Fiat Kobelco W110 Evolution Wheel Loader Service Manual

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W110 EVOLUTION
WHEEL LOADER

Service Manual
Print N° 604.02.404.00 English
IV - 2003

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Read and heed carefully the safety instructions listed and follow the precautions recommended to
avoid potential risks and to safeguard your health and your safety.

You will find this symbol in the text of this Manual referred to the following key words:

WARNING
Cautions directed to avoid improper repair interventions involving potential consequences for the
operator’s safety.

DANGER
These warnings qualify specifically potential dangers for the safety of the operator or other per-
sons directly or indirectly involved.

IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service
Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the
recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own, for
the damages that may result.

Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional
or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts
and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or
merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or mer-
chandized by the Factory, when failures are caused by the use of parts and/or components not approved by the
Factory.

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 AVOID ACCIDENTS

Most accidents and injuries occurring in industry, on

the farm, at home or on the road, are caused by the
failure of some individual to follow simple and funda-
mental safety rules or precautions. For this reason,
MOST ACCIDENTS CAN BE PREVENTED by recog-
nizing the real cause and taking the necessary pre-
cautions, before the accident occurs.
Regardless of the care used in design and construc-
tion of any type of equipment, there may be conditions
that cannot be completely safeguarded against with-
out interfering with reasonable accessibility and effi-
cient operation.
A careful operator is the best insurance against acci-
dents. The complete observance of one simple rule
would prevent many thousands serious injuries each
year.
This rule is: Never attempt to clean, lubricate or adjust
a machine while it is in motion.

WARNING
On machines having hydraulically, mechanically and/or cable
controlled equipment (such as showels, loaders, dozers,
scrapers etc.) be certain the equipment is lowered to the
ground before servicing, adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suit-
ably supported by means other than the hydraulic lift cylin-
ders, cable and/or mechanical device used for controlling the
equipment.
 SUMMARY

GENERALITIES .................................................... Section 0

ENGINE ................................................................ Section 1
TRANSMISSION ................................................... Section 2
BRAKE SYSTEM .................................................. Section 3
STEERING SYSTEM ............................................ Section 4
BUCKET BOOMS AND FRAME .......................... Section 5
EQUIPMENT HYDRAULIC SYSTEM ................... Section 6
ELECTRICAL SYSTEM ........................................ Section 7
CAB ...................................................................... Section 8
 SECTION 0

GENERALITIES

INDEX

SUBJECT PAGE

SAFETY RULES ........................................................................................................................................... 0-1

SPECIFICATIONS - WHEEL LOADER W110 EVOLUTION ........................................................................... 0-8

DIMENSIONS AND WEIGHT ....................................................................................................................... 0-19

TABLE OF FLUID CAPACITIES ................................................................................................................... 0-20

UNITS OF MEASURE ................................................................................................................................. 0-21

STANDARD TORQUE SPECIFICATION ....................................................................................................... 0-23

LOCTITE PRODUCT CHART ....................................................................................................................... 0-27

W110 EVOLUTION GENERALITIES 0-1

SAFETY RULES
GENERALITIES Ensure that nobody is in the machine operating range
before moving off or operating the attachment. WALK
Read this Manual carefully before starting, operating,
COMPLETELY AROUND the machine before mounting.
maintaining, fuelling or servicing the machine.
Sound the horn.
Read and comply with all safety precautions before any
Before starting machine, check, adjust and lock the driver's
intervention.
seat for maximum comfort and control of the machine.
Do not allow unauthorised personnel to operate or serv-
Fasten your seat belts(when fitted).
ice this machine.
Obey all flag signals and signs.
Do not wear rings, wrist watches, jewellery, loose or hang-
ing garments, such as ties, torn clothing, scarves, unbut- Due to the presence of flammable fluids on the machine,
toned or unzipped jackets that can get caught in moving never check or fill fuel tanks or accumulator batteries near
parts. Wear certified safety clothes such as: hard hat, no- fires, open flames, or sparks.
slip footwear, heavy gloves, ear protection, safety glasses, REMEMBER THAT SPECIAL STARTING FLUIDS ARE
reflector vests, respirators. Ask your employer about spe- FLAMMABLE. Scrupolously follow recommendations
cific safety equipment requirements. printed on the containers and in this Manual.
Keep the operator’s compartment, step plates, grab-rails DO NOT PUNCTURE OR BURN CONTAINERS.
and handles clean and clear of foreign objects, oil, grease,
mud or snow to minimize the danger of slipping or stum- Containers must be stored in fresh, well ventilated places
bling. Remove mud or grease from your shoes before and out of the reach of unauthorised persons. Strictly
attempting to mount or operate the machine. follow the instructions provided by the Manufacturer.
Do not jump on or off the machine. Always keep both hands Never use these products near fires, open flames, or
and one foot, or both feet and one hand in contact with sparks.
steps and grab rails.
Do not use controls or hoses as hand holds when climbing
on or off the machine. Hoses and controls are movable
parts and do not provide solid support. Besides, controls
OPERATING
may be inadvertently moved and cause unexpected
movement of the machine or its attachments. Check wheel and rim retainers before each working shift.
If necessary, tighten to the torque specified.
Never operate the machine or its attachments from any
position other than sitting in the driver’s seat. Do not run the engine of this machine in closed buildings
without proper ventilation capable to remove harmful
Keep head, body, limbs, hands and feet inside the opera-
exhaust gases.
tor’s compartment at all times to reduce exposure to
external hazards . Roll Over Protective Structures (ROPS) are required on
wheel or crawler loaders, dozers, or graders. NEVER
Be careful of possible slippery conditions of the steps and
OPERATE the machine if such protective structure is
hand rails as well as of the ground around the machine.
removed.
Do not leave the machine until it is has come to a complete
Keep the operator’s compartment free of foreign objects,
stop.
especially if not firmly secured. Never use the machine to
Check the seat safety belt at least twice per year and transport objects, unless proper securing points are pro-
replace it if it shows signs of wear, fraying or other vided.
weakness that could lead to failure.
DO NOT CARRY RIDERS ON THE MACHINE
Study and familiarize with escape routes alternate to
normal exit routes.
According to law provisions, seat belts must be fitted with
STARTING Roll Over Protection Structures or cabs. Keep safety belts
NEVER START OR OPERATE A FAILED MACHINE. Be- fastened during operation.
fore operating the machine, always ensure that any unsafe For your personal safety, do not climb on or off the machine
condition has been satisfactorily corrected. while it is in motion.
Check brakes, steering and attachment controls before Make sure that bystanders are clear of the machine oper-
moving off. Report any malfuctioning part or system to the ating range before starting the engine and operating the
maintenance managers for proper action. attachment. Sound the horn. Obey all indications provided
Ensure all protective guards and panels as well as all by flags, signs and signals.
safety devices provided are in place and in good operating DO NOT COAST OR FREEWHEEL down hills. Engage the
condition. most suitable gear speed to keep the machine under control.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-2 GENERALITIES W110 EVOLUTION

SAFETY RULES
Do not operate the machine if you are extremely tired or feel When working on slopes or near sudden level drops in the
ill. Be especially careful towards the end of the working shift. terrain, avoid areas where ground is loose or soft since
Do not operate a machine with misadjusted brakes. overturn or loss of machine control could result.

Operate the machine at low speed which can ensure If noise level is high and continuosly exceeds 90 dBA over
complete control at all times. 8 hours at the operator's ear, wear approved ear protection
in compliance with local regulations.
Travel slowly over very rough terrain, slopes or near drop-
offs, in congested areas or on frozen or slippery surfaces. Where counterweights are provided, do not operate the
machine if they have been removed.
When backing, always look to where the machine is to be
moved. Be alert of the position of bystanders. Should When transporting a loaded bucket, keept it as rolled-back
someone enter the work area, STOP THE MACHINE. and low as possible for maximum visibility, stability and
safety of there machine. Ground speed should be ad-
Maintain a safe distance from other machines or obstacles equate to the load and ground conditions.
to ensure required visibility conditions. Give way to loaded
machines. The load must always be properly arranged in the bucket;
move with extreme care when transporting oversize loads.
Maintain a clear vision of the surroundings of the travel or
work area at all times. Keep cab windows clean and Use only the type of bucket recommended for the machine
repaired. and the materials to be handled. Follow the recommenda-
tions concerning loading capacity, arrangement of the
When machines are operating in tandem, the pusher (rear) materials, characteristics of the ground and job to be
must be equipped with the appropriate deflectors to protect performed.
the front unit driver against the air stream coming from the
blower fan. Do not lift and move loads overhead where persons are
standing or working, nor downhill when working crosswise
When pulling or towing through a cable or chain, do not on slopes. In this case, the bucket should be unloaded on
start suddenly at full throttle. Take-up slack carefully. the uphill side, whenever possible.
Carefuly inspect the towing items for flaws or problems Start and stop the machine carefully when the bucket is full.
before proceedig. Do not move off without first reducing engine speed.
Avoid kinking or twisting chains or cables. Do not pull
Overtaking manoeuvres should be performed only when
through a kinked chain or cable as the high stresses
absolutely necessary and unavoidable. Beware possible
existing in this condition may induce failures. Always wear
uneven terrains, poor visibility, presence of other machin-
heavy gloves when handling chains or cables.
ery or persons out of sight.
Chains and cables should be securely anchored. Anchor
Operate the machine at a speed adequate to the working
points should be strong enough to withstand the expected
site conditions and in any case slow enough to ensure
load. Keep anyone clear of anchor points and cables or
complete control at all times.
chains.
Check instruments at start-up and frequently during
DO NOT PULL UNLESS THE OPERATOR’S COMPART-
operation. Stop the machine immediately should any
MENTS OF THE MACHINES INVOLVED ARE PROP-
malfunction be signalled.
ERLY PROTECTED AGAINST POSSIBLE BACKLAS IN
CASE OF CABLE OR CHAIN FAILURE OR DETACH- Never use the bucket as a man lift or to carry riders.
MENT. Never use the machine as a work platform or scaffolding,
Be alert of soft ground conditions close to newly con- nor for other improper use (such as pushing railway cars,
structed walls. The fill material and machine weight may trucks or other machines).
cause the wall to collapse.
Pay attetion to people within the machine operating range.
In darkness, check area of operation carefully before Load trucks from the driver’s side whenever possible.
moving in with the machine. Use all lights provided. Do not
Prior to operating the machine, check which obstacles
move into low visibility areas.
and/or difficulties you will encounter, such as narrow
If the engine tends to stall for whatever reason under load streets, overhead doors, cables, piping, as well as ground,
or at idle, immediately report this problem to the mainte- bridges, paving and ramps bearing load limitations.
nance managers for proper action. Do not operate the
In case of road transfers, find out beforehand what condi-
machine until this condition has been corrected.
tions are likely to be encountered, such as size restrictions,
On machines fitted with suction radiator fans, regularly heavy traffic, paving type, etc.. Beware fog, smoke or dust
check the engine exhaust system for leaks, as exhaust that obscure visibility.
fumes expelled towards the operator are toxic.
When crossing gullies or ditches, move at an angle with
Operators must know thoroughly the performances of the reduced speed after ensuring ground conditions will per-
machine they are driving. mit a safe traverse.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W110 EVOLUTION GENERALITIES 0-3

SAFETY RULES
Always inspect the working area to identify potential risks Always remember to move the gearshift lever to the neutral
such as: inclines, overhangs, trees, demolition rubble, position and engage the control lever lock for safety
fires, ravines, steep slopes, rough terrain, ditches, crowns, purposes.
ridge trenches, heavy traffic, crowded parking and service Apply the parking brake (if fitted).
areas, closed ambients. In such conditions, proceed with
extreme care. NEVER LEAVE THE MACHINE UNATTENDED with the
engine running.
Whenever possible, avoid going over obstacles such as
very rough terrain, rocks, logs, steps, ditches, railroad Prior to leaving the operator’s seat,and after making sure
tracks. When obstructions must be crossed, do so with that all people are clear of the machine, always slowly
extreme care and at an angle, if possible. Slow down and lower the attachment until resting it safely to the ground
select a lower gear. Ease up to the break-over point, pass Park the machine in a non-operating and no-traffic area.
the balance point slowly and ease down the other side. Park on firm level ground. If this is not possible, position the
In steep down-hill operation, do not allow the engine to machine at a right angle to the slope, making sure there is
over-speed. Select the proper gear before starting down no danger of uncontrolled sliding. Apply the parking brake.
grade. If parking in traffic lanes cannot be avoided, provide
Avoid crosswise hill travel, whenever possible. Drive up appropriate flags, barriers, flares and signals as required
and down the slope. Should the machine start slipping to adequately warn the oncoming drivers.
sideways when going uphill, steer and turn machine front Keep head, body, limbs, hands and feet clear of the dozer,
immediately downhill. arms, bucket or ripper when raised.
The gradient you may attempt to overcome is limited by Always switch off the battery isolator switch before serv-
factors such as ground conditions, load being handled, icing the machine in whatever manner (i.e., cleaning,
machine type and speed, and visibility. repairing, maintaining, etc.). Do the same when the
There is no substitute for good judgement and experience machine is to remain parked for prolonged periods of time
when working on slopes. to avoid accidental or unauthorized starting.
Avoid operating the attachment too close to an overhang Never lower the attachments other than sitting in the
or high wall, either above or below the machine. Beware operator’s seat. Sound the horn. Make sure that nobody is
of caving edges, falling objects and landslips. Remember within the machine operating range. Lower the attachment
that such hazards are likely to be concealed by bushes, slowly. DO NOT USE FLOAT POSITION in case of hydrau-
undergrowth and such. lic controls.
When pushing-over trees, the machine must be equipped Securely block the machine and lock it every time you
with proper overhead guards. Never drive a machine up leave it unattended. Return keys to authorized security.
the roots, particularly while the tree is being felled. Use Perform all necessary operations as detailed in the Opera-
extreme care when pushing over any tree with dead tion and Maintenance Instruction Manual. Apply the park-
branches. ing brake (if fitted) every time you leave the machine.
Avoid faggots, bushes, logs and rocks.
NEVER DRIVE OVER THEM, nor over any other surface
irregularities that discontinue adherence or traction with MAINTENANCE
the ground, especially near slopes or drop-offs.
Be alert to avoid changes in traction conditions that could GENERALITIES
cause loss of control. AVOID driving on ice or frozen Before operating or performing any intervention on the
ground when working on steep slopes or near drop-offs. machine:
Working in virgin rough terrains is characterized by the - carefully read all the norms contained in this Manual;
presence of all the perils and risks listed above. In these - read and observe all safety plates and instructions
conditions, it is emphasised the danger represented by located on the machine.
large tree limbs (possibly falling on the machine), large
roots (which may act as a leverage under the machine Do not allow unauthorized personnel to service the ma-
when up-rooted and cause the unit to overturn), etc. chine. Do not carry out any maintenance work without prior
authorization. Follow all recommended maintenance and
service procedures.
Keep the operator’s compartment free of loose objects that
STOPPING are not properly secured.
When the machine is to be stopped for whatever reason, Do not wear rings, wrist watches, jewellery, loose or
do so following the instructions given in chapters “Stop- hanging garments, such as ties, torn clothing,
ping the machine” and “Shutting off the engine" in the scarves,unbuttoned or unzipped jackets that can get
Operation and Maintenance Instruction Manual. caught in moving parts.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-4 GENERALITIES W110 EVOLUTION

SAFETY RULES
Wear certified safety clothes such as: hard hat, no-slip The fuel filler pipe nozzle must be constantly kept in contact
footwear, heavy gloves, ear protection, safety glasses, with the filler neck. Keep this contact from the beginning to
reflector vests, respirators. Ask your employer about spe- the end of the fuelling operation to avoid possible genera-
cific safety equipment requirements. tion of sparks due to static electricity.
Never service the machine with someone sitting in the Tow the machine only from the attaching points provided.
driver's seat, unless this person is an authorized operator Use care in making connections and ensure pins and/or
assisting in the maintenance being carried out. bolt are firmly secured before pulling. Stay clear of draw-
bars, cables or chains under load.
Keep the operator’s compartment, step plates, grab rails
and handles clear of foreign objects, oil, grease, mud or To move a failed machine, use a trailer or a low platform
snow to minimize the danger of slipping or stumbling. truck, if available. In case towing is needed, use all neces-
sary signals required by local regulations, and follow
Clean mud or grease from your shoes before climbing on
directions provided in this Manual.
the machine or driving it.
Load/unload the machine from transporter on firm level
Never attempt to operate the machine or its attachments
ground providing safe support to the wheels of the truck or
from any position other than sitting in the operator’s seat.
trailer. Use strong access ramps, with adequate height and
Never stand under the boom. angle. Keep the loading platform free of mud, oil or slippery
Should it be necessary to move the attachment through the materials.
hydraulic controls for maintenance purposes, remember Tie the machine securely to the platform of the truck or
that this should be done while sitting in the operator’s seat. trailer and opportunely wedge machine wheels or tracks
Before starting the machine or moving its attachment, as required.
apply the brakes, sound the horn and call that you are
about to manoeuvre. Raise the attachment slowly. Never align holes or slots using your fingers; always use
appropriate aligning tools.
Always lock machine arms or any other parts that must be
lifted for maintenance purposes using adequate external Remove all sharp edges and burrs from re-worked parts.
means. Do not allow anyone to pass near or even below Use only approved and effectively grounded auxiliary
a raised yet unlocked attachment. If you are not absolutely power sources for heaters, battery chargers, pumps and
sure about your safety, do not stay under a raised attach- similar equipment to reduce electrical shock hazard.
ment, even if it is locked.
Lift and handle heavy components using hoisting devices
Do not place body, limbs, or fingers near articulated cutting of appropriate capacity. Ensure the sling has been cor-
edges of uncontrolled machine parts or deprived of the rectly applied. Use lifting eyes if provided. Pay attention to
necessary guards, unless they are suitably and safely bystanders.
locked.
Never pour gasoline or diesel fuel into open, wide and low
Never perform any work on the machine with the engine containers. Never use gasoline, solvents or other flamma-
running, except when this is specifically required. Do not ble fluids to clean parts. Use proprietary certified non-
wear loose clothing, jewellery or such near moving parts. flammable, non-toxic solvents only.
When service or maintenance require access to areas that When using compressed air to clean parts, wear safety
cannot be reached from the ground, use a ladder or step glasses with side shields. Limit pressure to max 2 bars, in
platform conforming to regulations in force. If such means accordance with local safety regulations in force.
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with the Do not run the engine in closed buildings without proper
greatest care and attention. ventilation capable to remove lethal fumes.

Shop and/or field service platforms or ladders should be Do not smoke, use open flames or produce sparks nearby
manufactured in accordance with safety regulations in while refuelling the unit or handling highly flammable
force. materials.
Disconnect batteries and label all controls to warn that Do not use any flame as a light source during maintenance
service work is in progress. Block the machine and all work or to look for leaks anywhere on the machine.
attachments to be raised.
Make sure that all tools provided are in good condition at
Do not check or fill fuel tanks, batteries and accumulators, all times. NEVER USE tools with mushroomed or dam-
nor use the starting liquid if you are smoking or near open aged heads. Always wear eye protections.
flames. These fluids are flammable!
Move with extreme care when working under the machine,
BRAKES ARE INOPERATIVE when manually released for its attachments, and even on or near them. Always wear
servicing. Provisions must be made to maintain control of protective safety equipment as required, such as hard hat,
the machine using suitable blocks or other means. goggles, safety shoes, and ear plugs.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W110 EVOLUTION GENERALITIES 0-5

SAFETY RULES
In case tests during which the engine should be kept Metal cables get frayed after prolonged use. Always wear
runinng, a qualified operator must sit in the driver’s seat appropriate protections (heavy gloves, goggles, etc.)
with the mechanic in sight at all times. Place the transmis- while handling them.
sion in neutral, apply and lock the brakes. KEEP HANDS
Handle all parts carefully. Keep hands and fingers away
OFF MOVING PARTS.
from gaps, gears, and similar. Always use and wear the
In case of field service, move machine to level ground, if appropriate protections.
possible, and block it. If work on an incline cannot be
Water can build up in pneumatic systems from condensate
advised, block the machine and its attachments securely.
moisture due to changes in atmospheric conditions. If
Move damaged to level ground as soon as possible.
necessary, drain such deposits following instructions.
Do not trust worn and/or kinked chains and cables. Never
Before carrying out any maintenance work or service, lock
use them for lifting or pulling. Always wear heavy gloves
the machine articulated frame modules using the appro-
to handle chains or cables.
priate safety device. Remember to remove and store it
Be sure chains and cables are firmly fastened and that properly at the end of work.
anchor points are strong enough to withstand the expected If the machine is equipped with hydraulic brakes, make
load. Nobody should stay near the anchor points, cables sure that the reservoir is always filled up to the correct level.
or chains. DO NOT PULL OR TOW UNLESS THE OPERA-
TOR’S COMPARTMENTS OF THE MACHINES IN- Always block all wheels, front and rear, before bleeding
VOLVED ARE FITTED WITH THE PROPER GUARDS the braking system or disconnecting control hoses and/or
AGAINST BACKLASH IN CASE OF CABLE OR CHAIN cylinders.
FAILURE OR DETACHMENT.
Keep the area where maintenance is carried out CLEAN
and DRY at all times. Clean immediately all water and oil
spillages. STARTING
Do not pile up oily or greasy rags as they represent a major Do not run the engine in closed buildings without proper
fire hazard. Always store them in closed metal containers. ventilation capable to remove lethal exhaust fumes.
Before starting the machine or its attachment, check, adjust Do not place head, body, limbs, feet, hands or fingers near
and lock the operator’s seat. Also ensure that nobody is rotating fans or belts.
within the machine operating range. Sound the horn.
Be especially careful near blower fans.
Rust inhibitors are volatile and flammable. Use them only
in well ventilated areas. Keep open flames away - DO NOT REMEMBER THAT THE STARTING FLUID IS HIGHLY
SMOKE - Store containers in a cool well ventilatedplace FLAMMABLE. Follow recommendations provided in this
where they could not be reached by unauthorised people. Manual and printed on the containers. Containers must be
stored in a cool, well ventilated place out of the reach of
Do not carry loose objects in your pockets that might fall unauthorised persons.
unnoticed into open compartments. DO NOT PUNCTURE OR BURN CONTAINERS.
Wear safety glasses with side shields, hard hat, safety
shoes, heavy gloves when metal particles or similar may
be ejected and hit you.
Wear appropriate protective equipment such as dark ENGINE
safety glasses, hard hat, protective clothing, special
gloves and footwear while welding. Nearby persons Loosen the radiator cap very slowly to relieve system
should also wear dark safety glasses even if they are not pressure before removing it. Always top-up coolant level
welding. DO NOT LOOK THE WELDING ARC WITHOUT with the engine off.
PROPER EYE PROTECTION. Avoid that flammable materials could touch exhaust parts.
If not possible, provide necessary protections.
Become acquainted with all your jacking equipment and
its capacity. Remember that the jacking point on the Do not refuel with the engine running, especially if hot, as
machine should be appropriate for the load applied. Also, this increases fire hazard.
be sure the support area of the jack at the machine and on
Never attempt to check or adjust fan belt tensions when the
the ground is appropriate and stable.
engine is running.
Any load supported by a jack represents a possible haz-
Do not adjust the fuel pump when the machine is motion.
ard. Always transfer the load onto appropriate support
means according to local or national safety requirements Do not lubricate the machine with the engine running.
before proceeding with service or maintenance work.
Do not run the engine with air intakes, door or guards open.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-6 GENERALITIES W110 EVOLUTION

SAFETY RULES
ELECTRICAL SYSTEM Do not use the machine to transport loose objects, unless
proper devices to this purpose are provided.
Always disconnect the batteries prior to any intervention
on the machine or its electrical system (cleaning, repair, Clutches and brakes of this machine as well as auxiliary
maintenance). devices and attachments (such as drive cylinder or winch
control valves) should always be properly adjusted in
Should booster batteries be used, remember to connect
accordance with the instructions provided by the Manufac-
ends of the booster cables in the proper manner: (+) to (+)
turer. Never perform adjustments with the engine running,
and (-) to (-). Do not short-circuit terminals. Thoroughly
except when this is specifically required by the relevant
follow instructions given in this Manual.
procedures.
Before any intervention, make sure that the battery isolator
switch is off.
BATTERY GAS IS HIGHLY FLAMMABLE. Leave the bat-
tery compartment open during recharging to improve
ventilation. Never check battery charge by placing metal
TYRES AND WHEELS
objects across the posts. Keep sparks or open flames away
from batteries. Do not smoke near the battery to prevent Make sure that the tyre inflation pressure corresponds to
explosion hazard. specifications issued by the Manufacturer. Regularly
check inflation pressure.
Before any intervention, make sure that there are no fuel
or electrolyte leakages. If any, correct prior to proceeding Should pressure be changed, do this while staying on the
with further work. Do not recharge batteries in confined tyre side and at a safe distance.
spaces. Ensure proper ventilation is provided to avoid Pressure checks should always be carried out with the
accidental explosions due to build-up of gas released machine unloaded and cold tyres.
during charging.
Never use reconditioned tyre rims, since possible
weldings, incorrect heat-treatments or repairs can
weaken the wheels and cause damages or failures.
Do not cut, nor weld rims with inflated tyres installed.
The spare tyre should be inflated only enough to keep the
HYDRAULIC SYSTEM
rim components assembled. Remember that when not
Pressure fluid escaping from a very small hole can be installed on the disc, a tyre inflated to maximum pressure
almost invisible and still have sufficient force to penetrate can explode.
the skin. Always check any suspected pressure leaks Therefore, maximum care must be taken when handling a
using a piece of cardboard or wood. DO NOT USE HANDS. fully inflated tyre.
If injured by escaping fluid, obtain medical attention imme-
diately or serious infection or reaction may develop. Before servicing tyres, block all wheels, front and rear. After
jacking up the machine, block it in the raised position using
Stop the engine and relieve all system pressure before suitable stands conforming to current safety regulations.
removing panels, housings, caps, plugs or covers.
Deflate the tyre before removing objects from the tyre tread.
Always use gauges of adequate capacity (end-of-scale
reading) and follow recommended procedures. Never inflate tyres with flammable gas: explosions and
severe bodily injuries may result.
When starting your work shift, check for loose wheel or rim
bolts and brackets and retighten to correct torque as
necessary.

TOOLS
Always keep head, body, limbs, feet, or hands away from
bucket, blade, or ripper when in the raised position. Prior
to any intervention, install all safety devices according to
current regulations. In case the attachment is to be oper-
ated through the machine hydraulic system for mainte-
nance purposes, remember to do so only while sitting in the
driver's seat. Make sure that nobody is within the machine
operating range. Before operating the attachment, alert
people by sounding the horn and by voice. Raise the
attachment slowly.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W110 EVOLUTION GENERALITIES 0-7

SAFETY RULES
DECOMMISSIONING THE MACHINE
For the decommissioning of the machine, the availability WARNING
of particular tooling (hoists, hydraulic presses. contain- • The decommissioning of the machine must be
ers for liquids etc.) is required as well as specific tools performed exclusively by personnel trained,
listed in the Repair Manuals, available from FIAT qualified and authorised to perform such op-
KOBELCO Dealers. eration.
This has the purpose of avoiding that during disassem-
bly operations, dangerous situations may arise both for • Start the disassembly of hydraulic components
the personnel involved and the environment. only after the same, the hydraulic oil and lubri-
cants have fully cooled-off and after all residual
In the machine are present: pressures have been released, as described by
• Fluids under pressure (hydraulic system, cooling the Repair Instruction Manual.
system etc.)
• Gases (air conditioning system and accumulator, if • Prior to proceeding with disassembly opera-
installed) tions, comply with the GENERAL SAFETY
• Mechanical devices mounted under pressure (track RULES and drain each components of the ma-
tensioner etc.) chine filled with fluids, both in the reservoirs
• Heavy machine components (frames, blades, buck- and the relevant systems.
ets etc.)

WARNING
Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing
machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators,
loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, me-
chanically, or cable controlled attachment to gain access to certain items, make sure the attachment is
adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or
mechanical devices used for controlling it.

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0-8 GENERALITIES W110 EVOLUTION

SPECIFICATIONS - WHEEL LOADER W110 EVOLUTION

ENGINE - EMISSION

Make New Holland

Model 4TAA-4502 Diesel

Fuel #2 Diesel (#1 & 2 Mixture Permitted For Cold

Temperature)

Number of Cylinders 4

Bore and Stroke 4.29" (104 mm) x 5.20" (132 mm)

Displacement 275 cu. in. (4.5 Liters)

Electrical System 24 Volts

Batteries (2) 12 Volts

Alternator 70 Amp

Compression Ratio 17.5 to 1

Fuel Pump Bosch

Air Cleaner Dry Type Elements With Warning Restriction Indicator

Oil Filter Full Flow Replaceable Cartridge

Lubrication Positive Pressure

Cooling System Mid-mount Air/Water

Power
- Gross (per SAE J1995) 119 hp (89 kW) Maximum

- Net (per SAE J1349) 110 hp (82 kW) Maximum

Torque, Max.
- Gross (per SAE J1195) 355 lb-ft (481 Nm) @ 1400 RPM

- Net (per SAE J1349) 336 lb-ft (455 Nm) @ 1400 RPM

Valve clearance (Engine cold)

- Intake valves 0.267 mm (0.011 inch)

- Exhaust valves 0.572 mm (0.023 inch)

Governor Bosch

Complies with 1996 US EPA and CARB Heavy Duty Non-Road Emissions for 100-750 hp (75-560 kW) engines.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W110 EVOLUTION GENERALITIES 0-9

POWER TRAIN

TRANSMISSION

Make ZF
Model 4WG130

Radio 1st 2nd 3rd 4th

Forward 4.012 2.024 1.088 0.619

Reverse 3.804 1.919 1.031 -

TORQUE CONVERTER

Make ZF
Model 06.004.08

Stall Ratio 2.549:1

SPEEDS: mph (km/h)

1st 2nd 3rd 4th
(15.5 x 25 L2/L3 Tires)
- Forward 4.1 (6.5) 7.9 (12.7) 13.9 (22.4) 22.4 (36.1)
- Reverse 4.3 (6.9) 8.3 (13.4) 14.6 (23.4)

(17.5 x 25 L2/L3 Tires)

- Forward 4.3 (6.9) 8.3 (13.3) 14.5 (23.4) 23.4 (37.6)
- Reverse 4.5 (7.2) 8.7 (14.0) 15.2 (24.5)

AXLES Front Rear

- Differential Ratio 2.917 2.917
- Planetary Ratio 6.400 6.400
- Final Axle Ratio 18.67 18.67

Make ZF
Model Front MTL3065
Rear MTL3065

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0 - 10 GENERALITIES W110 EVOLUTION

BRAKES
Hydraulic, wet four-wheel disc. One brake pedal, pedal applies brakes and electrically neutralilzes power flow to
wheels with transmission disconnect switch activated. The brake pedal applies brakes only when transmission
disconnect switch is not activated. Hydraulic brake valve for front and rear split system. Spring applied/hydraulic
released disc parking brake on transmission output shaft neutralizes power flow to wheels when it is engaged.

Brake Area of Service Brakes 184 in2 (.119 m2)/Hub

Brake Area of Parking Brake 9.0 in2 (58 cm2)

Brake Pressure Front: 899 psi (6200 kPa)

(@ 30 sec. Setting method)
Rear : 856 psi (5900 kPa)

ACCUMULATOR DATA
Cut In 2275 psi (15686 kPa)

Cut Out 2800 psi (19305 kPa)

Low Pressure Warning 1500 psi (10342 kPa)

Transmission Declutch 350 psi (2413 kPa)

Charge Pressure (N2) 800 psi (5516 kPa)

Rear : 856 psi (5900 kPa)

TIRES
17.5 R 25 XTLA TL★ 50 psi Front 40 psi Rear
(345 kPa) (275 kPa)

17.5 R 25 XHA TL★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)

17.5 R 25 GP-2B ★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W110 EVOLUTION GENERALITIES 0 - 11

HYDRAULICS AND STEERING

Reservoir: Filtered vent with relief on hydraulic reservoir main-

tains 3-5 psi (20-34 kPa) on reservoir. Full time 10
micron return filters furnish only clean oil to all com-
ponents of the system.

Valves: Closed-center, load sensing circuit, positive low pres-

sure regeneration for bucket dump. Remote control
hydraulic power assit with electromagnet detents.

Inlet section gives steering priority with maximum pres-

sure of 3500 psi (24132 kPa). Bucket section gives
bucket priority. Relief valve provides maximum loader
pressure of 3625 psi (25,000 kPa).

Loader control valve section contains float circuitry.

Senses steering demand to control oil flow to loader

valve or steering valve as required by steering de-
mand.

System: A variable displacement piston pump is used to sup-

ply oil to the integrated loader and steering hydraulic
system.

Pump displacement 4.33 in3/rev (71 cc/rev).

35.4 GPM @ 2000 RPM @ 2750 psi
(134 l/min @ 2000 RPM @ 18961 kPa)

Pump uses full displacement at pressures up to 1800

psi. At pressures above 1800 psi the pump destrokes
(reduces its displacement) to prevent increasing the
hydraulic torque load. This allows more power for the
drivetrain in critical or severe applications without
sacrificing hydraulic force.

Steering Section
Center pivot articulated steering - front and rear wheels
always track. Two hydraulic cylinders controlled by a
hydrostatic steering gear and a priority valve.

The steering Orbitrol provider 3.9 turns lock-to-lock.

Lock-to-lock time at high idle is 1.75 sec.

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0 - 12 GENERALITIES W110 EVOLUTION

Hydraulic Cylinder:

Dump:
(Z-Bar, XR) 4.50 dia x 20.84 stroke x 2.50 rod
(114.3 mm dia x 529.2 mm stroke x 63.5 mm rod)

(XT) 3.75 dia x 36.32 stroke x 2.25 rod

(95.2 mm dia x 922.4 mm stroke x 57.2 mm rod)

Lift: 4.00 dia x 30.82 stroke x 2.25 rod

(101.6 mm dia x 783.0 mm stroke x 57.2 mm rod)

Steer: 2.50 dia x 18.21 stroke x 1.375 rod

(63.5 mm dia x 462.5 mm stroke x 35 mm rod)

Diameter of Hydraulic Inlet and Outlet Ports:

One Inlet 2.0" Split Flange (50.8 mm)

One Outlet 1.0" Split Flange (25.4 mm)

Maximum Oil Velocity at Hydraulic Pump @ 2000 RPM:

Outlets 14.4 ft/sec (4.40 m/sec)

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W110 EVOLUTION GENERALITIES 0 - 13

CAPACITIES

Cooling System:

5.8 US/gal (22 liters) to fill system

Gallons Ethylene Glycol (Prestone) required:

2.1 US/gal (7.8 liters) for 0 °F
2.5 US/gal (9.5 liters) for -20 °F
3.1 US/gal (11.7 liters) for -40 °F

Fuel Tank:
50.0 US/gal (189 liters) Usable Fuel

Engine:

Crankcase Only 12 quarts (11.4 liters)

Crankcase and Filter 13 quarts (12.3 liters)

Transmission: 6.78 US/gal (26 liters) initial capacity

5.0 US/gal (18.9 liters) service (w/filter)

Axles: Front/Rear

Total/Axle 23.2 quarts (22 liters)

Hydraulic Reservoir:

Reservoir, oil only 15.0 US/gal (56.8 liters)

Reservoir, oil plus air 23.8 US/gal (90.1 liters)

Total System 30.0 US/gal (113.6 liters)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Fiat Kobelco W110 Evolution Wheel Loader Service Manual
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0 - 14 GENERALITIES W110 EVOLUTION

SOUND LEVEL DATA

Emission Engine Sound Level (Arithmetic Average) dBA

Cab Closed Cab Open Canopy

Exterior Sound Level @ 15 meters

per SAE J88 SEP80

Stationary - Rated Speed - - -

Stationary - High Idle - - -
Moving - - -
IMI - - -
Component Cycling - - -

Operator's Station Sound Level

per SAE J919 JUN86

Stationary - Rated Speed - - -

Stationary - High Idle - - -
Moving - - -
IMI - - -
Component Cycling - - -

Time Weighted Average Sound Level (Leq) dBA

Cab Closed Cab Open Canopy

Operator's Station Work Cycle - - -

per SAE J1166 MAR85
(no blowers)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

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