSION
B C A
B4 A4
B3 A3 Pi
PA3
J J
H H
PB3
G G
F F
PA2 PB2
E B2 A2 E
PA1 PB1
B1 A1
D D
TS T P
B A
C
P2
RKS04460
P1. from gear pump (P4 port) A3: to attachment port (RH side)
P2. from gear pump (P5 port) A4: to HIGH FLOW attachment port (LH side)
Pi: From solenoid valve group (B port) B3: to attachment port (RH side)
A1: to lift arm cylinder (head side) B4: to HIGH-FLOW attachment port (LH side)
CK25-1 10-43
4 4
4 4
5
10
9
1
Section A - A
8
Section B - B RKS04321
1. Main relief valve 6. Series - parallel circuit switching valve

2. Plug 7. Spool (lift arm)
3. Suction valve (bucket bottom side) 8. Spool (bucket)
4. Plug 9. Spool (attachment)
5. Float valve 10. Spool (High-Flow)
10-44 CK25-1
13
AA
BB
14
Section AA-AA
AA
BB
6
Section D - D
7
11
5
9
4 1
3 12
2 Section BB-BB
1 RKS00703
Section C - C
1. Unload valve 8. Pressure compensation valve (attachment)

2. Pressure compensation valve (lift arm) 9 Pressure compensation valve (bucket)
3. Pressure compensation valve (bucket) 10. Pressure compensation valve (lift arm)
4. Pressure compensation valve (attachment) 11. Combination circulating valve
5. Pressure compensation valve F (High Flow) 12. Leveling circulating valve
6. Check valve (for High - Flow joining circuit) 13. Flow-divider
7. Pressure compensation valve R (High Flow) 14. Check valve (circulating circuit)
CK25-1 10-45
2 4
11 10
8 1 7 6
Section E - E
19
16 16
13 9 12
Section F - F
15
16 16
5 5
18 20
Section H - H
22
14 17
Section G - G
21 RKS04470
Section J - J
1. Pressure compensation valve (lift arm) 12. Pressure compensation valve (bucket)
2. Spool (lift arm) 13. Shuttle valve
3. Plug 14. Pressure compensation valve (attachment)
4. Float valve 15. Spool (attachment)
5. On - off solenoid 16. Plug
6. Spool (float) 17. Pressure compensation valve (attachment)
7. Pressure compensation valve (lift arm) 18. Pressure compensation valve (HIGH FLOW)
8. Shuttle valve 19. Spool (High - Flow)
9 Pressure compensation valve (bucket) 20 Pressure compensation valve (HIGH FLOW)
10. Spool (bucket) 21. Check valve (High - Flow joining circuit)
11. Suction valve 22. High - Flow joining spool
10-46 CK25-1
STRUCTURE AND FUNCTION CLSS
CLSS
1. OUTLINE
Features
CLSS stands for Closed centre Load Sensing System, and has the followings characteristics.
a. Controlability, not influenced by load;
b. Controllable digging force at fine control range;
c. Easy simultaneous operation by spool opening proportional flow dividing function.
2. PRESSURE COMPENSATION CONTROL

• A valve (pressure compensation valve) is installed to the inlet port side of the control valve to balance the load.
When there is compound operation of the actuators, this valve acts to make pressure difference ∆Pconstant for the
upstream flow (inlet port) and downstream flow (outlet port) of the notch of each spool.
In this way, the flow of oil from the pump is divided in proportion to area of opening S1 and S2 of each valve.
Load Load
W W
Actuator Actuator
ÐP ÐP
S1 S2
Pressure Pressure
compensation compensation
valve valve
RKS00691
Pump
CK25-1 10-47
3. OPERATION FOR EACH FUNCTION AND VALVE
Features
• The small capacity gear pump keeps high speed movement because lift arm and the bucket circuit are connected
in a series circuit.
• The control valve has built in self leveling function.
• If loading pressure of bucket becomes beyond a certain value, the lift arm and the bucket circuits automatically
change to parallel circuit to keep strong digging force.
• The lift arm, attachment and High-flow section are connected in a parallel circuit and it has pressure
compensationing function each section.
• During individual operations, attachment High-flow keep individual demand flow rate.
However during compound operations, they are divided in the proportion of 1 to 9 and keep High-flow section flow
rate.
Hydraulic circuit diagram and names of valves
P2
Ls
13
A4
Optional equipment
B4 High-flow
P1
A3
Optional equipment
B3
Pa3 Pa3 Port
5
A2
B2
Bucket cylinder
Pa2 11 Pa2
Dump bucket Curl bucket
4
11 A1
Pa1
Raise arm B1 Raise cylinder
9 8 3
12
10
Pa1
1 Lower arm
2
RKS04790
1. Unload valve 8. Leveling circulating valve

2. Main relief valve 9. Combination circulating valve
3. Pressure compensation valve (lift arm) 10. Flow-divider
4. Pressure compensation valve (bucket) 11. Shuttle valve
5. Pressure compensation valve (attachment) 12. Check valve (circulating circuit)
6. Pressure compensation valve (High - Flow) 13. High - Flow joining spool
7. Float valve
10-48 CK25-1
3.1 SERIES CIRCUIT
Function
• Return flow rate from the lift arm is recirculated to the bucket.
F
2 a 3
d
4
b
c
P1
Q1 P2
A B C
Q2
1
5
6
E RKS00720
Operation
When the lift arm raise and the bucket dump are operated at the same time.
• The lift arm spool (1) strokes fully and the bucket spool (2) stokes by half.
• When this happens, notch (a) doesn’t open, so all flow rate from pump supplies to the lift arm raise.
• The lift arm and the bucket PPC pressure are sent by passage E and F.
Then the leveling circulating valve (3) and the combination circulating valve (4) stroke fully.
• Return flow rate from the lift arm cylinder passes through passage A.
Then it is divided to passage B and C, by the leveling circulating valve (4) and the combination circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passage B and C
in proportion to the area of opening as below expression.
Q1: Q2= (notch (b) + notch (d)): notch (C)
Q1= flow rate flows to B
Q2=flow rate flows to C
• Q1 passes through the check valve (6) and then supplies to the bucket cylinder.
CK25-1 10-49
3.2 SELF LEVELING FUNCTION
Function
When the only lever of the lift arm raise is operated, the lift arm raise and the bucket dump are worked.
When this happens, the work equipment can raise with constant bucket bottom angle. (Only the lift arm raise).
F
2 a 3
d
4
b
c
P1
Q1 P2
A B C
Q2
1
5
6
E RKS00720
Operation
When the lift arm raise is operated individually.
• The lift arm spool (1) strokes fully and the bucket spool strokes by half.
• When this happens, notch (a) doesn’t open, so all flow rate from pump supplies to the lift arm raise.
• The lift arm raise PPC pressure is sent by passage E.
Then the leveling circulating valve strokes fully.
Then it is divided to passage B and C, by the leveling circulating valve (3).
Q1 passes through the check valve (6) and then supplies to the bucket cylinder.
10-50 CK25-1
3.3 THE FUNCTION TO SWITCH SERIES CIRCUIT TO PARALLEL CIRCUIT
Function
• (1) Low bucket load: Series circuit
• (2) High bucket load: Parallel circuit
• Depend on bucket load, a circuit can change automatically as above.
Then the machine gets high speed and strong digging power.
F
2 a 3
d
H 4
b
A c
P1
Q1 P2
B C
Q2
1
P3
5
6
E e
f G
7 RKS00730
CK25-1 10-51
Operation
When the lift arm raise and the bucket digging are operated at the same time.
• The lift arm spool (1) and the bucket spool (2) stroke fully.
• When this happens, the bucket digging PPC pressure is sent by passage H.
Then the combination circulating valve (3) strokes fully to the right and also the lift arm raise PPC pressure is sent
by passage E.
Then the leveling circulating valve (4) strokes fully to the left.
Then it is divided to passage B and C, by the leveling circulating valve (4) and the combination circulating valve (3).
• If the bucket load becomes beyond a certain valve by influences of digging, the series-parallel switching valve (7)
strokes to the right.
Then it passes thorough passage G by opening notch (e).
And then the spring chamber of flow divider (5) is connected to tank.
• As a result, flow divider (5) strokes fully to the right, and P2 = T.
Return flow rate from the lift arm is connected with tank totally, and Q1 = 0 l/min.
• When this happens, notch (f) of the lift arm spool and notch (a) of the bucket spool open, so the lift arm and the bucket
become parallel circuit (CLSS).
And flow rate of the lift arm raise (Q3) and the bucket digging flow rate are divided as below expression.
Q3: Q4 = notch f: notch (a )
10-52 CK25-1
3.4 PRESSURE COMPENSATION VALVE
Function
• During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to
increase, compensation is received. (When this happens, the other actuator being used for compound operation
(right side) is at a higher load than the actuator on this side (left side).
W W
A A
a a
PLS1 PPA PA
PPA
1
PA
2
PLS
PP
RKS00740
Operation
• If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in
actuator circuit A on this side (left side) tries to increase.
• If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing valve (1) and
flow control valve (2) are pushed to the left (i).
• Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA, and pressure
loss is generated between PP and PPA.
• Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure between PA
and PLS acting on both ends of reducing valve (2) and the pressure loss between PP andPPA on both sides of flow
control valve (1) are the same.
• In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of both spools
used during compound operations is the same, so the pump flow is divided in proportion to the area of opening of
notch a of each spool.
CK25-1 10-53
3.5 DIVIDING FUNCTION
Function
1. When each section is operated individually
Attachment: 60 l/min
HIGH-FLOW: 100 l/min
2. When standard attachment and high flow attachment are operated at the same time
1:9=attachment: HIGH-FLOW
1 2 3
Attachment section High-flow section
RKS00711
Operation
1. When each section is operated individually
• Attachment spool (1) and High-Flow spool (3) stroke fully and individually, therefore they keep demand flow rate
individually.
Attachment: 60 l/min max.
HIGH-FLOW attachment: 100 l/min max.
2. When attachment and High-Flow are operated at the same time.
• High-Flow attachment PPC pressure passes through passage A, is sent to retainer (2) and makes retainer (2) stroke
to the left.
• When this happens, attachment spool (1) can stroke by half.
• As a result, flow rate of attachment and High-Flow are divided as below expression.
Attachment: High-Flow= 1:9
• Therefore flow rate of high flow is kept.
10-54 CK25-1
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE GROUP ST1
(SERVOCONTROL - PARKING BRAKE - 2nd SPEED)
1 2 3
Z
T
A B C
View Z RKS01150
FUNCTION A Port – To travel motors (PP port)

1. 2nd speed B Port – To PPC valve
2. Servocontrol C Port – To travel motors (PS port)
3. Parking brake P Port – From hydraulic pump (E2 port)
T Port – To hydraulic tank
S Port – To accumulator
CK25-1 10-55
SOLENOID VALVE ST2

HIGH-FLOW CONTROL
P1 P2
RKS01140
T Port – To hydraulic tank

P1 Port – From control valve (PA3 port)
P2 Port – To control valve (PB3 port)
S Port – To control valve (Pi2 port)
10-56 CK25-1
SOLENOID VALVE ST3

OVERRIDE CONTROL
a c
RKS04490
1. SV4 - Backhoe boom lockout
a. T port - To transmission
b. Port 1 - From transmission
c. T1 port - Boom lockout cylinder
CK25-1 10-57
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
B
RKS01650
TECHNICAL DATA
Servocontrol feed unit
Nominal volume:0.35 l
Pre-loading: 8 bar
Working pressure: 25–27 bar
FUNCTION
• An elastic rubber bag (1) containing nitrogen is fitted inside the accumulator to maintain oil pressure in the circuit to
which the accumulator is connected.
OPERATION
• When the engine is running the chamber A of the rubber bag (1) (containing nitrogen) is compressed by oil under
pressure coming from line B.
• If the oil under in line B falls below the maximum calibration pressure (even after intensive use), the rubber bag (1)
will expand due to pressure from the nitrogen it.
10-58 CK25-1
STRUCTURE AND FUNCTION PATTERN CHANGE VALVE (OPTIONAL)
PATTERN CHANGE VALVE (OPTIONAL)
P out 4
P out 6
4 P out 3
6 3
T PO OS I
P out 1 1 5
2 P out 5
View Z
P out 2
Z
OPTIONAL
ISO PATTERN PATTERN
P out 4 P in 4
ISO PATTERN
P out 3 P in 3
P out 2 P in 2
P in 1
P out 1
P out 5
P in 1
P in 5
B
P out 6 P in 6
P in 5
1 5
Pout 4 P in 4
Pout 3 P in 3 P in 4
OPTIONAL
3
PATTERN
Pout 2 P in 2
Pout 1 P in 1
Pout 5
Pout 6
P in 5
P in 6
A A
4
P in 6 6 2 P in 3
P in 2 B
RKS00661
Pin 1. From L.H. PPC valve (P1 port) Pout 1. To hydraulic pump (DA1 port)
Pin 2. From L.H. PPC valve (P2 port) Pout 2. To hydraulic pump (DA2 port)
Pin 3. From L.H. PPC valve (P4 port) Pout 3. To hydraulic pump (DB1 port)
Pin 4. From L.H. PPC valve (P3 port) Pout 4. To hydraulic pump (DB2 port)
Pin 5. From R.H. PPC valve (P1 port) Pout 5. To control valve (PA1 port)
Pin 6. From R.H. PPC valve (P2 port) Pout 6. To control valve (PB1 port)
CK25-1 10-59
STRUCTURE AND FUNCTION PATTERN CHANGE VALVE (OPTIONAL)
C C
E E 3
F F
G G
D D
7
Section A - A Section H - H
5
7
4
3
1 H
2
6
Section B - B Section E - E Section E - E
Section C - C Section F - F Section F - F
Section D - D Section G - G Section G - G
RKS00650
1. Lever 5. Upper cover

2. Rotor 6. Lower cover
3. Valve seat 7. Pin lock
4. Ball
10-60 CK25-1
STRUCTURE AND FUNCTION OPERATION
OPERATION
PATTERN ISO
P1
L.H. TRAVEL
P2
P out 4 P in 4
P out 3 P in 2 P3
REVERSE FORWARD
P out 2 P in 1
A1 B1 P out 1 P in 3
P out 5 P in 5
A2 B2 R.H. TRAVEL
P out 6 P in 6 P4
P T
PA1 FORWARD
P1
DUMP
BUCKET
PB1
P2
RAISE LOWER
P3 ARM ARM
CURL
BUCKET
P4
P T
RKS03070
PATTERN OPTIONAL
P1
RAISE
ARM
P2
REVERSE FORWARD
P3 L.H. L.H.
LOWER
ARM
P4
P out 4 P in 4
P out 3 P in 2 P T
P out 2 P in 1
FORWARD
P out 1 P in 3
P out 5 P in 5 P1
A1 B1 P out 6 P in 6
DUMP
A2 B2 BUCKET
P2
REVERSE FORWARD
PA1 P3 R.H.
R.H.
CURL
PB1 BUCKET
P4
PT
RKS03080
CK25-1 10-61
STRUCTURE AND FUNCTION R.H. PPC VALVE (STANDARD)
R.H. PPC VALVE (STANDARD)

EQUIPMENT CONTROL
P2 P4
P3 P1
E E
D D
B T P
A C
C A
RKS00800
P1 port - To control valve (PA1 port) FUNCTION

P2 port - To control valve (PB1 port) P1 Lower arm
P3 port - To control valve (PA2 port) P2 Raise arm
P4 port - To control valve (PB2 port) P3 Curl bucket
P port - From solenoid valve group ST1 P4 Dump bucket
T port - To hydraulic tank
10-62 CK25-1
5 7
4
8
3
9
2 1
Section A - A Section B - B
Section D - D
Section C - C
Section E - E
RKS00810
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
CK25-1 10-63
FUNCTION
1. Control lever in NEUTRAL position

Ports P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f in spool
(1). (Fig. 1).
D
f T
P
1
P1 P2
Fig. 1 RKS00820
2. During fine control (NEUTRAL o fine control)
When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed by
metering 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, so
pilot pressure oil from the control pump passes
5
through fine control hole f and goes from port P1.
When the pressure at port P1 becomes higher, 4
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain 9
chamber D to release the pressure at port P1. 3
When this happens, spool (1) moves up or down so D
2
that the force of metering spring (2) is balanced with T
the pressure at port P1. f
The relationship in the position of spool (1) and
body (10) (fine control hole f is at a point midway P
between drain hole D and pump pressure chamber 1 PP
PP) does not change even if the pressure at port P1 10
becomes max. P1 P2
Therefore, metering spring (2) is compressed Fig. 2 RKS00830
proportionally to the amount of movement of the

control lever, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
a) until pressures on port P1 are perfectly

balanced;
b) pressure at port P1 on stem (1) reaches the
value needed to counteract the force of spring
(2).
This ensure proportionality between control lever
position, P1 circuit pressure, and main control valve
stem displacement (Fig. 2).
10-64 CK25-1
3. During fine control (when the lever is returned)

(fine control o neutral)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and
the pressure at port P1.
5
When this happens, fine control hole f is connected
4
to drain chamber D and the pressure oil at port P1 is
released.
If the pressure at port P1 drops too far, spool (1) is 9
pushed down by metering spring (2), and fine 3
control hole f is shut off from drain chamber D. 2 D
At almost the same time, it is connected to pump T
f
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to a
P f
pressure that corresponds to the lever position.
When control valve spool returns, oil goes back into 1 PP
port D, through fine control hole f', into port B of the
spool opposite the active spool. Oil flows through P1 P2
port P2 and into port B to maintain the fill level (Fig. Fig. 3 RKS00840
3).
CK25-1 10-65
STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)

EQUIPMENT AND TRAVEL CONTROL
P2 P4
P3 P1
E E
D D
B T P
A C
C A
RKS00800
P1 port - To pattern change valve (Pin 5 port) FUNCTION
P2 port - To pattern change valve (Pin 6 port) ISO PATTERN:
P3 port - To control valve (PA2 port) P1 Lower arm
P4 port - To control valve (PB2 port) P2 Raise arm
P port - From solenoid valve group ST1 P3 Curl bucket
T port - To hydraulic tank P4 Dump bucket
OPTIONAL PATTERN:
P1 R.H. travel forward
P2 L.H. travel reverse
P3 Curl bucket
P4 Dump bucket
10-66 CK25-1
5 7
4
8
3
9
2 1
Section D - D
Section C - C
Section E - E
RKS00810
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
CK25-1 10-67
FUNCTION

(1). (Fig. 1).
D
f T
P
1
P1 P2
Fig. 1 RKS00820
When piston (4) starts to be pushed by disc (5),
5
shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain 9
When this happens, spool (1) moves up or down so D
2
that the force of metering spring (2) is balanced with T
the pressure at port P1. f
between drain hole D and pump pressure chamber 1 PP
PP) does not change even if the pressure at port P1 10
becomes max. P1 P2
Therefore, metering spring (2) is compressed Fig. 2 RKS00830


balanced;

(2).
10-68 CK25-1

pushed up by the force of centering spring (3) and
5
When this happens, fine control hole f is connected
4
released.
If the pressure at port P1 drops too far, spool (1) is 9
f
supplied until the pressure at port P1 recovers to a
P f
spool opposite the active spool. Oil flows through P1 P2
3).
CK25-1 10-69
STRUCTURE AND FUNCTION L.H. PPC VALVE (STANDARD)
L.H. PPC VALVE (STANDARD)

TRAVEL CONTROL
P2 P4
P3 P1
T P
E E
F F
D D
A C
RKS00860
C A
P1 port - To hydraulic pump (DA2 port) FUNCTION

P2 port - To hydraulic pump (DB1 port) P1 L.H. travel forward
P3 port - To hydraulic pump (DA1 port) P2 L.H. travel reverse
P4 port - To hydraulic pump (DB2 port) P3 R.H. travel forward
P port - From solenoid valve group ST1 (B port) P4 R.H. travel reverse
T port - To hydraulic tank ★ When acting control lever, two ports are pressurised
contemporarily (i.e.: travel forward pressurise P1 and
P3 ports).
10-70 CK25-1
5 7
4
8
3
9
2 10
Section D - D
11
12
Section C - C
13
G G
14
Section F - F
Section E - E
Section G - G
RKS00870
1. Spool 8. Cover
2. Metering spring 9. Stopper
3. Centering spring 10. Body
4. Piston 11. Plug
5. Disc 12. Ball
6. Nut 13. Seat
7. Joint 14. Body (for shuttle valve)
CK25-1 10-71
FUNCTION
1. NEUTRAL
(1). (Fig. 1).
D
f T
P
2. During fine control (NEUTRAL o fine control) P1 (P3) P2 (P4)

When piston (4) starts to be pushed by disc (5), Fig. 1 RKS00890
shut off from pump pressure chamber PP. 4
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down so 3
that the force of metering spring (2) is balanced with 2
D
f T
between drain hole D and pump pressure chamber
PP) does not change even if the pressure at port P1
becomes max. 1 PP
Therefore, metering spring (2) is compressed 10
P1 P2
RKS00900
a) until pressures on port P1 are perfectly Fig. 2
balanced;

(2).
10-72 CK25-1

pushed up by the force of centering spring (3) and 5
When this happens, fine control hole f is connected 4
released. 3
If the pressure at port P1 drops too far, spool (1) is
control hole f is shut off from drain chamber D.
D
At almost the same time, it is connected to pump f T
pressure chamber PP, and the pump pressure is P
supplied until the pressure at port P1 recovers to a f
spool opposite the active spool. Oil flows through
port P2 and into port B to maintain the fill level (Fig.
Fig. 3 P1 P2
3). RKS00880
CK25-1 10-73
STRUCTURE AND FUNCTION L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)
L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)

EQUIPMENT AND TRAVEL CONTROL
P2 P4
P3 P1
E E
D D
B T P
A C
C A
RKS00800
P1 port - To pattern change valve (Pin 1 port) FUNCTION

P2 port - To pattern change valve (Pin 2 port) ISO PATTERN:
P3 port - To pattern change valve (Pin 4 port) P1 Travel forward
P4 port - To pattern change valve (Pin 3 port) P2 Travel reverse
P port - From solenoid valve group ST1 P3 L.H. travel
T port - To hydraulic tank P4 R.H. travel
OPTIONAL PATTERN:
P1 L.H. travel forward
P2 L.H. travel reverse
P3 Raise arm
P4 Lower arm
10-74 CK25-1
5 7
4
8
3
9
2 1
Section D - D
Section C - C
Section E - E
RKS00810
1. Spool 5. Disc
2. Metering spring 6. Nut
3. Centering spring 7. Joint
4. Piston 8. Cover
9. Stopper
10. Body
CK25-1 10-75
FUNCTION

(1). (Fig. 1).
D
f T
P

When piston (4) starts to be pushed by disc (5), 1
P1 P2
When this happens, fine control hole f is shut off RKS00820

Fig. 1
When the pressure at port P1 becomes higher,
shut off from pump pressure chamber PP. 5
At almost the same time, it is connected to drain
When this happens, spool (1) moves up or down so
that the force of metering spring (2) is balanced with 9
the pressure at port P1. 3
The relationship in the position of spool (1) and D
2
body (10) (fine control hole f is at a point midway T
between drain hole D and pump pressure chamber f
becomes max. P
Therefore, metering spring (2) is compressed 1 PP
control lever, so the pressure at port P1 also rises in P1 P2 10
proportion to the travel of the control lever. Fig. 2 RKS00830

balanced;

(2).
10-76 CK25-1

pushed up by the force of centering spring (3) and 5
released.
9
f
supplied until the pressure at port P1 recovers to a f
pressure that corresponds to the lever position. P
P1 P2
spool opposite the active spool. Oil flows through
3).
CK25-1 10-77
STRUCTURE AND FUNCTION EQUIPMENT CONTROL PPC VALVE
EQUIPMENT CONTROL PPC VALVE
5
4
c d 6
3 7
2
8
1
9
Section A - A
RKP00960
a. T port - to solenoid valve group ST1 (T port) 1. Spring

b. P port - from solenoid valve group ST1 (A port) 2. Metering spring
c. P1 port - to control valve (PB10 port) 3. Centering spring
d. P2 port - to control valve (PA10 port) 4. Piston
5. Lever
6. Cover
7. Stopper
8. Body
9. Filter (100 mesh)
10-78 CK25-1
PPC VALVE (foot) OPERATION

Control valve ports A and B and PPC valve ports
P1and P2 are connected to drain chamber D by
means of fine control hole f in stem (1) (See Fig. 1).
D
T
f P
2. During fine control (NEUTRAL ofine control)

1
When piston (4) starts to be pushed by lever (5),
retainer (9) is pushed; spool (1) is also pushed by P1 P2
it is connected to pump pressure chamber P P ,
A Control valve B
which is directly connected to the servocontrol
circuit. RKP00970
Pressure from servocontrol circuit passes through Fig. 1
fine control hole f and increases pressure at port
P1-A.
When the pressure P1 becomes higher, stem (1) is
pushed back and fine control hole f is reconnected
to drain chamber D. When this happens, spring (2)
is compressed. 5
body (10) (fine control hole f is at a point midway
4
between drain hole D and pump pressure chamber
becomes max.
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the 7 D
control lever (5) so the pressure at port P1 also rises T
in proportion to the travel of the control lever (5). 2
The balance position lasts until piston position 8
changes, i.e.:
a) until pressures on ports A and P1 are perfectly f P
balanced;
b) pressure at port A-P1 on stem (1) reaches the
1 P1 P2
(2). PP
This ensures proportionality between control lever
position, A-P1 circuit pressure, and main control
A Control valve B
valve stem displacement (See Fig. 2).
RKP00980
Fig. 2
CK25-1 10-79
3. During fine control (when the lever is

returned) (fine controloneutral)
When control lever (5) starts to be returned, piston
(4) is pushed up by spring (3) operating on retainer 5
(9) and spool (1) is pushed up by the force of
centering spring (2) and the pressure at port P1.
to drain chamber D and the pressure oil at port A-P1
is released.
pushed down by metering spring (2), and fine 7 D
control hole f is shut off from drain chamber D. At
T
almost the same time, it is connected to pump 2
pressure chamber PP , and the pump pressure is
supplied until the pressure at port P1 recovers to a P
pressure that corresponds to the lever position. f
When control valve spool returns, oil goes back into f'
spool opposite the active spool.
1 P1 P2 PP
Oil flows through port P2 and into port B to maintain
the fill level. (See Fig. 3).
A Control valve B
RKP00990
Fig. 3
4. Control lever at full position

(neutral ofull stroke)
When lever (5) pushes down on piston (4) and
retainer (9) pushes down on stem (1), fine control 5
hole f is connected to port PP, which connects to a
constantly pressurised servo-control circuit. 4
This way, oil flows into port A-P1 and pushes main
control valve stem to the end of its travel, thereby
sending the oil in port B to inlet P2, through fine
control hole f', into drain chamber D (See Fig. 4). 7 D
T
2
8
P
f
f'
1 P1 P2 PP
A Control valve B
Fig. 4 RKP01000
10-80 CK25-1
STRUCTURE AND FUNCTION CYLINDERS
CYLINDERS
BUCKET RAISE
7
2 3 4 5 6 9 8
1
13 12 11 10 7 RKS02000
BUCKET DUMP
6 7
2 3 4 5 9 8
1
13 12 11 10 7 RKS01110
1. Bushing 8. Bushing
2. Dust 9. Nut
3. Gasket 10. Piston
4. Gasket 11. Cylinder
5. Rod 12. Gasket
6. Gasket 13. Head
7. Ring
Unit: mm
Max. cylinder Min. cylinder

Cylinder Ø Rod Ø Piston Piston stroke Key size
length length
Lifting bucket 35 55 781 1822 1041±1 32
Bucket dump 30 60 357 970 613 32
CK25-1 10-81
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (ENGINE LINE) (1/3)
ELECTRICAL DIAGRAM (ENGINE LINE) (1/3)

RKS03210
RELE' POOL SOLENOIDE
POOL SOLENOID RELAY
X03
FILTRO ARIA
AIR FILTER SWITCH PRERISCALDO POOL-STOP SOLENOIDE CARBURANTE SENSORE LIVELLO COMBUSTIBILE
PREHEATING FUEL POOL-STOP SOLENOID FUEL LEVEL SENDER
S25
R1 X13 X17 SIRENA BACK-UP
BACK-UP ALARM
RELE' SICUREZZA
SAFETY RELAY
X29
X08
RELE' SICUREZZA
SAFETY RELAY
PRESSOSTATO OLIO MOTORE
XS1 ENGINE OIL PRESSURE SWITCH
S31
ISOLATORE
INSULATOR
XS
TIMER ARRESTO MOTORE

ENGINE STOP TIMER
X07
STOP LIGHT PRESSURE SWITCH 2

PRESSOSTATO 1 LUCI STOP
DIODO
DIODE
X20
MASSE
X06 GROUND
SENSORE TEMPERATURA ACQUA GND
ENGINE WATER TEMPERATURE SENDER
1
X18
8
2
9
3
10
4
5
A LINEA TELAIO PRESSOSTATO 2 BACK-UP

11
6
12
BACK-UP PRESSURE SWITCH 2

13
TO FRAME CABLE
X10 X23
A LINEA TELAIO
TO FRAME CABLE
X01
PRESSOSTATO 2 LUCI STOP
A LINEA TELAIO STOP LIGHT PRESSURE SWITCH 2
TO FRAME CABLE MASSE START(+50)
GROUND POMPA GASOLIO X21
START(+50) PRESSOSTATO 1 BACK-UP
X02 FUEL PUMP
GND5 XM BACK-UP PRESSURE SWITCH 1
X14
X22
ALTERNATORE
GENERATOR
v
X11
INT. FILTRO OLIO IDR.
HYDR. OIL FILTER SW. x
S26 ALTERNATORE
GENERATOR
G2 +30 IMPIANTO
POWER (+30) CONNECT WITH XS
XS*
MOTORINO AVV.
STARTER MOTOR
XB
FUSIBILE GENERALE(50A)
FG1
CK25-1 10-83

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
V1 K02 K03
SAFETY
POWER
K01 86 87 R-N2.5
BOX
X01
RELAY 4
M2.5
X01
R-B1
85 30 3
R4
R1
N1
G1
X01
2
X07
X07
X07
X07
X03 X03 X03 X03 X06 X06 XS1 XS1 X08 X08 X08 X08 X01
1
86 85 30 87 l - 4 3 2 1 A B 1 3 5 6
N4
XS
R-N1.5
R-N1.5
R-N2.5
R-N1.5
M-V1
R-G1
S-N1
L/B1
L/B1
B2.5
R4
GND5
M-V1
N1
N1
N1
B2
B1
X02
R10
l
L-R1
TO FRAME LINE OPT/STD

X02
-
R-N1.5
X10
13
X10
12
R2.5
X10
11
R-V1
X10
10
B1
X10
9
S1
X10
8
C-N1
X10
7
C-L1
X10
6
S-G1
X10
5
X10
4
B-N1
GND X10
3
R10
R-G1
X10
2
B-G1
1 X10
1
XF
1
X28
FG1
80A
HA3
S31
XF p
2
X29 X29
2 1
Z-N1
R10
N1
R10
R50
B2.5
R-G1
S-N1
S1
R-N1.5
R-G1
C-N1
G1
B-N1
S-G1
M2.5
C-L1
N2
N1
N1
N1
N1
B2
1 2 1 3
R-V1
Z-N1
L-R1
L-R1
L-R1
12Vcc 3 1 2 - + 1 2 1 C A - + 1
X09
X11
X11
X11
X13
1 1
X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 1 2 1 2 1 2 1 2
M1 XB XM G2 R1 R2 R3 X20 X20 X21 X21 X22 X22 X23 X23

N2.5
R1.5
B2.5
D+
30 50 30
G
W M2
M S25 S26 S27 S28 S29 S30
N50
3 Y0 M p p p p p p
U
t
31
RKS03220
10-84 CK25-1

COMPONENTS
FG1 General fuse 50A
G1 Battery 80Ah
G2 Generator
K01 Fuel solenid valve relay
K02 Fuel pull solenoid valve timer 1 second
K03 Safety relay
M1 Starter motor
M2 Fuel pump
R1 Preheating starter
R2 Fuel level sender
R3 Engine water temperature sender
S25 Air filter blocked switch
S26 Hydraulic oil filter blocked switch
S27 Stop lights pressure switch
S28 Stop lights pressure switch
S29 Back-up alarm pressure switch
S30 Back-up alarm pressure switch
S31 Engine oil min. pressure switch
V1 Diode 1A
X01 Frame line 3 way connector
X02 2 way connector
X03 Fuel solenoid relay connector
X06 Diode 2 way connector
X07 Pull solenoid timer 4 way connector
X08 Safety relay 6 way connector
X09 C6 generator terminal
X10 Frame line mark 13 way connector
X11 Generator 3 way connector
X13 Fuel pool-stop solenoid 3 way connector solenoid 3 way connector
X14 Fuel pump 2 way connector
X15 Preheating start C6 terminal
X16 Air filter blocked switch 2 way connector
X17 Fuel level sender 3 way connector
X18 Engine water temperature sender 2 way connector
X19 Hydraulic oil filter blocked switch C5 terminal
X20 Stop light pressure 1 switch 2 way connector
X21 Stop light pressure 2 switch 2 way connector
X22 Back-up pressure 1 switch 2 way connector
X23 Back-up pressure 2 switch 2 way connector
Y0 Stop fuel solenoid valve
CK25-1 10-85
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3)
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3)
A LINEA MOTORE
A LINEA CABINA TO ENGINE CABLE
TO CABIN CABLE X01.1
X46 A LINEA MOTORE
TO ENGINE CABLE
X02.1
8 9
1 2
A LINEA MOTORE
10
TO ENGINE CABLE
4 3
X10.1
11 12
5 6
13
A LINEA CABINA
7
TO CABIN CABLE
X47
MASSA
GROUND
GND5
8 9 10
1 2 3
A LINEA CABINA MASSA

TO CABIN CABLE GROUND
4
GND2
11 12 13
5 6 7
X45
PRESS. PPC SAFETY

1
4
A LINEA CABINA PPC SAFETY PRESSURE SWITCH

3
TO CABIN CABLE
5
X32
X48
PRESSOSTATO FRENO
BRAKE PRESSURE SWITCH
E/V SERV. PPC X37
PPC SERV. VALVE
X33 E/V SECONDA VELOCITA' ELETTROVALVOLA FRENO
2nd SPEED VALVE BRAKE VALVE
X32A X36 X35
E/V FLOTTANTE
FLOAT VALVE
X34
RKS03230
10-86 CK25-1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X01.1 R-N2.5
4
X01.1 M2.5
3
X01.1 R4 M1
2 X48
1
X01.1 R4 M-V1
1 X48
2
R-V1
X48
3
GND5 L-G1
X48
4
R-N2.5
X46
FROM ENGINE LINE STD/OPT
X02.1 4
l M2.5
X02.1 L-R1.5
X46
3
- R4
X46
2
R4
X46
TO CABIN LINE EURO/USA STD

X10.1 R-N1.5 1
13
X10.1
12 R-N1.5
X10.1 R1
X45
13
11 V-N1
X10.1 X45
12
10 M-B1
X10.1 B1
X45
11
9 L-R1.5
X10.1 S1
X45
10
8 B1
X10.1 C-N1
X45
9
7 M-N1
X10.1 C-L1
X45
8
6 R-G1
X10.1 S-G1
X45
7
5 S1
X10.1 X45
6
4 C-N1
X10.1 B-N1
X45
5
3 C-L1
X10.1 R-G1
X45
4
2 S-G1
X10.1 B-G1
X45
3
1 B-N1
X45
2
B-G1
X45
1
N4
X47
2
N4
X47
1
N2.5
M-N1
M-B1
M-V1
V-N1
L-G1
M1
R1
N1
N1
N1
N1
1 1 1 2 1 2 1 2 1 2 1
X32 X32A X33 X33 X34 X34 X35 X35 X36 X36 X37
S32 Y1 Y2 Y6 Y3 S33
p p
GND2
RKS03240
CK25-1 10-87
COMPONENTS
GND2 C8 ground terminal
S32 PPC safety pressure switch
S33 Brake valve pressure switch
X01.1 Engine line 4 way connector
X32 PPC safety pressure switch 1 way connector
X32A PPC safety pressure switch 1 way connector
X33 PPC valve 2 way connector
X34 Float valve 2 way connector
X35 Brake valve 2 way connector
X36 Second speed valve 2 way connector
X37 Brake pressure switch 1 way connector
X45 Cabin line 13 way connector
X47 Ground 2 way connector
Y1 PPC valve
Y2 Float valve
Y3 Second speed valve
Y6 Brake valve
10-88 CK25-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3)
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3)

A LINEA MOTORE
A LINEA CABINA TO ENGINE CABLE
TO CABIN CABLE X42 4 A LINEA MOTORE
X46
5
2 1 TO ENGINE CABLE
3
X01.1
A LINEA MOTORE
A LINEA MOTORE TO ENGINE CABLE
TO ENGINE CABLE X02.1
8 9
A LINEA MOTORE
1 2
A LINEA MOTORE X43
TO ENGINE CABLE
10
TO ENGINE CABLE
3
X10.1
4
X41
11 1
5 6
2 13
7
A LINEA CABINA
TO CABIN CABLE
X47
MASSA
GROUND
GND 5
8 9 10
1 2 3
A LINEA CABINA MASSA

TO CABIN CABLE GROUND
4
11 12 13
GND 2
5 6 7
X45
MASSA
GROUND
GND 1
1
PRESS. PPC SAFETY

4
A LINEA CABINA PPC SAFETY PRESSURE SWITCH

3
TO CABIN CABLE
5
X32
X48
PRESSOSTATO
FRENO
E/V SERV. PPC BRAKE PRESSURE
PPC SERV. VALVE SWITCH
E/V SECONDA
X33 VELOCITA' ELETTROVALVOLA X37
2nd SPEED E/V HI-FLOW E/V HI-FLOW FRENO
VALVE MOMENTARY DETENT BRAKE VALVE
HI-FLOW MOMENTARY HI-FLOW DETENT X35
7
1
2
3
X32A X36 VALVE VALVE
8 4
9
10
5
6 X40 X39
11
A LINEA CABINA
TO CABIN CABLE
E/V FLOTTANTE
X49 FLOAT VALVE
X34
RKS03250
CK25-1 10-89
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X01.1 R-N2.5
4
X01.1 M2.5 M1
X48
3 1
X01.1 R4 M-V1
X48
2 2
X01.1 R4 R-V1
X48
1 3
L-G1
GND5 N4 X48
4
R-N2.5
X02.1 X46
FROM ENGINE LINE STD/OPT
4
l M2.5
X02.1 L-R1.5 X46
3
- R4
X46
2
R4
X10.1 R-N1.5 X46
1
13
X10.1
12 R-N1.5
X10.1 R2.5 X45
13
11 V-N1
X10.1 R-V1 X45
12
10 M-B1
X10.1 B1 X45
TO CABIN LINE EURO/USA OPT

11
9 L-R1.5
X10.1 S1 X45
10
8 B1
X10.1 C-N1 X45
9
7 M-N1
X10.1 C-L1 X45
8
6 R-G1
X10.1 S-G1 X45
7
5 S1
X10.1 X45
6
4 C-N1
X10.1 B-N1 X45
5
3 C-L1
X10.1 R-G1 X45
4
2 S-G1
X10.1 B-G1 X45
3
1 B-N1
X45
2
B-G1
X45
1
C-B1
X49
11
C1
X49
10
V-B1
X49
9
V1
X49
8
A-N1
X49
7
A-B1
X49
6
A-G1
X49
5
Z-N1
X49
4
A-V1
X49
3
S-N1.5
X49
2
L-R1.5
X49
1
N2.5
M-B1
M-N1
Z-N1
M-V1
V-N1
L-G1
A-V1
R2.5
M1
N1
N1
N1
N1
N1
N1
GND1
GND2
N4
X47
1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2
N4
X47
X32 X32A X33 X33 X34 X34 X39 X39 X40 X40 X35 X35 X36 X36 X37 1
S-N1.5
L-R1.5
A-G1
A-N1
C-B1
A-B1
V-B1
N1.5
C1
V1
S32 Y1 Y2 Y5 Y4 Y6 Y3 S33
p p
4 3 2 1 5 4 3 2 1 1
X41
X41
X41
X41
X42
X42
X42
X42
X42
X43
( POWER BOX ATTACH. LINE )
RKS03260
10-90 CK25-1
COMPONENTS
S32 PPC safety pressure switch
S33 Brake valve pressure switch
X32 PPC safety pressure switch 1 way connector
X32A PPC safety pressure switch 1 way connector
X33 PPC valve 2 way connector
X34 Float valve 2 way connector
X35 Brake valve 2 way connector
X36 Second speed valve 2 way connector
X37 Brake pressure switch 1 way connector
X39 High-flow detent valve 2 way connector
X40 High-flow momentary valve 2 way connector
X41 Stabilizer 5 way connector
X42 Attachment 5 way connector
X43 ENPI valve 1 way connector
X47 Ground cabin line 2 way connector
Y1 PPC valve
Y2 Float valve
Y3 Second speed valve
Y4 Reverse hi-flow momentary valve
Y5 Super-flow detent valve
Y6 Brake valve
CK25-1 10-91
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5)
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5)

CENTRALINA SICUREZZE
SAFETY CONTROL BOX
X50
BUZZER
BUZZER
SCATOLA FUSIBILI RELE' PARKING
X52-X53 FUSES BOX PARKING RELAY
X56-X77 K14
ACCENDISIGARI 01171077
CIGARETTE LIGHTER
4
3
X78-79 ZOCCOLO RELE' FLOAT
11
1
10
FLOAT RELAY SOCKET
8
K04
7
6
5
DA LINEA TELAIO
FROM FRAME LINE
X48.1
4
1
2
5
3
SENSORE BRACCIOLO
PROXIMITY BAR 3 WAY
DA LINEA TELAIO
FROM FRAME LINE X54
X46.1
QUADRO AVVIAMENTO MANIPOLATORE SX

STARTING SWITCH LEFT LEVER
S10 X83
MANIPOLATORE DX
1
RIGHT LEVER
8
2
9
3
10
X84
4
DA LINEA TELAIO
5
11
FROM FRAME LINE

12
7
13
X45.1
SWITCH SEDILE
SAFETY SEAT SWITCH
GND X55
GROUND
X47.1
CABINA
CABIN LINE
X82 1
7 2
8 3
9 4
5
MASSE
10
11
6
GROUND
GND3
INT. LUCI
FRONT LIGHTS SWITCH
X86
INT. FARO LAVORO POST. PANNELLO
REAR WORK LIGHTS SWITCH DI CONTROLLO
X85 CONTROL PANEL
X80
PANNELLO
DI CONTROLLO
CONTROL PANEL PULSANTE FRENO INT. GIROFARO
BRAKE BUTTON BEACON LIGHT SWITCH
X81 X87 X88
RKS03270
10-92 CK25-1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BRAKE P.B. IN
X50 L/B1 H-R1
23
HA1
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
HI-SPEED P. B. IN
X50 A/B1 R-N2.5 G1.5
R2.5
22
FLOAT P. B. IN
X50 L/G1
21
SAF. BAR. SW IN
X50 C/N1
H-R2.5
20 1 1 1 1 1 1 1 1 1 1 1
M2.5
X50 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
B1
C-B1 X52 X53
SEAT SWITCH IN
19 1 1
POW. SUPP. +12V
X50 H-R1
Z-B1
18 R1 ACC BR R2 C
X50 H-L1
FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
EV BRAKE OUT OFF ACC
R1
17 R/N1 ST
STOP ENGINE OUT

X50 R-N1.5 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A
16
BRAKE LIGHT OUT

X50 S/N1 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77
15 S10
ELECTRONIC UNIT
1 1 1 1 1 1 1 1 1 1 1
X50 B/N1
SAF. BAR.LED OUT
14 S12
SEAT LED OUT
X50 G/N1 S11
R4
13
G-N1
X50 M/B1 G-N1
R-N2.5
R-G1
L-R1.5
H-R1
H/R1
B-R1
A-R1.5
G/R1
WARNING LED OUT
12
FLOAT OUT
X50 B-N1 X54 X54 X54 G1
11
C A B X55 X55
BUZZER OUT (-)
X50 Z-B1 2 1
H-R1.5
10
HI-SPEED OUT
X50 M-B1 G/R1
C/N1
N1
H-R1
C-B1
H-R1
9
GNDGND
X50 N1.5 A-R1.5
8
HORN OUT
X50 C1 H/R1
7
START SIGN. IN
X50 B1 L/B1
6
+12V HORN
X50 H-R1.5 A/B1
5
HORN PUSH B. IN
X50 B/R1 L/G1
4
PPC SAF. SW. IN

X50 L-G1 S/N1
3
EV PPC OUT
X50 V-N1 C1
2
BUZZER OUT (+)

X50 R/N1 B/R1
1
K06 X48.1 M1 B-N1

1
X48.1 M-V1 H0.5
2
X48.1 B-R1
3
X48.1 L-G1 B-R1
4
H-R1
X46.1 R-N2.5
4 M-N1
X46.1 M2.5
3
X46.1 R4 X44 86
K14 86 87a 87 N4
2
FROM FRAME LINE STD
X46.1 R4 M1 X44 87a

1 85 30
H-L1 X44 30
X45.1 R-N1.5
13
X45.1 V-N1 B-G1 X44 85
12
X45.1 M-B1
11
X45.1 L-R1.5
10
X45.1 B1
9
X45.1 M-N1
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
B-N1
B/N1
Z-B1
C-L1
H0.5
M1
8
N1
B1
S1
X45.1 R-G1
7
X45.1 S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
6
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
X45.1 C-N1
5
X45.1 C-L1
4
X45.1 S-G1 P1
3
X45.1 B-N1
2
X45.1 B-G1 CONTROL PANEL (UNIDECK)
X47.1 1
2
X47.1 N4
1
RKS03280
CK25-1 10-93
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H-R1
G1.5
S13 S14 S15
R-N0.5
R-N0.5
V/B0.5
L/G0.5
L/G0.5
RIGHT LEVER
K04 85 87
LEFT LEVER
86 30
X83 X83 X83 X83 X84 X84 X84
1 2 3 11 1 3 11
X89 X89 X89 X89

X78 X79
1 1 85 86 30 87
B-R1
B/R1
A/B1
N1
B-R1
L/G1
N1
H/R1
N1
B-N1
B-R1
B-R1
M-N1
G-N1
G1 G/R1 X85
9
H-R1.5 A-R1.5 X85
1
G/R1
1 9
1 0
A-R1.5
H/R1
5 10
S01
L/B1
A/B1 A-G1.5 X85

5
L/G1
N1 X85
S/N1 10
C1
B/R1 G/R1 X86

9
B-N1 G1.5 X86
8
H0.5 H-N1 X86
1
B-R1 S02 1 6 8 9
0 1 2
B-R1
H-R1
3 2 10
M-N1 H-R1.5 X86
3
H-R1 X86
N4 2
N1 X86
10
A-G1.5
G-N1
H-G1
H-N1
H-N1
N1.5
S/N1 X87
C1
6
H-R1 X87
GND3 3
1 2 3 4 5 6 7 8 9 10 11
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
15/1 30/3 L/6

0 1
49/4 30b/2 R/7

TO TOP CABIN LINE STD L/B1
S08
X87
2
H-R1 X87
7
G/R1 X88
9
H/R1 X88
1
1 9
1 0
5 10
H-G1
S07
X88
5
N1 X88
10
RKS03290
10-94 CK25-1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
CONTROL PANEL (EXTERNAL WIEW) INTERNAL CONNECTION CONTROL PANEL
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
+
L1 L2 L3 L4 L5 C2 C3
P1
FUEL WATER TEMP.

LEVEL INDICATOR
H F L1 L2 L3 L4 L5
C1 C2
00000 00 h
C E
C1
C3
HOUR COUNTER
DL1 DL2 DL3

L6 L7 L8 L9 L10
X80-6
-
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
L6 L7 L8 L9 L10 DL2 DL1 DL3
X80-9 X80-2 X80-3
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR
X80-1 X80-9 INTERNAL LIGHTS (+ LUCI) POSITIVE G-N1
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1
C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
+50 X80-4 START SIGNAL +50 B1 L2 X80-12 PREHEATING LAMP POSITIVE M1
GND X80-5 GROUND GND X80-13
GND X80-6 GROUND GND N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1
RKS03300
CK25-1 10-95
COMPONENTS
X63 Fuse 1 way connector
GND3 C6 ground terminal X64 Fuse 1 way connector
FU01 Fuse 3A left side lights X65 Fuse 1 way connector
FU02 Fuse 3A control panel lights X66 Fuse 1 way connector
FU03 Fuse 15A horn, front work lights X67 Fuse 1 way connector
FU04 Fuse 7.5A switch lights X68 Fuse 1 way connector
FU05 Fuse 15A rear work light X69 Fuse 1 way connector
FU06 Fuse 10A lever switch power supply, float X70 Fuse 1 way connector
FU07 Fuse 10A current intake 12V, beacon light X71 Fuse 1 way connector
FU08 Fuse 10A control panel, electronic unit, fuel shut off, safety bar proximity, seat safety switch, brake switch X72 Fuse 1 way connector
FU09 Fuse 7.5A back-up alarm X73 Fuse 1 way connector
FU10 Fuse 7.5A fuel pump, safety engine relay, generator X74 Fuse 1 way connector
FU11 Fuse 30A pull solenoid, PPC safety pressure switch X75 Fuse 1 way connector
HA1 Warning buzzer X76 Fuse 1 way connector
K04 Float relay X77 Fuse 1 way connector
K06 Elettronic unit X78 Current intake 1 way connector
K14 Brake relay X79 Current intake 1 way connector
P1 Control panel X80 Control panel 16 way connector
S01 Rear work lights switch X81 Control panel 8 way connector
S02 Panel lights and low beam lights switch X82 Lights line 11 way connector
S07 Beacon light switch X83 Left lever 12 way connector
S08 Brake switch X84 Right lever 12 way connector
S10 Starting switch X85 Rear work lights SWF switch
S11 Safety seat switch X86 Panel and front lights SWF switch connector
S12 Bar PNP safety sensor X87 Brake push button connector
S13 Horn push button X88 Beacon light switch connector
S14 Second speed push button X89 Float relay connector
S15 Float push button
X44 Brake relay connector
X45.1 From frame line mark 13 way connector
X46.1 From frame line 4 way connector
X47.1 From frame line 2 way ground connector
X50 Electronic unit 23 way connector
X52 Buzzer 1 way connector
X54 Proximity bar 3 way connector
X55 Safety seat switch 2 way connector
10-96 CK25-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7)
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7)

CENTRALINA SICUREZZE
SAFETY CONTROL BOX
X50
BUZZER
BUZZER
DA LINEA TELAIO X52-X53
FROM FRAME LINE
STAGNATURA X49.1 RELE' PARKING RELE' SPEGN. LUCI STOP
SOLDER JOINT 8
7
01171077 PARKING RELAY STOP LIGHT OFF RELAY
9 1
SAL 11
10 4
3
2
SCATOLA FUSIBILI K14 ZOC. RELE' FLOAT K95
6
5
FUSES BOX FLOAT RELAY S.
PRESA DI CORRENTE X56-X77 K04 CENTRALINA
CURRENT INTAKE COMANDO RELE'
4
10
3
X78-X79 15
RELAY COMAND UNIT
11
3
10
3 30
7.5
INT. E.V. ENPI X90
9
10 10
8
10
ENPI VALVE SWITCH
21 20 19 18 17
11 10 9 8 7
DA LINEA TELAIO
7
10
6
15
X91
5
FROM FRAME LINE
4
1
X48.1
2
5
6
3
16 15 14 13 12
5 4 3 2 1
SENSORE BRACCIOLO
DA LINEA TELAIO PROXIMITY BAR 3 WAY
FROM FRAME LINE
X46.1 X54
MANIPOLATORE SX
QUADRO AVVIAMENTO MANIPOLATORE DX LEFT LEVER
STARTING SWITCH RIGHT LEVER X83
DA LINEA TELAIO S10 X84
FROM FRAME LINE
X45.1
1
8
2
9
3
10
4
5
11
6
12
7
13
INT. STAB SX
LEFT STAB. SWITCH
X106
SWITCH SEDILE SWITCH HAZARD
SAFETY SEAT SWITCH SWITCH HAZARD
X55 X105
GND
GROUND
X47.1
INT. STAB. DX
X107
1
7 2
8 3
9 4
5
MASSE
CABINA
10
11
6
GROUND
CABIN LINE GND3
X82
INT. LUCI
FRONT LIGHTS SWITCH
X86
PANNELLO DI CONTROLLO
INT. FARO LAVORO POST. CONTROL PANEL
REAR WORK LIGHTS SWITCH X80 INT. GIROFARO
X85 BEACON LIGHT SWITCH
X88
INT. LUCI DIREZIONE
DIRECTION LIGHTS SWITCH
X104
PANNELLO DI CONTROLLO
CONTROL PANEL PULSANTE FRENO
X81 BRAKE BUTTON
X87
RKS03310
CK25-1 10-97
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BRAKE P.B. IN
X50 23 L/B1 H-R1
X50 A/B1 HA1 R-N2.5 G1.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
HI-SPEED P. B. IN 22
R2.5
FLOAT P. B. IN
X50 21 L/G1
X50 20 C/N1
H-R2.5
SAF. BAR. SW IN 1 1 1 1 1 1 1 1 1 1 1
M2.5
X50 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
B1
SEAT SWITCH IN 19 C-B1 X52 X53
1 1
POW. SUPP. +12V
X50 18 H-R1
FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
Z-B1
R1 ACC BR R2 C
X50 H-L1 30A 7.5A 10A 10A 10A 10A 15A 10A 15A 3A 3A
EV BRAKE OUT 17 R1
OFF ACC
R/N1 ST
STOP ENGINE OUT

X50 16 R-N1.5
BRAKE LIGHT OUT

X50 15 S/N1 S10 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77
X50 1 1 1 1 1 1 1 1 1 1 1
ELECTRONIC UNIT
B/N1
SAF. BAR.LED OUT 14 S12
X50
S11
SEAT LED OUT 13 G/N1
R4
X50
R-N2.5
R-G1
L-R1.5
H-R1
H/R1
B-R1
A-R1.5
G/R1
G-N1
WARNING LED OUT 12 M/B1 G-N1
FLOAT OUT
X50 11 B-N1 X54 X54 X54 G1
C A B X55 X55
BUZZER OUT (-)
X50 10 Z-B1 2 1 H-R1.5
HI-SPEED OUT
X50 9 M-B1 G/R1
C/N1
N1
H-R1
C-B1
H-R1
GND
X50 8 N1.5 A-R1.5
HORN OUT
X50 7 C1 H/R1
START SIGN. IN
X50 6 B1 L/B1
+12V HORN
X50 5 H-R1.5 A/B1
HORN PUSH B. IN
X50 4 B/R1 L/G1
PPC SAF. SW. IN

X50 3 L-G1 S/N1
EV PPC OUT
X50 2 V-N1 C1
BUZZER OUT (+)

X50 1 R/N1 B/R1
X48.1 M1 B-N1
K06 1
X48.1 M-V1 H0.5
2
X48.1 R-V1 B-R1
3
X48.1 L-G1 B-R1
4
H-R1
X46.1 R-N2.5
4 M-N1
X46.1 M2.5
3 R-V1
X46.1 R4 86 X44 K14 86 87a 87
2 L-N1
FROM FRAME LINE OPT
X46.1 R4 M1 87a X44

1 L-R1.5
85 30
H-L1 30 X44
X45.1 R-N1.5 L-R1.5
13
X45.1 V-N1 B-G1 85 X44
12
X45.1 M-B1
11 M1
X45.1 L-R1.5
10 N4
X45.1 B1
9
X45.1 M-N1
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
B-N1
B/N1
Z-B1
C-L1
L-N1
H0.5
8
M1
N1
B1
S1
X45.1 R-G1
7
X45.1 S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
6
X45.1 C-N1
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
5
X45.1 C-L1
X45.1
4 P1
S-G1
3
X45.1 B-N1
2
X45.1 B-G1 CONTROL PANEL (UNIDECK)
X47.1 1
2
X47.1 N4
1
RKS03320
10-98 CK25-1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H-R1
G1.5 TO TOP CABIN LINE OMOLOG./ STD
1 2 3 4 5 6 7 8 9 10 11
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
K04 85 87
K95 86 87a 87
A1
L1
G1
G-N1
R/N1
H-N1
H-N1
A-G1.5
C1
N1.5
H-G1
86 30 85 30
X95 X95 X95 X95

X78
X79
X89 X89 X89 X89 86 85 30 87a
1 1 85 86 30 87
M1
N1
L-R1
R-V1
B-N1
B-R1
B-R1
M-N1
H/R1
N1
G-N1
9
G1 G/R1 X85
1
H-R1.5 A-R1.5 X85
G/R1 S01 1 9
1 0
A-R1.5
H/R1
5 10
L/B1
5
A/B1 G-N1.5 X85
L/G1
10
N1 X85
S/N1
C1
9
B/R1 G/R1 X86
8
B-N1 G1.5 X86
1
H0.5 H-N1 X86
B-R1 S02
1 2
1 6 8 9
0
B-R1
H-R1
3 2 10
3
M-N1 H-R1.5 X86
2
R-V1 H-R1 X86
10
L-N1 N1 X86
L-R1.5
6
S/N1 X87
L-R1.5
3
H-R1 X87
M1. S08 15/1 30/3 L/6
0 1
N4
49/4 30b/2 R/7
2
L/B1 X87
7
H-R1 X87
9
G/R1 X88
1
GND3 H/R1 X88
S07 1 9
1 0
A-R1.5
L-R1.5
L-R1.5
G/R1
H/R1
B-R1
R-V1
R/N1
B/R1
L-N1
L/G1
A/B1
N1.5
N1
A1
L1
5 10
= Parts not included in the wiring H-G1
5
X88
10
N1 X88
RKS03330
CK25-1 10-99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H/R1
L-N1
B-R1
L1
A1
R-V1
L/G1
L-R1.5
A/B1
L-R1.5
B/R1
R/N1
N1
N1.5
A-R1.5
G/R1
RELAYS UNIT
K05
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
A-V1
C/B1
L-R1.5
A/N1
L-N1
A/V1
R/N1
R-V1
L/N1
Z-N1
N1.5
A-N1
V/B1
L/R1
A-G1
Z/N1
A-B1
A-R1.5
A1 X104
2
L1 X104
1
S03 1 2
1 0 2
54
A/N1 X104
54
N1 X105
10
A/N1 X105
5
G/R1 X105
8
H/R1 X105
2
S09 2 8 5 10
1 0
X49.1 C-B1
11
X49.1 C1
4 6 3 1 7
FROM FRAME LINE OPT
10
X49.1 V-B1 L/R1 X105
9
4
X49.1 V1 A1 X105
8
3
X49.1 A-N1 L1 X105
7
1
X49.1 A-B1 G/R1 X105
L-R1.5
6
G/R1
S-N1
7
X49.1 A-G1
N1
5 G/R1 X106
X49.1 Z-N1 9
4
5 1 9 10
V-B1 X106
X91
X91
X91
X91
X49.1 A-V1 7
3 V1 X106
X49.1 S-N1 1
A-G1
SWITCH EV ENPI
B-R1
B-R1
A-N1
B/R1
C/B1
Z-N1
2 A-B1
A/B1
V/B1
L/G1
A/V1
Z/N1
L/N1
1 7 9
N1
N1
X49.1 L-R1.5 1 0 2
1
1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11
3 10
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
L-R1.5 X106S05
3
X106
RIGHT LEVER N1
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.5
N0.8
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.5
A-G0.5
A-N0.5
Z-N0.5
N0.8
10
G/R1 X107
9
C-B1 X107
7
C1 X107
LEFT LEVER
1
S06 1 7 9
1 0 2
S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4
3 10
HL5 L-R1.5 X107

3
N1 X107
10
RKS3340
10-100 CK25-1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RELAYS UNIT
K12 86 87a 87 K08 85 30 K09 85 30 K11 86 87
85 30 86 87 86 87 85 30
K07 85 30 K13 +
K10
53M
53S
R CL(T)
31
15
T
86 87
-(53S)
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
K05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
RKS03350
CK25-1 10-101
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
CONTROL PANEL (EXTERNAL WIEW)

INTERNAL CONNECTION CONTROL PANEL
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
P1 L1 L2 L3 L4 L5 C2 C3 +
FUEL WATER TEMP.

H F LEVEL INDICATOR
L1 L2 L3 L4 L5
C1
00000 00 h C2
C E
C1 C3
HOUR COUNTER
DL1 DL2 DL3

L6 L7 L8 L9 L10
X80-6
-
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
X80-9 X80-2 X80-3
C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1
RKS03360
10-102 CK25-1
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7) S40 “B” way push button
X44 Parking brake relay connector
COMPONENTS X45.1 From frame line mark 13 way connector
X46.1 From frame line 4 way connector
X47.1 Ground 2 way connector
FU01 Fuse 3A left side lights, plate light
FU02 Fuse 3A control panel lights, right side lights
FU03 Fuse 15A horn, low beam or front work lights
X50 Safety control box 23 way connector
FU04 Fuse 10A switch lights, direction lights
FU05 Fuse 15A rear work light, stop light
FU06 Fuse 10A lever switch power supply, float
X54 Proximity bar 3 way connector
FU07 Fuse 10A current intake 12V, hazard, beacon light
X55 Safety seat switch 2 way connector
FU08 Fuse 10A control panel, electronic unit, fuel shut off, safety bar proximity, seat safety switch, brake switch
FU09 Fuse 10A back-up alarm, attachement 3 way, hi-flow, stabilizer, ENPI valve
FU10 Fuse 7.5A fuel pump, safety engine relay, generator
FU11 Fuse 30A pull solenoid, PPC safety pressure switch
HA1 Warning buzzer
HL1 Super-flow led diode
HL2 “C” way led diode
HL3 “A” way led diode
HL4 “B” way led diode
HL5 Optional led diode
K04 Float relay
K05 Relays box (without relays)
K06 Elettronic unit
K07 “B” way relay
K08 “A” way relay
K09 “C” way relay
K10 Super-flow detent step by step relay
K11 Reverse hi-flow momentary relay
K12 Stop lights relay
K13 Flasher unit
K14 Brake relay
K95 Stop light relay
P1 Control panel
X78 Current intake 1 way connector
S01 Rear work lights switch
X79 Current intake 1 way connector
S02 Panel lights and low beam lights switch
X80 Control panel 16 way connector
S03 Direction lights switch
X81 Control panel 8 way connector
S05 Up-down left stabilizer button
X82 Lights line 11 way connector
S06 Up-down right stabilizer button
X83 Left lever 12 way connector
S07 Beacon light switch
X84 Right lever 12 way connector
S08 Brake switch
X85 Rear work lights SWF switch
S09 Hazard switch
X86 Panel and front lights SWF switch connector
S10 Starting switch
X87 Brake push button connector
S11 Safety seat switch
X88 Beacon light switch connector
S12 Bar PNP safety sensor
X89 Float relay connector
S13 Horn push button
X90 Relays box 21 way connector
S14 Second speed push button
X91 Enpi valve SWF connector
S15 Float push button
X104 Direction lights switch connector
S36 Reverse hi-flow momentary push button
X105 SWF hazard connector
S37 Super-flow detent push button
X106 Stabilizer push button connector
S38 “C” way push button X107 Stabilizer push button connector
S39 “A” way push button
CK25-1 10-103
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (1/2)
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (1/2)
FARO DI LAVORO POSTERIORE DX

RKS03370
REAR RIGHT WORKING LIGHT
H11 FARO DI LAVORO POSTERIORE SX
REAR LEFT WORKING LIGHT
H10
B
A
A B
FARO DI LAVORO ANTERIORE SX

FRONT LEFT WORKING LIGHT
3 2 1
9 8 7
LINEA CRUSCOTTO
FROM DASHBOARD CABLE H4
A
B
4
X82.1
11 10
6 5
AVV. ACUSTICO
PRESA 12V HORN
CURRENT INTAKE(12V) HA2
XP1
B A
FARO DI LAVORO ANTERIORE DX
MASSE FRONT RIGHT WORKING LIGHT
GROUND H6
GND4
MASSA CLAXON
HORN GROUND
GND6
14 13 12 11 10 9 8 7 6 5 4 3 2 1
10-104 CK25-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (2/2)
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (2/2)
1 2 3 4 5 6 7 8 9 10
COMPONENTS
GND6 C8 horn ground terminal
H1 Beacon light
H4 Left front work lamp
H6 Right front work lamp
H10 Left rear work light
= Parts not included in the wiring H11 Right rear work light
HA2 Horn
X82.1 From cabin line 11 way connector
X108 Left front light 2 way connector
X109 Right front light 2 way connector
X82.1
11
H-G1
X110 Left rear work lights 2 way connector
X82.1
10
N1.5
X111 Right rear work lights 2 way connector
X82.1
9
C1
X113 Horn 1 way connector
X82.1
XP1
FROM CABIN LINE
8
A-G1
12V socket, beacon light 1 way connector
X82.1
7
H-N1 XP1A 12V socket, beacon light 1 way connector
X82.1 H-N1 GND4
6
X82.1
5
X82.1
4
X82.1
3
X82.1
2
X82.1
1
1 2 1 2 A B A B 2 1
X108 X108 X109 X109 X110 X110 X111 X111 XP1 XP1A
H-N1
N1
H-N1
N1
A-G1
N1
A-G1
N1
N1
H-G1
GND6
1
H1
X113
M
H4 H6 H10 H11
HA2
RKS03390
CK25-1 10-105
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2)
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2)
FARO DI LAVORO POSTERIORE DX

REAR RIGHT WORKING LIGHT
H11
A B
LUCE TARGA
NUMBER PLATE LIGHT
FARO DI LAVORO POSTERIORE SX
H12 REAR LEFT WORKING LIGHT
FANALE POSTERIORE SX
H10 REAR LEFT LIGHT
H8 FANALE ANTERIORE SX
FANALE POSTERIORE DX FRONT LEFT LIGHT
REAR RIGHT LIGHT
B
A
H5
H9
FARO ANABBAGLIANTE SX
3 2 1
9 8 7
LINEA CRUSCOTTO FRONT LEFT MAIN BEAM
A
FROM DASHBOARD CABLE H4
B
4
11 10
X82.1
6 5
AVV. ACUSTICO
PRESA 12V HORN
CURRENT INTAKE(12V) HA2
XP1
ł6 B A
ł6
MASSE
GROUND
FARO ANABBAGLIANTE DX
GND4 FANALINO ANTERIORE DX
ł8
FRONT RIGHT MAIN BEAM
FRONT RIGHT LIGHT
MASSA CLAXON H6
HORN GROUND
H7
GND6
RKS03540
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
10-106 CK25-1
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION)
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (2/2)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
= Parts not included in the wiring
X82.1 H-G1
11
X82.1 N1.5
10
X82.1 C1
FROM CABIN LINE
9
X82.1 A-G1
8
X82.1 H-N1
7
X82.1 H-N1
6
X82.1 R/N1
5
X82.1 G-N1
4
X82.1 G1
3 GND4
X82.1 L1
2
X82.1 A1
1
A B 1 1 1 A B 1 1 1 1 1 1 1 1 1 1 1 1 1 A B A B 1 1
X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X121 X122 X123 X124 X125 X126 X127 X128 X129 X130 X110 X110 X111 X111 XP1 XP1A
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
N1
L1
G1
R/N1
R/N1
G-N1
A1
N1
G1
N1
A-G1
N1
A-G1
N1
N1
H-G1
1
X113
GND6
HA2 H4 H5 H6 H7 H8 H9 H12 H10 H11 H1
58R
58R
58L
58L
54
54
R
R
L
L
31
31
31
31
RKS03550
COMPONENTS X109 Front low beam 2 way connector X127 Rear traffic lights 1 way connector
X110 Rear work lights 2 way connector X128 Rear traffic lights 1 way connector
GND4 Ground ø6 terminal
X111 Rear work lights 2 way connector X129 Plate light connector
GND6 Ground ø8 terminal
X115 Front traffic lights 1 way connector X130 Plate light connector
H1 Beacon light
X116 Front traffic lights 1 way connector XP1 Current intake 12v, beacon light
H4 Left low beam
X117 Front traffic lights 1 way connector XP1A Current intake 12v, beacon light
H5 Left side light
X118 Front traffic lights 1 way connector
H6 Right low beam
H7 Right side light
H8 Left rear lamp
X121 Rear traffic lights 1 way connector
H9 Right rear lamp
H10 Left rear work light
H11 Right rear work light
H12 Plate light
HA2 Horn
X108 Front low beam 2 way connector
CK25-1 10-107
PAGE INTENTIONALLY
LEFT BLANK
20 TESTING AND ADJUSTMENTS
NORMAL OR STANDARD TECHNICAL DATA..............3 ADJUSTING THE POSITION OF THE SERVO-

SPECIAL TOOLS..........................................................12 CONTROL ENGAGEMENT SAFETY SENSOR .......... 25
CHECKING THE ENGINE SPEED ...............................13 CONTROL AND REGULATION OF THE PRESSURES IN
THE HYDRAULIC CIRCUITS ...................................... 26
ADJUSTMENT OF VALVE CLEARANCE ....................14
TESTING THE HYDRAULIC PUMP............................. 27
MEASUREMENT OF THE COMPRESSION
PRESSURE ..................................................................16 VALVE CALIBRATION ................................................. 28
CONTROL AND ADJUSTMENT OF THE FAN CHECKING THE TRAVEL DEVIATION ....................... 30
BELT TENSION ............................................................17 CONTROL VALVE ....................................................... 32
CONTROL AND ADJUSTMENT OF THE CONTROL AND REGULATION OF THE SERVO-
INJECTION TIMING......................................................18 CONTROLPOWER SUPPLY ....................................... 33
CHECKING ENGINE OIL PRESSURE.........................20 ELIMINATION OF RESIDUAL PRESSURES - PRESSU-
ADJUSTING THE STROKE OF THE RISATION OF THE TANK............................................ 35
ACCELERATOR CABLES ............................................21 BLEEDING AIR FROM THE HYDRAULIC CIRCUITS. 36
REGULATION OF PPC VALVES’ DRIVE PRESSURE 22 TRACK TENSION TEST AND ADJUSTMENT ............ 38
ADJUSTMENT OF THE PPC VALVE CLEARANCES .24
k When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level ground.
Apply all the machine safety devices and use blocks to prevent any machine movement.
k When more than one person is engaged in the work, use the prescribed notices that indicate that the machine is un-
dergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
k When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed while the
liquid is still hot and under pressure, it may cause severe burns.
k Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
CK25-1 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
NORMAL OR STANDARD TECHNICAL DATA

FOR ENGINE

Engine 4D98E-2NFE
Standard Permissible
Check item Test conditions Unit
value value
High idling 2680 2630–2730
Engine speed Low idling rpm 1070 1020–1120
Set speed 2500 –
Exhaust gas Sudden acceleration Bosch

– –
colour At high idling speed index
Intake valve (20°C) mm 0.20 0.15– 0.25

Valve clearance
Exhaust valve (20°C) mm 0.20 0.15– 0.25
Compression
Oil temperature 40–60 °C kg/cm² 35±1 28±1
pressure
(Engine speed) (rpm) (250) (250)
(SAE30 oil)
Blow - by
Water temperature in operating range
pressure mm H2O – –
At high idling speed
(oil SAE30)
Oil temperature: 80 °C
Engine oil
At high idling kg/cm² 3.0–4.0 –
pressure
At low idling kg/cm² > 0.6 –
Oil
Entire speed range °C Max. 250 120 Max. 250 120
temperature
Fuel injection timing B.T.D.C. degrees – –
Fan belt Deflection when pressed with finge forceof

mm 10 10–15
tension approx. 10 kg
CK25-1 20-3
FOR MACHINE

Classifi Standard Permissible
cation value value
Travel forward Neutral o Forward 65 58.5–71.5
Travel reverse Neutral o Reverse 65 58.5–71.5
R.H. travel Neutral o R.H. 65 58.5–71.5
L.H. travel Neutral o L.H. 65 58.5–71.5

Stroke of levers and pedals
Raise arm Neutral o Raise 65 58.5–71.5

• Engine stopped.
Lower arm • At centre of lever knob Neutral o Lower mm 65 58.5–71.5
• Reading at end of travel
• Equipment on the ground
Dump bucket Neutral o Dump 65 58.5–71.5
Curled bucket Neutral o Curl 65 58.5–71.5
Neutral o R.H.
Attachment pedal 20 15–25
Neutral o L.H.
Travel speed lever Min. o Max. 105 100–110
Accelerator pedal Min. o Max. 40 30–50
Travel forward • Engine speed: min. 2.0 1.8–2.2

• Oil temperature: 45–55 °C
Travel reverse • For PPC valves: tool attachment 80 mm from 2.0 1.8–2.2
handle base
Operating force for control of levers and pedals
• Instrument coupling on outside edge

R.H. travel (for pedal control) 2.0 1.8–2.2
L.H. travel 80 mm 2.0 1.8–2.2
Raise arm 1.8 1.5–2.1

kg
Lower arm 1.8 1.5–2.1
Dump bucket 1.8 1.5–2.1
Curled bucket 1.8 1.5–2.1
Right 5.0 4.0–6.0

Attachment pedal
Left 5.0 4.0–6.0
Travel speed lever 7.5 5.0–10
20-4 CK25-1
FOR MACHINE

Classific Standard Permissible
ation value value
• Engine speed: ±50 rpm
Control valve 206 196–211
• Engine speed: 2500±10 rpm
Travel motors • Oil temperature: 45–55 °C
348 336–360
(forward) • Parking brake:
• nd speed
Hydraulic pressure

Travel motors • Oil temperature: 45–55 °C
348 336–360
(backward) • Parking brake:
• nd speed bar
Servocontrol 27 25–29
• Machine raised from grouns Low idling 11.8± 0.5 7.8–12.7
AS Valve • Oil temperature: 45–55 °C
• Travel levers: forward at 2500±30 rpm 15± 0.5 11.1–16.5
• Engine speed: max.
Charge safety valve • Oil temperature: 45–55 °C 25.5±29.4 19.6–29.4
• Travel levers: at neutral
Pilot system travel

– –
forward (start-up)*
Pilot system and secondary circuit pressures
Pilot system travel

16.5± 0.5 16–17
(maximum)
Pilot system travel
– –
reverse (start-up) *
Pilot system travel • Engine speed: 2500±10 rpm 16.5± 0.5 16–17
reverse (maximum) • Oil temperature: 45–55 °C
• Machine raised from grouns bar
Pilot system travel
*Pressure of wheels starting rotation
to right or left – –
(start-up) *
Pilot system travel

to right or left 16.5± 0.5 16–17
(maximum)
Pilot system with parking

min. 25 min. 25
brake disengaged

Engine speed (with load)
With travel pumps in stall • nd speed 2600 2500–2700

• Travel lever: at full stroke
• Parking brake: applied
rpm
With travel pumps in stall • Oil temperature: 45–55 °C
• nd speed
and equipment at max. 2300 2200–2400
• Travel lever: at full stroke
pressure • Parking brake: applied
• Raise: at end of stroke
CK25-1 20-5
FOR MACHINE

Classifi Standard Permissible
cation value value
Total work equipment

Downward
Max. 250 130 Max. 250 130
movement of tips of
the rake blade)
• Control position:
see Fig.A in this section.
• In this position, measure extension or retraction of
each cylinder, and any leakages occurring.
Hydraulic drift
Front bucket
• Horizontal and level ground

• Engine: switched off
Raising cylinder
• Oil temperature: 45–55 °C mm Max. 250 15 Max. 250 15
(Retraction) • Release all residual pressure as soon as you stop
the engine.
• Take all readings immediately after stopping the
engine and releasing all residual pressure.
• Measure the variation 15 minutes after engine
stop.
Bucket cylinder
Max. 8 Max. 8
(Extension)
20-6 CK25-1
FOR MACHINE

ation value value
Raise
4.4 3.96–4.84
Arm
Arm on the ground see Fig.B in this section.
• Average value over 3 tests.
I • Engine speed: max.
Cylinders fully • Oil temperature: 45–55 °C
extended
Lower
2.7 2.43–2.97
Standard
Bucket
Curl
2.1 1.89–2.31
Cylinders fully see Fig.C in this section.
extended • Average value over 3 tests.
Work equipment speed
Cylinders fully
Curl
retracted 2.3 2.07–2.53
sec.
Raise
4.6 4.14–5.06
Arm
see Fig.D in this section.
Arm on the ground
• Average value over 3 tests.
Pattern change version (optional)

Cylinders fully • Oil temperature: 45–55 °C
extended
Lower
2.9 2.61–3.19
Bucket
Curl
2.2 1.98–2.42
Cylinders fully see Fig.E in this section.
extended • Average value over 3 tests.
Cylinders fully
Curl
retracted 2.4 2.16–2.64
CK25-1 20-7
FOR MACHINE

ation value value
Normal
96±3 93–99
see Fig.F in this section.
Wheel swing • Engine speed: max.
drive wheel • Oil temperature: 45–55 °C rpm
• Machine raised from grouns
With increment
(without load)
• Track tensioning arrow
15-20 mm on central roller
155±4 151–159
Normal
11.7± 0.3 11.4–12.0

(7.5 km/h) (7.87–7.125 km/h)
see Fig.G in this section.
Travel speed sec.
• Track tensioning arrow
15-20 mm on central roller
With increment
• Travel 25 meters and then check the time

needed to cover 25 meters.
7.5± 0.3 7.2–7.8
Travel
(12 km/h) (12.6-11.4 km/h)

Engine speed max.
see Fig.H in this section.
• Oil temperature: 45–55 °C Max. 250 Max. 250
• Track tensioning arrow (Max. 250) 250) (Max. 250) 250)
15–20 mm on central roller
• Travel 20 metres on flat ground and measure
the deviation.
• Check all the direction
a The surface must be firm and horizontal.
Travel deviation mm
20m
Engine speed 1900±100 rpm
10m
RKS01710 Max. 250 Max. 250
(Max. 250) 250) (Max. 250) 250)
[Max 400] [Max 400]
( ): Value with speed increment
[ ]: Value in reverse gear
20-8 CK25-1
PAGE INTENTIONALLY
LEFT BLANK
Fig. A Fig. B
RKS05090
RKS05100
Fig. C Fig. D
RKS05110
RKS05100
20-10 CK25-1
Fig. E Fig. F
RKS05110
RKS05120
Fig. G Fig. H
RKS05140 RKS05140
CK25-1 20-11
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Measurement check points Symbol Code Name Q.ty Remarks

Commercially
1 Multi-scale tachometer 1 20 -4000 rpm
available
Engine speed A
Commercially
2 Stroboscopic tachometer 1 6 - 30000 rpm
available
Commercially
Valve clearance B 1 Feeler gauge 1 --
available
1 Compression gauge 1 Kit Yanmar
Compression pressure C
2 Adapter 1 TOL-97190080
Commercially
1 Pressure adapter 1 Thread 1/8”
available
Engine oil pressure D
Commercially
2 Compression gauge 1 Scale 10 bar
available
Commercially
available
Commercially 1 Scale 400 bar

2 Compression gauge
available 1 Scale 600 bar
Hydraulic pressure E Commercially

available
Commercially Sensocontrol kit
4 1 0–1000 bar
available (Differential pressure)
Commercially
5 Pressure adapter 1 Thread M10
available
20-12 CK25-1
TESTING AND ADJUSTMENTS CHECKING THE ENGINE SPEED
CHECKING THE ENGINE SPEED
k When checking the engine rpm , always be very careful

not to touch parts that reach high temperatures and not
to get entangled in rotating elements.
a Check the engine speed after the following conditions

have been reached:
• Temperature of engine cooling water: A1
68–80 °C.
• Oil temperature: 45–55 °C.
1 - Mount and connect the tachometer A1.
a If the stroboscopic tachometer A2 is used, remove

RKSA1250
plug (1).
2 - Start the engine and check:

• Low idling without load (accelerator lever in
“minimum” position).
• High idling without load (accelerator lever in
“maximum” position). A2
a Low idling: 1070±50 rpm
a High idling: 2680±50 rpm
1
a If the minimum and maximum speeds do not fall
within the permissible range when the engine is
without load, check the position locks of the RKSA1260
accelerator pedal, and the sheathing of the

accelerator cable, before carrying out any tests
under load.(See"ADJUSTING THE STROKE OF
Min Max
THE ACCELERATOR CABLES").
• Engine rpm with the pumps under load.
a Only for Pattern Change version.

Check that the Pattern change valve is in “ISO”
mode.
a Max. speed with parking brake engaged, in 2nd

speed, and with travel lever at full stroke forward.
2500–2700 rpm
a Max. speed with parking brake engaged, in 2nd RKS01191
speed, with travel lever at full stroke (forward) and

arm raise at the end of stroke:
2200–2400 rpm
a If engine efficiency does not fall within permissible

limits, have the engine checked by an authorised
workshop.
CK25-1 20-13
TESTING AND ADJUSTMENTS ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE

1. Zero setting
1 - Remove the air intake filter.
(For details, see "AIR INTAKE FILTER").
2 - Remove the valve cover. 2

(For details, see "VALVE COVER").
3 - Remove the feedback fuel pipe. 3

(For details, see "INJECTORS").
1
RKSA1270
4 - Loosen the nut (1) and the block (3) adjustment screw
(2).
5 - Operate on rocker (5) adjustment screw (4) for seat the

block on inner valve. 4
a Check that the valve cap is lying flat on the valve
stem and that there is no lop-sided wear.
• If the valve caps are damaged, replace them
with new ones. 5
• Make sure that the valve caps fit perfectly and
are lying flat on the valve stem.
RKSA1280
6 -Tighten the adjustment screw (2) until it is seated on the

2 1
outer valve. Lock the position with the nut (1).
3
0mm 0mm
YES NO
RKS02280
5
2. Adjustment
1 - Turn the drive shaft in the normal direction of rotation
until the line (1) marked as no. 1 on the flywheel is in
alignment with the reference notch (2) on the flywheel 2
1
housing.
a If the cylinder is in a compression stroke, the valves

do not move when the drive shaft is rotated slightly.
If the valves do move, rotate the drive shaft by one
turn and realign the reference marks (1) and (2).
RKSA1290
20-14 CK25-1
TESTING AND ADJUSTMENTS ADJUSTMENT OF VALVE CLEARANCE
2 - Loosen the lock nut (3) and unscrew the adjustment

screw (4) by approximately 1 turn.
5 3 4
B1
RKSA1300
3 - Insert the feeler gauge B1 between the rocker (5) and

the valve cap (6). Rotate the adjusting screw (4) until it
5
rubs against the feeler gauge B1.
Secure this position with the nut (3).
a After locking the nut (3), check the valve clearance

again. 6
4 - Adjust the clearance between valve and rockers to the
following values:
Unit: mm
With engine Suction valves Exhaust valves
cold 0.20 0.20 RKS02290
5 - After adjusting the No. 1 cylinder, rotate the drive shaft

180° each time and adjust the valve clearance of the
other cylinders according to the ignition sequence.
a Ignition sequence: 1 - 3 - 4 - 2.
CK25-1 20-15
TESTING AND ADJUSTMENTS MEASUREMENT OF THE COMPRESSION PRESSURE
MEASUREMENT OF THE COMPRESSION PRESSURE

k While measuring the compression, take care not to get
entangled in the cooling fan, the alternator belt, or in
other rotating parts.
Check all cylinders.
a Test conditions:
• Engine: at working temperature.
• Hydraulic oil: 45–55°C.
• Battery: fully charged
• Valve clearance: adjusted
(See "ADJUSTMENT OF VALVE CLEARANCE")
1 -Remove suction filter and holder.

(For details, see "AIR INTAKE FILTER".) 2
2 - Remove the valve cover. 1
3 - Disconnect the connector (1) of the engine-stopping
solenoid and close the fuel cock (2).
4 - Turn the engine over a few times, using the starting
motor.
RKSA1310
5 -Connect the test pressure gauge C1.
a Check that the seal is mounted in the adapter, and

C1
that it is undamaged.
6 - Turn the engine using the starting motor and read the
compression value.
a Read the compression value when the pressure

gauge has stabilised.
a While reading the compression, also check the

engine rpm using the tachometer A1 or A2. If the
speed does not correspond with the control value, RKSA1320
check it against the diagram.
7 - After the reading, re-assemble valve cover, the air

intake pipe and the connector (1).
3 Nut that secures the nozzle: 7.84±0.98 Nm

(kg/cm2)
40
3 High-pressure coupling: 31.85±2.45 Nm

Compression pressure
35
30
25
20
200 250 300 350 400

Engine speed (rpm)
RKS01510
20-16 CK25-1
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION
CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION

1. Checking the tension
1 - Depress the belt (1) at the centre of the section between 4
the alternator (2) and the pulley (3) that drives the water
pump. Check the flexion.
At a pressure of 98 N, the flexion should be 7–10 mm. If
this value is not found, adjust the belt tension.
a With a new belt the flexion should be 5–8 mm. 2
RKSA1330
2. Adjusting the belt tension

1 - Loosen the screws (4) that secure the alternator (2) 710 mm
2 - Rotate the alternator (2) to give the belt (1) the correct 3
tension and tighten the screw (4).
2
3 - Check the belt (1) tension.
a If the belt has been replaced with a new one, check

the tension again after about 20 hours of operation.
1
3 Screw: 25–32 Nm Engine shaft
pulley
RKS02300
CK25-1 20-17
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING

a Check the injection timing of the No.1 cylinder by means
of the No.1 union of the injection pump.
a The cylinders are numbered 1-2-3-4 counting from the

flywheel side.
a The spark advance notches of 0°-10°-15°-20°; are also

marked on the flywheel. In order to read the intermediate
values, sub-divide the sections between the two marks
1
into equal lengths.
1 - Remove the cap (1) of the flywheel casing.
RKSA1340
2 - Pass a screwdriver between the teeth and rotate the

flywheel in a counter-clockwise direction (as seen from
the flywheel side) until the 1/4 notch of the flywheel is
aligned with the notch (2) marked inside the hole in the 2
casing.
a In this position, the piston of the No. 1 cylinder is at

the top dead centre (B.T.D.C.). Check that the
cylinder is in a compression stroke, i.e. that both
valves are closed.
a Once the B.T.D.C. has been ascertained, rotate the

drive shaft in a clockwise direction (seen from the
RKSA1291
flywheel side) for about 25 teeth.
3 - Take off the clamp (3) and disconnect all the fuel
delivery tubes (4) from the injection pump.
4 - Rotate the flywheel slowly in a counter-clockwise

direction (seen from the flywheel side), checking
carefully the level of the fuel in the No. 1 union of the
3
injection pump. Stop the rotation when the fuel level
starts to rise.
4
RKSA1350
5 - Check the position of the notches at 15° and 10° that

appear in the hole in the casing and, in function of the
position, establish the true fuel injection timing. 15°
a In order to determine the degrees of intermediate
fuel injection advance, subdivide the space 10°
between 10° and 15°.
Mark
2
RKSA1360
20-18 CK25-1
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
6 - After you have loosened the check nuts for the pump (6)
and the screws (7), rotate the injection pump (5) 8
outwards or towards the engine.
• To ADVANCE injection, rotate pump (4) outwards.
• To DELAY injection rotate the pump (4) towards the
cylinder block.
a Check the extent of the movement on the scale (8).

7 - Lock the nuts (6) that fasten the pump to its block.
5
a After adjustment of the fuel injection timing:
6 7
8 - Connect the fuel delivery tubes (5) to the pump and RKSA1370
replace the clamp (3).
9 - Bleed any air from the fuel circuit.
CK25-1 20-19
TESTING AND ADJUSTMENTS CHECKING ENGINE OIL PRESSURE
CHECKING ENGINE OIL PRESSURE

k When measuring the engine oil pressure, take great
care not to touch high-temperature parts, or to become
entangled in rotating elements.
a Check pressure with the engine at working temperature.

a Low and high idling within permissible limits.
1 - Start the engine and wait for it to reach working
temperature.
a Working temperature:
Coolant liquid: 90°C
Engine oil: 120°C
2 - Stop the engine and remove the oil pressure sensor (1).
RKSA1430
3 - Mount the adapter D1 and connect the pressure gauge

D2.
D2
4 - Start the engine and check the oil pressure at low idling
(accelerator lever in low idling position) and at high
idling ((accelerator lever in high idling position).
5 - Remove the adapter D1 and install the oil pressure
sensor (1).
D1
RKSA0110
20-20 CK25-1
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR CABLES
ADJUSTING THE STROKE OF THE ACCELERATOR CABLES

a Conditions for the adjustment:
• Engine: stopped Min Max
• Working equipment: resting on the ground
• Cab: raised
a If the protective sheaths need to be substituted, block

the lever (or pedal) side of the sheaths in an
intermediate position before carrying out the
adjustment.
1
1 - Place the accelerator command lever (1) in low idling
position.
RKS01190
2 - Temporarily block the protective sheath (2) in an

intermediate position and block the retainer (3) at
8
approx. 1 mm from the injection pump lever (4). 7
3 - Put the accelerator command lever (1) into the high 2
idling position.
RKSA1400
4 - Use the nuts (7) and (8) to reset the position of the
injection pump lever (5) to approx. 0.5 mm from the high
idling adjustment screw (6). 3
RKSA1410
5 - Bring the accelerator command lever back to the low

idling position and check that the retainer (3) has
sufficient clearance.
3
6 - Repeat the same procedure for the accelerator pedal
cable. 5
RKSA1420
CK25-1 20-21
TESTING AND ADJUSTMENTS REGULATION OF PPC VALVES’ DRIVE PRESSURE
REGULATION OF PPC VALVES’ DRIVE PRESSURE

a Regulate the PPC valves’ drive pressure by performing
the following steps.
1 - Rest the working equipment on the ground and
stop the engine.
2 - Turn the ignition key to the I position and shift the
control levers in all directions to release the
hydraulic circuit pressure completely.
3 - Turn the ignition key to the O (OFF) position and
remove the ignition key.
Gently loosen the oil fill cap to eliminate any
residual pressure.
Disassembly and regulation

1 - Remove the complete PPC VALVE.
(For details, refer to section "PPC VALVES".
2
2 - Lift the boot (1) and mark the position of the lever (2) in 1
relation to the PPC valve body (3).
RKSA2360
3 - Loosen the screw (4), remove the washer (5) and pull
out the complete handle (6). [*1]
4
RKSA2370
4 - Remove the joint (7) and retainer plate (8).

[*2]
7 9
5 - Remove the boot (9) and remove the O-ring (10).
10
RKSA2380
20-22 CK25-1
TESTING AND ADJUSTMENTS REGULATION OF PPC VALVES’ DRIVE PRESSURE
6- Loosen 4 retaining screws (11) from the plate (12) and

remove the plate. [*3]
11
12
RKSA2390
7 - Remove the piston (13) and seals. [*4]

a Use a soft tool to remove. 14
13
8 - Remove the complete spool (14).
9 - Remove the retainer (15), spring (16) and shims (17)

from the spool (14).
10 - Add shims until you reach the admitted calibration

value; bear in mind that 0.3 mm thickness corresponds
to a variation in pressure of about 0.6 bar. (For details,
please refer to «TECHNICAL DATA»).
RKSA2400
Assembly
• To assemble, perform the disassembly procedure in the
reverse order. 15 16
17
a Thoroughly clean all parts.
2 Cleaner: Loctite 7063
14
[*1]
3 Screw: 64-74 Nm
[*2]
a Press down on the stoppers (13) to ease setting into RKSA2410
place; tighten the retainer plate (8) until it is properly

seated and adjust clearance. (For details, please
refer to «PPC VALVE CLEARANCE
ADJUSTMENT»).
3 Joint: 112.8±14.7 Nm
[*3]
3 Screws: 13.2±1.5 Nm
[*4]
a Lubricate the stoppers (13).
CK25-1 20-23
TESTING AND ADJUSTMENTS ADJUSTMENT OF THE PPC VALVE CLEARANCES
ADJUSTMENT OF THE PPC VALVE CLEARANCES

The clearance of the PPC valve (hand and foot) levers is
adjusted as follows.
k Lower the working equipment to the ground and stop 2

the engine.
Turn the ignition key to the I position and move the 1 3
control levers in all directions in order to release all
pressure in the hydraulic circuits. 4
Return the ignition key to the O (OFF) position and
remove it.
Slowly loosen the oil-tank fill cap to eliminate residual
pressure.
1 - Remove boot (1).
2 - Loosen the nut (2) that retains the disc (3).
3 - Tighten the disc (3) until it makes light contact with the 4
push-rods (4).
a During this adjustment, take care not to activate any

of the push-rods (4) individually.
4 - Secure this position by tightening the retaining nut (2) to

the specific torque.
3 Retaining nut: 113±15 Nm RKS01700
20-24 CK25-1
TESTING AND ADJUSTMENTS ADJUSTING THE POSITION OF THE SERVO-CONTROL
ADJUSTING THE POSITION OF THE SERVO-CONTROL

ENGAGEMENT SAFETY SENSOR
k Lower the working equipment to the ground, stop the
engine and remove starter key.
RKSA0140
1 -Lower the LH safety bar (1) and adjust the position of the
sensor (2) by loosening and tightening the adjustment
nuts (3).
a Distance between safety bar and sensor: 1 mm

1mm
2 3
RKS01260
CK25-1 20-25
TESTING AND ADJUSTMENTS CONTROL AND REGULATION OF THE PRESSURES IN THE
CONTROL AND REGULATION OF THE PRESSURES IN THE

HYDRAULIC CIRCUITS
a Conditions for checking. "ELIMINATION OF RESIDUAL PRESSURES -
• Engine: at working temperature. PRESSURISATION OF THE TANK") and move the
• MIN and MAX. engine speeds: within permissible safety engagement levers to their locked positions.
k After having connected the pressure gauges,

limits.
• Oil temperature: 45–55 °C. pressurise the tank. For details, see "ELIMINATION
k Before unplugging in order to measure the pressure,
OF RESIDUAL PRESSURES - PRESSURISATION
OF THE TANK".
release all residual pressure from the circuits (see
L.H. TRAVEL MOTOR
ENGINE
P1 P2 P3 P4 P5
CONTROL VALVE
R.H. TRAVEL MOTOR RKS01290
• The control valve consists of the spools that command:
Command Ports
Arm (Lower - Raise) A1 - B1 3
Bucket (Dump - Curled) A2 - B2 2
Equipment (R.H. - L.H.) A3 - B3 B 1 A
RKS01130
20-26 CK25-1
TESTING AND ADJUSTMENTS TESTING THE HYDRAULIC PUMP
TESTING THE HYDRAULIC PUMP

1. Check the working pressure of the travel circuit
HST charge valve TOP VIEW 1
a Machine raised from the ground.
• Engine: high idling
• Safety bar: raised
k Do not activate the travel lever.
1 - Remove the plugs (1) and (2) and mount the two
pressure adapters E5.
RKS04610
2 -Connect two pressure gauges E1 (60 bar), start the
engine and accelerate to high idling.
k Do not activate the travel lever. BOTTOM VIEW 2

3 - Check that the pressure remains within permissible
limits.
a Use the lower of the two pressure values taken.
a Normal pressure: 25.5–29.4 bar
4 - Remove the pressure adapters and tighten the plugs (1)

and (2).
3 Plugs: 19.6–27.4 Nm
RKS04620
2. Check the working pressure of the AS valve

1
• Engine: high idling
• Safety bar: lowered
• Machine raised from ground
1 - Remove the plug (1) and mount a pressure adapter E5.
2 - Connect a pressure gauge E1 (60 bar) and start the

engine at low idling (1070±50 rpm).
L.H. SIDE VIEW
RKS01320
3 - Push the travel lever full stroke for forward travel and
read the pressure.
a Normal value: 11.8±0.5 bar
4 - Repeat reading with engine at 2500±30 rpm.
a Normal value: 15.0±0.5 bar
5 - Remove the pressure adapter and tighten the plug (1).
3 Plugs: 19.8-27.4 Nm
CK25-1 20-27
TESTING AND ADJUSTMENTS VALVE CALIBRATION
VALVE CALIBRATION
1. HST valve calibration
1 - Loosen the nut (1), taking care not to move the
adjustment screw (2).
2 - Adjust the working pressure of the HST valve,

proceeding as follows: A
• To INCREASE pressure, turn the screw (2) in a
CLOCKWISE direction.
• To REDUCE pressure, turn the screw (2) in a A
COUNTER-CLOCKWISE direction.
a Rotating the screw by one turn (2) will vary pressure TOP VIEW RKS01330
by 15.5 bar.
3 - Tighten the nut (1) and check that the working pressure
remains within permissible limits. 2 1
3 Nut: 58.8–78.5 Nm
Section A - A
RKS01340
2. AS valve calibration A
• Pressure adjustment at low idling
1 - Loosen the nut (1), and adjust the working pressure of

the AS valve (with the engine at low idling), proceeding
as follows:
• To REDUCE pressure, turn the screw (2) in a
A
a Rotating the screw by one turn (2) will vary pressure
by 3.37 bar. RKS01350
remains within permissible limits.
1 2
3 Nut: 34.3–58.8 Nm
Section A - A
RKS01360
20-28 CK25-1
TESTING AND ADJUSTMENTS VALVE CALIBRATION
• Pressure adjustment at high pressure
1 - Loosen the nut (3), and adjust the operating pressure of 4 3

the AS valve (with the engine at 2690±30) using the
following procedure:
• To REDUCE pressure, turn the screw (4) in a
a Rotating the screw by one turn (4) will vary pressure

by 2.55 bar. Section A - A
RKS01361
remains within permissible limits.
3 Nut: 34.3–58.8 Nm
CK25-1 20-29
TESTING AND ADJUSTMENTS CHECKING THE TRAVEL DEVIATION
CHECKING THE TRAVEL DEVIATION

a Conditions for checking.
• Engine: at max. speed
a Drive the machine onto solid, level ground.
RKS05150
1. Checking the deviation

1 - Position the boom and bucket in their travelling
positions.
a Boom lowered and bucket fully curled.
2 - Bring the engine up to maximum rpm.
3 - Push the travel lever to full stroke forwards
4 - Travel 10 metres, then measure the deviation of the

machine over the next 20 metres.
5 - Check the deviation also in reverse gear and while

accelerating in both directions.
Theorical travel line 10 m
Deviation
m
10
m
10
RKS04600
20-30 CK25-1
TESTING AND ADJUSTMENTS CHECKING THE TRAVEL DEVIATION
2. Adjusting the deviation

1 - Select the adjustment screw to be re-set:
Travel Deviation Screw

Forwards Left A1
Forwards Right A2
2 1
Reverse Left B1
Reverse Right B2
2 - Loosen the nut (1) and tighten the screw (2).

RKS01380
a Be careful not to move the screw (2) while loosening

the nut (1).
a A 60° turn of the screw (2) will reduce the deviation

by about 500 mm.
3 - Tighten the nut (1).
3 Nut: 26.5–32.4 Nm
A1 A2
RKS04580
B1 B2
CK25-1 20-31
TESTING AND ADJUSTMENTS CONTROL VALVE
CONTROL VALVE
1. Control of operating pressure (unloading valve)
1 - Remove the plug (1) and mount a pressure adapter.
2 - Connect a pressure gauge E3 (10 bar). E3
3 - Start the engine and bring it up to high idling with all
levers in neutral position. 1
4 - Check the pressure.
a Normal pressure: 4.8 bar
k Take care do not operate the equipment levers.
k The unloading valve cannot be re-adjusted. If the

RKSA0180
pressure differs from the normal value the valve
must be substituted.
2. Control the operating pressures of the working

equipment
E2
1 - Remove the plug (1) and mount a pressure adapter.
2 - Connect a pressure gauge E2 (400 bar or 600 bar). 1
3 - Start the engine and bring it up to high idling.
4 - Check the pressure for each movement with the
command lever at the end of its stroke and with the
pressure stabilised.
k To check the pressure of the working equipment,

RKSA0190
push the piston to the end of its stroke.
Valve adjustment
a The unloading valve cannot be re-adjusted, only
substituted.
1. Adjustment of the main relief valve

If the pressures measured for the working equipment and
machine travel do not fall within normal values, adjust the
main relief valve (1) as follows:
1 - Loosen the lock nut (2) and rotate the adjusting screw A A
(3).
• To INCREASE pressure, turn in a CLOCKWISE
direction. 1
• To DECREASE pressure, turn in a COUNTER-
a Each turn of the adjusting screw (3) varies the 2

pressure by about 55 bar.
2 - Lock the nut (2).
3 Nut: 69±10 Nm
3
a After adjustment, check the adjustment of the main relief
valve with the same procedures as used for the
measurements. Section A - A RKS01400
20-32 CK25-1
TESTING AND ADJUSTMENTS CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER
CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER

SUPPLY
• Engine: at working temperature.
Before unplugging in order to measure the pressure,

release all residual pressure from the circuits (see
"ELIMINATION OF RESIDUAL PRESSURES -
PRESSURISATION OF THE TANK") and move the
safety engagement levers to their locked positions.
k After having connected the pressure gauge, pressurise

the tank. For details, see "ELIMINATION OF
RESIDUAL PRESSURES - PRESSURISATION OF
THE TANK".
1. Checking the pressure of the servo-controls

1 - Disconnect the delivery pipe (1) and install a tee and a E1
adapter; reconnect the pipe (1).
2 - Connect the pressure gauge E1 (60 bar)

1
3 - Start the engine and bring it up to 2800 rpm with all leers
in neutral position.
4 - Lower the safety bars and check the pressure.
a Normal pressure: 25–29 bar

RKSA0200
2. Test the pressure of the travel pilot system

A2 A1
a Test conditions:
• Machine raised from ground.
1 - Disconnect the hose (1) of the actuator to be tested,

mount a union tee and a pressure adapter, and then
reconnect the hose (1).
a During travel in one direction, two actuators are

nevertheless activated.
Always check both pressures:
B2 B1
Action involved RKS04570
Action
DA1 DA2 DB1 DB2
FORWARD Q Q
REVERSE Q Q
RIGHT Q Q
LEFT Q Q
CK25-1 20-33
TESTING AND ADJUSTMENTS CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER
2 - Connect a manometer E1 (60 bar).

3 - Lower the cabin and sit down on the driver’s seat.
4 - Start the engine and rev it up to operating speed (2800 E1
rpm) with all the levers in neutral position.
5 - Lower the safety bar, slowly activate the travel lever in
the direction of the test to be performed, and then check
the following conditions:
• pressure of tracks starting rotation
• Pressure with the levers at full stroke
a Normal pressure:
- tracks starting rotation: 4–7 bar
- lever at end of its travel: 16.5±0.5 bar RKSA0210
3. Parking brake system pressure check

1 - Disconnect the brake control hose (1); connect a “T”
fitting and a pressure tap and reconnect the hose.
2 - Connect a manometer E1 (60 bar).
3 - Lower the cabin and sit down on the driver’s seat.

E1
4 - Start the engine and rev it up to operating speed (2500
rpm) with all the levers in neutral position.
1
5 - Lower the safety bars; operate the parking brake control
and check the pressure. RKSA1480
a Parking brake pressure: min. 25 bar
20-34 CK25-1
TESTING AND ADJUSTMENTS ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF

THE TANK
1. Elimination of pressures from the hydraulic
circuits.
1 - Rest the working equipment on the ground and stop the
engine.
2 - Turn the ignition key to the position I and, with safety

bars lower, move the command lever in all directions to
release all pressure in the main hydraulic circuits and
the servo-controls .
3 - Return the ignition key to the position O (OFF) and

remove it.
2. Elimination of pressure in the tank

The hydraulic oil tank is of the sealed and pressurised
type. 1
When tubes are to be removed or disconnected for
controls or repairs, or when caps are removed, tank
pressure must be eliminated using the following
method:
1 - Rest the working equipment on the ground and stop the

engine.
2 - Slowly loosen the oil-refuelling cap (1) in order to

release residual pressure. RKSA0220
3. Pressurising the tank

a This operation should be performed every time the oil-
refuelling cap is moved for removal of the tubes or other
hydraulic equipment.
1 - Start the engine and position the machine as in the

figure.
2 - Stop the engine, loosen the tank cap (1) and then close
it again.
a This operation lets air into the tank when the level of
the remaining oil is at minimum. RKS05160
3 - Start the engine and lower the working equipment to the

ground.
CK25-1 20-35
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS

Sequence of operations or procedures for bleeding the
air
Procedures for bleeding air
1 2 3 4 5
Bleeding air Starting Bleeding air Pressurising

Starting tasks
from pumps engine from cylinders tank
• Substitution of hydraulic oil

Q Q Q Q Q
• Cleaning tank filter
• Substitution filter Q Q Q Q
• Repair - substitution pump
Q Q Q Q Q
• Removal of suction tube
• Substitution - repair control valve Q Q Q Q

• Repair-Substitution cylinders
Q Q Q Q
• Removal of cylinders tube
• Repair - substitution travel motor

• Removal of tubes from Q Q Q
travel motor
1. Bleeding air from the pump

1 - Loosen and remove the cap (1) from the pump body (2).
2 - Pour hydraulic oil through the hole until the entire casing 2
is full.
1
3 - Replace the cap (1).
a After filling the casing, start the engine and allow it to

run at low idling for about 10 minutes before
proceeding to bleed the air from the circuits.
RKSA1050
20-36 CK25-1
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
2. Bleeding air from the cylinders

1 - Start the engine and let it run at low idling for about 5
minutes.
2 - Lower and raise the boom 4-5 times.

a Lower and raise the piston of the boom up to about
100 mm of the end of its stroke.
Every care must be taken to avoid pressurising the
circuits.
3 - Bring the engine up to high idling and repeat the

operations described in point 2. Return the engine to RKS05101
low idling and pout the piston through its entire stroke
until it reaches max. pressure in both directions.
4 - Repeat the operation (starting from point 2) for bucket

cylinder.
3. Bleeding air from any optional equipment

a This method must be used for all the optional working
equipment, unless otherwise indicated.
1 - Each time an item of optional working equipment is

installed, operate the equipment repeatedly, with the
engine at low idling, until all air has been completely
RKS05111
eliminated.
CK25-1 20-37
TESTING AND ADJUSTMENTS TRACK TENSION TEST AND ADJUSTMENT
TRACK TENSION TEST AND ADJUSTMENT

1. Test
a Test conditions:
• Firm level ground.
• Working equipment: resting on the ground
1 -Move the machine forward or rearward until the seam (M

mark) in the track is in the top part and half way between
drive wheel and track tensioner wheel. 300 mm
2 -Force the blade of the bucket into the ground until track
tensioner idler wheel lifts by approx 300 mm off the
ground.
RKSA5000
3 -Measure gap “A” between 3rd idler roller (1) – starting

from front roller – and track (2).
a Standard distance: 15-20 mm

1
2 RKSA3890
2 -Adjustment
If track tension values are not within the permissible

range, adjust tensions as follows: 1
a Before engaging greasing pump G1, and when
G1
adjustment is complete, thoroughly clean grease
fitting and surrounding area.
1 - If tension is too low:
inject grease using grease fitting (1) and greasing
pump G1.
a If injection is awkward, briefly move vehicle
forward and rearward slowly.
RKSA3900
2 - If tension is too high: slowly loosen fitting (2) to let
grease out of the valve.
k Do not loosen the valve by more than three turns.

The tensioning cylinder contains pressurized
grease, which may cause serious injury.
a If grease is hard to come out, briefly move vehicle
forward and rearward slowly. 2
k Do not remove the safety pin (3).
RKSA3910
20-38 CK25-1
30 REMOVAL AND INSTALLATION
HOW TO READ THE MANUAL .....................................3 • Installation............................................................... 32

PRECAUTIONS TO BE TAKEN WHILE WORKING .....4 ENGINE-PUMP GROUP .............................................. 33
ENGINE HOOD...............................................................5 • Removal.................................................................. 33
• Removal ....................................................................5 • Installation............................................................... 36
• Installation .................................................................5 COMPLETE HYDRAULIC PUMP ................................ 37
CAB ................................................................................6 • Removal.................................................................. 37
• Ribaltamento .............................................................6 • Installation............................................................... 39
• Removal ..................................................................10 GEAR PUMP................................................................ 40
• Installation ...............................................................13 • Removal.................................................................. 40
BATTERY .....................................................................14 • Installation............................................................... 40
• Removal ..................................................................14 ENGINE-PUMP COUPLING ........................................ 41
STARTING MOTOR .....................................................15 • Installation............................................................... 41
• Removal ..................................................................15 CONTROL VALVE....................................................... 42
ALTERNATOR .............................................................16 • Installation............................................................... 42
• Removal ..................................................................16 PPC VALVES............................................................... 43
AIR INTAKE FILTER ....................................................17 • Installation............................................................... 43
• Removal ..................................................................17 BUCKET CYLINDER ................................................... 46
MUFFLER .....................................................................18 • Installation............................................................... 47
• Removal ..................................................................18 WORK EQUIPMENT CYLINDERS .............................. 48
• Installation ...............................................................19 • Disassembly ........................................................... 48
VALVE COVER ............................................................20 • Assembly ................................................................ 50
• Removal ..................................................................20 • Installation............................................................... 56
• Removal.................................................................. 58
INJECTORS..................................................................21
• Installation............................................................... 59
• Removal ..................................................................21
• Installation ...............................................................21 WORKING EQUIPMENT SUPPORT FRAME ............. 60
• Removal.................................................................. 60
INJECTION PUMP........................................................22
• Installation............................................................... 60
• Removal ..................................................................22
• Installation ...............................................................24 HEATING SYSTEM BLOWER FAN ............................ 61
• Removal.................................................................. 61
CYLINDER HEAD.........................................................25
• Installation............................................................... 62
• Removal ..................................................................25
• Installation ...............................................................27 TRACK......................................................................... 63
• Removal.................................................................. 63
COOLANT LIQUID PUMP............................................28
• Installation............................................................... 64
• Removal ..................................................................28
• Installation ...............................................................28 LOWER IDLER ROLLER ............................................ 65
• Removal.................................................................. 65
RADIATOR GROUP .....................................................29
• Installation............................................................... 65
• Removal ..................................................................29
• Installation ...............................................................30 IDLER WHEELS .......................................................... 66
• Removal.................................................................. 66
FUEL TANK..................................................................31
• Installation............................................................... 66
• Removal ..................................................................31
CK25-1 30-1
DRIVE WHEEL............................................................. 67
• Removal.................................................................. 67
• Installation............................................................... 67
TRACK TENSIONER CYLINDER................................ 68
• Removal.................................................................. 68
• Installation............................................................... 68
FINAL DRIVE ............................................................... 69
• Removal.................................................................. 69
• Installation............................................................... 71
FINAL DRIVE ............................................................... 72
• Disassembly............................................................ 72
• Assembly ................................................................ 84
30-2 CK25-1
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) Each special method that only applies to the installation procedure is marked with [*1]; the same symbol will
appear at the end of each important step in the removal procedure to indicate which part for installation the
information refers to.
(Example)
REMOVAL GROUP qqq:.........................................................Title of operation
: ............................................................................................Safety precautions to be followed when carrying

out the operation.
1 - Remove XXXX (1): ..............................................................Step in removal procedure.
★:.........................................................................................Technique or important point to remember when
removing XXXX (1)
2 - eee (2): ...................................................................... [*1] Advises reader that there is technical
information to be used during installation
3 - Remove ttt (3):
6 ........... l:.........................................................................Oil or water recovery and amount to be recovered
INSTALLATION GROUP qqq:.................................................Title of operation
• To install, reverse the removal procedure.
[*T] .............................................................................................Technique to be used for installation

★:.........................................................................................Technique or important point to remember during
installation eee (2)
• Addition of water or oil: ........................................................Step in removal procedure
★:.........................................................................................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
«PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS».
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
procedures, 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 3, 4 , 5, 2, 6; In the following
order, these represent the values for «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS»,
«QUANTITIES OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS
AND LUBRICATION» - «LUBRICATING GREASE» and «QUANTITIES OF OIL OR LIQUIDS TO BE
DRAINED».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
CK25-1 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
PRECAUTIONS TO BE TAKEN WHILE 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.
• Drain the oil before removing mechanical assemblies.
• 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
installation 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.
• Replace O-ring seals, cotter pins and retainer rings with new ones.
• 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
adhesive 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 (Lithium EP MS2 NLGI 2) 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.
• Fill with lubricant when installing mechanical assemblies.
• 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.
a For details, see «20. TESTING AND ADJUSTMENTS».
• After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.
30-4 CK25-1
REMOVAL AND INSTALLATION ENGINE HOOD
ENGINE HOOD
Removal
5
k Completely lower the working equipment to the ground
and stop the engine. 1 1
1 - Remove the retainer screws (1) from hinges (2) and (3). 4
2 - While keeping the hood lifted, remove the retainer nut

(4) from the shock absorber (5).
[*1]
4 Engine hood: 18.5 kg

3
2
RKSA1490
Installation
• To install, reverse removal procedure.
[*1]
a Check the centre and the lock engagement
adjustment.
CK25-1 30-5
REMOVAL AND INSTALLATION CAB
CAB
Dump
1 -Remove the lower idler roller.
(See "LOWER IDLER ROLLER" for details). 1
2 - Completely raise the working equipment and secure
2
them in their safety positions.
3 - Loosen the four screws (1) and remove the foot-rest (2).
4 - Only if engine or pump assembly are to be removed.

Remove engine hood.
(See "ENGINE HOOD" for details).
RKSA0240
With front door

5 - Loosen screws (3) and remove bulkhead (4), and close
the front door.
RKSA1500
6 - Loosen the screws (5) (two to each side) and raise the
cab as far as the safety cables allow.
[*1]
7 - Insert the safety pin. 5
RKSA1510
a If the engine or pump are to be removed, proceed as

10 9
follows.
8 - Disconnect the four pipes (6) on the RH side, the two
servo-control feed-pipes (7) and the four pipes (8) on 6
the LH side.
a To disconnect the hoses, remove the retainer (9), fit
hose (6) snugly inside union (10) and extract hose
(6). [*2] 7
8
a Mark the hoses to avoid mixing them during re- 6
assembly.
RKSA0261
30-6 CK25-1
9 - Disconnect the accelerator command lever cable (12)

from the engine (11).
12
11
RKSA1520
With heating system
10 - Remove the clamp (13) retaining the hoses.

13
RKSA3672
11 - Disconnect the heating system’s delivery (14) and

return (15) hoses from the engine. Drain engine coolant
from the hoses and disconnect the washer hoses from
the washer tank.
a Mark the hoses to avoid mixing them during 15

installation.
14
RKSA1541
12 - Connect the cab (16) to some hoisting tackle.
16
21
RKSA5010
CK25-1 30-7
13 - Remove the safety cotter pin (17) and the washers (18).
14 - Remove the safety cotter pin.

20 20
15 - Push the cab (16) slightly towards its “at rest” position to
relieve the tension on the safety cables (19), and
disconnect the cables from the pins (19).
19
k Apply a slight tension to the hoisting-tackle chains
19
to prevent the cab from moving unexpectedly. 17 18

17 18
RKSA0287
16 -Tilt the cab (16) slowly until the distance between the
centres of the dumper fixing hooks (21) is 1100 mm.
a The distance of 1100 mm corresponds to the

maximum stretch of the dumper hooks. 16
17 - Remove the pins (20) from the dumper fixing hooks
(21).
21
RKSA5010
18 - Position a stand “A”, about 1200 mm high, and tilt the

cab (16) until it is resting on the stand.
a Make sure that the connecting cables between the

cab and the engine are not being strained.
A
RKSA5020
30-8 CK25-1
Lower
• To lower the cab back into position, reverse the tilting
procedure.
[*1]
3 Screws: 98±7.3 Nm
[*2]
• Connect the hoses by pushing them fully home into
their seatings. Test for proper connection by
attempting to pull the hoses out of their seats.
[*3]
• Adjust accelerator lever cable travel.
(See "20 TESTING AND ADJUSTMENTS" for
details).
1 - Fill up the coolant liquid circuit to maximum level.
2 - Start the engine to circulate the coolant and check that

there are no leaks.
3 - Stop the engine, check the levels and, if necessary, top

them up.
CK25-1 30-9
Removal
1 2 1
1 - Remove the complete attachments.
(For details, see "COMPLETE WORKING
EQUIPMENT").
2 - Loosen the nuts (1) and tilt the rear panel (2) towards the
front of the machine.
1 1
RKSA0520
3 - Disconnect the connectors (3) from the cab cabling (4)

and release the engine cabling (5) from its retaining 3
clamps.
RKSA0530
4 - Tilt the cab. (For details, see "CAB").
5 - Disconnect the four pipes (6) on the RH side, the two

servo-control feed-pipes (7) and the four pipes (8) on
the LH side.
a To disconnect the pipes, remove the retainer (9)

push the pipe (6) completely inside the union (10)
and extract the pipe (6).
Then, mount the retainer (9) on the pipe (6). 7 6
5
[*1]
a Mark the tubes to avoid exchanging them during re- 8
assembly. RKSA0540
6 - Pull out the cab cabling (5).
10
9
5
6
RKSA0550
30-10 CK25-1
With front door

7 - Remove the straps (11) retaining the hoses. 11
RKSA5100
8 - Disconnect the heating system’s delivery (12) and

return (13) hoses from the engine and drain any engine
coolant from the hoses.
a Mark the hoses to avoid mixing them during

installation. 13
12
RKSA1547
9 - Remove strap (14) and disconnect hose (16) from tank

(15).
15
16
14
RKSA3660
All version
10 - Disconnect the accelerator lever cable (18) from the

engine (17). [*2]
18
17
RKSA1523
CK25-1 30-11
11 - Connect the cab (19) to some hoisting tackle.
19
RKSA5030
12 - Remove the safety cotter pins (20) and the washers

24
(21).
13 - Push the cab slightly towards its “at rest” position to 23 23

relieve the strain on the safety cables (22), and
disconnect the cables from the pins (23).
k Apply a slight tension to the chains of the hoisting

22 22
tackle to prevent the cab from swinging about
unexpectedly. 20 21 20 21
14 - Tilt the cab (19) slowly until the distance between the
centres of the shock absorber attaching holes is 1100
mm. RKSA0286
a The distance of 1100 mm corresponds to the

maximum stretch of the dumper hooks.
15 - Remove the pins (23) from the dumper fixing hooks

(24).
16- Loosen the nuts (25) and remove the screws (26) and 27
washers (27).
17 - Remove the complete cab (19).
4 Cab: approx. 250 kg 25 26
RKSA5070
30-12 CK25-1
Installation
[*1]
a Mount the retainers (9) on the hoses and connect 9
the pipes by pushing them fully home in their
seatings.
Check for proper connection by attempting to pull
the hoses out of their seatings.
[*2]
a Adjust accelerator lever cable travel. RKSA1241

details).

there are no leaks.

them up.
CK25-1 30-13
REMOVAL AND INSTALLATION BATTERY
BATTERY
Removal
1 - Disconnect cables from the battery (3) in the following 2
sequence: negative cable (–) (1) first, and then positive
cable (+) (2). 3
1
RKSA3080
2 - Loosen nuts (4) securing battery clamp (5), release tie-

rods (6) from battery support, and remove battery
clamp. 4
5
3 - Remove battery.
RKSA3090
Installation
30-14 CK25-1
REMOVAL AND INSTALLATION STARTING MOTOR
STARTING MOTOR
Removal
1 - Tilt the cab and secure it in its safety position.
2 - Remove the battery (1).

1
(For details, see "BATTERY")
RKSA3110
3 - Disconnect the cables (2) and (3).
4 - Loosen the screws (4) and take out the starter (5). 4
[*1]
2
5
3
RKSA1560
Installation
[*1]
3 Screws: 78.4–98 Nm
CK25-1 30-15
REMOVAL AND INSTALLATION ALTERNATOR
ALTERNATOR
Removal
1 - Remove the battery. 1
2 - Tilt the cab.

(For details, see "CAB").
3 - Disconnect cables (1), (2) and connector (3). 3 2
RKSA1570
4 - Loosen screws (4), (5) to leave the alternator free to

turn. 4
5 - Release the pulley from the fan-belt (6) and take out the 6
alternator (7). [*1]
5 RKSA1331
Installation
[*1]
a Adjust fan-belt tension.

(See "20 TESTING AND ADJUSTMENTS" -
"CONTROL AND ADJUSTMENT OF THE FAN BELT
TENSION" for details).
30-16 CK25-1
REMOVAL AND INSTALLATION AIR INTAKE FILTER
AIR INTAKE FILTER

Removal
k Disconnect the battery’s negative end cable (–).
2 - Remove strap (1).

6
3 - Disconnect the connector (2) of the air filter restriction 2
sensor.
4 - Loosen the straps (3) and remove the sleeve (4).
4 5
5 - Loosen the screws (5) and take out the complete air
filter (6).
3
1
3
RKSA1594
Installation
CK25-1 30-17
REMOVAL AND INSTALLATION MUFFLER
MUFFLER
Removal
1 - Loosen the nuts (1) and screws (2) retaining support (3), 1
3
and remove the support.
1 2
RKSA1601
2 - Unfasten clamps (4) and remove support (5) and

protection (6).
6
4
4
RKSA1611
3 - Loosen the screws (7) retaining the muffler (8) to the

support (9).
8
9
RKSA1621
4 - Loosen the nuts (10) retaining the muffler (8), and

remove the muffler.
a The seal (11) must be replaced at each

disassembly.
10
RKSA1631
30-18 CK25-1
REMOVAL AND INSTALLATION MUFFLER
Installation
11
RKS02341
CK25-1 30-19
REMOVAL AND INSTALLATION VALVE COVER
VALVE COVER
Removal
k Disconnect the negative terminal cable (–) from the 1
battery.
1 - Remove suction filter (1).

(For details, see "AIR INTAKE FILTER".)
RKSA1591
2 - Loosen the screws (2) and remove the clamp (3).

3 - Remove the screw (4) retaining the oil dipstick (5).
4 - Loosen the screws (6) retaining the support (7), and 7
remove the support.
3
5
4
6
2
RKSA1640
6 - Remove the high-pressure pipes (8).
[*1]
8
7 - Loosen the two screws (9) (n° 2), remove the four
centering bushings (10) and the valve cover (11). RKSA1661
[*2]
Installation 11
[*1] 9
3 Pipe union: 19.6-24.5 Nm
[*2]
a Check the state of valve cover seal and replace if 11
necessary. 10
3 Valve cover clamping screw:...........Nm

RKSA1671
30-20 CK25-1
REMOVAL AND INSTALLATION INJECTORS
INJECTORS
Removal
1 - Remove air suction filter (1).
2 - Remove the valve cover.

3 - Loosen the five screws (1) and remove the fuel pipe (2)..
1
a Take care to not damage the five gasket (3).
[*1] 2
1 3
RKSA1680
4 - Loosen the screws (4) and remove the four bracket (5).
[*2]
4
5 - Remove the nozzle (6). 4
5
6 6
RKSA1690
Installation
[*1]
3 Screw: 7.8-9.8 Nm
[*2]
3 Screws: 22.6-28.4 Nm
CK25-1 30-21
REMOVAL AND INSTALLATION INJECTION PUMP
INJECTION PUMP
Removal
k 1 -Disconnect the negative terminal cable (–) from the
battery.
2 - Close the cock of separator to prevent fuel leakage.

2
1 - Remove radiator assembly.
(See "RADIATOR GROUP" for details).
2 - Disconnect connector (1) and accelerator cable (2). 1

[*1]
RKSA1700
3 - Remove the complete suction filter (3).

3
RKSA1592
4 - Disconnect fuel feed (5) and fuel return (6) hoses, fuel
feedback pipe (7) and coolant hoses (8) and (9) from
injection pump (4).
5 - Disconnect high pressure pipes (10) from injection

pump (4). 7
[*2] 10
8
6
5
9
4
RKSA2170
6 - Disconnect injection pump (4) lubricating pipe (11).
11
RKSA1710
30-22 CK25-1
7 - Remove fan (12) and cover (13).
[*3]
13
12
RKSA1720
8 - Loosen and remove the nut (14) and the lock washer
retaining the pump driving gear (15).
[*4]
a Be extremely careful not let nut (14) and lock washer
drop into the housing.
14
RKS02350
9 - Remove pump (4) driving gear (15).
a Before removing pump driving gear, mark position X2

compared to idling gear.
19
a For removal, use a puller (X1) and tighten its screws

(X2) directly in the gear (15).
a During removal be careful not let key drop (16) in the

housing.
16 X1
15 X2
RKS01731
10 - Loosen nuts (17) (No. 4).

[*5]
17
RKSA1711
CK25-1 30-23
11- Loosen three screws (18) and remove the complete

injection pump (4) with its O-ring (19).
[*6]
18
18
RKSA1730
Installation
[*1]
a Check accelerator cable travel.

details).
[*2]
3 High pressure pipe: 19.6-24.5 Nm

[*3]
2 Cover contact surface
liquid gasket
3 Fan screws: 22.6-28.4 Nm
[*4]
a Align marks between gears before installing pump

and nut.
3 Nut: 113-123 Nm
[*5]
3 Pump clamping nut:........... Nm

a Check injection point timing.
details).
[*6]
3 Pump screws: 22.6-28.4 Nm
30-24 CK25-1
REMOVAL AND INSTALLATION CYLINDER HEAD
CYLINDER HEAD
Removal
1
k Disconnect accumulator negative terminal cable (–). 3
a Drain the engine coolant liquid.

[*1]
6 Coolant liquid: max. 15 l 2

1 - Remove the coolant liquid pump.
(For details, see "COOLANT LIQUID PUMP")
2 - Remove the suction filter (1) and the bracket (2).

(For details, see "AIR INTAKE FILTER".) RKSA1593
3 - Remove the muffler (3).

(For details, see "MUFFLER".) 6
4 - Loosen the screws (4) and remove the complete filter
(5).
5 - Remove the valve cover (6).

4
5
RKSA1740
6 - Remove the nozzles (7). [*2]
7 7
RKSA1691
7 - Disconnect the pre-heater cable (8).
RKSA1750
CK25-1 30-25
8 - Remove the complete rocker-arm shaft (8). [*2]

8
a Loosen the lock nuts and unscrew the valve tappets
by 2-3 turns.
[*3] 9
9 - Take out the rocker-arm control rods (9).
RKS02360
10 - Take out the screws (10) in the sequence given and

remove the complete cylinder head (11). [*4] 10
11
a The cylinder head gasket (12) must be substituted
every time it is dismantled.
12
RKS02370
Exhaust side
Flywheel side
7 16 14 6
1 9 18 12 4
3 11 17 10 2
5 13 15 8
Suction side
RKS01630
30-26 CK25-1
Installation
[*1]
1 - Fill up the coolant liquid circuit.
5 Coolant liquid: approx. 15 l
2- Start the engine to circulate the liquid through all

circuits. Stop the engine and check the level.
3 - Pressurize the hydraulic tank and bleed air from the

hydraulic circuits.
(For details, see "20 TESTING AND ADJUSTMENTS").
[*2]
3 Screws: 22.6-28.4 Nm
[*3]
a Adjust valve clearance.
(For details, see "20 TESTING AND ADJUSTMENTS" -
"ADJUSTMENT OF VALVE CLEARANCE").
[*4]
a Raise the cylinder head, keeping it horizontal, and place
it on the gasket without shifting anything.
Exhaust side
Flywheel side
a Lubricate the screw-threads with engine oil. 12 3 5 13

18 10 1 7 15
a Tighten the screws in the sequence given.
(See illustration on the side). 16 8 2 9 17
3 Screws:
14 6 4 11
Suction side
1st tightening: 49.0–58.8 Nm
2nd tightening: 103.1-112.9 Nm
RKS01640
CK25-1 30-27
REMOVAL AND INSTALLATION COOLANT LIQUID PUMP
COOLANT LIQUID PUMP

Removal
k
1
Disconnect the cable from the negative (–) battery
terminal.

[*1]
6 Engine coolant liquid: max. 15 l

1 - Remove radiator assembly (1).
(See "RADIATOR GROUP" for details).
RKSA1760
2 - Loosen the screws (2), remove the fan (3) and the
spacer (4). 3
Loosen the alternator drive belt and disengage the
circulation pump pulley.
[*2]
3 - Loosen the screws (5) and remove the complete pump
(6) and the seal (7).
[*3] 2
4
RKS02380
Installation
7
• To install, reverse the removal procedure. 6
[*1]
5
1 - Fill up the coolant liquid circuit.

2 - Start the engine to circulate the liquid and oil in all
circuits. Stop the engine and check the levels.
3 - Pressurise the tank and bleed the air from all circuits.
[*2]
RKS02390
a Adjust the belt tension. (For details, see "20 TESTING
AND ADJUSTMENTS" - "CONTROL AND
ADJUSTMENT OF THE FAN BELT TENSION").
3 Fan screws: 22.6-28.4 Nm

[*3]
a Replace the seal (7) at each disassembly.
3 Pump screws: 22.6-28.4 Nm
30-28 CK25-1
REMOVAL AND INSTALLATION RADIATOR GROUP
RADIATOR GROUP
Removal
k Completely raise the working equipment and tilt the 1
cab.
(For detail see: "CAB"). 3
a Drain the hydraulic oil.

[*1]
2
6 Hydraulic oil: max. 39 l
a Drain the coolant liquid:
6 Coolant liquid: max. 9 l RKSA0460
1 - Disconnect the hose (2) from the pump (1).
2 - Disconnect the coolant liquid drainage pipe (3) from the

radiator.
4
3 - Disconnect the cable (4) of the hydraulic-oil clogging- 5
sensor filter.
4 - Loosen the clamp (5) and disconnect the coolant liquid 6

delivery pipe (6).
7
5 - Disconnect the coolant liquid return pipe (7).
RKSA0470
6 - Attach the radiator group (8) to some hoisting tackle and

apply a slight tension to the cables.
10
4 Radiator-oil cooler group: 62 kg 8
7 - Loosen the screws (9), raise the radiator assembly (8)

until the lower supports can be released, and move it a
little way away from the frame. [*2]
9 9
8 - Disconnect the reversing siren connector (10).
RKSA0480
9 - Disconnect the pipes (11) and (12) and remove the

complete group (8).
11
12
RKSA0490
CK25-1 30-29
REMOVAL AND INSTALLATION RADIATOR GROUP
Installation
[*1]
1 - Fill up the hydraulic oil to maximum level.
5 Hydraulic oil: approx. 39 l
2 - Fill the coolant liquid circuit up to maximum level.
3 - Start the engine to circulate the oil and the coolant, and
check that there are no leaks.

them up.
[*2]
3 Screws: 190 Nm
30-30 CK25-1
REMOVAL AND INSTALLATION FUEL TANK
FUEL TANK
Removal
a Drain the fuel. 1
6 Fuel: max 50 l
1
1 - Remove screws (1) and loosen screws (2), without

removing them. [*1]
2
2
RKSA3420
2 - Disconnect the connector (3) from the level sensor and

disconnect the connector from the reverse gear chime,
if installed.
3 4
3 - Loosen the screw (4) and disconnect the level sensor
harness (5) from the tank.
RKSA3430
4 - Disconnect the delivery (8) and return (9) lines from the
settler (6) and filter (7).
9
8 7
6
RKSA3650
5 - Loosen the screw (10) and remove the support (11).
10
11
RKSA3450
CK25-1 30-31
REMOVAL AND INSTALLATION FUEL TANK
6 - Loosen the screws (12) and remove the support (13).
7 - Remove the complete tank.
13
12
RKSA3460
Installation
[*1]
3 Screws: 190 Nm
30-32 CK25-1
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
ENGINE-PUMP GROUP
Removal
1 - Tilt the cab until it is resting on a support. (For details,
see"CAB"). [*1]
2 - Remove the battery.

6 Liquid: max. 9 l
a Drain the hydraulic oil. [*2]
6 Oil: max. 39 l
RKSA5021
a Drain the fuel.
6 Fuel: max. 50 l 1 3 4
2
3 - Remove the radiator group. (For details, see
"RADIATOR GROUP").
4 - Remove the cover of the control unit (1) and disconnect

the connectors (2), (3) and (4) that connect the control
unit (1) to the frame wiring harness (5).
5
RKSA0570
5 - Loosen the nuts (6) and disconnect the control unit from
the frame (7).
6
6
RKSA0580
6 - Disconnect the connector (8) from the fuel level sensor

(9) and remove the screw (10) retaining the electric
harness (11).
8
10
9
11
RKSA3870
CK25-1 30-33
7 - Disconnect the servo-control pressure sensor

connectors (12) and disconnect the support (13) from 14
the engine (14).
8 - Disconnect the accelerator pedal cable (15) from the 12

engine (14).
15
13 13
RKSA3700
9 - Disconnect the delivery (18) and return (19) pipes from

the prefilter (16) and the filter (17).
19
18
17
16
RKSA3651
10 - Disconnect the pipes (21), (22) and (23) from the pump
(20).

assembly.
23
21 22
RKSA3710
11 - Disconnect the pipes (24), (25), (26), and (27) from the
pump.
a Mark the tubes to avoid exchanging them during re-

assembly. 27
25
26
24
RKSA3720
30-34 CK25-1
With front door

12 - Disconnect the heating system’s supply (28) and return
(29) hoses from the engine and drain any engine
29
28
RKSA3530
13 - Attach the engine-pump group to some hoisting tackle

and apply a slight tension to the cables.
14 - Loosen the four nuts (30) that secure the engine and
remove the complete group.
[*3]
4 Engine-pump group: 330 kg

30
RKSA5040
CK25-1 30-35
Installation
[*1]
a Adjust accelerator cable travel.
(See "20 TESTING AND ADJUSTMENTS" for details).
[*2]
1 - Fill the hydraulic oil tank up to maximum level.
k While filling the tank, bleed the air from the pump. (For
details, see "20 TESTING AND ADJUSTMENTS").
5 Hydraulic oil requirement: approx. 39 l
2 - Fill the coolant liquid circuit up to maximum level.
3 - Fill the fuel tank and bleed the air from the system. (For
details, see "20 TESTING AND ADJUSTMENTS").
5 Fuel: max. 50 l
4 - Start the engine to circulate the oil and coolant liquid and
check that there are no leaks.

them up.
6 - Bleed the air from the hydraulic circuits and pressurise

the tank. (For details, s ee "20 TESTING AND
ADJUSTMENTS").
[*3]
3 Engine nuts: 60-75 Nm
30-36 CK25-1
REMOVAL AND INSTALLATION COMPLETE HYDRAULIC PUMP
COMPLETE HYDRAULIC PUMP

Removal
Completely raise the attachment and tilt the cab.
(See "CAB" for details).
1 - Disconnect the pipes (2), (3) and (4) from the pump (1).

installation. 1
4
2 3
RKSA3711
2 - Disconnect the pipes (5), (6), (7), and (8) from the pump.

installation.
8
5
6
RKSA3721
3 - Disconnect the servo-control pressure sensor

connectors (9) and disconnect the support (10) from the
engine. 11
10
9
RKSA3840
CK25-1 30-37
With front door

4 - Disconnect the heating system’s supply (12) and return
(13) hoses from the engine and drain any engine
13
installation.
12
RKSA1547
5 - Attach the pump (1) to some hoisting tackle and apply a

slight tension to the cables.
RKSA3740
6 - Loosen the eight screws (14) and remove the pump (1)
complete with the flange (15). 16
[*1] 15
4 Pump: 82 kg
7 - Loosen the screws (16) and disconnect the pump (1) 1
from the flange (15).
14
[*2]
RKSA2681
30-38 CK25-1
Installation
[*1]
3 Flange screws: 80 Nm
2 Flange screws: Loctite 262
2 Pump shaft: Lithium EP MS2 NLGI 2
[*2]
3 Pump screws: 195 Nm
2 Pump screws: Loctite 262
1 - Fill the tank up to maximum level.
5 Hydraulic oil requirement: approx. 39 l
k Bleed the air from the pump.

(For details, see "20 TESTING AND
ADJUSTMENTS").
2 - Start the engine to circulate the oil and check that there
are no leaks.

them up.
4 - Bleed the air from the hydraulic circuits and pressurise

the tank.
CK25-1 30-39
REMOVAL AND INSTALLATION GEAR PUMP
GEAR PUMP
Removal
k Completely raise the attachment and tilt the cab. 2
1
1 - Disconnect from the pump (1) the suction pipe (2) and
the pipe (3) (one for the normal version, two for the
HIGHFLOW version. 4
3
RKSA0660
2 - Loosen the two screws (4) and remove the pump (1)
complete with the O-ring (5).
[*1] 5
4 RKS01740
Installation
a To install, reverse removal procedure.
[*1]
3 Screws: 59–74 Nm
30-40 CK25-1
REMOVAL AND INSTALLATION ENGINE-PUMP COUPLING
ENGINE-PUMP COUPLING
Removal
k Completely raise the attachment and tilt the cab. 3
1
1 - Remove the pump.
(For details, see "COMPLETE HYDRAULIC PUMP")
Half sleeve on pump

2 - Loosen security dowels (1) on half sleeve (2) in multiple 2
sequences and in an alternate manner. [*1] 4
a Heat the dowels at 85–100°C. RKS02410
3 - Remove the pump half sleeve (2).
a If necessary, use a puller.
Half sleeve on flywheel

4 - Remove screws (3) and remove drive flange (4).
[*2]
Installation
[*1]
2 Pump half-sleeve clamping screw: Loctite.....
3 Pump half-sleeve clamping screw:...........Nm
[*2]
2 Drive flange screw: Loctite 262
3 Drive flange screw: 50 Nm
1 - Fill the tank up to maximum level.
k Bleed the air from the piston pump while filling the
tank. (For details, see "20 TESTING AND
ADJUSTMENTS").
2 - Start the engine to circulate the oil and check that there
are no leaks.
3 -Stop engine and top up as necessary.
CK25-1 30-41
REMOVAL AND INSTALLATION CONTROL VALVE
CONTROL VALVE
Removal
k Fully raise the working equipment and tilt the cab. (For
1
details, see "CAB").
2
k Fully release residual pressures from all circuits and 2

from the tank.
(For details, see "20 TESTING AND ADJUSTMENTS".

3
RKSA0680
1 - Disconnect from the control valve (1) the servo-control

pipes (2), the delivery pipes to the actuators, and the
delivery and return pipes (3).
1
assembly.
2 - Loosen the three screws (4) and remove the control

valve (1).
[*1]
4 Control valve: max. 24 kg
RKS01880
Installation
a To install, reverse removal procedure.
[*1]
3 Control valve screws: 35 Nm
1 - Fill the hydraulic oil tank up to maximum level.
2 - Start the engine at low idling to circulate the oil

throughout the system.
30-42 CK25-1
REMOVAL AND INSTALLATION PPC VALVES
PPC VALVES
Removal
2
k Lower the working equipment until it is resting on the
ground, stop the engine and remove the ignition key. 1
6
k Release residual pressures from all circuits and from
the tank. (For details, see "20 TESTING AND
ADJUSTMENTS").
3
With front door 4
1 - Remove the heater group.
(For details see: "HEATING SYSTEM BLOWER FAN"
until point 6.)
5 RKSA0690
2 - Raise the switch-box cover (1) disconnect the

connectors (2) and remove the cover (1).
3 - Disconnect the protective sleeve (3).

H Take care not to damage the frame (4). 9 7
4 - Loosen the four screws (5) and remove the casing (6).
5 - Take out the three screws (7) and disconnect the PPC
valve (8) from the support (9).
8
6 - Disconnect the six pipes (10) from the PPC valve and
plug the tubes to prevent entry of impurities. 10
a Check the marks on the tubes to avoid exchanging RKSA0700
them during re-assembly.

[*1]
L.H. PPC VALVE
Installation
[*1]
a Check very carefully the positions for the pipe P2
P T
connections.
L.H. PPC VALVE P4

Position
P3
P T P1 P2 P3 P4 P1
RKSA0710
M S A R L R
White White Yellow Yellow Blue Blue
R.H. PPC VALVE STANDARD

R.H. PPC VALVE R.H. AND L.H. PPC VALVES PATTERN CHANGE
Position
P T P1 P2 P3 P4
P2
M S D S C A
P T
White White Red Red Yellow Yellow
k If the union fittings are removed from the PPC valve, P4

make sure that a union with filter is mounted at theP P3
inlet. P1
RKSA0720
CK25-1 30-43
REMOVAL AND INSTALLATION RAISING CYLINDER
RAISING CYLINDER
Removal
k Lower the working equipment until it is resting on the
ground.
k Release residual pressures from all circuits.

ADJUSTMENTS").
1 - Remove all the working equipment.

(For details see: "COMPLETE WORKING EQUIP-
MENT").
2 - Remove the lift lever.

(For details see "LIFT LEVER").
3 - Loosen the screws (1) and remove the front bracket (2)
1
retaining the plate (3).
2
3
RKSA2020
4 - Push the cylinder (4) towards the front of the machine,

loosen the screws (5), remove the rear bracket (6) re-
taining the plate (3) and remove the plate. 5
4
3
RKSA2030
5 - Loosen the 4 screws (7) and remove the lower lock (8).
7
7
RKSA5050
30-44 CK25-1
REMOVAL AND INSTALLATION RAISING CYLINDER
6 - Remove the clamps (9); disconnect the hoses (10) from

the fittings (11). 10
a Mark the hoses for position to avoid mixing them
during installation.
9
a Plug the hoses (10) and fittings (11) to prevent
foreign material from entering.
10 11
10
9 RKSA2050
7 - Connect the cylinder (4) to a hoist, tension the belt, loos-

en the screw (12) and remove the pin (13).
[*1][*2]
4 12
8 - Remove the cylinder (4) together with the hoses (10). 13
10
RKSA2060
INSTALLATION OF THE
RAISING CYLINDER
[*1]
2 Bushing inner side: Lithium EP MS2 NLGI2
3 Pin retaining screws: 49 Nm
[*2]
k When the positions of hole and pin line up, idle the
engine.
Do not introduce your fingers into the holes to
check alignment.
1 - Start the engine and draw air from the cylinder.

(For details see "20 TESTING AND ADJUSTMENTS").
a When air bleeding is complete, check the oil level in

the tank.
CK25-1 30-45
REMOVAL AND INSTALLATION BUCKET CYLINDER
BUCKET CYLINDER
Removal
k Lower the working equipment and rest the equipment
support frame on the ground.
RKSA3770
1 - Remove the pin (1) and fully retract the piston rod (2).
[*1] [*2]
a Check and make a note of the positions of the
2
adjustments to a given clearance.
RKSA3800
2 - Disconnect the pipes (4) and (5) from the cylinder (3).
a Plug the tubes to prevent entry of impurities.

a Mark the tubes to avoid exchanging them during re-
assembly.
5
3
RKSA3780
3 - Remove the pin (6) and take away the cylinder (3).
[*1] [*3]
6
3
RKSA3790
30-46 CK25-1
REMOVAL AND INSTALLATION BUCKET CYLINDER
Installation
[*1]
k When aligning the positions between the hole and

the pin, do not insert fingers into the holes to check
alignment.
2 Inside the bushings: Lithium EP MS2 NLGI 2

3 Pin screws: 49 Nm
[*2]
MAX 1mm MAX 1mm
a Insert the removed shims and, if necessary, add
more until the residual clearance is about 1 mm.
RKS03830
[*3]
a Insert the removed shims and, if necessary, add
more until the residual clearance is about 1 mm.
1 - Start the engine and bleed the air from the cylinder.
a After bleeding the air, check the level of oil in the

tank
MAX 1mm MAX 1mm RKS02460
CK25-1 30-47
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
WORK EQUIPMENT CYLINDERS

Disassembly
1
1 - Take off the guard rings (1) from both sides of the
cylinder and from the piston rod.
a Make sure that the tube unions are not plugged.
1
RKS01660
2 - Place the cylinder (2) on the apparatus A. Engage the

cylinder in the tools B, having the same bushing
diameter. B
2 A
RKSA1060
3 - Attach the special wrench C (adjusted to fit the cylinder)

to the head (3) and apply the dynamometric tool D.
D
C
3
RKSA1070
4 - Unscrew the head (3) and extract it completely from the

cylinder (2).
2 3
RKSA1080
30-48 CK25-1
5 - Raise the cylinder and hook the piston rod to the mobile
group of the tool A.
6 - Extract the piston rod group (4) from the cylinder.
7 - Remove the cylinder (2) and the piston rod group.

4
RKSA1090
8 - Lock the complete piston rod (4) onto the apparatus A.
9 - Attach the socket wrench E to the lock nut (5) of the 4 6

piston (6) and, using the dynamometric tool with a
multiplier D, remove the nut.
a Socket wrench measurement: 41 mm
10 - Take all the groups to pieces and remove all the seals,
guard rings and guide rings.
5
E D
k The seals, guard rings, and guide rings cannot be
used again.
RKSA1100
CK25-1 30-49
Assembly
a Take great care not to damage the seal and the sliding
surfaces.
a Prepare each individual component before 7

commencing the final assembly. F
1. Assembly of the cylinder head
1 - Position the guard ring (7) and, using a press and the 3 3
push rod F, press it home in the head (3).
a Check the orientation carefully. RKSA1110
2 - Mount the snap ring (8).
3 - Using the tool G, mount the lip-seal (9).

8
a Check that the lips face into the cylinder.
RKSA1120
4 - Mount the O-ring (10), the anti-extrusion ring (11) and

the O-ring (12) onto the cylinder head (3).
10 3 11 12
7 9
RKS01800
30-50 CK25-1
2. Piston assembly
1 - Using the tool H, mount the piston seal. Mount in H
sequence the rubber ring (13), the outer seal (14) and
the anti-extrusion rings (15).
13 14 15
RKSA1130
2 - Mount the guide ring (16).
3 - Calibrate the diameter of the gasket (14) of the piston

(6), mounting the group beneath the press and using the 15 14 15 16
calibrating ring J adapted to fit the piston diameter. J
13
RKSA1140
3. Piston rod group assembly

1 - Using a press and the tool B adapted to the diameter,
insert the bushing (17) into the piston rod (4).
4
2 - Insert the support K beneath the piston rod.
17
B
K
RKSA1150
3 - Mount the pilot boss L adapted to the diameter onto the

extremity of the piston rod.
4 - Slide the head (3) onto the piston rod (4). 4 L 4 3

5 - Remove the pilot boss L from the extremity of the piston
rod.
RKSA1160
CK25-1 30-51
6 - Mount the complete piston (6).
RKSA1170
7 - Mount the nut (5) that secures the piston and tighten it
with the socket wrench E and the dynamometric tool
with a multiplier D.
2 Nut: Loctite 262

3 Nut lifting cylinder: 430±43 Nm
Nut Bucket cylinder: 350±35 Nm
5
E D
RKSA1101
4. Cylinder assembly
1 - Mount the tools A onto the apparatus B.
B
2 - Position the bushing (20) and mount it onto the cylinder
(2). 2 A
a Leave the cylinder in position, ready for the next
assembly operation.
19
RKSA1061
3 - Lubricate the threading and the first part of the cylinder

(2).
2 Cylinder: Lithium EP NLGI 2 2 M

4 - Mount the two halves of the tool M, adapted to the
diameter, onto the mouthpiece of the cylinder (2).
RKSA1180
30-52 CK25-1
5 - Mount the piston rod group (4) onto the tool A and raise
the mobile part up to the end of its stroke.
6 - Put the cylinder (2) into a vertical position and guide the
piston into the tool M.
4
7 - Lower the apparatus supporting the piston rod (4) in
order to insert the piston into the cylinder liner (2).
A
8 - Remove the tool M from the cylinder and then lower the
apparatus A even further, until the head (3) and the
piston rod approach the cylinder.
M
9 - Place the cylinder (2) in position for screwing in the head
(3).
10 - Insert the head into the cylinder and screw it in by hand
for a few turns. 2
RKSA1091
11 - Attach the special wrench C to the dynamometric tool D

and screw the head (3) fully home.
3 Head lifting cylinder: 412±41 Nm

D
C
Head bucket cylinder: 450±45 Nm 3
12 - Mount the guard rings (1) on both sides of the cylinder 2
and the piston rod.
RKSA1071
CK25-1 30-53
REMOVAL AND INSTALLATION COMPLETE WORKING EQUIPMENT
COMPLETE WORKING EQUIPMENT

Removal
k Completely lower the working equipment to the ground. 1
k Drain any residual hydraulic pressure.

(For details see "20 TESTING AND ADJUSTMENTS"). 2
Road-homologation version only
1 - Remove the rear headlight support (1). 3
2 - Loosen the screws (2) and remove the rear-view mirrors
(3).
RKSA2080
HIGH-FLOW version only

3 - Disconnect the power socket (5) and electrical harness
(6) from the arm (4). 6
5
RKSA2090
4 - Disconnect hoses (7) and (8).

8
a Mark the pipes for position to avoid mixing them 7
9 10
during installation.
a Plug hoses (7) (8) and pipes (9), (10) to prevent

foreign bodies from entering.
RKSA2100
5 - Connect the complete arm (4) to a hoist and tension the

cables. 4
a Cable length: 2 m
RKSA5110
30-54 CK25-1
6 - Remove the snap ring (11) and 6 shims (12).

11
7 - Loosen the screw (14) and remove the pin (15). [*1]
a Check for a damaged seal (13). Replace if 12
14
necessary.
13
15
RKSA2290
8 - Introduce wooden shims “A” between the lift lever (16)

and fulcrum lever (17).
A
16 17
RKSA2120
9 - Lift the arm until the tool holder frame fulcrum pin and
the arm fulcrum pin line up.
RKS05170
10 -Loosen the screw (18), remove the pin (19) and remove
the working equipment.
a Check for damaged seals (20); replace if

necessary.
a Check and note down the position of shims.

[*1][*2]
4 Working equipment (without bucket):

19
20 18
approx. 470 kg
RKSA2300
CK25-1 30-55
COMPLETE WORKING EQUIPMENT

Installation
• To install, reverse removal procedure. MAX 1mm MAX 1mm
[*1]
k During the hole and pin alignment procedure, do not

introduce your fingers to feel the position.

[*2]
a Introduce shims between arm and frame until
RKS02480
residual clearance is less than 1 mm.
1 - Start the engine and bleed the air from the cylinder.
a After bleeding the air, check the level of oil in the

tank.
30-56 CK25-1
FULCRUM LEVER
Removal
k Completely lower the working equipment to the ground.
3
2
1
k Release any residual hydraulic pressure.
1 - Remove the complete working equipment.

(For details see "COMPLETE WORKING EQUIP-
MENT").
RKSA2130
2 - Connect the lever (1) to a hoist and slightly tension the

cable.
3 - Loosen the screw (2) and remove the pin (3). 4
a Check for any damaged seals (4); replace if
necessary.

[*1][*2]
RKS02500
INSTALLATION OF THE
FULCRUM LEVER
[*1]
k During the hole and pin alignment procedure, do

not introduce your fingers to feel the position.

[*2]
MAX 1mm MAX 1mm
a Introduce shims between lever and frame until the
RKS02490
CK25-1 30-57
REMOVAL AND INSTALLATION LIFT LEVER
LIFT LEVER
Removal
k Completely lower the working equipment to the ground.
k Release any residual hydraulic pressure

1 - Remove the complete working equipment.

(For details see "COMPLETE WORKING EQUIP-
MENT").
2- Introduce a pin into the centre hole on the lever (1), con-
nect a hoist and slightly tension the cables.
1
RKSA2140
3- Loosen the screw (2) and remove the pin (3).
.[*1]
2
3
RKSA2150
4- Lift the lever (1) until the centre hole on the lever and the
fulcrum hole on the frame line up.
RKS05180
30-58 CK25-1
REMOVAL AND INSTALLATION LIFT LEVER
5- Loosen the screw (4), remove the pin (5) and remove
the lever (1). 1
a Check for any damaged seals (6) and replace if
necessary.
6
[*1][*2]
5 4
RKSA2310
LIFT LEVER
Installation
[*1]
k During the hole and pin alignment procedure, do not

introduce your fingers to feel the position.

[*2]
a Introduce shims between lever and frame until
MAX 1mm MAX 1mm RKS02520
CK25-1 30-59
REMOVAL AND INSTALLATION WORKING EQUIPMENT SUPPORT FRAME
WORKING EQUIPMENT SUPPORT FRAME

Removal
1 - Lower the working equipment until the supporting frame
is lying flat on blocks "A".
RKSA3771
2 - Remove the pins (1) and retract the cylinder piston rods
(2). 2
[*1] [*2]
RKSA0990
3 - Remove the pins (3) and take off the complete working
equipment support frame (4). [*3]
4 Equipment support frame: 57 kg
Installation 4
• To install, reverse removal procedure. RKSA3830
[*1]
a Insert the removed shims and if necessary add
more until the residual clearance is less than 3 mm.
[*2]
k Idle the engine when aligning the positions

between the hole and the pin.
CAUTION! Do not insert fingers into the holes
to check alignment.
2 Inside the bushings: Lithium EP MS2 NLGI 2
30-60 CK25-1
REMOVAL AND INSTALLATION HEATING SYSTEM BLOWER FAN
HEATING SYSTEM BLOWER FAN

Removal
k Disconnect the cable from the accumulator negative (–
1
) terminal.
1 - Remove the straps (1) retaining the hoses.
RKSA3671
2 - Disconnect the heating system’s delivery (2) and return

(3) hoses from the engine and drain any engine coolant
from the hoses.

installation. 3
RKSA1548
3 - Loosen the screws (4) and remove the front part of the
inlet hose (5).
4
RKSA1971
4 - Remove the upper screws (6) retaining the heater

assembly.
6
RKSA1981
CK25-1 30-61
REMOVAL AND INSTALLATION HEATING SYSTEM BLOWER FAN
5 - Remove the lower screws (7) retaining the heater

assembly.
RKSA1991
6 - Rotate the heater assembly (8) towards the inside of the

vehicle and remove the clamp (9) retaining the washer 10
hose (10). 9
8
RKSA2001
7 - Disconnect the connector (11) and remove the heater

assembly (8) together with its delivery and return hoses. 8
11
RKSA2011
Installation

there are no leaks.

them up.
30-62 CK25-1
REMOVAL AND INSTALLATION TRACK
TRACK
Removal
k Disconnect the negative (–) battery terminal cable.
1 -Lift machine off the ground by 10 cm approx.
RKSA5060
2 -Remove protection (1) and loosen valve (2) slowly.
k Do not loosen the valve (2) by more than 3 turns.

2
3
The track tensioning cylinder contains pressurized 1
grease, which may cause serious injury to the
Operator. [*1]
k Do not remove the safety pin (3).
RKSA3930
3 -Connect the track (4) to a hoist suitable for belt

tensioning in order to assist reentry of the track
tensioner idler wheel.
RKSA5090
4 -Push track (4) outwards and remove track.
4 Track: 170 kg
4
RKSA5080
CK25-1 30-63
REMOVAL AND INSTALLATION TRACK
Installation
[*1]
a Adjust track tension.

ADJUSTMENTS").
30-64 CK25-1
REMOVAL AND INSTALLATION LOWER IDLER ROLLER
LOWER IDLER ROLLER

Removal
) terminal. 1
1 -Remove track on disassembly side. (For details, see
"TRACK").
2 -Unfasten and remove two screws (1). [*1]
a To assist screw removal, loosen inner screw first to

neutralise the action of the thread locker, then
tighten again and loosen the outer screw.
RKSA3960
3 -Remove the complete roller (2).
RKSA3970
Installation
[*1]
2 Screws: Loctite 242

3 Screws: 574 Nm
CK25-1 30-65
REMOVAL AND INSTALLATION IDLER WHEELS
IDLER WHEELS
Removal
) terminal.

"TRACK"). 1
2 -Attach the front idler roller (1) to some hoisting tackle

and apply a slight tension to the cables.
RKSA3980
3 -Unfasten and remove the 2 screws (2). [*1]
a To assist screw removal, loosen inner screw first to

neutralise the action of the thread locker, then
tighten again and loosen the outer screw. 2
RKSA3990
4 -Remove the complete idler wheel (1).
4 Front idler wheel: 48 kg

Rear idler wheel: 32 kg
Installation
[*1]

3 Screws 574 Nm
30-66 CK25-1
REMOVAL AND INSTALLATION DRIVE WHEEL
DRIVE WHEEL
Removal
1
k Disconnect the cable from the accumulator negative (– 2
) terminal.

"TRACK").
2 -Unfasten and remove two screws (1). [*1] 1
3 -Remove drive wheel (2).
RKSA4000
Installation
[*1]

3 Screws: 230-270 Nm
CK25-1 30-67
REMOVAL AND INSTALLATION TRACK TENSIONER CYLINDER
TRACK TENSIONER CYLINDER

Removal
k Disconnect the cable from the accumulator negative (–)
terminal.
1
"TRACK").
2 -Position a suitable connection under the track tensioner

wheel (1).
RKSA4010
3 -Partly eject the track tensioner idler wheel (1) by

injecting grease into the track tensioner cylinder.
a Be careful not to let track tensioner cylinder move for

more than 140 mm on its stroke. 1
4 -Remove the complete track tensioner wheel (1).
4 Track tensioner wheel: 95 kg
RKSA4020
5 -Partly extract the track tensioner cylinder (2), connect it

to some suitable hoisting tackle and remove it.
[*1]
4 Track tensioner cylinder: 32 kg

2
RKSA4030
Installation
[*1]
a Ensure the track tensioner cylinder fits snugly in A
hole “A” on the frame.
RKS04680
30-68 CK25-1
REMOVAL AND INSTALLATION FINAL DRIVE
FINAL DRIVE
Removal
2
1 -Remove track on removal side. (For details, see
"TRACK").
2- Fully raise the working equipment and tilt the cab. (For 1
details, see "CAB").
3 -Remove 5 screws (1) and remove protections (2) and

3
(3).
1
RKSA4040
4 -Remove all nuts (4) and move bulkhead (5) to one side.
4
RKSA4050
5 -Remove screw (6) and remove bracket (7).
RKSA4060
6 -Remove 4 nuts (8) and disconnect the front and rear

bulkheads (9) from the frame.
9
RKSA4070
CK25-1 30-69
7 -Disconnect hoses (10) and (11).
a Plug all hoses to prevent any entrance of dirt.
10
11
RKSA4080
8 -Attach the frame (12) to some hoisting tackle and apply

light tension to the cables.
12
RKSA4090
9 -Remove all nuts (13) (6+6 pcs.) and screws (14) (4+4
pcs.). 13
[*1]
14
RKSA4100
10 -Slightly move the rear of the frame to one side and

disconnect all hoses (15) from final drive (16).
a Plug all hoses to prevent any entrance of dirt. 15
RKSA4110
30-70 CK25-1
11 -Remove the complete frame (12) and place it on a flat

surface.
4 Frame: approx. 490 kg
12
RKSA4090
12 -Attach the final drive (16) to some hoisting tackle and

apply light tension to the cable.
16
RKSA4130
13 -Remove all screws (17) and remove final drive (16).

[*2]
4 Final drive: 92 kg
17
14 -Remove the drive wheel.

(For details, see "DRIVE WHEEL"). 17
16
RKSA4120
Installation
[*1]
3 Nuts: 185-225 Nm
3 Screws: 285–325
[*2]
3 Screws: 230-270 Nm
CK25-1 30-71
FINAL DRIVE
Disassembly
1 2
1 -Remove the plugs (1) and their seals (2) and completely
drain the oil.
6 Final drive oil: 1.3 l

a Replace seals at each disassembly.
RKSA4140
2 -Remove snap ring (3).

3
RKSA4150
3 -Remove cover (4).
RKSA4160
4 -Remove sun gear (5) .
RKSA4170
30-72 CK25-1
5 -Remove the complete planetary gear assembly (6).

6
RKSA4180
6 -Remove shaft (7).
RKSA4190
7 -Remove O-ring seal (8).

8
RKSA4230
8 -Remove snap rings (9).
RKSA4200
CK25-1 30-73
9 -Remove the side gears (10) (4 pcs.) together with

bearings (11).
12
10
RKSA4220
RKSA4210
10 -Remove snap ring (12).
12
RKSA4220
11 -Remove the complete housing (13) from the drive motor

(14).
13
14
RKSA4240
12– Remove the first ring of packing (15) from drive motor
(14).
15
14
RKSA4250
30-74 CK25-1
13 -Remove the second ring of packing (15) from drive

motor (14).
14
15
RKSA4260
14 -Remove inner snap ring (16).
16
RKSA4270
15 -Remove bearing (17) from housing (13).
17
13
RKSA4280
16 -Remove plugs (18) (1 on each side).
a Check the condition of the O-ring and put in a new

one if necessary. 18
RKSA4290
CK25-1 30-75
17 -Pull out springs (19) and spring seats (20) (1 on each

side).
19
20
RKSA4300
18 -Extract spool (21) from cylinder head (22).

22
21
RKSA4310
19 -Remove plug (23).

one if necessary.
23
RKSA4320
20 -Extract spool (24) and spring (25).
25
24
RKSA4330
30-76 CK25-1
21 -Remove plug (26) and extract spool (27) from plug.

one, if necessary. 26 27
26
RKSA4340
22 -Recover shims (28) from plug (26) or spool (27).
27
28
RKSA4350
23 -Extract spring (29) and valve (30).
29
30
RKSA4360
24 -Remove plugs (31) and remove restrictors (32) and

(33).
33
31
32
RKSA4370
CK25-1 30-77
25 -Remove screws (34).
34
RKSA4380
26 -Lift the cylinder head (22).
a Mark cylinder head and flanged hub.

22
RKSA4390
27 -Do not discard O-rings (35).
35
35
RKSA4400
28 -Remove pins (36) and (37).

37
36
RKSA4410
30-78 CK25-1
29 -Remove valve plate (38).
38
RKSA4420
30 -Using a puller, remove outer and inner rings of bearing

(39).
39
RKSA4430
31 -Remove O-ring seal (40) from flanged hub.

40
41
RKSA4440
32 -Remove all springs (42) and (43) from brake piston (44).
42
44
43
RKSA4450
CK25-1 30-79
33 -Inject compressed air at low pressure into hole "A” and

eject piston (44).
a Hold piston (44) in position with two service screws A

to prevent it from being ejected at high speed and
being damaged.
a Mark piston and hub to assist in the assembly

procedures.
44
RKSA4460
34 -Remove O-rings (45) and (46) from piston (44).

45
46
44
RKSA4470
35 -Remove friction disc (47).

47
RKSA4480
36 -Extract spacer (48) and remove O-ring seal (49).

48
a Check condition of O-ring seals.
49
RKSA4490
30-80 CK25-1
37 -Remove remaining friction discs (47) and steel discs

(50). 47
RKSA4500
38 -Extract the cylinder block (51) from the flanged hub (41).
51
41
RKSA4510
39 -Do not discard ball joint (52) and pins (53).

52
53
RKSA4520
40 -Remove pistons (54) and detach pistons from disc (55).

54
55
RKSA4530
CK25-1 30-81
41 -Remove raking plate (56).
56
RKSA4540
42 -Remove two pistons (57) from flanged hub (41).
57
41
RKSA4550
43 -Detach pistons (57) from springs (58).
57
58
RKSA4560
44 -Remove balls (59).
59
RKSA4570
30-82 CK25-1
45 -Remove drive shaft (60), then remove inner ring of

bearing (61) using a puller.
60
61
RKSA4580
46 -Extract outer ring of bearing (61).
61
RKSA4590
47 -Remove grommet (62).
62
RKSA4600
CK25-1 30-83
Assembly
1 -Install grommet (62) to flanged hub (41) so it is flush with 41
the hub.
a Pay attention to grommet orientation.

2 Grommet lip: grease 62
RKSA4610
2 -Install the outer ring of bearing (61) to the flanged hub

(41) and install the inner ring to the drive shaft (60).
a Pay attention to ring orientation.
61
60
41
RKSA4620
3 -Install the complete drive shaft (60).
60
RKSA4630
4 -Install springs (58) to pistons (57).
57
58
RKSA4560
30-84 CK25-1
5 -Install the complete pistons (57) and balls (59) to the

flanged hub (41).
59
a Ensure that pistons (57) slide easily in their seats.
57
41 RKSA4640
6 -Install raking plate (56).
56
RKSA4540
7 -Install pins (53) to cylinder block (51) and position the

ball joint (52).
52
51
53
RKSA4521
8 -Ensure that the lubrication holes in pistons (54) are free

from dirt.
54
RKSA4650
CK25-1 30-85
9 -Install pistons (54) to disc (55).
a Pay attention to the orientation of disc (55) in

relation to the pistons.
54
55
RKSA4660
10 -Install pistons (54) to cylinder block (51).
54
51
RKSA4670
11 -Install the complete cylinder block (51) to the flanged

hub (41).
51
41
RKSA4680
12 -Install one friction disc (47) first, and then one steel disc
(50), and continue in this sequence until brake pack is
complete. The brake pack consists of 3 friction discs and
2 steel discs.
47 50
RKSA4690
30-86 CK25-1
13 -Install O-ring seal (49) to spacer (48).
2 O-ring seal: hydraulic oil: 49
48
RKSA4700
14 -Install O-rings (45) and (46) to brake piston (44).
2 O-ring seal: hydraulic oil: 45
44
48
RKSA4710
15 -Install the complete spacer (48) to piston (44).
48
44
RKSA4720
16 -Install the complete piston (44) to the flanged hub (41),

aligning the marks previously scribbled during
disassembly. 41
44
RKSA4730
CK25-1 30-87
17 -Install O-ring seal (40).

40
RKSA4740
18 -Install springs (42) and (43) to piston (44).
43
44
42
RKSA4750
19 -Install inner and outer rings of bearing (39).
39
RKSA4760
20 -Position valve plate (38) to cylinder head (22).

22
a Ensure the bronze plated surface is installed face
up.
38
RKSA4770
30-88 CK25-1
21 -Install pins (36) and (37).

37
36
RKSA4410
22 -Install O-rings (35).
35
35
RKSA4400
23 -Turn cylinder head (22) upside down and place it on the

flanged hub (41), aligning the scribbled marks.
a If marks are illegible, align the pins with the

displacement change holes.
22
41
RKSA4780
24 -Tighten screws (34).
3 Screws: 145 Nm
34
RKSA4790
CK25-1 30-89
25 -Install restrictors (32) and (33) plugs (31).
2 Plugs and restrictors: teflon band

3 Plugs and restrictors: 2.5±0.5 Nm 33
31
32
RKSA4800
26 -Install spring (25) to spool (24) and install to cylinder

head (22).
22
25
24
RKSA4810
27 -Install O-ring seal to plug (23) and tighten plug.
3 Plug 54±5 Nm
23
RKSA4820
28 -Install O-ring seal to plug (26) and introduce parts in the

following sequence: shims (28), spool (27) spring (29)
and valve (30).
26
30 29 27 28
RKSA4830
30-90 CK25-1
29 -Install the complete valve to the cylinder head (22) and

tighten plug (26).
3 Plug 92±4 Nm
22
26
RKSA4840
30 -Install spool (21) to cylinder head (22).

22
21
RKSA4310
31 -Install spring seat (20) and spring (19).
19
20
RKSA4850
32 -Install O-ring seal to plug (18) and tighten plug (18).
3 Plug 157±8 Nm
33 -Repeat the procedure on the opposite side of spool.
18
RKSA4860
CK25-1 30-91
34 -Install bearing (17) to housing (13) and make solid

contact with the seat using a suitable push rod.
17
13
RKSA4870
35 -Lock bearing (17) in place using snap ring (16).

16
17
RKSA4880
36 -Install the first ring of the packing (15) to the tool.

15
RKSA4890
37 -Install the first ring of the packing (15) to the hydraulic

motor.
15
RKSA4900
30-92 CK25-1
38 -Using tool A1, install the second ring of packing (15) to

housing (13).
15
13
RKSA4910
39 -Thoroughly clean the contact surfaces of packing rings

and lightly lubricate the rings.
2 Ring surface SAE oil 10W-30
RKSA4920
40 -Position the housing (13) with the bearing on a spacer.
13
RKSA4930
41 -Connect hydraulic motor (14) to some hoisting tackle

and fit motor inside housing (13).
14
13
RKSA4940
CK25-1 30-93
42 -Using a press and a suitable push rod, complete the

assembly of the motor (13).
13
RKSA4950
43 -Lock motor (13) in place using snap ring (12).
12
RKSA4960
44 -Install the complete side gears (10) (4 pcs.).
10
RKSA4970
45 -Lock gears (10) in place using snap rings (9).
10
RKSA4201
30-94 CK25-1
46 -Install O-ring seal (8).

8
RKSA4230
47 -Install shaft (7).
RKSA4190
48 -Install the complete planetary gear assembly (6).

6
RKSA4180
49 -Install sun gear (5) .
RKSA4170
CK25-1 30-95
50 -Install cover (4) and lock in place using snap ring (3).
3
RKSA4151
51 -Install the plugs (1) and their seals (2) without tightening.
52 -Mount the final drive on frame and fill up with final drive
oil.
5 Final drive: approx. 1.3 l of SAE 10W-30
1 2
RKSA4980
30-96 CK25-1
PAGE INTENTIONALLY
LEFT BLANK
30-98 CK25-1
40 STANDARD MAINTENANCE
P.T.O. ........................................................................................ 2
FRAME AND BUMPER SPRING .............................................. 3
TRACK TENSIONER IDLER WHEEL ....................................... 4
DRIVE WHEEL.......................................................................... 5
LOWER IDLER ROLLERS ........................................................ 6
REAR IDLER WHEEL ............................................................... 7
HYDRAULIC PUMP .................................................................. 8
CONTROL VALVE .................................................................. 10
R.H. PPC VALVE .................................................................... 23
L.H. PPC VALVE ..................................................................... 24
PATTERN CHANGE VALVE (OPTIONAL) ............................. 26
CYLINDERS ............................................................................ 27
WORKING EQUIPMENT......................................................... 28
CK25-1 40-1
STANDARD MAINTENANCE P.T.O.
P.T.O.
3 50 Nm
3 195 Nm
3 82 Nm
RKS02071
40-2 CK25-1
STANDARD MAINTENANCE FRAME AND BUMPER SPRING
FRAME AND BUMPER SPRING
RKS04101
Unit: mm
No. Check item Criteria Remedy

Standard clearance Clearancelimit Reconstru
1 Vertical clearance between frame and wheel bearing ct by
1.00
welding or
2 Side clearance between frame and wheel bearing 0.75 each side replace
Standard dimensions Repair limit
Freelength Length with

3 Bumper spring Installed Free Installed Replace
preload load length load
265 225 6.442 kg
CK25-1 40-3
STANDARD MAINTENANCE TRACK TENSIONER IDLER WHEEL
TRACK TENSIONER IDLER WHEEL
1 2
3 574 Nm
with Loctite 242
8 4 3 RKS04161
Unit: mm
Criteria
No. Check item Remedy
Standard size Repair limit
1 Track guide outer diameter
Reconstru
2 Track rest outer diameter ct by
3 Track rest width welding or
replace
4 Track guide width
Tolerance Minimum Clearance
Standard
size Shaft Hole clearance limit
5 Clearance between shaft and bushings
–0 + 0.183 0.044–
25 1.5
– 0.013 + 0.144 0.196
– 0.073 + 0.030 0.018–
6 Interference between bushing and roller 32 –
– 0.048 +0 0.073 Replace
Standard size Clearancelimit
7 Roller float
0.20 0.74
8 Metal shim at roller rest
26.25 22.25
40-4 CK25-1
STANDARD MAINTENANCE DRIVE WHEEL
DRIVE WHEEL
4
3
2 1
3 230-270 Nm
RKS04210
with Loctite 242
Unit: mm
Criteria
Standard size Tolerance Repair limit
1 Wear at bottom of drive wheel tooth
2 Wear of tooth tip Repair by
welding or
3 Tooth tip width replace
4 Tooth base width
CK25-1 40-5
STANDARD MAINTENANCE LOWER IDLER ROLLERS
LOWER IDLER ROLLERS
3 574 Nm
with Loctite 242
2 1
4 3
7 RKS04191
Unit: mm
Criteria
1 Track guide outer diameter
Reconstru
2 Track rest outer diameter ct by
3 Track rest width welding or
replace
4 Track guide width
Tolerance Minimum Clearance Remedy
Standard
Replace
6 Interference between bushing and roller
Standard size Clearancelimit

7 Roller float Replace
40-6 CK25-1
STANDARD MAINTENANCE REAR IDLER WHEEL
REAR IDLER WHEEL
3 574 Nm
with Loctite 242
2
RKS04201
Unit: mm
Criteria Remedy
No. Check item
Standard size Repair limit Reconstru
ct by
1 Outer diameter 350 –
welding or
2 Track guide width 44 20 replace
Tolerance Minimum Clearance

Standard
Replace
4 Interference between bushing and roller
Standard size Clearancelimit Replace

5 Roller float
bushing
CK25-1 40-7
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
3 147-186.2 Nm
3 19.6-27.4 Nm
3 58.8-73.5 Nm
JAPAN
3 49-58.8 Nm
Komatsu.Ltd.
3 19.6-27.4 Nm
3 19.6-27.4 Nm 3 147-186.2 Nm
3 58.8-73.5 Nm RK
40-8 CK25-1
STANDARD MAINTENANCE HYDRAULIC PUMP
AS VALVE
3 34.3-58.8 Nm 3 34.3-58.8 Nm
1 2 3
3 44.1-53.9 Nm Sezione A - A 3 58.8–78.4 Nm

RKS01450
Unit: mm
Criteria
Free Installed Installed Free Installed
length length load length load
1 Spring 38.1 30 52 N – 41.1 N

2 Spring 25.9 23 16.7 N – 13.7 N Replace
3 Spring 38.5 34.9 88.2 N – 70.6 N
CK25-1 40-9
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
STANDARD VERSION
3 11.3±1.5 Nm
3 31.9±2.5 Nm
3 11.3±1.5 Nm
3 11.3±1.5 Nm
B
A C
D D
3 31.9±2.5 Nm
B C
3 31.9±2.5 Nm
A
3 23.5±3.9 Nm
3 11.3±1.5 Nm
RKS04270
View Z
40-10 CK25-1
2
2
3
3
3 8.3±1.5 Nm
3 23.5±4 Nm
1
3 23.5±4 Nm
8
9
5 Section B- B
8
3 53.0±5.9 Nm
9
6 7
3 139.7±22.1 Nm 3 22.5±2.9 Nm
Section A - A RKS04260
Unit: mm
Criteria
Free
Installed Installed Free Installed
installed
length load length load
x Øe
1 Spool return spring (lift arm) 28.8x17.1 28.5 6.9 N – 30.6 N
2 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.2 N
3 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N
4 Spool return spring (ATT) 29x17.5 25 180.4 N – 144.4 N Replace
Spring of series - parallel circuit springs.
5 switching valve 38.3x15.2 24 161.8 N – 129.5 N If there are
damage
6 Spring of unload valve 32.9x18.2 18 74.0 N – 59.2 N or
7 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N deformation
Spring of pressurecompensation
8 valve 15.4x6 8 7.5 N – 2.0 N
9 valve 20x8.4 15 4.3 N – 5.5 N
CK25-1 40-11
3 53.0±5.9 Nm
3 AA
BB
3 53.0±5.9 Nm
4
Section AA-AA AA
BB
Section D - D
3 44.1±4.9 Nm
3 44.1±4.9 Nm
3 8.3±1.5 Nm
1
Section BB-BB
Section C - C RKS04230
Unit: mm
Criteria

Free
installed x
Øe
Spring of combination
1 circulating valve 37.5x16.6 22.5 177.0 N – 142.0 N
Replace
springs.
2 Spring of leveling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N If there are
damage
3 Spring of flow divider 30.2x9.4 23 2.9 N – 2.4 N or
deformation
4 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N
40-12 CK25-1
FLOAT VERSION
3 11.3±1.5 Nm
3 31.9±2.5 Nm
3 11.3±1.5 Nm
3 11.3±1.5 Nm
B
A C
D D
3 31.9±2.5 Nm
B C
A
3 31.9±2.5 Nm
3 23.5±3.9 Nm
3 11.3±1.5 Nm
View Z
RKS04240
CK25-1 40-13
2
2
3 8.3±1.5 Nm 1 3
3 23.5±4 Nm
8
9
5 Section B- B
8
3 53.0±5.9 Nm
9
6 7
3 139.7±22.1 Nm 3 22.5±2.9 Nm
RKS04250
Section A - A
Unit: mm
Criteria
Free
installed x length load length load
Øe
damage
8 valve 15.4x6 8 7.5 N – 2.0 N
9 valve 20x8.4 15 4.3 N – 5.5 N
40-14 CK25-1
3 53.0±5.9 Nm
3 AA
BB
3 53.0±5.9 Nm
4
Section AA-AA AA
BB
Section D - D
3 44.1±4.9 Nm
3 44.1±4.9 Nm
3 8.3±1.5 Nm
1
Section BB-BB
Section C - C RKS04230
Unit: mm
Criteria
Free
installed x
Øe
1 circulating valve 37.5x16.6 22.5 177.0 N – 142.0 N Replace
springs.
damage
4 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N deformation
CK25-1 40-15
HIGH-FLOW VERSION
3 11.3±1.5 Nm 3 11.3±1.5 Nm
3 31.9±2.5 Nm
B 3 11.3±1.5 Nm
A C
D D
3 31.9±2.5 Nm
B C
A
3 31.9±2.5 Nm
3 23.5±3.9 Nm
3 11.3±1.5 Nm
RKS04280
View Z
40-16 CK25-1
2
2
3 8.3±1.5 Nm 3
3 23.5±4 Nm
1
8
9
5 Section B- B
8
3 53.0±5.9 Nm
9
3 139.7±22.1 Nm
6 7
3 22.5±2.9 Nm
RKS04290
Section A - A
Unit: mm
Criteria
Free
installed x
Øe
damage
8 valve 15.4x6 8 7.5 N – 2.0 N
9 valve 20x8.4 15 4.3 N – 5.5 N
CK25-1 40-17
3
3 53.0±5.9 Nm AA
BB
3 53.0±5.9 Nm
4
Section AA-AA
AA
BB
3 44.1±4.9 Nm
Section D - D
3 44.1±4.9 Nm
1 3 8.3±1.5 Nm
Section BB-BB
RKS04300
Section C - C
Unit: mm
Criteria
Free
installed x
Øe
1 circulating valve 37.5x16.6 22.5 177.0 N – 142.0 N Replace
springs.
damage
4 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N deformation
40-18 CK25-1
SUPER HIGH-FLOW VERSION
3 11.3±1.5 Nm
3 31.9±2.5 Nm 3 11.3±1.5 Nm
B 3 11.3±1.5 Nm
C A
F F
E E
D D
B 3 31.9±2.5 Nm A
C
3 31.9±2.5 Nm
3 23.5±3.9 Nm
3 11.3±1.5 Nm
RKS04310
View Z
CK25-1 40-19
3 44.1±4.9 Nm
3 90.7±2.3 Nm
3 44.1±4.9 Nm
3 44.1±4.9 Nm
4
3
Section A - A
2 2
3 8.3±1.5 Nm
1 6
7
Section B - B RKS04320
Unit: mm
Criteria
Free
installed x
Øe
2 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.1N
3 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N Replace
springs.
4 Spool return spring (ATT) 28x11.5 24.5 137.3 N – 109.8 N If there are
damage
5 Spool return spring (High-Flow) 29x17.6 25.5 131.4 N – 105.1 N or
6 Spool return spring (float) 14.7x4.4 9.5 4.9 N – 3.9 N deformation
Spring of series - parallel circuit
7 switching valve 38.3x15.2 24 161.8 N – 129.5 N
40-20 CK25-1
3 53.0±5.9 Nm
7
AA
BB
3 53.0±5.9 Nm
8
Section AA-AA
AA
BB
4
Section D - D
3
4
4 5 3 8.3±1.5 Nm
3
4
6
3 53.0±5.9 Nm
Section BB-BB
3 139.7±22.1 Nm
1 2 3 22.1±2.5 Nm
RKS00702
Section C - C
Unit: mm
Criteria
Free
installed x
Øe
1 Spring of unload valve 23.9x18.2 18 74.0 N – 59.2 N
2 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N
3 valve 15.4x6 13 2.5 N – 2.0 N
Replace
Spring of pressurecompensation springs.
4 valve 20x8.4 12 6.9 N – 5.5 N If there are
damage
Spring of combination or
5 circulating valve 37.5x16.6 22.5 177.5 N – 142.0 N
deformation
6 Spring of leveling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N
7 Spring of flow divider 30.2x9.4 23 2.9 N – 2.4 N
8 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N
CK25-1 40-21
3 22.1±2.5 Nm
3 11.3±1.5 Nm
2
3 31.9±2.5 Nm
3 77.9±12.3 Nm 3 34.3±4.9 Nm
1
Section H - H 3 11.3±1.5 Nm
Section J - J
RKS04480
Unit: mm
Criteria
Free
installed x
Øe
1 Spring of check valve 13x6.5 9.5 2.0 N – 1.6 N Replace
springs.
If there are
Spool return spring damage
2 (High-Flow joining circuit) 25.7x11.1 22 66.7 N – 53.4 N
or
deformation
40-22 CK25-1
STANDARD MAINTENANCE R.H. PPC VALVE
R.H. PPC VALVE
3 112.8±14.7 Nm
3 13.2±1.5 Nm
2
3 44.1±4.9 Nm
4
5
P2 P1
3 39.2±4.9 Nm
1
Section D - D
P3 P4
Section C - C
Section E - E RKS00854
Unit: mm
Criteria Remedy
No. Check item
Free
installed x
Øe Replace
springs.
1 Centering spring (for P3 and P4) 44.6x15.5 34 22.1 N – 17.7 N If there are
damage
2 Centering spring (for P1 and P2) 38.56x15.5 34 30.4 N – 24.3 N or
3 Metering spring (for P3 and P4) 32.65x8.15 25.6 40.8 N – 32.6 N deformation
4 Metering spring (for P2) 26.2x8.15 25.3 5.27 N – 4.2 N

CK25-1 40-23
STANDARD MAINTENANCE L.H. PPC VALVE
L.H. PPC VALVE

STANDARD
3 112.8±14.7 Nm
3 44.1±4.9 Nm
3 13.2±1.5 Nm
2 4
3 13.7±1 Nm
3
P2 P1
1
Section D - D
P3 P4
Section C - C G G
Section F - F
Section E - E Section G - G RKS00912
Unit: mm
Criteria Remedy
No. Check item
Free
installed x
length load length load Replace
Øe
springs.
damage
deformation
Metering spring
3 (for P2, P3 and P4) 26.2x8.15 25.3 5.27 N – 4.2 N
40-24 CK25-1
STANDARD MAINTENANCE L.H. PPC VALVE
PATTERN CHANGE (OPTIONAL)
3 112.8±14.7 Nm
3 13.2±1.5 Nm
1
3 44.1±4.9 Nm
3 39.2±4.9 Nm
2
Section D - D
Section C - C
Section E - E RKS00851
Unit: mm
Criteria Remedy
No. Check item
Free
installed x
length load length load Replace
Øe
springs.
damage
deformation
Metering spring
3 (for P2, P3 and P4) 26.2x8.15 25.3 5.27 N – 4.2 N
CK25-1 40-25
STANDARD MAINTENANCE PATTERN CHANGE VALVE (OPTIONAL)
PATTERN CHANGE VALVE (OPTIONAL)
3 27.5-34.3 Nm
3 11.8-14.7 Nm
4
6 3
1 5
2
3 27.5-34.3 Nm RKS00940
40-26 CK25-1
STANDARD MAINTENANCE CYLINDERS
CYLINDERS
1 2
3 Lifting bucket: 430±43 Nm (wrench: 32 mm)

3 Lifting bucket: 412±41 Nm
3 Dump bucket: 350±35 Nm (wrench: 32 mm)
with Loctite 262
3 Dump bucket: 441±44 Nm
with Loctite 262
3
RKS01990
Unit: mm
Criteria
No. Check item Cylinder Standard Tolerance Minimum Clearance Remedy

– 0.01 + 0.072 0.082–

Tolerance between Lifting bucket 35 1.0
– 0.05 + 0.134 0.184
1 bushing and piston rod
mounting pin – 0.01 + 0.072 0.082–
Bucket dump 35 – 0.05 + 0.134 0.184 1.0
Replace
– 0.01 + 0.072 0.082– bushing
Tolerance between Lifting bucket 35 1.0
– 0.05 + 0.134 0.184
2 bushing and cylinder
mounting pin – 0.01 + 0.072 0.082–
Bucket dump 35 1.0
– 0.05 + 0.134 0.184
Lifting bucket 35
-- 0.025 + 0.039 0.025–
0.426
Tolerance between -- 0.087 +0 0.126 Replace
3 piston rod and cylinder
-- 0.020 + 0.033 0.020– head
head Bucket dump 30 0.405
-- 0.072 +0 0.105
CK25-1 40-27
STANDARD MAINTENANCE WORKING EQUIPMENT
WORKING EQUIPMENT
D
F F
E
A G
A
B
E G
B
H
C
H
Sezione A - A
Sezione B - B
2
3
Sezione D - D
RKS05190
Sezione C - C
40-28 CK25-1
2
6
Section D - D Section E- E
RKS03530
Unit: mm
Criteria
No. Check item Standard Tolerance Minimum Clearance Remedy

Clearance between bushing

– 0.01 + 0.072 0.082–
1 and mounting pin of arm and support 35 1.0
– 0.05 + 0.134 0.184
frame
Clearance between bushing – 0.01 + 0.072 0.082–
2 and mounting pin of arm 35 – 0.05 + 0.134 0.184 1.0
Clearance between bushing and – 0.01 + 0.072 0.082–

3 35 1.0
mounting pin lift cylinder (head side) – 0.05 + 0.134 0.184 Replace
Clearance between bushing and bushing
4 mounting pin bucket cylinder (bottom 35 – 0.01 + 0.072 0.082– 1.0
– 0.05 + 0.134 0.184
side)
5 35 1.0
mounting pin bucket cylinder (head side) – 0.05 + 0.134 0.184
6 35 1.0
mounting pin lift cylinder (bottom side) – 0.05 + 0.134 0.184
CK25-1 40-29
4 8
Sezione F- F
Sezione E- E
5 9
Sezione G- G
Sezione H- H
RKS01980
Unità di misura: mm
Valore
N° Particolare da controllare Misura Tolleranza Gioco Gioco Rimedio
nominale Albero Foro normale massimo
Gioco tra boccola e perno – 0,01 + 0,72 0,082–

1 35 1,0
leva di sollevamento – 0,05 +0,134 0,184
Gioco tra boccola e – 0,01 + 0,72 0,082–
2 perno fulcro telaio porta attrezzi 35 – 0,05 +0,134 0,184 1,0
Gioco tra boccola e – 0,025 + 0,105 0,130–

3 perno leva di fulcro 40 – 0,064 + 0,135 0,199 1,0

4 35 1,0
leva di sollevamento – 0,05 +0,134 0,184
Gioco tra boccola e – 0,025 + 0,105 0,130– Sostituire
5 40 1,0
perno leva di fulcro – 0,064 + 0,135 0,199 boccola
6 martinetto benna (lato base) 35 – 0,05 +0,134 0,184 1,0

7 35 1,0
martinetto benna (lato testa) – 0,05 +0,134 0,184
8 35 1,0
martinetto sollevamento (lato testa) – 0,05 +0,134 0,184
9 Gioco tra boccola e 35 – 0,01 + 0,72 0,082– 1,0

martinetto sollevamento (lato base) – 0,05 +0,134 0,184
40-30 CK25-1
PAGE INTENTIONALLY
LEFT BLANK
40-32 CK25-1
90 OTHER
ELECTRICAL DIAGRAM (STANDARD) ................... 3

ELECTRICAL DIAGRAM (OPTIONAL) ..................... 5
CK25-1 90-1
OTHER ELECTRICAL DIAGRAM (STANDARD)
ELECTRICAL DIAGRAM (STANDARD)
C
S13
ON
S14
CN
C
ON
X13
X14, X18
CN
1 2 K06
H-R1
+ - BRAKE P.B. IN
X50 L/B1
3
RIGHT LEVER
S13 S14 S15
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
23
X50 A/B1 HA1 R-N2.5 G1.5
LEFT LEVER
HI-SPEED P. B. IN
R2.5
22
FLOAT P. B. IN
X50 L/G1
X08
R-N0.5
R-N0.5
21
H-R2.5
R-N2.5
V/B0.5
L/G0.5
L/G0.5
X07 SAF. BAR. SW IN
X50 C/N1
M2.5
20
1 1 1 1 1 1 1 1 1 1 1
K04 85 87
X50
B1
SEAT SWITCH IN
C-B1 X52 X53 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
1 2 3 1 2 19
X50 1 1
POW. SUPP. +12V
H-R1 FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 86 30
Z-B1
18 R1 ACC BR R2 C X83 X83 X83 X83 X84 X84 X84
4 5 6 EV BRAKE OUT
X50 H-L1 OFF ACC 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A
3 4
X89
X89
X89
X89
17 R/N1 R1
ST 1 2 3 11 1 3 11
X78
X79
STOP ENGINE OUT
X50 R-N1.5
B-R1
B/R1
A/B1
N1
B-R1
L/G1
N1
16
ELECTRONIC UNIT
X50 85 86 30 87
BRAKE LIGHT OUT
S/N1 S10 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77 1 1
15
X50 B/N1 S12 1 1 1 1 1 1 1 1 1 1 1
M-N1
B-N1
B-R1
B-R1
H/R1
N1
SAF. BAR.LED OUT
14
SEAT LED OUT
X50 G/N1 S11
R4
WIRE POSITIONING
H-R1.5
A-R1.5
13
G/N1
R2.5
X50
G1
M/B1
R-N2.5
L-R1.5
R-G1
H-R1
G/R1
H/R1
B-R1
WARNING LED OUT
ON CONNECTOR X50
12
FLOAT OUT
B-N1 X54 X54 X54 G/R1 X85 9
( WIRE SIDE WIEW WIRING ) X50
11
Z-B1 C A B X55 X55
A-R1.5 X85 1
BUZZER OUT (-) 2 1
= Parts not included in the wiring X50
10
M-B1
C/N1
N1
H-R1
C-B1
H-R1
HI-SPEED OUT 1 9
9 1 0
GND
X50 N1.5
KUE 37C-06-11312 8
HORN OUT
X50 C1
5 10
X50
7
B1 S01
START SIGN. IN
6
0A005893 +12V HORN
X50 H-R1.5 A-G1.5 X85 5
5
HORN PUSH B. IN
X50 B/R1
4 N1 X85 10
PPC SAF. SW. IN
X50 L-G1
3
EV PPC OUT
X50 V-N1
V1 K02 X50
2
R/N1 G/R1 X86
POWER
BUZZER OUT (+) 9

K01 1
G1.5 X86
SAFETY
BOX
8
86 87 R-N2.5 X01 X01.1 R-N2.5
M1 X48 X48.1 M1 H-N1 X86
RELAY M2.5 4 4
X01.1 M2.5
1
R-B1
X01 1
H0.5
M-V1 1 M-V1
X48 X48.1
X07 G1
X07 R1
X07 N1
85 30 3 1 6 8 9
K03 R4 X01 3
X01.1 R4 2 0 1 2
R-V1 2
2 X48 X48.1
X07
X01 2
X01.1 R4 3 3
X03 X03 X03 X03 X06 X06 XS1 XS1 X08 X08 X08 X08 1 L-G1 X48 X48.1 L-G1
86 85 30 87 l - 4 3 2 1 A B 1 3 5 6 GND5 1
4 4 S02 3 2 10
N4 N4 H-R1.5 X86 3
XS R4 R-N2.5 R-N2.5 H-R1 X86
X46 X46.1 K14 2
X02.1GND5
B2.5
R-G1
B1
N1
S-N1
X02 4 H-L1 X44 86 86 87a 87

M-V1
L/B1
R-N2.5
B2
R-N1.5
R-N1.5
N1
M-V1
L/B1
R-N1.5
N1
M2.5 4 M2.5 N1
l X46 X46.1 X86 10
L-R1 l
X02.1 L-R1.5
R10
X02 3 M1 X44 87a

R4 4 R4
- X46 X46.1 85 30
-
2 H-L1 X44 30 S/N1 X87 6
R4 2 R4
X46 X46.1
R-N1.5 X10 X10.1 R-N1.5 H-R1 X87 3
A-G1.5
1 1
B-G1 X44 85
G-N1
H-G1
H-N1
H-N1
13
N1.5
13
X10 X10.1 15/1 30/3 L/6
G1
C1
12 R-N1.5 X45 X45.1 R-N1.5 0 1
R2.5 X10 12
X10.1 R2.5 13 GND3
11 V-N1 X45 13 X45.1 V-N1
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
R-V1 X10 11
X10.1 R-V1 12
10 M-B1 X45 12 X45.1 M-B1 S08 49/4 30b/2 R/7
B1X10 10 X10.1 B1 11
1 2 3 4 5 6 7 8 9 10 11 L/B1 X87 2
L-R1.5 X45 11 X45.1 L-R1.5
B-N1
C-N1
B1
N1
H-R1
G/N1
Z-B1
S-G1
M1
C-L1
S1
B-G1
B/N1
M-N1
M-V1
M-B1
H0.5
M/B1
G/N1
9
S1X10 9 X10.1 S1 10 1 2 3 4 5 6 7 8 9 10 11
H-R1 X87 7
8 B1 X45 10 X45.1 B1
C-N1 X10 8
X10.1 C-N1 G/R1 X88
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
9 9
M-N1 9 M-N1
7 X45 X45.1
C-L1 X10 7
X10.1 C-L1 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 H/R1 X88 1
R-G1 8 R-G1
6 X45 X45.1
S-G1 6
X10.1 S-G1
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
X10 7 7 1 9
5 S1 X45 X45.1 S1 P1 1 0
R10
H-G1
H-N1
H-N1
A-G1
N1.5
X10 X10.1
C1
6 6
4 C-N1 X45 X45.1 C-N1
B-N1 X10 4
X10.1 B-N1
GND 3 C-L1 X45 5 5
X45.1 C-L1 S07 5 10
R-G1 X10 3
X10.1 R-G1 H-G1 X88
B-G1 X10 2 2
X10.1 B-G1
S-G1 X45 4 4
3
X45.1 S-G1 CONTROL PANEL (UNIDECK) N1 X88
5
10
1 3
1 B-N1 X45 X45.1 B-N1
1
XF 2 2
1
B-G1 X45 X45.1 B-G1
FG1 1 1
50A X28
HA3
N4 X47 X47.1 N4 = Parts not included in the wiring
S31 N4 X47 1 1
X47.1 N4
XF p 2 2 H-G1 KUE 37A-06-11343
2
N1.5
X29
X29
C1
2 1
0A007930
A-G1
R10 INTERNAL CONNECTION CONTROL PANEL
P1 CONTROL PANEL (UNIDECK) H-N1
X80-15
X80-16
X80-12
X80-14
X80-11
N1
Z-N1
R10
H-N1
R50 X80-8
R-G1
+
S-N1
B2.5
S1
R-N1.5
R-G1
C-N1
S-G1
B-N1
M2.5
C-L1
L1 L2 L3 L4 L5 C2 C3
N2
N1
N1
N1
N1
B2
G1 GND4
M-N1
M-B1
M-V1
L-G1
V-N1
L1 L2 L3 L4 L5
R2.5
FUEL WATER TEMP.

R-V1
Z-N1
L-R1
L-R1
L-R1
M1
1 2 1 3
N1
N1
N1
N1
LEVEL INDICATOR
X09
X11
X11
X11
12Vcc
N2.5
3 1 2 - + 1 2 1 C A - + 1
X13
1 1 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 1 2 1 2 1 2 1 2 1 1 1 2 1 2 1 2 1 2 1 H F
XB XM C2
M1 G2 R1 R2 R3 X20 X20 X21 X21 X22 X22 X23 X23 X32 X32A X33 X33 X34 X34 X35 X35 X36 X36 X37
N2.5
B2.5
50
D+ M2 C1
30 30
G W
S25 S26 S27 S28 S29 S30 S32 S33 00000 00 h 1 2 1 2 A B A B 2 1
N50
M Y0
3 M p p p p p p p p
XP1A
X108
X108
X109
X109
X110
X110
X111
X111
XP1
U C E
t GND2 C1
31 HOUR COUNTER C3
Y1 Y2 Y6 Y3
H-G1
H-N1
H-N1
A-G1
A-G1
N1
N1
N1
N1
N1
ENGINE PARTS X80-6
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
- KUE 37A-06-11471
X80-9 GND6 0A005425

X80-2 X80-3
1
X113
H1
H4 H6 H10 H11 M
HA2

KUE 37C-06-11321
= Parts not included in the wiring 0A005935 C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
NOME DESCRIZIONE COSTRUTTORE TIPO QTA
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 H1 GIROFARO /BEACON LIGHT CIAM (KUE) 110450 (885111118) 1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 H4 FARO DI LAVORO ANT. SX / LEFT FRONT WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
H6 FARO DI LAVORO ANT. DX / RIGHT FRONT WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
H10 FARO DI LAVORO POSTERIORE SX / LEFT REAR WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
H11 FARO DI LAVORO POSTERIORE DX / RIGHT REAR WORK LAMP COBO (KUE) 05-531-000 (885111132) 1
POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR HA2 AVVISATORE ACUSTICO /HORN CIAM (KUE) 112001 (885100005) 1
X82.1 CONNETTORE MARK 11 VIE DA LINEA CABINA / FROM CABIN LINE 11 WAY CONN. AMP * 1
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 X108 CONNETTORE 2 VIE LUCE ANTERIORE SX / LEFT FRONT LIGHT 2 WAY CONN. PACKARD * 1
NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT./SUPPL. TIPO/TYPE QTA L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5 X109 CONNETTORE 2 VIE LUCE ANTERIORE DX / RIGHT FRONT LIGHT 2 WAY CONN. PACKARD * 1
X110 CONN. 2 VIE FARO LAVORO POST. SX / LEFT REAR WORK LIGHTS 2 WAY CONN. DEUTSCH * 1
FG1 FUSIBILE GENERALE 80A /GENERAL FUSE 50A CIAM 163028 1 L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1 X111 CONN. 2 VIE FARO LAVORO POST. DX / RIGHT REAR WORK LIGHTS 2 WAY CONN. DEUTSCH * 1
G1 BATTERIA /BATTERY 100Ah FIAMM (KUE) L5 600 103 085 (37C-06-11110) 1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 XP1, XP1A CONN. 1 VIA PRESA 12V, GIROFARO / 12V SOCKET, BEACON LIGHT 1 WAY CONN. AMP * 1
G2 ALTERNATORE /GENERATOR YANMAR (DENSO) 129423-77200 1
X113 CONNETTORE 1 VIA CLAXON / HORN 1 WAY CONN. AMP * 1
K01 RELE' SOLENOIDE CARBURANTE /FUEL SOLENID VALVE RELAY MATSUSHITA (KUE) CB1aH (885071022) 1
GND4 OCCHIELLLO C6 MASSA / C6 GROUND TERMIMAL AMP * 1
K02 TIMER 1 SECONDO PULL SOLENOIDE / FUEL PULL SOLENID VALVE TIMER 1 SECOND 1
GND6 OCCHIELLLO C8 MASSA CLAXON/ C8 HORN GROUND TERMIMAL AMP * 1
K03 SAFETY RELAY YANMAR (KUE) 119802-77200 1
M1 MOTORINO AVVIAMENTO / STARTER MOTOR YANMAR 123900-77010 1
M2 POMPA GASOLIO / FUEL PUMP YANMAR 129612-52100 1
R1 RESISTENZA PRERISCALDO /PREHEATING STARTER YANMAR 129100-77500 1
R2 SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER COBO (KUE) 29-0419-0000 (37A-04-11140) 1
NOME/ NAME DESCRIZIONE/ DESCRIPTION COSTRUT./ SUPP. TIPO/ TYPE QTA
R3 TRASDUTTORE DI TEMP. ACQUA MOTORE /ENGINE WATER TEMPERATURE SENDER YANMAR (KUE) (7861-92-3320) 1
FU01 FUSE 3A (LEFT SIDE LIGHTS) 1 NOME/ NAME DESCRIZIONE/ DESCRIPTION COSTRUTT./ SUPP. TIPO/ TYPE QTA
S25 SENSORE INTASAMENTO FILTRO ARIA /AIR FILTER BLOCKED SWITCH DONALDSON (KUE) X770317 (37A-06-11960) 1
S26 PRESSOSTATO INTASAMENTO OLIO IDRAULICO /HYDRAULIC OIL FILTER BLOCKED SWITCH FMDI (KUE) 11716/1 (885261034) 1 FU02 FUSE 3A CONTROL PANEL LIGHTS 1 X54 CONNETTORE 3 VIE SENSORE BARRA / PROXIMITY BAR 3 WAY CONN. DEUTSCH * 1
S27 PRESSOSTATO LUCI STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU03 FUSE 15A HORN, FRONT WORK LIGHTS 1 X55 CONNETTORE 2 VIE SENSORE SICUREZZA SEDILE /SAFETY SEAT SWITCH 3 WAY CONN. DEUTSCH * 1
S28 PRESSOSTATO STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU04 FUSE 7.5A SWITCH LIGHTS 1 X56 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
S29 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU05 FUSE 15A REAR WORK LIGHT 1 X57 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
S30 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 FU06 FUSE 10A LEVER SWITCH POWER SUPPLY, FLOAT X58 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 WIRING COLOURS
S31 PRESSOSTATO MINIMA PRESSIONE OLIO MOTORE /ENGINE OIL MIN. PRESSURE SWITCH YANMAR * 1 FU07 FUSE 10A CURRENT INTAKE 12V, BEACON LIGHT 1 X59 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
V1 DIODO 1A / DIODE 1A CIAM 1A 1N4007 1 FU08 FUSE 10A CONTROL PANEL, ELECTRONIC UNIT, FUEL SHUT OFF, SAFETY BAR PROXIMITY, SEAT SAFETY SWITCH, BRAKE SWITCH 1 X60 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 A LIGHTBLUE
Y0 ELETTROVALVOLA STOP SOLENOIDE CARBURANTE /STOP FUEL SOLENOID VALVE YANMAR 129005-77950 1 FU09 FUSE 7.5A BACK-UP ALARM 1 X61 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 B WHITE
X01 CONNETTORE 3 VIE LINEA TELAIO /FRAME LINE 3 WAY CONNECTOR * * 1 FU10 FUSE 7.5A FUEL PUMP, SAFETY ENGINE RELAY, GENERATOR 1 X62 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 C ORANGE
X02 CONNETTORE 2 VIE / 2 WAY CONN. * * 1 FU11 FUSE 30A PULL SOLENOID, PPC SAFETY PRESSURE SWITCH 1 X63 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 G YELLOW
X03 CONNETTORE RELE SOLENOIDE CARBURANTE / FUEL SOLENOID RELAY CONN. * * 1 1 X64 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 H GREY
1 1 X65 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 L BLUE
1 1 X66 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 M BROWN
X06 CONNETTORE 2 VIE DIODO ANTIDISTURBO / DIODE 2 WAY CONN. * * 1 HA1 BUZZER SEGNALAZIONE ANOMALIE / WARNING BUZZER 1 X67 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 N BLACK
X07 CONNETTORE 4 VIE TIMER PULL SOLENOIDE/PULL SOLENOID TIMER 4 WAY CONN. * * 1 1 X68 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 R RED
X08 CONNETTORE 6 VIE SAFETY RELAY /SAFETY RELAY 6 WAY CONN. SUMITOMO 6195-0021 1 X69 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 S PINK
X09 OCCHIELLO C6 ALTERNATORE / C6 GENERATOR TERMINAL * * 11 K04 RELE' FLOAT / FLOAT RELAY CIAM 157061 (KUE 885071043) 1 X70 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 V GREEN
X10 CONNETTORE MARK 13 VIE LINEA TELAIO /FRAME LINE MARK 13 WAY CONN. * * 1 X71 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 Z VIOLET
X11 CONNETTORE 3 VIE ALTERNATORE /GENERATOR 3 WAY CONN. SUMITOMO 6189-0442 1 K06 CENTRALINA ELETTRONICA / ELECTRONIC UNIT CIAM 01171077 (KUE 885070046) 1 X72 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
1 K14 RELE' FRENO / BRAKE RELAY CIAM * 1 X73 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 EXAMPLE:
X13 CONNETTORE 3 VIE POOL-STOP SOLENOIDE CARBURANTE /FUEL POOL-STOP SOLENOID 3 WAY CONN. DEUTSCH DT06-3S 1 NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT. / SUPPL. TIPO/ TYPE QTA P1 PANNELLO STRUMENTI /CONTROL PANEL UNIDECK 04610027 (KUE 37A-54-14291) 1 X74 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 G/V ->YELLOW/GREEN (TRANSVERSE MARKED)
X14 CONNETTORE 2 VIE POMPA GASOLIO / FUEL PUMP 2 WAY CONN. * * 1 S32 PRESSOSTATO PPC SAFETY / PPC SAFETY PRESSURE SWITCH FMDI (KUE) 11717.75 (37A-06-11670) 1 X75 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
X15 OCCHIELLO C6 RESISTENZA PRERISCALDO / PREHEATING START C6 TERMINAL * * 1 S33 PRESSOSTATO FRENO STAZIONAMENTO /BRAKE VALVE PRESSURE SWITCH FMDI (KUE) * 1 X76 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1 YELLOW GREEN
X16 CONNETTORE 2 VIE SENSORE INTASAMENTO FITRO ARIA / AIR FILTER BLOCKED SWITCH 2 WAY CONN. AMP MINITIMER 1 Y1 ELETTROVALVOLA SERVOCOMANDI /PPC VALVE HYDRAFORCE * 1 S01 INTERRUTTORE SWF 1 POS. STABILE FARI LAVORO POST /REAR WORK LIGHTS SWITCH CIAM 106AA008 (KUE 885081160) 1 X77 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP * 1
Y2 ELETTROVALVOLA FLOAT /FLOAT VALVE HYDRAFORCE * 1 S02 INTERRUTTORE SWF 2 POSIZIONI STABILI LUCI STRUMENTO E ANAB. /PANEL LIGHTS AND LOW BEAM LIGHTSCIAM
SWITCH 106AA018 (KUE 885081159 ) 1 X78 CONNETTORE 1 VIA PRESA DI CORRENTE /CURRENT INTAKE 1 WAY CONN. AMP * 1
X17 CONNETTORE 3 VIE SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER 3 WAY CONN. * * 1 Y3 ELETTROVALVOLA SECONDA VELOCITA' /SECOND SPEED VALVE HYDRAFORCE * 1 S07 INTERRUTTORE SWF LAMPADA ROTANTE /BEACON LIGHT SWITCH CIAM 106AA008 (KUE 885081160) 1 X79 CONNETTORE 1 VIA PRESA DI CORRENTE /CURRENT INTAKE 1 WAY CONN. AMP * 1 G-V ->YELLOW-GREEN(LONGITUDINAL COLOURS)
X18 CONNETTORE 2 VIE TRASDUTTORE TEMP. ACQUA /ENGINE WATER TEMPERATURE SENDER 2 WAY CONN. * * 1 Y6 ELETTROVALVOLA FRENO /BRAKE VALVE HYDRAFORCE * 1 S08 PULSANTE FRENO / BRAKE SWITCH CIAM 0A003455 (KUE 37A-06-11410) 1 X80 CONNETTORE 16 VIE PANNELLO DI CONTROLLO / CONTROL PANEL 16 WAY CONN. AMP * 1
X19 OCCH. C5 SENSORE INTASA. FILTRO OLIO IDRAULICO / IDRAULIC OIL FILTER BLOCKED SWITCH C5 TERMINAL* * 1 X01.1 CONNETTORE 4 VIE LINEA MOTORE / ENGINE LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 S10 QUADRO AVVIAMENTO /STARTING SWITCH 1 X81 CONNETTORE 8 VIE PANNELLO DI CONTROLLO /CONTROL PANEL 8 WAY CONN. AMP * 1 YELLOW GREEN
X20 CONNETTORE 2 VIE PRESSOSTATO 1 LUCI STOP / STOP LIGHT PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X02.1 CONNETTORE 2 VIE LINEA MOTORE /ENGINE LINE 2 WAY CONN. * * 1 S11 FINECORSA SICUREZZA SEDILE /SAFETY SEAT SWITCH 1 X82 CONNETTORE MARK 11 VIE LINEA FARI /LIGHTS LINE 11 WAY CONN. AMP * 1
X21 CONNETTORE 2 VIE PRESSOSTATO 2 LUCI STOP / STOP LIGHT PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X10.1 CONNETTORE MARK 13 VIE LINEA MOTORE /ENGINE LINE 13 WAY CONN. * * 1 S12 PROXIMITY DI SICUREZZA PNP BRACCIOLO /BAR PNP SAFETY SENSOR SAIET E-A1TMU/3AP (KUE 37A-06-11250) 1 X83 CONNETTORE MARK 12 VIE MANIPOLATORE SX / LEFT LEVER 12 WAY CONN. DEUTSCH DT04-12P,DT06-12-S 1
X22 CONNETTORE 2 VIE PRESSOSTATO 1 BACK-UP / BACK-UP PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X32 CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY / PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 S13 PULSANTE CLAXON /HORN PUSH BUTTON 1 X84 CONNETTORE MARK 12 VIE MANIPOLATORE DX / RIGHT LEVER 12 WAY CONN. DEUTSCH DT04-12P,DT06-12-S 1
X23 CONNETTORE 2 VIE PRESSOSTATO 2 BACK-UP /BACK-UP PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 X32A CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY / PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 S14 PULSANTE SECONDA VELOCITA' /SECOND SPEED PUSH BUTTON 1 X85 CONNETTORE SWF INTERRUTTORE FARI LAVORO POSTERIORI /REAR WORK LIGHTS SWF SWITCH SWF * 1
X28 TERMINALE MINIMA PRESSIONE OLIO MOTORE /ENGINE MIN.PRESSURE SWITCH TERMINAL * * 1 X33 CONNETTORE 2 VIE EV. SERVOCOMANDI (PPC) /PPC VALVE 2 WAY CONN. * * 1 S15 PULSANTE FLOAT / FLOAT PUSH BUTTON 1 X86 CONNETTORE SWF LUCI STRUM. E FARI ANABB. ANTERIORI /PANEL AND FRONT LIGHTS SWF SWITCH CONN.SWF * 1
X29 CONNETTORE 2 VIE SIRENA BACK-UP /BACK UP ALARM 2 WAY CONN. * * 1 X34 CONNETTORE 2 VIE EV. FLOAT / FLOAT VALVE 2 WAY CONN. * * 1 X44 CONNETTORE RELE' BRAKE / BRAKE RELAY CONN. 1 X87 CONNETTORE PULSANTE FRENO / BRAKE SWITCH CONN. PNEUTRON * 1
XB OCCHIELLO C8 SU MOTORINO AVV. / C8 START MOTOR TERMINAL * * 1 X35 CONNETTORE 2 VIE EV. FRENO /BRAKE VALVE 2 WAY CONN. * * 1 X88 CONNETTORE SWF INTERRUTTORE LAMPEGGIANTE /BEACON LIGHT SWITCH CONN. SWF * 1
XF CONNETTORE 2 VIE FUSIBILE GENERALE / GENERAL FUSE 2 WAY CONN. * * 1 X36 CONNETTORE 2 VIE EV. SECONDA VELOCITA' /SECOND SPEED VALVE 2 WAY CONN. * * 1 X45.1 CONNETTORE MARK 13 VIE DA LINEA TELAIO / FROM FRAME LINE 13 WAY CONN. AMP * 1 X89 CONNETTORE RELE' FLOAT / FLOAT RELAY CONN. 1
GND OCCHIELLO C8 MASSA / C8 GROUND TERMINAL * * 1 X37 CONNETTORE 1 VIA PRESSOSTATO FRENO /BRAKE PRESSURE SWITCH 1 WAY CONN. * * 1 X46.1 CONNETTORE 4 VIE DA LINEA TELAIO / FROM FRAME LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 GND3 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL AMP * 1
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL * * 1 X45 CONNETTORE 13 VIE LINEA CABINA / CABIN LINE 13 WAY CONN. * * 1 X47.1 CONNETTORE 2 VIA MASSA DA LINEA TELAIO / FROM FRAME LINE 2 WAY GROUND CONN. DEUTSCH DTP04-2P 1
XM OCCHIELLO C4 SU MOTORINO AVV. / C4 START MOTOR TERMINAL * * 1 X46 CONNETTORE 4 VIE LINEA CABINA / CABIN LINE 4 WAY CONN. DEUTSCH DTP-06-4S 1 X48.1 CONNETTORE MARK 5 VIE DA LINEA TELAIO / FROM FRAME LINE 5 WAY CONN. AMP * 1
XS CONNETTORE 2 VIE SAFETY RELAY / SAFETY RELAY 2 WAY CONN. SUMITOMO 6195-0060 1 X47 CONNETTORE 2 VIe MASSA / GROUND 2 WAY CONN. DEUTSCH DTP06-2S 1
XS1 ISOLATORE / INSULATOR * * 1 X48 CONNETTORE 5 VIE LINEA CABINA / CABIN LINE 5 WAY CONN. * * 1 X50 CONNETTORE 23 VIE CENTRALINA ELETTRONICA / ELECTRONIC UNIT 23 WAY CONN. AMP * 1
HA3 SIRENA BACK-UP /BACK UP ALARM CIAM (KUE) 0A001357 (312612100) 1 GND2 OCCHIELLO C8 MASSA / C8 GROUND TERMINAL * * 1 X52 CONNETTORE 1 VIA BUZZER /BUZZER 1 WAY CONN. AMP * 1
RKS03410
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL 1 X53 CONNETTORE 1 VIA BUZZER /BUZZER 1 WAY CONN. AMP * 1
CK25-1 90-3
OTHER ELECTRICAL DIAGRAM (OPTIONAL)
ELECTRICAL DIAGRAM (OPTIONAL)
NOME DESCRIZIONE COSTRUTTORE TIPO QTA
H1 GIROFARO /BEACON LIGHT CIAM 110450 (KUE 885111118) 1

H10 FARO DI LAVORO POSTERIORE SX / LEFT REAR WORK LIGHT COBO 05-531-000 (K. 885111132) 1
H11 FARO DI LAVORO POSTERIORE DX / RIGHT REAR WORK LIGHT COBO 05-531-000 (K. 885111132) 1
H12 LUCE TARGA / PLATE LIGHT COBO 02224.600 (KUE 885110052) 1
H4 FARO ANABBAGLIANTE SX / LEFT LOW BEAM COBO (KUE 885111133) 1
H5 FANALINO ANTERIORE SX / LEFT SIDE LIGHT COBO (KUE 885110035) 1
GND4
H6 FARO ANABBAGLIANTE DX / RIGHT LOW BEAM COBO (KUE 885111133) 1
H7 FANALINO ANTERIORE DX / RIGHT SIDE LIGHT COBO (KUE 885110035) 1 KUE 37A-06-11391
X14, X18 X13 H8 FANALINO POSTERIORE SX / LEFT REAR LAMP COBO (KUE 885111135) 1
H9 FANALINO POSTERIORE DX /RIGHT REAR LAMP COBO (KUE 885111134) 1
0A005426
HA2 AVVISATORE ACUSTICO /HORN CIAM 112001 (KUE 885100005) 1
G-N1
H-G1
H-N1
H-N1
A-G1
R/N1
N1.5
1 2
G1
C1
A1
L1
X82.1 CONNETTORE MARK 11 VIE / 11 WAY CONN. AMP 1
+ -
3 X108-X109 CONNETTORI 2 VIE FANALI ANTERIORI / FRONT LOW BEAM 2 WAY CONN. PACKARD 2 A B 1 1 1 A B 1 1 1 1 1 1 1 1 1 1 1 1 1 A B A B 1 1
X110-X111 CONNETTORI 2 VIE FARI LAVORO POST/ REAR WORK LIGHTS 2 WAY CONN. PACKARD 2 X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X121 X122 X123 X124 X125 X126 X127 X128 X129 X130 X110 X110 X111 X111 XP1 XP1A
1 2 3 4 5 6 7 8 9 10 11
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X50 23 L/B1 H-R1
X08 X115-X116-X117 CONNETTORI 1 VIA FANALI POSIZIONE ANT./ FRONT TRAFFIC LIGHTS 1 WAY CONN. AMP 3 BRAKE P.B. IN
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
X07 HI-SPEED P. B. IN
X50 22 A/B1 HA1 R-N2.5 G1.5
R2.5
X118-X119-X120 CONNETTORI 1 VIA FANALI POSIZIONE ANT. / FRONT TRAFFIC LIGHTS 1 WAY CONN. AMP 3
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
N1
L1
G1
R/N1
R/N1
G-N1
A1
N1
G1
N1
A-G1
N1
A-G1
N1
N1
H-G1
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
FLOAT P. B. IN
X50 21 L/G1
1 2 3 1 2 X121-X122-X123-X124 CONNETTORI 1 VIA FANALI POSIZIONE POST. / REAR TRAFFIC LIGHTS 1 WAY CONN. AMP 4
H-R2.5
R-N2.5
M2.5
SAF. BAR. SW IN
X50 20 C/N1 1 2 3 4 5 6 7 8 9 10 11
X125-X126-X127-X128 CONNETTORI 1 VIA FANALI POSIZIONE POST. / REAR TRAFFIC LIGHTS 1 WAY CONN. AMP 4 1 1 1 1 1 1 1 1 1 1 1
K04
C1
85 87
4 5 6
B1
SEAT SWITCH IN
X50 19 C-B1 1 1 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76
3 4
X50 H-R1 X52 X53
A-G1.5
1 18
G-N1
H-G1
H-N1
H-N1
R/N1
N1.5
POW. SUPP. +12V FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 86 30
Z-B1
G1
C1
A1
L1
X113 R1 ACC BR R2 C
EV BRAKE OUT
X50 17 H-L1 OFF ACC 30A 7.5A 10A 10A 10A 10A 15A 10A 15A 3A 3A
R/N1 R1
ST
X78
X79
STOP ENGINE OUT
X50 16 R-N1.5 X89 X89 X89 X89
HA2 H5 H7 H8 H9 H1
WIRE POSITIONING 85 86 30 87
ELECTRONIC UNIT
1 1
58L
58R
58L
54
54
58R
R
H4 H6 H12 H10 H11 M BRAKE LIGHT OUT
X50 15 S/N1 S10 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77
H/R1
N1
B-N1
B-R1
B-R1
M-N1
X50
ON CONNECTOR GND6 SAF. BAR.LED OUT 14 B/N1 S12
S11
1 1 1 1 1 1 1 1 1 1 1
31
31
31
31
X50 G/N1
R4
SEAT LED OUT 13
R-N2.5
H-R1.5
A-R1.5
L-R1.5
R-G1
G-N1
H-R1
G/R1
H/R1
B-R1
( WIRE SIDE WIEW WIRING )
G1
WARNING LED OUT
X50 12 M/B1
= Parts not included in the wiring FLOAT OUT
X50 11 B-N1 C A B G/R1 X85 9
2 1
X50 Z-B1 X54 X54 X54 A-R1.5
10
X55 X55 X85 1
H-R1
C/N1
BUZZER OUT (-)
KUE 37C-06-11312
N1
H-R1
C-B1
HI-SPEED OUT
X50 9 M-B1 1 9
1 0
GND4-GND6 OCCH. C6 MASSA /C6 GROUND TERMINAL GND
X50 8 N1.5
0A005893
= Parts not included in the wiring X129-X130
XP1-XP1A
CONN. LUCE TARGA / PLATE LIGHT CONN.
CONN.. PRESA 12V , GIROFARO /
HORN OUT
X50 7 C1
S01 5 10
START SIGN. IN
X50 6 B1
CURRENT INTAKE 12V, BEACON LIGHT +12V HORN
X50 5 H-R1.5 A-G1.5 X85 5
HORN PUSH B. IN
X50 4 B/R1
V1 K02 N1 X85 10
K06 X50 L-G1
POWER
PPC SAF. SW. IN 3

K01 SAFETY X50 V-N1
BOX
EV PPC OUT 2
86 87 R-N2.5 X01.1 R-N2.5
RELAY M2.5
4
X01 4
X01.1 M2.5
BUZZER OUT (+)
X50 1 R/N1 G/R1 X86 9
R-B1
85 30 3
X01 3 G1.5 X86 8
X07 G1
X07 R1
X07 N1
K03 R4 X01.1 R4 M1 X48 1 X48.1 M1

2
X01 2 H-N1 X86 1
M-V1 X48 1
X07
R4 X01.1 R4 2 X48.1 M-V1

X03 X03 X03 X03 X06 X06 XS1 XS1 X08 X08 X08 X08 1
X01 1 1 6 8 9
86 85 30 87 l - 4 3 2 1 A B 1 3 5 6
GND5 N4 R-V1 X48 2 3 X48.1 R-V1 0 1 2
N4
XS L-G1 X48 3 4 X48.1 L-G1
R4
GND5 X02.1 4
S02 3 2 10
X02 R-N2.5 X46 X46.1 R-N2.5 H-R1.5
M-V1
L/B1
R-N2.5
B2
R-N1.5
R-N1.5
N1
M-V1
L/B1
R-N1.5
N1
R10
4 X86 3
B2.5
R-G1
B1
N1
S-N1
l l
L-R1 X02.1 L-R1.5
-
X02 M2.5 X46 4 3 X46.1 M2.5 H-R1 X86 2
-
H-L1 X44 86
K14 86 87a 87
R4 X46 3 2 X46.1 R4 N1 X86 10
R-N1.5 X10.1 R-N1.5 M1 X44 87a
13
X10 13 R4 X46 2 1 X46.1 R4 85 30
X10.1 H-L1 X44 30 S/N1 X87 6
12
X10 12
1
R2.5 X10.1 R2.5 R-N1.5 X45 13 X45.1 R-N1.5 H-R1 X87 3
11
X10 11 13 B-G1 X44 85
R-V1 X10.1 R-V1 V-N1 X45 12 X45.1 V-N1 15/1 30/3 L/6
10
X10 10 12 0 1
B1 X10.1 B1 M-B1 X45 11 X45.1 M-B1
9
X10 9 11
S1 X10.1 S1 L-R1.5 X45 10 X45.1 L-R1.5
8
X10 8 10 S08 49/4 30b/2 R/7
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
C-N1 B1 X45 B1 L/B1
B-N1
B/N1
X45.1
Z-B1
C-L1
L-N1
X10.1 9 X87
H0.5
X10 C-N1 2
M1
N1
B1
S1
7 7
C-L1 X10.1 C-L1 M-N1 X45 9 8 X45.1 M-N1 H-R1 X87 7
6
X10
S-G1
6
R-G1 X45 8 X45.1 R-G1 K95 G/R1
X10 X10.1 S-G1 7 86 87a 87 X88 9
5 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
R10
X10.1 S1 X45 7 6 X45.1 S1 GND3 H/R1 X88 1
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
4
X10 4 85 30
B-N1 C-N1 X45 6 C-N1
GND X10.1 B-N1 5 X45.1 1 9
3
X10 3 1 0
R-G1 X10.1 R-G1 C-L1 X45 5 4 X45.1 C-L1 P1 86 85 30 87a
2
X10 2 X95 X95 X95 X95
1 B-G1 X10.1 B-G1 S-G1 X45 4 3 X45.1 S-G1
X10 CONTROL PANEL (UNIDECK) 5 10
M1
N1
L-R1
R-V1
1 1
B-N1 X45 3 S07
XF 2 X45.1 B-N1 H-G1 X88 5
1
FG1 B-G1 X45 2 1 X45.1 B-G1 N1 X88 10
50A X28 1
C-B1 X49 11 X49.1 C-B1
S31
HA3 C1 X4911 10 X49.1 C1 RELAYS UNIT
XF p V-B1 X4910 9 X49.1 V-B1
2
V1 X49 9 8 X49.1 V1
2 1 A-N1 X49 8 7 X49.1 A-N1 K12 86 87a 87 K08 85 30 K09 85 30 K11 86 87
X29 X29 A-B1 X49 7 6 X49.1 A-B1

N1
Z-N1
85 30 86 87 86 87 85 30
R10 A-G1 X49 6 5 X49.1 A-G1
R10
Z-N1 X49 5 4 X49.1 Z-N1
R50
B2.5
R-G1
S1
S-N1
A-V1 X49 4 3 X49.1 A-V1

R-N1.5
R-G1
C-N1
S-G1
B-N1
M2.5
C-L1
S-N1.5 X49 3 2 X49.1 S-N1.5

N2
N1
N1
N1
N1
G1
B2
R-V1
Z-N1
L-R1
L-R1
L-R1
1 2 1 3 L-R1.5 X49 2 1 X49.1 L-R1.5

12Vcc
X09
X11
X11
X11
3 1 2 - + 1 2 1 C A - + 1 N2.5 1
1 1 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 1 2 1 2 1 2 1 2
K07 K10
G2 85 30
K13 +
M-N1
M-B1
M-V1
XB XM
L-G1
Z-N1
A-V1
V-N1
M1 R1 R2 R3
R2.5
N2.5
R1.5
B2.5
X20 X20 X21 X21 X22 X22 X23 X23
53M
M1
D+ M2
N1
N1
N1
N1
N1
N1
53S
R CL(T)
31
15
30 50 30 W
GND2
G
T
S25 S26 S27 S28 S29 S30
GND1
86 87
M N4 X47 1
X47.1 N4
N50
Y0
S-N1.5
L-R1.5
3 M p p p p p p -(53S)
A-G1
1 1 1 2 1 2 1 2 1 2 1 2 1 2 1
C-B1
A-N1
A-B1
V-B1
1
N1.5
U
N4 X47 2
X47.1 N4
C1
V1
t X32 X32A X33 X33 X34 X34 X39 X39 X40 X40 X35 X35 X36 X36 X37 2
31
S32 S33
X41
X41
X41
X41
X42
X42
X42
X42
X42
X43
p p
4 3 2 1 5 4 3 2 1 1
ENGINE PARTS X8 X8 X8 X8 X8
P1 CONTROL PANEL (EXTERNAL WIEW)
5 4 3 2 1
Y1 Y2 Y5 Y4 Y6 Y3
INTERNAL CONNECTION CONTROL PANEL
X80-15
X80-16
X80-12
X80-14
X80-11
N1.5
R1.5
A-N1.5
A-B1.5
A-G1.5
L1 L2 L3 L4 L5 C2 C3
X80-8 KUE 37A-06-11363
+
NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT./SUPPL. TIPO/TYPE QTA
L1 L2 L3 L4 L5
K05 0A007932
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
FG1 FUSIBILE GENERALE 80A /GENERAL FUSE 80A CIAM 163028 1 H F FUEL WATER TEMP.
KUE 37C-06-11331 LEVEL INDICATOR
G1 BATTERIA /BATTERY 100Ah FIAMM (KUE) L5 600 103 085 (37C-06-11110) 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
X121 H A WAY C1
00000 00 h
G2 ALTERNATORE /GENERATOR YANMAR (DENSO) 129423-77200 1
A-V1
C/B1
L-R1.5
A/N1
L-N1
A/V1
R/N1
R-V1
L/N1
Z-N1
N1.5
A-N1
V/B1
L/R1
A-G1
Z/N1
A-B1
A-R1.5
X121 G WAY C2
K01 RELE' SOLENOIDE CARBURANTE /FUEL SOLENID VALVE RELAY MATSUSHITA (KUE) CB1aH (885071022) 1 0A005936
A-B1.5 X121 F C (-) C E
K02 TIMER 1 SEC PULL FUEL SOLENOID VALVE YANMAR (KUE) 1 "B" WAY ATTACHEMENT C D E
N1.5 X121 E
K03 SAFETY RELAY YANMAR (KUE) 119802-77200 1 GROUND B A
A-G1.5 X121 D C1
M1 MOTORINO AVVIAMENTO / STARTER MOTOR YANMAR 1 "A" WAY ATTACHEMENT H G C3 A1 X104
A-N1.5
F HOUR COUNTER 2
X121 C
M2 POMPA GASOLIO / FUEL PUMP YANMAR 129612-52100 1 "C" WAY ATTACHEMENT (+12V) L1 X104 1
R1.5 X121 B WAY L6 L7 L8 L9 L10 DL1 DL2 DL3
R1 RESISTENZA PRERISCALDO /PREHEATING STARTER YANMAR 129100-77500 1 +15 KEY 1 2
N1.5 X121 A 1 0 2
R2 SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER COBO (KUE) 29-0419-0000 (37A-04-11140) 1 GROUND B X80-6
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
R3 TRASDUTTORE DI TEMP. ACQUA MOTORE /ENGINE WATER TEMPERATURE SENDER YANMAR (KUE) (7861-92-3320) 1 -
54
S25 SENSORE INTASAMENTO FILTRO ARIA /AIR FILTER BLOCKED SWITCH DONALDSON (KUE) X770317 (37A-06-11960) 1 a c b L6 L7 L8 L9 L10 DL2 DL1 DL3 S03
A/N1 X104 54
S26 PRESSOSTATO INTASAMENTO OLIO IDRAULICO /HYDRAULIC OIL FILTER BLOCKED SWITCH FMDI (KUE) 11716/1 (885261034) 1
X80-9 X80-2 X80-3 N1 X105 10
S27 PRESSOSTATO LUCI STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1
A/N1 X105 5
S28 PRESSOSTATO STOP /STOP LIGHTS PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1 NOME DESCRIZIONE COSTRUTTORE TIPO QTA
G/R1 X105 8
S29 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1
X121 ATTACHEMENT 8 WAY CONN. DEUTSCH HD34 18-8PN 1 POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR POS. PIN FUNCTION SIGNAL WIRE COLOUR H/R1 X105 2
S30 PRESSOSTATO BACK-UP /BACK-UP ALARM PRESSURE SWITCH FMDI (KUE) 11717.70 (37A-06-11680) 1
X121 NUT DEUTSCH 114020-90 1 2 8 5 10
S31 PRESSOSTATO MINIMA PRESSIONE OLIO MOTORE /ENGINE OIL MIN. PRESSURE SWITCH YANMAR * 1 X80-1 X80-9 INTERNAL LIGHTS (+ LUCI) POSITIVE G-N1 DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 1 0
X121 WASHER DEUTSCH 114021 1
V1 DIODO / DIODE CIAM 1A 1N4007 1
X121 MALE PIN DEUTSCH 0460-204-12141 6 C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 L8 X81-2 FLOAT LAMP POSITIVE M-N1
Y0 ELETTROVALVOLA STOP SOLENOIDE CARBURANTE /STOP FUEL SOLENOID VALVE YANMAR 129005-77950 1 S09 4 6 3 1 7
X121 PLUG DEUTSCH HDC36-18 1 L/R1 X105 4
X01 CONNETTORE 3 VIE LINEA TELAIO /FRAME LINE 3 WAY CONNECTOR * * 1 A B C3 X80-3 WATER TEMPERAT. INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1 L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1
X8 5 WAY FEMALE MARK II CONN. CIAM (AMP) 125216 1 A1 X105 3
X02 CONNETTORE 2 VIE / 2 WAY CONN. * * 1
C X8 MALE PIN CIAM (AMP) 120072 5 +50 X80-4 START SIGNAL +50 B1 L2 X80-12 PREHEATING LAMP POSITIVE M1 L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 L1 X105 1
S-N1.5
L-R1.5
X03 CONNETTORE RELE SOLENOIDE CARBURANTE / FUEL SOLENOID RELAY CONN. * * 1
G/R1
G/R1 X105 7
N1
X06 CONNETTORE 2 VIE DIODO ANTIDISTURBO / DIODE 2 WAY CONN. * * 1 GND X80-5 GROUND GND X80-13
X07 CONNETTORE 4 VIE TIMER / TIMER 4 WAY CONN. * * 1 POS. PIN FUNCTION SIGNAL WIRE COLOUR G/R1 X106 9
GND X80-6 GROUND GND N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1 5 1 9 10
X08 CONNETTORE 6 VIE SAFETY RELAY /SAFETY RELAY 6 WAY CONN. SUMITOMO 6195-0021 1
RIGHT LEVER L9 X81-5 DIRECTION LAMP POSITIVE L-N1 V-B1 X106 7
X91
X91
X91
X91
KUE 37A-06-11460
X09 OCCHIELLO C6 ALTERNATORE / C6 GENERATOR TERMINAL * * 1 X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 V1 X106 1
A-G1
B-R1
B-R1
A-N1
B/R1
C/B1
Z-N1
A-B1
A/B1
V/B1
L/G1
A/V1
Z/N1
L/N1
L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
N1
N1
X10 CONNETTORE MARK 13 VIE LINEA TELAIO /FRAME LINE MARK 13 WAY CONN. * * 1
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 SWITCH EV ENPI 1 0 2
1 7 9
X11 CONNETTORE 3 VIE ALTERNATORE /GENERATOR 3 WAY CONN. SUMITOMO 6189-0442 1 0A003433 DL1 X81-7 WARNING LED NEGATIVE M/B1
1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11
X13 CONNETTORE 3 VIE POOL-STOP SOLENOIDE CARBURANTE /FUEL POOL-STOP SOLENOID 3 WAY CONN. DEUTSCH DT06-3S 1
3 10
DL2 X81-8 SEAT LED NEGATIVE G/N1 S05
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
X14 CONNETTORE 2 VIE POMPA GASOLIO / FUEL PUMP 2 WAY CONN. * * 1 L-R1.5 X106 3
X15 OCCHIELLO C6 RESISTENZA PRERISCALDO / PREHEATING START C6 TERMINAL * * 1 RIGHT LEVER N1 X106 10
R-N0.8
R-N0.8
A-G0.5
A-N0.5
A-B0.5
A-B0.5
Z-N0.5
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
N0.8
N0.8
X16 CONNETTORE 2 VIE SENSORE INTASAMENTO FITRO ARIA / AIR FILTER BLOCKED SWITCH 2 WAY CONN. AMP MINITIMER 1
LEFT LEVER
G/R1 X107 9
X17 CONNETTORE 3 VIE SENSORE LIVELLO CARBURANTE /FUEL LEVEL SENDER 3 WAY CONN. * * 1 NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT. /SUPP. TIPO/ TYPE QTA NOME/NAME DESCRIZIONE/DESCRIPTION COSTRUT. /SUPP. TIPO/ TYPE QTA
C-B1 X107 7
X18 CONNETTORE 2 VIE TRASDUTTORE TEMP. ACQUA /ENGINE WATER TEMPERATURE SENDER 2 WAY CONN. * * 1 FU01 FUSE 3A LEFT SIDE LIGHTS, PLATE LIGHT 1 S32 PRESSOSTATO PPC SAFETY /PPC SAFETY PRESSURE SWITCH FMDI (KUE) 11717.75 (37A-06-11670) 1 C1 X107 1
X19 OCCH. C5 SENSORE INTASA. FILTRO OLIO IDRAULICO / IDRAULIC OIL FILTER BLOCKED SWITCH C5 TERMINAL* * 1 FU02 FUSE 3A CONTROL PANEL LIGHTS, RIGHT SIDE LIGHTS 1 S33 PRESSOSTATO FRENO STAZIONAMENTO /BRAKE VALVE PRESSURE SWITCH FMDI (KUE) 11717.15 (885411439) 1
X20 CONNETTORE 2 VIE PRESSOSTATO 1 LUCI STOP / STOP LIGHT PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU03 FUSE 15A HORN, LOW BEAM OR FRONT WORK LIGHTS 1 S36 PULSANTE INVERSIONE HI-FLOW MOMENTARY / REVERSE HI-FLOW MOMENTARY PUSH BUTTON 1
= Parts not included in the wiring S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4 HL5
1 0 2
1 7 9
X21 CONNETTORE 2 VIE PRESSOSTATO 2 LUCI STOP / STOP LIGHT PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU04 FUSE 10A SWITCH LIGHTS, DIRECTION LIGHTS 1 S37 PULSANTE SUPER- FLOW DETENT / SUPER-FLOW DETENT PUSH BUTTON 1
3 10
X22 CONNETTORE 2 VIE PRESSOSTATO 1 BACK-UP / BACK-UP PRESSURE 1 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU05 FUSE 15A REAR WORK LIGHT, STOP LIGHT 1 S38 PULSANTE "C" WAY / "C" WAY PUSH BUTTON 1 S06
L-R1.5 X107 3
X23 CONNETTORE 2 VIE PRESSOSTATO 2 BACK-UP /BACK-UP PRESSURE 2 SWITCH 2 WAY CONN. DEUTSCH DT06-2S 1 FU06 FUSE 10A LEVER SWITCH POWER SUPPLY, FLOAT 1 S39 PULSANTE "A" WAY / "A" WAY PUSH BUTTON 1 N1 X107 10
X28 TERMINALE MINIMA PRESSIONE OLIO MOTORE /ENGINE MIN.PRESSURE SWITCH TERMINAL 1 FU07 FUSE 10A CURRENT INTAKE 12V, HAZARD, BEACON LIGHT 1 S40 PULSANTE "B" WAY / "B" WAY PUSH BUTTON 1
X29 CONNETTORE 2 VIE SIRENA BACK-UP /BACK UP ALARM 2 WAY CONN. * * 1 FU08 FUSE 10A CONTROL PANEL, ELECTRONIC UNIT, FUEL SHUT OFF, SAFETY BAR PROXIMITY, SAFETY SEAT SWITCH, BRAKE SWITCH 1
XB OCCHIELLO C8 SU MOTORINO AVV. / C8 START MOTOR TERMINAL * * 1 FU09 FUSE 10A BACK-UP ALARM, ATTACHEMENT 3 WAY, HI-FLOW, STABILIZER, ENPI VALVE 1 X104 CONNETTORE INTERRUTTORE LUCI DI DIREZIONE / DIRECTION LIGHTS SWITCH CONN. 1 LEFT LEVER RIGHT LEVER
XF CONNETTORE 2 VIE FUSIBILE GENERALE / GENERAL FUSE 2 WAY CONN. * * 1 FU10 FUSE 7.5A FUEL PUMP, SAFETY ENGINE RELAY, GENERATOR 1 X105 CONNETTORE SWF HAZARD / SWF HAZARD CONN. SWF 1
GND OCCHIELLO C8 MASSA / C8 GROUND TERMINAL * * 1 FU11 FUSE 30A PULL SOLENOID, PPC SAFETY PRESSURE SWITCH 1 X106 CONNETTORE SWF PULSANTI PIEDI STABILIZZATORI /STABILIZER PUSH BUTTON CONN. SWF 1 HL1 HL3 HL2 HL4
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL * * 1 HA1 BUZZER SEGNALAZIONE ANOMALIE /WARNING BUZZER 1 X107 CONNETTORE SWF PULSANTI PIEDI STABILIZZATORI /STABILIZER PUSH BUTTON CONN. SWF 1
XM OCCHIELLO C4 SU MOTORINO AVV. / C4 START MOTOR TERMINAL * * 1 HL1 DIODO LED SUPER-FLOW / SUPER-FLOW LED DIODE 1 X44 CONNETTORE RELE' FRENO PARCHEGGIO / PARKING BRAKE RELAY CONN. BOSCH 1
XS CONNETTORE 2 VIE SAFETY RELAY / SAFETY RELAY 2 WAY CONN. SUMITOMO 6195-0060 1 HL2 DIODO LED "C" WAY / "C" WAY LED DIODE 1 X45.1 CONNETTORE MARK 13 VIE DA LINEA TELAIO/ FROM FRAME LINE MARK 13 WAY CONN. AMP 1
XS1 ISOLATORE / INSULATOR * * 1 HL3 DIODO LED "A" WAY / "A" WAY LED DIODE 1 X46.1 CONNETTORE 4 VIE DA LINEA TELAIO / FROM FRAME LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 WIRING COLOURS
HA3 SIRENA BACK-UP /BACK UP ALARM CIAM (KUE) 0A001357 (312612100) 1 HL4 DIODO LED "B" WAY / "B" WAY LED DIODE 1 X47.1 CONNETTORE 2 VIE MASSA / GROUND 2 WAY CONN. DEUTSCH DTP04-2P 1
Y1 ELETTROVALVOLA SERVOCOMANDI /PPC VALVE HYDRAFORCE * 1 HL5 DIODO LED OPZIONALE / OPTIONAL LED DIODE 1 X48.1 CONNETTORE MARK 5 VIE DA LINEA TELAIO / FROM FRAME LINE MARK 5 VIE CONN. AMP 1
C
A LIGHTBLUE S13 S38
ON
ON
Y2 ELETTROVALVOLA FLOAT /FLOAT VALVE HYDRAFORCE * 1 K04 RELE' FLOAT / FLOAT RELAY CIAM 01170922 (KUE 885070040) 1 X49.1 CONNETTORE MARK 11 VIE DA LINEA TELAIO / FROM FRAME LINE MARK 11 VIE CONN. AMP 1 S14 S15
B WHITE
CN
CN
C
C
Y3 ELETTROVALVOLA SECONDA VELOCITA' /SECOND SPEED VALVE HYDRAFORCE * 1 K05 SUPPORTO RELE' / RELAYS BOX (WITHOUT RELAYS) CIAM 122010 (KUE 885411196) 1 X50 CONNETTORE 23 VIE CENTRALINA SICUREZZE /SAFETY CONTROL BOX 23 WAY CONN. AMP 1
ON
ON
C ORANGE
CN
CN
Y4 ELETTROVALVOLA INVERSIONE HI-FLOW MOMENTARY / REVERSE HI-FLOW MOMENTARY VALVE HYDRAFORCE * 1 K06 CENTRALINA ELETTRONICA / ELETTRONIC UNIT CIAM 01171077 (KUE 885070046) 1 X52 CONNETTORE 1 VIA BUZZER /BUZZER 1 WAY CONN. AMP 1 G YELLOW S36 S37 S39 S40
Y5 ELETTROVALVOLA SUPER-FLOW DETENT / SUPER-FLOW DETENT VALVE HYDRAFORCE * 1 K07 RELE' "B" WAY / "B" WAY RELAY KUE 885071044 1 X53 CONNETTORE 1 VIA BUZZER / BUZZER 1 WAY CONN. AMP 1 H GREY
Y6 ELETTROVALVOLA FRENO /BRAKE VALVE HYDRAFORCE * 1 K08 RELE' "A" WAY / "A" WAY RELAY KUE 885071044 1 X54 CONNETTORE 3 VIE SENSORE BARRA / PROXIMITY BAR 3 WAY CONN. DEUTSCH 1 L BLUE
X01.1 CONNETTORE 4 VIE LINEA MOTORE /ENGINE LINE 4 WAY CONN. DEUTSCH DTP04-4P 1 K09 RELE' "C" WAY / "C" WAY RELAY KUE 885071044 1 X55 CONNETTORE 2 VIE SENSORE SICUREZZA SEDILE /SAFETY SEAT SWITCH 3 WAY CONN. DEUTSCH 1 M BROWN
X02.1 CONNETTORE 2 VIE LINEA MOTORE /ENGINE LINE 2 WAY CONN. AMP * 1 K10 RELE' PASSO PASSO SUPER-FLOW DETENT / SUPER-FLOW DETENT STEP BY STEP RELAY CIAM 01170923 (KUE 37A-06-11430) 1 X56-X57-X58-X59-X60 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 N BLACK
X10.1 CONNETTORE MARK 13 VIE LINEA MOTORE /ENGINE LINE 13 WAY CONN. AMP * 1 K11 RELE' INVERSIONE HI-FLOW MOMENTARY / REVERSE HI-FLOW MOMENTARY RELAY CIAM 157061 (KUE 885071043) 1 X61-X62-X63-X64-X65 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 R RED
X32 CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY /PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 K12 RELE' LUCI STOP /STOP LIGHTS RELAY CIAM 157061 (KUE 885071043) 1 X66-X67-X68-X69-X70 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 S PINK
X32A CONNETTORE 1 VIA PRESSOSTATO PPC SAFETY /PPC SAFETY PRESSURE SWITCH 1 WAY CONN. AMP SUPERSEAL 1 K13 INTERMITTENZA /FLASHER UNIT CIAM 00105013 (KUE 885151012) 1 X71-X72-X73-X74-X75 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 5 V GREEN
X33 CONNETTORE 2 VIE EV. SERVOCOMANDI (PPC) /PPC VALVE 2 WAY CONN. DEUTSCH DT06-2S 1 K14 RELE' FRENO / BRAKE RELAY CIAM 157061 (KUE 885071043) 1 X76-X77 CONNETTORE 1 VIA FUSIBILE /FUSE 1 WAY CONN. AMP 2 Z VIOLET
X34 CONNETTORE 2 VIE EV. FLOAT /FLOAT VALVE 2 WAY CONN. DEUTSCH DT06-2S 1 K95 RELE' LUCI STOP / STOP LIGHTS RELAY CIAM 157061 (KUE 885071043) 1 X78-X79 CONNETTORE 1 VIA PRESA DI CORRENTE /CURRENT INTAKE 1 WAY CONN. AMP 2
X35 CONNETTORE 2 VIE EV. BRAKE /BRAKE VALVE 2 WAY CONN. DEUTSCH DT06-2S 1 P1 PANNELLO STRUMENTI /CONTROL PANEL UNIDECK 04610027(KUE 37A-54-14291) 1 X80 CONNETTORE 16 VIE PANNELLO DI CONTROLLO /CONTROL PANEL 16 WAY CONN. AMP 1 EXAMPLE:
X36 CONNETTORE 2 VIE EV. SECONDA VELOCITA' /SECOND SPEED VALVE 2 WAY CONN DEUTSCH DT06-2S 1 S01 INTERRUTTORE SWF FARI LAVORO POST / REAR WORK LIGHTS SWITCH CIAM 106AA008 (KUE 885081160) 1 X81 CONNETTORE 8 VIE PANNELLO DI CONTROLLO /CONTROL PANEL 8 WAY CONN. AMP 1 G/V ->YELLOW/GREEN (TRANSVERSE MARKED)
X37 CONNETTORE 1 VIA PRESSOSTATO FRENO /BRAKE PRESSURE SWITCH 1 WAY CONN. AMP * 1 S02 INTERRUTTORE LUCI STRUMENTO E ANAB./ PANEL LIGHTS AND LOW BEAM LIGHTS SWITCH CIAM 106AA018 (KUE 885081159) 1 X82 CONNETTORE MARK 11 VIE LINEA FARI / LIGHTS LINE 11 WAY CONN. AMP 1
X39 CONNETTORE DEUTSCH 2 VIE EV. HIGHT FLOW DETENT /HIGHT FLOW DETENT VALVE 2 WAY CONN. DEUTSCH * 1 S03 INTERRUTTORE FRECCIE /DIRECTION LIGHTS SWITCH CIAM 116003 (KUE 885081161) 1 X83 CONNETTORE 12 VIE MANIPOLATORE SX / LEFT LEVER 12 WAY CONN. DEUTSCH DT04-12P, DT06-12S 1 YELLOW GREEN
X40 CONNETTORE DEUTSCH 2 VIE EV. HIGHT FLOW MOMENTARY /HIGHT FLOW MOMENTARY VALVE 2 WAY CONN.DEUTSCH * 1 S05 PULSANTE SU-GIU STABILIZZATORE SX /UP-DOWN LEFT STABILIZER BUTTON CIAM 106AA002 (KUE 885081163) 1 X84 CONNETTORE 12 VIE MANIPOLATORE DX / RIGHT LEVER 12 WAY CONN. DEUTSCH DT04-12P, DT06-12S 1
X41 CONNETTORE 5 VIE STABILIZZATORI / STABILIZER 5 WAY CONN. AMP * 1 S06 PULSANTE SU-GIU STABILIZZATORE DX /UP-DOWN RIGHT STABILIZER BUTTON CIAM 106AA002 (KUE 885081163) 1 X85 CONNETTORE SWF INTERRUTTORE FARI DI LAVORO POSTERIORI /REAR WORK LIGHTS SWF SWITCH SWF 1
X42 CONNETTORE 5 VIE ATTACHEMENT / ATTACHEMENT 5 WAY CONN. AMP * 1 S07 INTERRUTTORE SWF LAMPADA ROTANTE /BEACON LIGHT SWITCH CIAM 106AA008 (KUE 885081160) 1 X86 CONNETTORE SWF LUCI STRUM. E FARI ANABB. ANTERIORI /PANEL AND FRONT LIGHTS SWF SWITCH CONN.SWF 1 G-V ->YELLOW-GREEN(LONGITUDINAL COLOURS)
X43 CONNETTORE 1 VIA VALVOLE ENPI / ENPI VALVE 1 WAY CONN. AMP * 1 S08 PULSANTE FRENO / BRAKE SWITCH CIAM 0A003455 (KUE 37A-06-11411) 1 X87 CONNETTORE PULSANTE FRENO / BRAKE SWITCH CONN. PNEUTRON 1
X45 CONNETTORE 13 VIE LINEA CABINA / CABIN LINE 13 WAY CONN. AMP * 1 S09 INTERRUTTORE 4 FRECCIE /HAZARD SWITCH CIAM 106AA014 (KUE 885081162) 1 X88 CONNETTORE SWF INTERRUTTORE LAMPAGGIANTE /BEACON LIGHT SWITCH CONN. SWF 1 YELLOW GREEN
X46 CONNETTORE 4 VIE LINEA CABINA / CABIN LINE 4 WAY CONN. DEUTSCH DTP06-4S 1 S10 QUADRO AVVIAMENTO /STARTING SWITCH 1 X89 CONNETTORE RELE' FLOAT / FLOAT RELAY CONN. BOSCH 1
X47 CONNETTORE 2 VIE MASSA LINEA CABINA / GROUND CABIN LINE 2 WAY CONN. DEUTSCH DTP06-2S 1 S11 FINECORSA DI SICUREZZA SEDILE /SAFETY SEAT SWITCH 1 X90 CONNETTORE 21 VIE CENTRALINA RELE' / RELAYS BOX 21 WAY CONN. AMP 1
X48 CONNETTORE 5 VIE LINEA CABINA / CABIN LINE 5 WAY CONN. AMP * 1 S12 PROXIMITY DI SICUREZZA PNP BRACCIOLO /BAR PNP SAFETY SENSOR SAIET E-A1TMU/3AP (KUE 37A-06-1250) 1 X91 CONNETTORE SWF VALVOLE ENPI / ENPI VALVE SWF CONN. CEMBRE 1
X49 CONNETTORE 11 VIE LINEA CABINA / CABIN LINE 11 WAY CONN. AMP * 1 S13 PULSANTE CLAXON / HORN PUSH BUTTON 1 X95 CONNETTORE RELE' LUCI STOP/STOP LIGHT RELAY CONN. AMP 1
GND1-GND2 OCCHIELLO C8 MASSA / C8 GROUND TERMINAL AMP * 1 S14 PULSANTE SECONDA VELOCITA' /SECOND SPEED PUSH BUTTON 1
GND5 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL AMP * 1 S15 PULSANTE FLOAT /FLOAT PUSH BUTTON 1 GND3 OCCHIELLO C6 MASSA / C6 GROUND TERMINAL SWF 1
RKS03420
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20. TESTING AND ADJUSTING ........................................................................................... 20-1

30. REMOVAL AND INSTALLATION ................................................................................... 30-1

40. MAINTENANCE STANDARD .......................................................................................... 40-1

90. OTHER .....................................................................................................................90-1

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

Time of Time of Time of Time of Time of

00-1 10-16 10-59 10-102 20-36

Time of Time of Time of Time of Time of

k IMPORTANT SAFETY NOTICE

STRUCTURE AND FUNCTION

TESTING AND ADJUSTMENTS

REMOVAL AND INSTALLATION

HOW TO READ THE SHOP MANUAL

Safety Extra special safety precautions

Weight of parts or systems.

REVISED EDITION MARK

serious accident can result. Hooks have maximum

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

hoist etc. In the Removal and Installation 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

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the hook.

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

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

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

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

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

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

1.3/16 - 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

Function Code Applications