Professional Documents
Culture Documents
SM B110-B115 EN
SM B110-B115 EN
TO READER
This manual has been printed for a skilful engineer CNH ITALIA S.p.A.
to supply necessary technical information to carry Technical Information
out service operations on this machine. Viale delle Nazioni, 55
41100 MODENA - Italy
Read carefully this manual to collect correct infor-
mation relevant to repair procedures.
REFERENCES
Beyond this Service Manual, also refer to
documents hereunder listed:
Operator’s Manual
Parts Catalogue
COMPLETE HANDBOOK FOR INSTRUCTIONS The Service Manuals for “Loader backhoe” and
AND REPAIRS “Engine” contain the necessary technical informa-
The complete Service Manual consists of two tion to carry out service and repair on machine and
volumes: on engine, necessary tools to carry out those op-
erations and information on service standard, on
B110 - B115 procedures for connection, disconnection, disas-
Service Manual “LOADER BACKHOE” sembly and assembly of parts.
B110 - B115
Service Manual “Engine” The complete Service Manual which covers the
loader backhoe models B110 - B115 consists of
the following volumes, which can be identified
through their print number as stated below:
AVOID ACCIDENTS
The majority of accidents and injuries which occur in industry, on the farm, at home or on the
road, are caused by the failure of some individual to follow simple and fundamental safety rules
or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the
real cause and taking the necessary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be
conditions that cannot be completely safeguarded against, without interfering with reasonable
accessibility and efficient operation.
A careful operator and / or technician is the best insurance against accidents. The complete ob-
servance of one simple rule would prevent many thousands of serious injuries each year.
This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.
WARNING
Before carrying out any maintenance operation, adjustment and or repair on machines equipped
with attachments, controlled hydraulically or mechanically, make sure that the attachment is low-
ered and safely set on the ground. If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suitably supported by means other than
the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
3
B110 B115
Powershift
Powershuttle /
Stabilizer sideshift
Stabilizer centre pivot /
Cab
4WD
4WS /
Pilot control
Mechanical control
Engine Iveco 82 kW - 110 HP model F4HE9484C*J102 /
Engine Iveco 82 kW - 110 HP model F4HE9484C*J103 /
Long dipper
4
1
INDEX
SECTION 00 - SAFETY PRECAUTIONS
SECTION 01 - MAINTENANCE
SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 TIGHTENING TORQUES ...................................................................................................................... 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS ....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 4WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION REMOVAL ............................................................................................................... 28
1.10 DISASSEMBLY AND ASSEMBLY..................................................................................................... 29
1.11 FAULT FINDING................................................................................................................................ 87
1.12 SPECIAL TOOLS............................................................................................................................... 90
2
SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 6
2.1 COMPONENTS WITHIN THE CHASSIS............................................................................................... 6
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 7
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 9
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS......................................................................... 10
2.5 TIGHTENING TORQUES .................................................................................................................... 12
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 4
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 7
3. LOADER ATTACHMENT SAFETY STRUT................................................................................................ 10
4. LOADER BUCKET REMOVAL ................................................................................................................... 12
5. LOADER REMOVAL (2WS)........................................................................................................................ 15
6. LOADER REMOVAL (4WS)........................................................................................................................ 17
SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROL VERSION............................................................... 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS VERSION ............................................................. 14
4. REMOVAL AND INSTALLATION ............................................................................................................... 16
5. TELESCOPIC DIPPER REVISION............................................................................................................. 26
7
SECTIONS INDEX
Where disassembly of a specific component is required refer to the relevant repair manual section.
TO PREVENT ACCIDENTS
Most accidents and personal injuries that occur in industry, on the farm, at home or on the road, are caused by
the failure of some individual to follow simple and fundamental safety rules or precautions.
For this reason, MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the nec-
essary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be conditions that
cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient oper-
ation.
A careful operator or technician is the best precaution against accidents. The complete observance of one sim-
ple rule would prevent many thousands of serious injuries each year.
This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.
4 SECTION 00 - SAFETY PRECAUTIONS
SAFETY RULES
Carefully follow specified repair and maintenance For electrical heaters, battery-chargers and similar
procedures. equipment use exclusive auxiliary power supplies
Do not wear rings, wristwatches, jewels, unbut- with a efficient ground to avoid electrical shock
toned or flapping clothing such as ties, torn hazard.
clothes, scarves, open jackets or shirts with open Always use lifting equipment and similar of appro-
zips which could get hold into moving parts. priate capacity to lift or move heavy components.
We advise to use approved safety clothing such as Pay special attention to bystanders.
anti-slipping footwear, gloves, safety goggles, hel- Never pour gasoline or diesel oil into open, wide
mets, etc. and low containers.
Never carry out any repair on the machine if some- Never use gasoline, diesel oil or other flammable
one is sitting on the operator’s seat, except if they liquids as cleaning agents. Use non-flammable
are certified operators to assist in the operation to non-toxic proprietary solvents.
be carried out. Wear protection goggles with side guards when
Never operate the machine or use attachments cleaning parts using compressed air.
from a place other than sitting at the operator’s Do not exceed a pressure of 2.1 bar (30 psi), in ac-
seat. cordance with local regulations.
Never carry out any operation on the machine Do not run the engine in a closed building without
when the engine is running, except when specifi- proper ventilation.
cally indicated. Do not smoke, use open flames, cause sparks in
Stop the engine and ensure that all pressure is re- the nearby area when filling fuel or handling highly
lieved from hydraulic circuits before removing flammable liquids.
caps, covers, valves, etc. Do not use flames as light sources when working
All repair and maintenance operations should be on a machine or checking for leaks.
carried out with the greatest care and attention. Move with caution when working under a Machine,
Service stairs and platforms used in a workshop or and also on or near a Machine. Wear proper safety
in the field should be built in compliance with the accessories:
safety rules in force. helmets, goggles and special footwear.
Disconnect the batteries and label all controls to During checks which should be carried out with the
warn that the Machine is being serviced. Block the engine running, ask an assistant to sit at the oper-
machine and all equipment which should be ator’s seat and keep the service technician under
raised. visual control at any moment.
Never check or fill fuel tanks and accumulator bat- In case of operations outside the workshop, drive
teries, nor use starting liquid if you are smoking or the machine to a flat area and block it. If working
near open flames as such fluids are flammable. on an incline cannot be avoided, first block the Ma-
Brakes are inoperative when they are manually re- chine carefully. Move it to a flat area as soon as
leased for maintenance purposes. In such cases, possible with a certain extent of safety.
the machine should be kept constantly under con- Ruined or plied cables and chains are unreliable.
trol using blocks or similar devices. Do not use them for lifting or trailing. Always han-
The fuel filling gun should remain always in contact dle them wearing gloves of proper thickness.
with the filler neck. Chains should always be safely fastened. Ensure
Maintain this contact until the fuel stops flowing that fastening device is strong enough to hold the
into the tank to avoid possible sparks due to static load foreseen. No persons should stop near the
electricity buildup. fastening point, trailing chains or cables.
Use exclusively specified towing points for towing The working area should be always kept CLEAN
the machine. Connect parts carefully. and DRY. Immediately clean any spillage of water
Ensure that foreseen pins and/or locks are steadily or oil.
fixed before applying traction. Do not pile up grease or oil soaked rags, as they
Do not stop near towing bars, cables or chains constitute a great fire hazard. Always place them
working under load. into a metal container. Before starting the Machine
To transfer a failed machine, use a trailer or a low or its attachments, check, adjust and block the op-
loading platform trolley if available. erator’s seat. Also ensure that there are no per-
To load and unload the machine from the transpor- sons within the Machine or attachment operating
tation mean, select a flat area providing a firm sup- range.
port to the trailer or truck wheels. Firmly tie the Do not keep in your pockets any object which
machine to the truck or trailer platform and block might fall unobserved into the Machine’s inner
wheels as required by the forwarder. compartments.
SECTION 00 - SAFETY PRECAUTIONS 5
Whenever there is the possibility of being reached dental explosion hazard due to build-up of gasses
by ejected metal parts or similar, use protection relieved during charging.
eye mask or goggles with side guards, helmets, Always disconnect the batteries before performing
special footwear and heavy gloves. Wear suitable any type of service on the electrical system.
protection such as tinted eye protection, helmets,
special clothing, gloves and footwear whenever it HYDRAULIC SYSTEMS
is necessary to carry out welding procedures. All Some fluid slowly coming out from a very small
persons standing in the vicinity of the welding proc- port can be almost invisible and be strong enough
ess should wear tinted eye protection. NEVER to penetrate the skin. For this reason, NEVER USE
LOOK AT THE WELDING ARC IF YOUR EYES YOUR HANDS TO CHECK FOR LEAKS, but use
ARE NOT SUITABLY PROTECTED. a piece of cardboard or a piece of wood for this
Metal cables with the use get frayed. Always wear purpose. If any fluid is injected into the skin, seek
adequate protections (heavy gloves, eye protec- medical aid immediately. Lack of immediate medi-
tion, etc.). cal attention, serious infections or dermatitis may
Handle all parts with the greatest caution. Keep result.
your hands and fingers far from gaps, moving Always take system pressure readings using the
gears and similar. Always use approved protective appropriate gauges.
equipment, such as eye protection, heavy gloves
and protective footwear. WHEELS AND TYRES
Check that the tyres are correctly inflated at the
START UP
pressure specified by the manufacturer. Periodi-
Never run the engine in confined spaces which are cally check possible damages to the rims and
not equipped with adequate ventilation for exhaust tyres.
gas extraction. Keep off and stay at the tyre side when correcting
Never bring your head, body, arms, legs, feet, the inflation pressure.
hands, fingers near fans or rotating belts. Check the pressure only when the machine is un-
loaded and tyres are cold to avoid wrong readings
ENGINE due to over-pressure. Do not reuse parts of recov-
Always loosen the radiator cap very slowly before ered wheels as improper welding, brazing or heat-
removing it to allow pressure in the system to dis- ing may weaken the wheel and make it fail.
sipate. Coolant should be topped up only when the Never cut, nor weld a rim with the inflated tyre as-
engine is stopped or idle if hot. sembled.
Do not fill up fuel tank when the engine is running, To remove the wheels, block both front and rear
mainly if it is hot, to avoid ignition of fires in case of Machine wheels. Raise the Machine and install
fuel spilling. safe and stable supports under the Machine in ac-
Never check or adjust the fan belt tension when the cordance with regulations in force.
engine is running. Never adjust the fuel injection Deflate the tyre before removing any object caught
pump when the machine is moving. into the tyre tread.
Never lubricate the machine when the engine is Never inflate tyres using flammable gases as they
running. may originate explosions and cause injuries to by-
standers.
ELECTRICAL SYSTEMS
If it is necessary to use auxiliary batteries, cables REMOVAL AND INSTALLATION
must be connected at both sides as follows: (+) to Lift and handle all heavy components using lifting
(+) and (-) to (-). Avoid short-circuiting the termi- equipment of adequate capacity. Ensure that parts
nals. GAS RELEASED FROM BATTERIES IS are supported by appropriate slings and hooks.
HIGHLY FLAMMABLE. During charging, leave the Use lifting eyes provided to this purpose. Take
battery compartment uncovered to improve venti- care of the persons near the loads to be lifted.
lation. Avoid checking the battery charge by Handle all parts with great care. Do not place your
means of “jumpers” made by placing metallic ob- hands or fingers between two parts. Wear ap-
jects across the terminals. Avoid sparks or flames proved protective clothing such as safety goggles,
near the battery area. Do not smoke to prevent ex- gloves and footwear.
plosion hazards. Do not twist chains or metal cables. Always wear
Prior to any service, check for fuel or coolant leaks. protection gloves to handle cables or chains.
Remove these leaks before going on with the work.
Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent acci-
6 SECTION 00 - SAFETY PRECAUTIONS
Helpful hints
Avoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
In general, avoid skin contact with all fuels, oils, ac-
ids, solvents, etc.
Most of them contain substances which can be
harmful to your health.
Modern oils contain additives. Do not burn contam-
inated fuels and/or waste oils in ordinary heating
systems.
Avoid spillage when draining off used engine cool-
ant mixtures, engine, transmission and hydraulic
oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubri-
cants. Store them safely until they can be disposed
of in a proper way to comply with local legislation
and available resources.
Modern coolant mixtures, i.e. antifreeze and other
additives, should be replaced every two years.
They should not be allowed to get into the soil but
should be collected and disposed of safely.
Do not open the Air-Conditioning system yourself.
It may contain gases which should not be released
into the atmosphere. Your air conditioning special-
ist has special equipment for discharging and
charging the system.
Repair any leaks or defects in the engine cooling or
hydraulic system immediately.
Do not increase the pressure in a pressurized cir-
cuit as this may lead to a catastrophic failure of the
system components.
Protect hoses during welding as penetrating weld
chips may burn a hole or weaken them, causing
the loss of oils, coolant, etc.
B110
B115
SECTION 01 - MAINTENANCE
2 SECTION 01 - MAINTENANCE
SECTION 01 - MAINTENANCE 3
All maintenance and repair operations described in Ballooning of the hose indicates an internal leakage
this manual should be carried out exclusively by au- due to structural failure. This condition rapidly dete-
thorized workshops. All instructions detailed should riorates and total hose failure soon occurs.
be carefully observed and special equipment indi- Kinked, crushed, stretched or deformed hoses gen-
cated should be used if necessary. erally suffer internal structural damage which can
Everyone who carries out service operations de- result in oil restriction, a reduction in the speed of
scribed without carefully observing these prescrip- operation and ultimate hose failure.
tions will be directly responsible of deriving Free-moving, unsupported hoses must never be al-
damages. lowed to touch each other or related working surfac-
es. This causes chafing which reduces hose life.
GENERAL
Clean the exterior of all components before carrying O-RING FLAT FACE SEAL FITTINGS
out any form of repair. Dirt and dust can reduce the When repairing O-ring face seal connectors, the fol-
efficient working life of a component and lead to lowing procedures should be observed.
costly replacement.
Time spent on the preparation and cleanliness of WARNING
working surfaces will pay dividends in making the Never disconnect or tighten a hose or tube that is
job easier and safer and will result in overhauled under pressure, if in doubt, actuate the operating le-
components being more reliable and efficient in op- vers several times with the engine switched off prior
eration. Use cleaning fluids which are known to be to disconnecting a hose or tube.
safe. Certain types of fluid can cause damage to O-
rings and cause skin irritation. Solvents should be Release the fittings and separate the hose or tube
checked that they are suitable for the cleaning of assembly, then remove and discard the O-ring seal
components and also that they do not risk the per- from the fitting.
sonal safety of the user. Dip a new O-ring seal into clean hydraulic oil prior to
Replace O-rings, seals or gaskets whenever they installation. Install a new O-ring into the fitting and,
are disturbed. Never mix new and old seals or O- if necessary, retain in position using petroleum jelly.
rings, regardless of condition. Always lubricate new Assemble the new hose or tube assembly and tight-
seals and O-rings with hydraulic oil before installa- en the fitting finger tight, while holding the tube or
tion. hose assembly to prevent it from turning.
When replacing component parts, use the correct Use two suitable wrenches and tighten the fitting to
tool for the job. the specified torque according to the size of the fit-
ting.
HOSES AND TUBES
Always replace hoses and tubes if the cone end or NOTE: to ensure a leak-free joint is obtained, it is
the end connections on the hose are damaged. important that the fittings are not over or under
When installing a new hose, loosely connect each torqued.
end and make sure the hose takes up the designed
position before tightening the connection. Clamps
should be tightened sufficiently to hold the hose SHIMMING
without crushing and to prevent chafing. At each adjustment, select adjusting shims, meas-
After hose replacement to a moving component, ure them individually using a micrometre and then
check that the hose does not foul by moving the sum up recorded values.
component through the complete range of travel. Do not rely on measuring the whole shimming set,
Be sure any hose which has been installed is not which may be incorrect, or on rated value indicated
kinked or twisted. for each shim.
Hose connections which are damaged, dented,
crushed or leaking, restrict oil flow and the produc- ROTATING SHAFT SEALS
tivity of the components being served. Connectors To correctly install rotating shaft seals, observe the
which show signs of movement from the original following instructions:
swagged position have failed and will ultimately sep- let the seal soak into the same oil as it will seal for
arate completely. at least half an hour before mounting;
A hose with a chafed outer cover will allow water en- thoroughly clean the shaft and ensure that the
try. Concealed corrosion of the wire reinforcement shaft working surface is not damaged;
will subsequently occur along the hose length with
resultant hose failure.
4 SECTION 01 - MAINTENANCE
place the sealing lip towards the fluid. In case of a NOTES FOR SPARE PARTS
hydrodynamic lip, consider the shaft rotation direc- Only genuine parts guarantee same quality, life,
tion and orient grooves in order that they deviate safety as original components as they are the same
the fluid towards the inner side of the seal; as mounted in production. Only the genuine spare
coat the sealing lip with a thin layer of lubricant (oil parts can offer this guarantee.
rather than grease) and fill with grease the gap be- All spare parts orders should be complete with the
tween the sealing lip and the dust lip of double lip following data:
seals; machine model (commercial name) and chassis
insert the seal into its seat and press it down using number;
a flat punch. Do not tap the seal with a hammer or engine type and number;
a drift; part number of the ordered part, which can be
take care to insert the seal perpendicularly to its found on the “Spare Parts Catalogue”, which is the
seat while you are pressing it. Once the seal is set- base for order processing.
tled, ensure that it contacts the thrust element if re-
quired; NOTES FOR EQUIPMENT
to prevent damaging the sealing lip against the
shaft, place a suitable protection during installa- Equipment which proposes and shows in this man-
tion. ual are as follows:
studied and designed expressly for use on compa-
O-RINGS ny machines;
necessary to make a reliable repair;
Lubricate the O-rings before inserting them into their accurately built and strictly tested to offer efficient
seats. This will prevent the O-rings from rolling over and long-lasting working means.
and twisting during mounting which will jeopardize We also remind the repair personnel that having
sealing. these equipment means:
work in optimal technical conditions;
BEARINGS
obtain best results;
It is advisable to heat the bearings to 80 to 90 °C save time and effort;
(176 to 194 °F) before mounting them on their shafts work more safely.
and cool them down before inserting them into their
seats with external tapping. NOTICES
Wear limits indicated for some details should be in-
SPRING PINS
tended as advised, but not binding values. The
When mounting split socket spring pins, ensure that words “front”, “rear”, “right hand”, and “left hand” re-
the pin notch is oriented in the direction of the effort ferred to the different parts should be intended as
to stress the pin. seen from the operator’s seat oriented to the normal
Spiral spring pins should not be oriented during in- sense of movement of the machine.
stallation.
HOW TO MOVE THE MACHINE WITH THE
HARDWARE TORQUE VALUES BATTERY REMOVED
Check the tightness of hardware periodically. Cables from the external power supply should be
Use the following charts to determine the correct connected exclusively to the respective terminals of
torque when checking, adjusting or replacing hard- the Machine positive and negative cables using pli-
ware on the Backhoe loader. ers in good condition which allow proper and steady
contact.
IMPORTANT: Torque values listed are for general Disconnect all services (lights, wind-shield wipers,
use only. Make sure fastener threads are clean and etc.) before starting the Machine.
not damaged. If it is necessary to check the machine electrical sys-
tem, check it only with the power supply connected.
At check end, disconnect all services and switch the
NOTE: a torque wrench is necessary to properly power supply off before disconnecting the cables.
torque hardware.
B110
B115
SECTION 02 - TECHNICAL
SPECIFICATIONS
1. MODELS....................................................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
4. LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ................................................................ 8
5. BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ........................................................... 12
6. LIFTING CAPACITIES................................................................................................................................ 15
7. LOADER BUCKET WITH FORKS DIMENSIONS AND PERFORMANCE................................................. 18
8. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 19
2 SECTION 02 - TECHNICAL SPECIFICATIONS
1.
SECTION 02 - TECHNICAL SPECIFICATIONS 3
1. MODELS
B110 B115
Powershift
Powershuttle /
Stabilizer sideshift
Stabilizer centre pivot
Cab
4WD
4WS /
Pilot control
Mechanical control
Engine Iveco 82 kW - 110 HP model F4HE9484C*J102 /
Engine Iveco 82 kW - 110 HP model F4HE9484C*J103 /
Long dipper
4 SECTION 02 - TECHNICAL SPECIFICATIONS
3. TECHNICAL SPECIFICATIONS
ENGINE - IVECO 110 HP - 82 KW MODEL F4HE9484C*J102 (B110) *J103 (B115)
Power................................................................................... 110 hp/ 82 kW, turbocharged - Charge Air Cooled
Type .......................................................................................................................................................... Diesel
No. of cylinders ................................................................................................................................................. 4
Bore .............................................................................................................................................. 104 mm (4 in)
Stroke......................................................................................................................................... 132 mm (5,2 in)
Displacement ......................................................................................................................4485 cm3 (273.6 in3)
Compression Ratio ................................................................................................................................... 17.5:1
Firing Order .............................................................................................................................................. 1.3.4.2
Idle Speed .................................................................................................................................. 750-950 rev/mn
Maximum “No-Load” Speed ................................................................................................... 2380-2480 rev/mn
Maximum “Full Load” Speed ........................................................................................................... 2200 rev/mn
Maximum Torque (CEE) .....................................................................................................516 Nm (380.5 lbf·ft)
COOLING SYSTEM
Type .................................................................................................................................. Pressurized Full Flow
Fan Belt Type..................................................................................................................... 8 Groove Serpentine
Fan Belt Tension ..................................................................................................................Automatic tensioner
Air Conditioning Compressor Belt .......................................................................................................... Single V
Air Conditioning Belt Tension...................................................................................................................Manual
Thermostat:
Starts to Open at.......................................................................................................................... 81 °C (178 °F)
Fully Open at................................................................................................................................ 96 °C (205 °F)
Radiator Cap ............................................................................................................................. 0.90 bar (13 psi)
FUEL SYSTEM
Supply:
Type ........................................................................................................... BOSCH high pressure, common rail
Overfeed ..................................................................................................................................... with intercooler
Turbocharger .............................................................................................................................. HOLSET HX35
Injectors ...................................................................................................................................................CRIU 2
Injection sequence ................................................................................................................................... 1-3-4-2
Injection pressure........................................................................................... 250 - 1600 bar (3625 - 23197 psi)
TRANSMISSION (B110)
Transmission TURNER Model COM-T4-2025 POWERSHUTTLE 4x4 = 4 Forward and 4 Reverse Gears
Torque Convertor Ratio ............................................................................................................................ 2.38:1
Transmission DANA T16000 POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears
Torque Convertor Ratio ............................................................................................................................ 2.54:1
TRANSMISSION (B115)
Transmission DANA T16000 POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears
Torque Convertor Ratio ............................................................................................................................ 2.54:1
ELECTRICAL SYSTEM
Alternator Type ........................................................................................................... BOSCH NCBI 28 90 amp
Battery Type......................................................................................... 95 amp hr (12V/900 CCA) SAE - Single
............................................................................................................ 60 amp hr (12V/600 CCA) SAE - Double
Battery Disconnect via the Isolator Switch .................................................................on Negative/chassis cable
Regulator ...................................................................................................................................... Transistorized
Ground (Earth) ...................................................................................................................................... Negative
Starting Motor ..................................................................... Positive Engagement, Solenoid Operated (2.7 kW)
6 SECTION 02 - TECHNICAL SPECIFICATIONS
BRAKES (B110)
Type ............................................................................................ Wet Multi-Discs x8 per Axle (x4 per half Axle)
Braking air ..............................................................................................................................1440 cm2 (223 in2)
Parking brake ................................................................................................................. Single disc on driveline
BRAKES (B115)
Type ............................................................................................ Wet Multi-Discs x6 per Axle (x3 per half Axle)
Braking air ..............................................................................................................................1440 cm2 (223 in2)
Parking Type .................................................................................................................. Single disc on driveline
STEERING
Power Steering Type......................................................................................................................... Hydrostatic
Power Steering Displacement 2WS ................................................................................ 125 cc/rev (7.6 in3/rev)
Power Steering Displacement 4WS ................................................................................ 160 cc/rev (9.7 in3/rev)
Turns Lock to Lock..............................................................................................................Left 3.25; Right 3.25
System Pressure...................................................................................................... 177 ± 3 bar (2566 ± 44 psi)
HYDRAULIC SYSTEM
Hydraulic pump:
- Manufacturer.................................................................................................................................... CASAPPA
- Type ...........................................................Twin Gear Pump; Hydraulic System and Priority Steering System
- 110 HP Model .................................................................................................................... KP30.38-0556-LMF
Pump Displacement:
- 110 HP ........................................40.258 + 35.427 cm3/rev (2.457 + 2.161 in3/rev) (38 + 34 cc (2.3 + 2.1 in3))
Hydraulic System Pressure:
Main Relief Valve Pressure................................................................................206 - 210 bar (2987 - 3045 psi)
Stabilizer Relief Valve Pressure.........................................................................196 - 202 bar (2842 - 2929 psi)
FRONT COUNTERWEIGHT
Weight ...................................................................................................................................... 223.4 kg (492 lb)
Weight (extra counterweight) ........................................................................... 26.2 kg + 31.5 kg (58 lb + 69 lb)
Weight (B115) ............................................................................................................................. 170 kg (374 lb)
RADIATOR COOLANTS
Anti-freeze should be changed every 2000 hours or 24 months.
In order to reduce deposits and corrosion, water in the cooling system should not exceed the following limits:
Total hardness ................................................................................................................... 300 parts per million
Chloride ............................................................................................................................... 100 parts per million
Sulphates ............................................................................................................................ 100 parts per million
SECTION 02 - TECHNICAL SPECIFICATIONS 7
NOISE LEVEL
Certified by the manufacturer.
In accordance with European directive 2000/14/EC - Stage II.
Internal noise level (LpA) .................................................................................................................. 77 decibels
External noise level (LwA) .............................................................................................................. 103 decibels
VIBRATION LEVEL INSIDE THE CAB
Upper members ........................................................................................ level lower than 2.5 m/s² (8 ft 3 in/s²)
Abdomen................................................................................................... level lower than 0.5 m/s² (1 ft 8 in/s²)
LOADER BUCKETS
BACKHOE BUCKETS
TYRES - B110
TYRES - B115
Dimensions 4WD
A 4359 mm (14 ft 4 in)
B 3530 mm (11 ft 7 in)
C 2785 mm (9 ft 2 in)
D 40°
E 45°
F 786 mm (2 ft 7 in)
G 2950 mm (9 ft 9 in)
H 55 mm (3 in)
I 1942 mm (6 ft 5 in)
J 2175 mm (7 ft 2 in)
K 1325 mm (4 ft 5 in)
L 1630 mm (5 ft 5 in)
M 5747 mm (18 ft 11 in)
N 4000 mm (13 ft)
P 2430 mm (7 ft 12 in)
Q 2250 mm (7 ft 5 in)
Performance 4WD
Lift capacity at maximum height 3553 kg (7817 lb)
Breakout force 6176 daN (13884 lbf)
SECTION 02 - TECHNICAL SPECIFICATIONS 9
Dimensions 4WD
A 4284 mm (14 ft 1 in)
B 3456 mm (11 ft 4 in)
C 2710 mm (8 ft 11 in)
D 40°
E 45°
F 795 mm (2 ft 7 in)
G 2885 mm (9 ft 6 in)
H 130 mm (5.12 in)
I 1997 mm (6 ft 7 in)
J 2175 mm (7 ft 2 in)
K 1120 mm (3 ft 8 in)
L 2934 mm (9 ft 8 in)
M 7040 mm (23 ft 1 in)
N 3973 mm (13 ft)
P 2250 mm (7 ft 5 in)
Q 2230 mm (7 ft 4 in)
Performance 4WD
Lift capacity at maximum height 3560 kg (7832 lb)
Breakout force 6430 daN (14455 lbf)
10 SECTION 02 - TECHNICAL SPECIFICATIONS
telescopic dipper
Dimensions standard dipper
(extended)
A 1877 mm (6 ft 2 in) 2820 mm (9 ft 3 in)
B 204°
C 5777 mm (18 ft 11 in) 6467 mm (21 ft 3 in)
D 3946 mm (12 ft 11 in) 4664 mm (15 ft 4 in)
E 5868 mm (19 ft 3 in) 6953 mm (22 ft 10 in)
F 7913 mm (25 ft 12 in) 8278 mm (27 ft 2 in)
G 6300 mm (20 ft 8 in) 7380 mm (24 ft 3 in)
J 4594 mm (15 ft 1 in) 5778 mm (18 ft 11 in)
K 2280 mm (7 ft 6 in) 2280 mm (7 ft 6 in)
L 2790 mm (9 ft 2 in) 2790 mm (9 ft 2 in)
M 14°
telescopic dipper
Performance standard dipper
(extended)
Swing arc 180°
Maximum digging force - dipper cylinder 3552 daN (7985 lbf) 2542 daN (5714 lbf)
Maximum digging force - bucket cylinder 5523 daN (12416 lbf) 5523 daN (12416 lbf)
Lift capacity through dipper arc 1865 kg (4103 lb) 1380 kg (3036 lb)
Lift capacity, dipper 3.66 m (12 ft 1 in) above ground 1925 kg (4235 lb) 1400 kg (3080 lb)
Lift capacity at 4.26 m (13 ft 12 in) above ground 1560 kg (3432 lb) 1030 kg (2260 lb)
Telescopic dipper extension length - 1050 mm (3 ft 5 in)
SECTION 02 - TECHNICAL SPECIFICATIONS 13
telescopic dipper
Dimensions standard dipper
(extended)
A 1877 mm (6 ft 2 in) 2818 mm (9 ft 3 in)
B 204°
C 5717 mm (18 ft 9 in) 6374 mm (20 ft 11 in)
D 3905 mm (12 ft 10 in) 4593 mm (15 ft 1 in)
E 5867 mm (19 ft 3 in) 6952 mm (22 ft 10 in)
F 7193 mm (23 ft 7 in) 8278 mm (27 ft 2 in)
G 6492 mm (21 ft 4 in) 7500 mm (24 ft 7 in)
J 4302 mm (14 ft 1 in) 5527 mm (18 ft 2 in)
K 2280 mm (7 ft 6 in) 2280 mm (7 ft 6 in)
L 2790 mm (9 ft 2 in) 2790 mm (9 ft 2 in)
M 14°
telescopic dipper
Performance standard dipper
(extended)
Swing arc 180°
Maximum digging force - dipper cylinder 3552 daN (7985 lbf) 2542 daN (5714 lbf)
Maximum digging force - bucket cylinder 5523 daN (12416 lbf) 5523 daN (12416 lbf)
Lift capacity through dipper arc 2350 kg (4103 lb) 1625 kg (3575 lb)
Lift capacity, dipper 3.66 m (12 ft 1 in) above ground 2425 kg (4235 lb) 1625 kg (3575 lb)
Lift capacity at 4.26 m (13 ft 12 in) above ground 1500 kg (3432 lb) 995 kg (2189 lb)
Telescopic dipper extension length - 1200 mm (3 ft 11 in)
14 SECTION 02 - TECHNICAL SPECIFICATIONS
telescopic dipper
Dimensions standard dipper
(extended)
A 1956 mm (6 ft 6 in) 2902 mm (9 ft 7 in)
B 204°
C 5711 mm (18 ft 9 in) 6371 mm (20 ft 11 in)
D 3908 mm (12 ft 10 in) 4592 mm (15 ft 1 in)
E 5836 mm (19 ft 2 in) 6923 mm (22 ft 9 in)
F 6957 mm (22 ft 10 in) 8043 mm (26 ft 5 in)
G 6250 mm (20 ft 7 in) 7336 mm (24 ft 1 in)
J 4586 mm (15 ft 1 in) 5760 mm (18 ft 11 in)
K 2230 mm (7 ft 4 in) 2230 mm (7 ft 4 in)
L 3000 mm (9 ft 11 in) 3000 mm (9 ft 11 in)
M 14°
telescopic dipper
Performance standard dipper
(extended)
Swing arc 180°
Maximum digging force - dipper cylinder 3600 daN (8093 lbf) 2568 daN (5773 lbf)
Maximum digging force - bucket cylinder 5700 daN (12814 lbf) 5700 daN (12814 lbf)
Lift capacity through dipper arc 2560 kg (5632 lb) 1500 kg (3300 lb)
Lift capacity, dipper 3.66 m (12 ft 1 in) above ground 2620 kg (5764 lb) 1600 kg (3520 lb)
Lift capacity at 4.26 m (13 ft 12 in) above ground 1458 kg (1458 lb) 975 kg (2145 lb)
Telescopic dipper extension length - 1200 mm (3 ft 11 in)
SECTION 02 - TECHNICAL SPECIFICATIONS 15
6. LIFTING CAPACITIES
The following tables reflect the lifting capacities of the backhoe dipper (A) and boom (B) on a typical 4WD ma-
chine.
B115
(A) Reach Full Height ............................... 2350 mm
(B) Reach Ground Level ..........2700 mm (8 ft 11 in)
(C) Lift Height ...........................3458 mm (11 ft 5 in)
(D) Lift Height .......................... 3040 mm (9 ft 12 in)
Fork Spacing - Minimum centres .....275 mm (11 in)
Fork Spacing - Maximum centres... 1773 mm (5 ft 10 in)
Fork Length ............................... 1026 mm (3 ft 4 in)
Fork Width........................................ 80 mm (3.1 in)
SECTION 02 - TECHNICAL SPECIFICATIONS 19
NOTE:
B110
B115
Hydraulic tests
Tachometer setting .......................................................................................................................2000 revs/min
Test temperature, oil ........................................................................................................80-85 °C (176-185 °F)
Cold start valve (For reference only).......................................................................................... 26 bar (377 psi)
System pressure test ...............................................................................................13.7-15.2 bar (199-220 psi)
Torque converter............................................................................................................. 7-11 bar (102-160 psi)
1.3 OVERHAUL
1.4 INSPECTION
(See section “TRANSMISSION” chapter “TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST
POINTS” at page 18)
SECTION 17 - TORQUE CONVERTERS 7
Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the torque converter and is the primary component which starts the oil flow-
ing to the other components which results in torque multiplication. This element can be compared to a centrif-
ugal pump in that it picks up fluid at its centre discharges at its outer diameter. The torque converter turbine is
mounted opposite the impeller and is connected to the turbine shaft or clutch shaft. This element receives fluid
at its outer diameter and discharges at its centre. The stator of the torque converter is located between and at
the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is
exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation
into the impeller element. This recirculation will make the converter to multiply torque. The torque multiplication
in function of following elementes, impeller, turbine and stator, and the converter output speed (turbine speed).
The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is
at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multipli-
cation is increasing. In the impeller cover a splined shaft is fitted which runs inside and through the turbine shaft
to drive a hydraulic pump which is fitted at the back of the transmission. Since the shaft is connected to the
centre of the impeller cover, the pump speed will be the same as engine speed. The rear side of the impeller
cover has a tanged drive which drives the transmission charging pump located in the converter housing. The
transmission charging pump speed is also the same as the engine speed.
(See section “TRANSMISSION” chapter “PRESSURE SPECIFICATIONS AND CHECK POINTS” at page 103)
8 SECTION 17 - TORQUE CONVERTERS
Hydraulic tests
Tachometer setting .......................................................................................................................2200 revs/min
Test temperature, oil ........................................................................................................82-93 °C (179-199 °F)
Torque converter relief valve...................................................................................................... 10 bar (145 psi)
Oil temperature converter out:
Normal operating range .........................................................................................80-90 °C (176-194 °F)
Maximum temperature ..................................................................................................... 120 °C (248 °F)
2.3 OVERHAUL
2.4 INSPECTION
DISASSEMBLY
Remove the drive plate screws.
ASSEMBLY
Install the torque converter assy on input shaft.
(See section “TRANSMISSION” chapter “PRESSURE SPECIFICATIONS AND CHECK POINTS” at page 103)
B110
B115
SECTION 21 - TRANSMISSION
GEAR RATIO
Forward Reverse
1 2 3 4 1 2 3 4
4.824 2.998 1.408 0.792 4.020 2.496 1.173 0.660
DETENT SPRING
Free length (Approximately).................................................................................................... 42.06 mm (1.6 in)
4 SECTION 21 - TRANSMISSION
END FLOAT
Input forward Primary Shaft ............................................................................0.0508-0.41 mm (0.002-0.016 in)
Input reverse Primary Shaft ............................................................................0.0508-0.41 mm (0.002-0.016 in)
Output shaft........................................................................................1st Gear - 0.33-0.508 mm (0.013-0.02 in)
....................................................................................................... 2nd Gear - 0.35-0.558 mm (0.014-0.022 in)
........................................................................................................ 3rd Gear - 0.38-0.838 mm (0.015-0.033 in)
........................................................................................................ 4th Gear - 0.20-0.558 mm (0.007-0.022 in)
4WD Shaft.........................................................................................................0.050-0.28 mm (0.002-0.011 in)
Bearing End Floats........................................................................................0.025-0.076 mm (0.0009-0.003 in)
Bearing End Float Shims available .....0.050/0.076/0.127/0.177/0.381/0.508 mm (0.002/0.003/0.005/0.015/0.02 in)
HYDRAULIC TESTS
Tachometer setting .......................................................................................................................2000 revs/min
Test temperature, oil ........................................................................................................80-85 °C (176-185 °F)
Cold Start Valve (For reference only)......................................................................................... 26 bar (377 psi)
System Pressure Test..............................................................................................13.7-15.2 bar (199-220 psi)
Torque Converter .............................................................................................................7-11 bar (102-160 psi)
Reverse Clutch.........................................................................................................13.7-15.2 bar (199-220 psi)
Forward Clutch.........................................................................................................13.7-15.2 bar (199-220 psi)
4WD Supply .............................................................................................................13.7-15.2 bar (199-220 psi)
RECOMMENDED SEALANTS
Transmission case joint ................................................................................................................... Loctite 5203
4WD Output gear ............................................................................................................................... Loctite 649
4WD gear (Permanent 4WD assy) ....................................................................................................Loctite 649
4WD clutch supply pipe .....................................................................................................................Loctite 542
Gear lever housing...................................................................................................................Loctite 5900 RTV
Shimming access plug .......................................................................................................................Loctite 649
6 SECTION 21 - TRANSMISSION
1. GEAR LEVER: Four gears are selectable for the 5. TRANSMISSION POWERSHUTTLE DIREC-
required ground speeds in both forward or re- TION LEVER: Movement of this lever from the
verse travel. neutral position will engage forward or rearward
2. TRANSMISSION DISCONNECT BUTTON: Prior travel.
to changing gear depress and hold down this
switch which disengages transmission drive, se- NOTE: in reverse gear an audible alarm device
lect the required gear with the gear lever and re- sounds.
lease the switch to re-engage drive.
3. LOADER ATTACHMENT CONTROL LEVER 6. WARNING HORN BOTTON
4. MECHANICAL DIFFERENTIAL LOCK PEDAL: 7. TRANSMISSION DISCONNECT BUTTON (on
Depressing this pedal will lock both rear wheels the loader attachment control lever)
together giving equal drive and will disengage 8. ROLLER FOR THE PROPORTIONAL CON-
when wheel torque equalizes or foot brakes are TROL OF LOADER BUCKET 4X1
applied.
SECTION 21 - TRANSMISSION 7
Transmission
The transmission is fully synchronised providing four
forward and four reverse speeds allowing gear ratio
changes on the move. A torque converter is used to
connect the engine to the transmission and the col-
umn mounted powershuttle lever (4) enables shifts
between forward and reverse travel without disen-
gaging gear ratios.
A device for “transmission disconnect” is activated
by pushing button (2), placed on the gear shift lever
(1) or by pushing button (5), placed on the loader
control lever (3).
WARNING
Always apply the parking brake whenever the ma-
chine is parked as the machine is free to roll even
though the transmission gearshift lever and power
reversing lever may be “In Gear” and the engine is
turned “OFF”.
Transmission Disconnect
The 4x4 transmission provides for easy upward and
downward gear ratio changes on the move. Howev-
er, as a clutch is not used between the engine and
transmission, the power flow from the engine to the
transmission must be interrupted to shift from one
gear ratio to another. This is accomplished by using
a transmission disconnect (dump) button.
The finger operated button (2) on the main gearshift
lever knob (1) is easy to operate.
WARNING
To avoid personal injury do not use the disconnect
switch control to coast down hill. Excessive speed
may cause loss of control, personal injury to a by-
stander or failure of the transmission.
SECTION 21 - TRANSMISSION 9
WARNING
Never use the differential lock at speeds above 8 km/h
or when turning the machine.
When engaged the lock will prevent the machine turn-
ing and personal injury could result.
SECTION 21 - TRANSMISSION 11
1.4 LUBRICATION
To ensure proper lubrication and operating temperatures it is most important that appropriate lubricants are
used and that the correct oil level is maintained.
Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the
churning action of the gears. Early breakdown of the oil will result in heavy sludge deposits that block oil ports
and build up on splines and bearings. Overfilling may also cause oil leaks.
Oil changes
An initial oil change and flush is recommended after the transmission is placed in actual service.
This change should be made at any time following 50 hours in service, but should not exceed 100 hours.
When changing the oil it is essential to renew the oil filter and clean out the suction strainer.
The object in draining the oil is to eliminate possible bearing surface abrasion and attendant wear. Minute par-
ticles of metal, the result of normal wear in service are deposited in and circulated with the oil. Oil changes are
best carried out when the transmission is thoroughly warm.
WARNING
To prevent oil starvation and possible seizure of the transmission whilst towing the vehicle, it is imperative that
the propeller shafts are disconnected.
Failure to observe this precaution may result in extensive damage to the transmission.
Suggested oil:
For use in ambient temperatures of between -20 and 40 °C (-4 and 104 °F) are allowed mineral oils Grade 10W
or 10W30.
Suggested oil type: Ambra Multi G NH 410 B.
12 SECTION 21 - TRANSMISSION
Úîççêé
Pressure oil
Disengaged
Lubrication
SECTION 21 - TRANSMISSION 13
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SECTION 21 - TRANSMISSION 17
OIL FLOW SOLENOID CONTROL VALVE OPERATION (FORWARD DRIVE ONLY SHOWN)
The solenoid valve when in neutral position dead
heads the oil flow at the spool (1) from the supply ï
port and no oil is allowed to pass through the valve.
Therefore the oil in the galleries beyond the spool at
the fill time metering valve (2) remains static.
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NOTE: the control valve also includes a pressure Regulated Pressure Oil
regulating (feathering) valve and a fill time metering Return Oil
valve for the reverse clutch pack. Pressure Oil
18 SECTION 21 - TRANSMISSION
1. Cold Start oil pressure relief valve 10. Torque converter pressure regulating valve
26 bar (377 psi) reference only 7-11 bar (102-160 psi)
2. Forward Solenoid valve 11. Oil in from cooler, test port
13.7-15.2 bar (199-220 psi) 3.5 bar (51 psi)
3. Test port for reverse clutch pack 12. Backhoe Boom Lock supply
13.7-15.2 bar (199-220 psi) 13.7-15.2 bar (199-220 psi)
4. Test port for forward clutch pack 13.System pressure test point
13.7-15.2 bar (199-220 psi) 13.7-15.2 bar (199-220 psi)
5. System pressure sequencing valve 14. Converter pressure oil test port
13.7-15.2 bar (199-220 psi) 7-11 bar (102-160 psi)
6. Oil flow OUT to cooler 15. Front Wheel Drive Solenoid
7. Oil OUT to cooler, test port 13.7-15.2 bar (199-220 psi)
6.5 bar (94 psi) 16. Oil Filter
8. Front Wheel Drive test point 17. Reverse Solenoid valve
13.7-15.2 bar (199-220 psi) 13.7-15.2 bar (199-220 psi)
9. Oil flow IN from cooler
SECTION 21 - TRANSMISSION 19
Power flow for all four reverse gear ratios is the same
as for all four forward gear ratios except that the rear
clutch (4) is engaged to transmit power to the reverse
idler gear. The reverse idler gear in turn transmits
power to the gear on the countershaft and in turn
transmits power to the output shaft.
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Input Output
Intermediate
SECTION 21 - TRANSMISSION 21
Úîéëïî
24 SECTION 21 - TRANSMISSION
SECTION 21 - TRANSMISSION 25
TRANSMISSION DISASSEMBLY
Invert the transmission on a suitable bench.
For convenience the bench top should have a hole
in it to accommodate the input shaft and pump. Re-
move 3 screws and withdraw the gear shift lever as-
sembly.
Invert the shaft and refit the 3rd gear, the synchro
hub and the circlip.
52 SECTION 21 - TRANSMISSION
Invert the shaft and refit the two needle bearings and
spacer.
TRANSMISSION ASSEMBLY
All nylon patch bolts may be re-used 5 to 6 times pro-
vided a prevailing thread torque of 20 to 25 Nm (14
to 18 lbf·ft) is recorded.
All shafts and bearings should be lubricated with
transmission fluid prior to assembly.
To prevent possible contamination of hydraulic parts
lint or cotton rags should not be used.
Invert the case and then refit the bearing cups if pre-
viously removed.
Slide the 1st/2nd fork onto the 3rd/4th rail then refit
the 3rd/4th shift fork and tighten the screw to a
torque of 18-25 Nm (13-18 lbf·ft). Hold the forks and
rail in place on the output shaft then refit the com-
plete assembly into the case. The shift rail should
displace the dummy plug as it enters the bore.
Refit the 1st/2nd shift rail and tighten the shift fork
screw to a torque of 13-18 Nm (9-13 lbf·ft).
Check that the interlock ball is correctly positioned in
between the two rails.
Refit the cold start ball, the spring and the housing.
Then tighten to a torque of 46-60 Nm (34-44 lbf·ft).
Refit the strainer, the spacer, the O-ring and the cov-
er plate. Then tighten the two screws to a torque of
18-31 Nm (13-22 lbf·ft).
Refit the 4th gear lock out screw, (when this feature
is not required a shorter blanking screw is fitted). On
some applications an additional sealing plug may be
fitted.
TEST PORT
The transmission oil, should be at an approximate
temperature of 80 °C (176 °F) during pressure tests.
All pressure test ports have a 9/16” UNF thread.
Forward, reverse and 4WD clutch pack pressures
should not be more than 1 bar lower than the oil
pump pressure.
PARKING BRAKE
The caliper assembly is mounted directly onto the
rear face of the transmission housing.
1. Mounting face
2. Locknut
3. Mounting bolt
4. Outer locknut
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A. Adjust the two mounting bolts and locknuts to
leave a 0.25/1.50 mm (0.01/0.05 in) gap be-
tween the locknut and sleeve.
Then torque locknuts against mounting surface
to 155 Nm (114 lbf·ft).
B. Adjust this nut until pads are in contact with the
brake pads.
Then loosen 1/2 turn.
Finally torque outer locknut to 60-70 Nm (44-51
lbf·ft).
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IMPORTANT:
BRAKE PAD: the minimum acceptable thickness of
the brake pads is 2.286 mm (0.09 in).
BRAKE DISK: the nominal thickness of the disk is
9.5 mm (0.4 in).
The maximum total wear limit for the disk is
1.524 mm (0.06 in).
Based on the nominal thickness of 9.5 mm (0.4 in)
this would give a minimum thickness of 7.976 mm
(0.3 in).
86 SECTION 21 - TRANSMISSION
FAULT CAUSE
Transmission fails to drive in Low or no pump pressure.
either direction Low or no oil in transmission.
Mechanical failure in transmission.
Worn or broken input shaft sealing rings.
Pressure regulator valve faulty.
Direction control valve not operating.
Blockage in oil ports restricting flow.
Transmission drives in one Low oil pressure on one clutch pack due to leaks.
direction only Clutch piston seals worn or damaged.
Clutch pack excessively worn.
Direction valve or coil faulty.
Mechanical failure in transmission.
Blockage in oil ports restricting flow.
Worn or damaged input shaft sealing ring.
Delay in taking up drive Low converter pressure.
Low oil level.
Low clutch pressure.
Faulty modulation in direction control valve.
Blockage in direction valve.
Blockage in oil ports restricting flow.
No drive from 4WD 4WD solenoid valve or coil not operating.
Mechanical failure in transmission.
Low 4WD clutch pack pressure.
4WD clutch pack worn.
Transmission overheating Oil level too high or low.
Restriction in cooler flow.
Low oil pressure.
Clutch packs slipping due to low pressure or wear.
Mechanical failure in transmission.
Excessive stall operation.
Operating in too high of gear Shift to lower gear.
range for conditions
Difficult gear selection Forward or reverse clutch pack pressurized when not selected.
Direction valve faulty.
Input shaft sealing rings leaking.
Mechanical failure in transmission.
Forward or reverse clutch pack not releasing due to mechanical failure.
Vehicle moves with direction See “Difficult gear selection”.
valve in neutral position
High stall speed Low oil level. Air in oil.
Clutch plates slipping due to low pressure or wear.
Torque converter faulty.
Converter relief valve faulty.
Incorrect torque converter fitted.
Low stall speed Poor engine performance.
Torque converter defective.
Incorrect torque converter fitted.
88 SECTION 21 - TRANSMISSION
FAULT CAUSE
Noise Vehicle driveline problem:
Axles, propshafts, engine, engine mounts.
Misalignment of transmission/engine.
Bearings worn or damaged.
Gear teeth damaged or broken.
Excessive end float of shafts or gears.
Clutch plate failure forward, reverse or 4WD.
Incorrect grade of oil in transmission.
Low oil level.
Gear or thrust washer beginning to seize.
Difficult gear selection Shift rods worn or bent.
Shift forks worn, loose or twisted.
Synchronizer assemblies worn or damaged.
Clutch pack not releasing due to mechanical fault.
Clutch pack not releasing due to hydraulic fault.
Gear shift stub lever worn or damaged.
Incorrect grade of oil in transmission.
Low oil level.
Jumping out of gear Detent springs worn or broken.
Synchronizer or gear dog teeth worn or damaged.
Synchronizer assemblies worn or damaged.
Shift forks worn, loose or twisted.
Restriction or wear in gear linkage or stub lever assy.
not allowing gears to be fully selected.
Excess end float on output shaft assembly or gears.
90 SECTION 21 - TRANSMISSION
Úîééïè
HYDRAULIC SPECIFICATIONS
Suitable for operation from ambient to 120 °C (248 °F) continuous operating temperature.
Must withstand a 20 bar (290 psi) continuous pressure and a 40 bar (580 psi) variable pressure.
Conform SAE J1019 and SAE J517, 100RI.
BOLT TORQUES
Output flanges..................................................................................................... 339 - 407 Nm (250 - 300 lbf·ft)
Filter torque ................................................................................................................. 30 - 38 Nm (22 - 28 lbf·ft)
Control valve, connector nut to cover ................................................................................. 6 - 8 Nm (4 - 6 lbf·ft)
ELECTRICAL SPECIFICATIONS
Solenoid (forward reverse, high/low, 2nd/1st, modulation, disconnect) coil resistance28 ± 2 at 20 °C (68 °F)
Electronic controlled modulation valve, coil resistance ....................... 3.55 Ohm ± 0.25 Ohm at 20 °C (68 °F)
Speed sensor:
- type ..................................................................................magneto resistive sensor with 7/14 mA current loop
- frequency ......................................................................................................................................0 - 25000 Hz
- sensing distance ........................................................................................................... 0 - 2.5 mm (0 - 0.09 in)
92 SECTION 21 - TRANSMISSION
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Reset Mode:
When the microprocessor defaults to reset mode
both the T and N LED’s are displayed simultaneously
to indicate that a reset has taken place.
If no critical faults are active the microprocessor se-
lects N2 and goes to the Neutral lock state. See
“Driving with Powershift” chapter.
Limp home:
If a fault is detected at power up the limp home facil-
ity is automatically selected.
Selecting Neutral
At power up, “Neutral and 2nd Gear” are automati-
cally selected regardless of the Powershift lever po-
sition (1). The LED-2 and the N-LED are illuminated
RED, (neutral 2nd), the microprocessor is in a neu-
tral lock state.
If after driving, neutral is selected and the shift lever
stays in neutral for more than 3 seconds the micro-
processor automatically defaults to the neutral lock
state for safety. In neutral an automatic shift routine
takes effect to prevent damage to the transmission
due to overspeeding.
Leaving Neutral
A feature of the Powershift lever is the neutral lock
state, which does not allow forward or reverse direc-
tion drive to be selected. This feature prevents the
machine accidentally moving should the lever be
knocked into forward or reverse. To leave the neutral
lock state, you select drive direction followed by an
upshift by rotating the shift lever.
Selecting Forward
To select forward travel push the lever away from
you and the LED will illuminate green.
Selecting Reverse
To select reverse travel pull the lever towards you
and the reverse LED will illuminate orange.
Upshifting
Upshifting to a desired gear from neutral is achieved
by twisting the handgrip counter clockwise (+) in sin-
gle movements. If held in this position the processor
will advance the shift selection from 2 through to 4 in
1.8 sec intervals.
Downshifting
WARNING
If descending down a steep incline select 2nd and
proceed, upshifting only when safe to do so. You can
not downshift to reduce speed if the machine speed
is above 15 km/h (9 mph).
Direction Changes
Changing driving direction is achieved simply by
shuttling the Powershift lever between forward and
reverse and vice versa which is allowed at any time.
The system response however depends on machine
speed and currently engaged gear. When driving in
1st or 2nd gear direction changes are unrestricted
and are granted immediately.
F1 - R1 F2 - R2
R1 - F1 R2 - F2
Transmission Powershift
In the previous paragraphs shift changes have been
shown as precise movements and twist actions of
the Powershift lever. However the transmission can
change gear automatically in forward or reverse as
described in the following paragraph:
Select forward and 4th gear on the Powershift lever
and with the handbrake released apply pressure to
the foot accelerator. As the engine revs and machine
speed increase the transmission will start from 2nd
gear and change up through 3rd and 4th gears up to
maximum road speed.
When you require to slow down or stop release the
foot accelerator and apply the foot brake, the trans-
mission will automatically downshift through 4th, 3rd
and 2nd gear as the machine speed decreases.
Once stopped apply the handbrake and neutral will
be selected by the microprocessor.
To select drive again, simply twist the handgrip to se-
lect 4th and with the handbrake released apply pres-
sure to the foot accelerator.
Kick Down
The kick down facility (2nd to 1st gear only) on this
transmission increases torque instantly to the driving
wheels and hence pushing power. For example
when the loader is pushing into a pile and more
torque is required at the wheels.
This is achieved by the instant gear change from 2nd
to 1st by the use of the button (1) without the need to
use the twist grip on the Powershift lever.
Transmission Disconnect
The disconnect feature is useful when loading, for
example; when pushing the loader into a pile and you
have sufficient dirt in the bucket press the disconnect
switch which disengages the transmission and al-
lows the full power of the engine to be directed to the
hydraulic oil pump.
Disconnect is available in 1st and 2nd gear.
Speed Ranges
The microprocessor controlling the Powershift trans-
mission is pre-programmed to control the speed at
which the gear changes take place.
This effectively protects the transmission from ex-
cess forces, should gear changes be selected at
higher speeds than is desirable.
Shown in the chart opposite with an 18.4 X 26 R4
tyre fitted is the approximate (within 10%) maximum
speed available and at which speed an automatic
shift takes place in each gear.
(...) = Automatic upshift speed
[...] = Automatic downshift speed
As can be seen when downshifting from 4th gear at
maximum speed 39.5 km/h (24 mph) the microproc-
essor will not allow the downshift to take place until
the speed has lowered to approximately 19.9 km/h
(12 mph).
Refer to the chart for complete upshift and downshift
speed change details.
2.3 LUBRICATION
Daily
Check oil level daily with engine running at idle
(600 rpm) and oil at 82 - 93 °C (179 - 199 °F).
Maintain oil level at full mark.
Normal operating temperature 70 - 120 °C (158 - Filter by-pass valve set at 4.1 - 5 bar (59 - 73 psi) (*).
248 °F) measured at temperature check port to cool-
er. Lube pressure (*) 0.3 - 0.5 bar (4 - 7 psi) at 47 l/min
(12.40 gal/min) pump flow (±1800 rpm).
Maximum allowed transmission temperature 120 °C
(248 °F). Internal leakage (*) 1.5 - 3.0 l/min (0.40 - 0.80 gal/
min) for each clutch.
Transmission regulator pressure (*) - (neutral 2nd Maximum total leakage 6.8 l/min (1.80 gal/min)
speed). (1.8 GPM) (clutch leakage + range + converter leak
at 600 rpm: 16.5 bar (239 psi). + valve leak) without disconnect clutch.
at 2200 rpm: 19.6 - 23.1 bar (284 - 335 psi).
Safety valve: cracking pressure (*) 9,5 - 10,5 bar
Pump flow (*) (138 - 152 psi).
at 2200 rpm in neutral 2nd speed: 64.9 l/min
(17.10 gal/min) minimum. To cooler (converter out) pressure (*) 2 bar (29 psi)
at 2200 rpm in reverse 1st, 2nd, forward 1st, 2nd minimum at 2000 rpm and maximum 5 bar (73 psi)
maximum 3 l/min (0.80 gal/min) less than in neutral at no load governed speed.
2nd.
at 2200 rpm in forward 3rd and 4th: maximum Converter by-pass valve set at 5 - 7 bar (73 -
5 l/min (1.30 gal/min) less than in neutral 2nd. 102 psi) (*).
Clutch pressures (*) at 2200 rpm: (*) All pressures and flows to be measured with oil
18.1 - 21.5 bar (262 - 312 psi) clutch activated. temperature of 82 - 93 °C (179.6 - 199.4 °F).
0 - 0.2 bar (0 - 3 psi) clutch released.
Úîééïè
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Pressure check port
È
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Temperature check port
1. Operator compartment 19. Pressure booster 0 - 5.5 to 0 - 20 bar (0 - 80 to 0 -
2. Pressure gauge 290 psi)
3. Temperature gauge 20. Electronic controlled modulation valve 5.5 to 0 bar
4. Torque converter (80 to 0 psi)
5. Torque converter (pressure difference 4 bar 21. Modulated pressure 0 to 20 bar (0 to 290 psi)
(58 psi)) by-pass valve 22. Clutch pressure 20 bar (290 psi)
6. Cooler 23. Solenoid N/forward
7. Lubrication 24. Solenoid N/reverse
8. Safety valve 10 bar (145 psi) cracking pressure 25. Solenoid high/low
9. Solenoid pressure 5 bar (73 psi) 26. Solenoid 2nd/1st
10. Pressure regulator valve 20 bar (290 psi) 27. Solenoid range modulation
11. By-pass valve pressure difference 4.3 bar (62 psi) 28. Solenoid disconnect
12. Filter 29. Reverse clutch
13. Pump 30. Forward low clutch
14. Air breather 31. Forward high clutch
15. Filter 32. 2nd clutch
16. Oil sump 33. 1st clutch
17. Pressure reducer to 5.5 bar (80 psi) 34. Disconnect clutch
18. Accumulator
SECTION 21 - TRANSMISSION 107
2.7 OPERATION
The transmission and hydraulic torque converter of the power train enacts an important role in transmitting en-
gine power to the driving wheels. In order to properly maintain and service these units it is important to first
understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system.
With the engine running, the transmission charging pump draws oil through the oil suction filter and directs it
through the oil filter and pressure regulating valve.
Across the oil filter is a filter by-pass valve which will open if the pressure difference becomes higher than
4.3 bar (62 psi).
The pressure regulating valve maintains pressure for the control valve and clutches at 20 bar (290 psi).
Excess oil volume is bled off into the converter circuit. A safety valve is fitted between the pressure regulator
and converter.
The valve will open if pressure in this line becomes higher than 10 bar (145 psi).
After entering the converter the oil is directed through the converter blade cavity and exits in the passage be-
tween the turbine shaft and pump drive shaft and flows to the cooler.
After leaving the cooler the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates and cools the transmission bearings and clutches.
The oil then gravity drains back to the transmission sump.
Across the converter and oil cooler is a converter by-pass valve which will open if the pressure difference is
higher than 4 bar (58 psi) (during start up from cold or at high rpm).
108 SECTION 21 - TRANSMISSION
Úîééîí
pressure through tubes and passages to the select- The input or directional clutches
ed clutch shafts.
Oil seals are located on the clutch shafts.
These rings direct the oil through a drilled passage
in the shaft to the desired clutch.
Pressure of the oil forces the piston and discs
against the back up plate.
The discs with splines on the outer diameter clamp-
ing against discs with teeth on the inner diameter en-
ables the drum and hub to be locked together and
allows them to drive as one unit.
When the clutch is released, a return spring will push
the piston back and oil will drain back via the control
valve into the transmission sump.
The T16000 transmission has one reverse clutch
and two forward clutches (forward low and forward
high).
This in combination with the two range clutches re-
sult in the transmission having 4 forward speeds and
2 reverse speeds.
The engagement of the directional clutches is modu-
lated; which means that clutch pressure is built up
gradually.
This will enable the unit to make forward, reverse
shifts while the vehicle is still moving and will allow
smooth engagement of drive.
The modulation is controlled electronically in the
control valve.
SECTION 21 - TRANSMISSION 111
Úîééîê
Úîééîé
a curve from 0 to 20 bar (0 to 290 psi) is available for The transmission controls
the directional clutches.
Between the electronic modulation valve and the
booster is an accumulator to damper any hydraulic vi-
bration.
When forward is selected the electronic modulation
valve and the forward solenoid are activated.
The pilot pressure of the forward solenoid will move
the shift spool so that a forward clutch can be fed with
modulated pressure.
If the high/low solenoid is not activated the forward
high clutch is engaged, if it is activated the forward low
clutch is engaged.
When reverse is selected the electronic modulation
valve and the reverse solenoid are activated, the pilot
pressure of the reverse solenoid will move the shift
spool so that the reverse clutch can be fed with mod-
ulated pressure.
The shift spools from forward and reverse are located
against each other with a return spring in between;
this is to make sure that only one direction can be se-
lected.
Range is selected as follows:
if the range solenoid (2nd/1st) is not activated, regu-
lated pressure is fed through the modulation shift
spool and through the 2nd/1st shift spool to the 2nd
clutch.
If the range solenoid (2nd/1st) is activated, the pilot
pressure will move the shift spool so that 1st clutch is
fed.
The range clutches also have modulation which oper-
ates as follows:
When the range is changed, oil will flow through the
modulation shift spool to the chosen range clutch mo-
mentary until the friction discs are closed against the
dished plate. At that moment the range modulation
solenoid is activated.
SECTION 21 - TRANSMISSION 113
Úîééîç Úîééíð
Úîééíï Úîéïíî
Úîééíí Úîééíì
Úîççèê
Úîççèé
Úîççèè
Úîççèç
Úîçççð
Úîçççï
1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar (62 psi)
7. System pressure test port 20 bar (290 psi)
8. System pressure regulating valve 20 bar (290 psi)
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar (80 psi)
11. 2nd / 1st Solenoid
12. 2nd / 1st shift spool
13. 2nd gear clutch
14. 1st gear clutch
15. Range modulation solenoid
16. Range modulation spool
17. Range modulation restriction
18. 4WD solenoid
19. 4WD shift spool
20. 4WD clutch
21. High / low solenoid
22. High / low shift spool
23. Forward high clutch
24. Forward low clutch
25. Neutral reverse solenoid
26. Neutral reverse shift spool
27. Reverse clutch
28. Neutral forward solenoid
29. Neutral forward shift spool
30. Electronic modulation valve 0-5.5 bar (0-80 psi)
31. Accumulator
32. Pressure booster 0-20 bar (0-290 psi)
SECTION 21 - TRANSMISSION 123
Úîçççî
1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar (62 psi)
7. System pressure test port
8. System pressure regulating valve 20 bar (290 psi)
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar (80 psi)
11. 2nd / 1st Solenoid
12. 2nd / 1st shift spool
13. 2nd gear clutch
14. 1st gear clutch
15. Range modulation solenoid
16. Range modulation spool
17. Range modulation restriction
18. 4WD solenoid
19. 4WD shift spool
20. 4WD clutch
21. High / low solenoid
22. High / low shift spool
23. Forward high clutch
24. Forward low clutch
25. Neutral reverse solenoid
26. Neutral reverse shift spool
27. Reverse clutch
28. Neutral forward solenoid
29. Neutral forward shift spool
30. Electronic modulation valve 0-5.5 bar (0-80 psi)
31. Accumulator
32. Pressure booster 0-20 bar (0-290 psi)
SECTION 21 - TRANSMISSION 125
Úîçççí
1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar (62 psi)
7. System pressure test port 20 bar (290 psi)
8. System pressure regulating valve 20 bar (290 psi)
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar (80 psi)
11. 2nd / 1st Solenoid
12. 2nd / 1st shift spool
13. 2nd gear clutch
14. 1st gear clutch
15. Range modulation solenoid
16. Range modulation spool
17. 4WD solenoid
18. Range modulation restriction
19. 4WD shift spool
20. 4WD clutch
21. High / low solenoid
22. High / low shift spool
23. Forward high clutch
24. Forward low clutch
25. Neutral reverse solenoid
26. Neutral reverse shift spool
27. Reverse clutch
28. Neutral forward solenoid
29. Neutral forward shift spool
30. Electronic modulation valve 0-5.5 bar (0-80 psi)
31. Accumulator
32. Pressure booster 0-20 bar (0-290 psi)
SECTION 21 - TRANSMISSION 127
Úîçççì
Suction Oil
High Pressure Oil
Torque Converter and Lubrication Oil
Return to oil tank
Pilot Pressure
Modulated Pilot Oil
128 SECTION 21 - TRANSMISSION
Úîééíë
Forward low
Forward high
Reverse and 1st
2nd
Disconnect
Input shaft
130 SECTION 21 - TRANSMISSION
REMOVAL
WARNING
Before performing any service or maintenance on the machine ensure the wheels are chocked / blocked to
prevent the machine from moving.
1. Lower the loader to the ground or raise and secure (dependent upon lifting apparatus) and release any
pressure in the system as required. Apply the handbrake and chock the wheels.
2. Switch off engine.
3. Isolate battery.
4. Remove all engine panels.
5. Remove front cast cowling.
6. Drain engine coolant and remove hoses.
IMPORTANT: air conditioning where fitted - Do not disconnect the air conditioning hoses from the compressor
or condenser unless a refrigerant reclaim system is to be used. Engine / Transmission removal from the ma-
chine does not require the system to be discharged.
Remove the condenser from the front radiator and place the condenser to one side of the chassis.
Disconnect the air conditioning compressor attaching hardware and place the compressor to one side of the
chassis.
Disconnect the expansion bottle connections from the radiator.
7. Remove all attaching bolts from radiator.
8. Disconnect transmission cooler pipes.
9. Remove radiator, taking care not to damage the fan or hydraulic oil cooler.
10. Remove air cleaner assembly.
11. Disconnect all electrical connections.
12. Disconnect hydraulic pipe clamps.
13. Disconnect the fuel tank feed and return pipes.
14. Disconnect the foot accelerator cable at the fuel injection pump.
15. Remove the cab mat.
16. Remove the cab floor access panel.
SECTION 21 - TRANSMISSION 131
Úîééíê
Úîééíé
Úîééíç
î
Úîééìð
INSTALLATION
Place a stud in one tang of the flexi plate and as the
transmission is assembled up to the engine guide
the stud through a bolt hole of the flywheel, remove
the stud and refit a bolt.
Refit the attaching bolts which couple the transmis-
sion to engine.
Turn the engine crankshaft using a torque bar to ex-
pose in turn each attaching bolt hole of the flywheel
through the flexi plate and refit all of the bolts.
Hoist the engine / transmission assembly back into
the vehicle and centralize in the machine using a
measure between the chassis and centre line of the
crankshaft pulley. This ensures the engine is cen-
trally positioned before torque up of the engine /
transmission to chassis bolts.
Reconnect all ancillary equipment as previously de-
scribed.
Ensure all attaching hardware is tightened to the
correct torque value as detailed in the specifications.
Ensure after installation that all fluid levels are cor-
rect prior to start up.
Start and run the engine until correct operating tem-
perature is achieved to purge air from cooling sys-
tem.
Stop engine, check for leaks, rectify as required and
recheck fluid levels.
SECTION 21 - TRANSMISSION 133
specified torque.
INPUT SHAFT, TORQUE CONVERTER, PUMP DRIVE, INTERNAL CHARGING PUMP AND DRIVE PLATE
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Úîééìé
SECTION 21 - TRANSMISSION 143
2ND SHAFT
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Úîééìè
146 SECTION 21 - TRANSMISSION
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Úîééìç
PARKING BRAKE
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ê í
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ASSEMBLY INSTRUCTIONS
Úîééëî
3. Teflon seals must be sized prior to assembly, add • Assembly see (6)
some grease to inner and outer diameter of • Clearance:
clutch drum before assembly. min. clearance = 3.66 mm (0.14 in) (for carbon
4. Pump must be filled up with test oil prior to as- plates)
sembly. max. clearance = 6.78 mm (0.26 in) (for car-
5. Pump drive shaft must be installed after torque bon plates)
converter. If clearance is more than 5,66 mm (0.22 in), add
6. Forward low, reverse, 1st, and 2nd clutch: 9 sep- one separator plate upon last separator plate.
arator plates with inner splines. 8 friction plates 9. Installation force of disc spring is 3280 N
(friction material both sides) with outer splines, 2 (737 lbf).
1-side friction plates (friction material 1 side) with 10. Be sure that shielded and sealed bearings are
outer splines. mounted as shown.
Start with one 1-side friction plate, metal against 11. Seals must be pressed in perpendicular upon
piston, then alternately separator and friction shaft axis from bearing side. Except lower rear
plate. output.
End with a 1-side friction plate, metal side against 12. Plug to be screwed in and torqued but without
end plate or disc spring. Loctite.
Be sure disc spring is mounted as shown. 13. First clutch springs concave side of first disc
• Clearance: forward low and reverse: spring to be placed against clutch piston wear
min. clearance = 2.79 mm (0.11 in) (for carbon sleeve.
plates) Remaining 10 springs to be stacked alternately
max. clearance = 5.21 mm (0.20 in) (for car- reversed as shown.
bon plates) 14. Shipping strap: only used during shipment of the
If clearance is more than 4.79 mm (0.18 in), add individual transmission.
one separator plate upon last separator plate.
• Clearance: First and second: NOTE: check if safety valve and valve block are test-
min. clearance = 2.54 mm (0.10 in) ed before assembly.
max. clearance = 5.41 mm (0.21 in)
If clearance is more than 4.54 mm (0.17 in), add 15. Heat gears up to 150 °C (302 °F) before assem-
one separator plate upon last separator plate. bling.
7. • Forward high clutch: 4 separator plates, 3 fric- 16. Parking brake.
tion plates and two 1-side friction plates. 17. Mounting: tighten locking nuts with 0.25 to
• Assembly see (6) 1.25 mm (0.009 to 0.049 in) clearance between
• Clearance: nuts and sleeves.
min. clearance = 1.24 mm (0.05 in) (for carbon Adjustment: loosen the (2) adjustment locking
plates) nuts (1 and 2). Put lever in correct position.
max. clearance = 2.76 mm (0.11 in) (for car- Tighten inner adjustment nut (2) with 11 Nm
bon plates) (8 lbf·ft). Back off inner adjustment nut (2).
8. • Disconnect clutch: 12 separator plates, 11 fric- Tighten outer locking nut (1) against inner adjust-
tion plates and two 1-side friction plates. ment nut (2). Clearance must be from 0.8 to
1.1 mm (0.03 to 0.04 in).
Úîééëí
154 SECTION 21 - TRANSMISSION
TRANSMISSION DISASSEMBLY
Remove the oil filter.
Remove the output shaft, the 2nd shaft and the oil
baffle at the same time.
166 SECTION 21 - TRANSMISSION
Install the piston inner seal and install the clutch pis-
ton in clutch drum; use caution as not to damage the
sealing rings.
WARNING
Be sure that bearing shield is on the outside.
SECTION 21 - TRANSMISSION 207
WARNING
Be sure that bearing shield is on the outside.
Turn the shaft and install the input shaft forward high
gear retaining ring.
Install the forward low shaft and the high shaft into
the housing. Using caution as not to damage any
sealing rings.
Warm the forward low and the high shaft rear bear-
ing to 120 °C (248 °F), install the bearing.
TRANSMISSION ASSEMBLY
Remove the lower output bore plug. Position the
transmission case on the converter housing (using
lifting bracket).
Position the lower output bore plug and the tap bore
plug into the place.
254 SECTION 21 - TRANSMISSION
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îï
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Úîééëð
Loosen two adjustment locking nuts (4 and 5) enough to slide each torque plate (16 and 18) away from disc
far enough to provide clearance to remove old pads assembly and install new ones. (It may be necessary to
remove one or both nuts).
Collapse pad retraction spring (21) and remove from brake head assembly.
Slide torque plates (16 and 18) away from disc, move pads assembly (17) out of pockets, and remove from
the brake head assembly from the side.
Install new pads assembly (17) in each torque plate (16 and 18).
Install pad retention spring (21) into brake head assembly. Be sure spring’s “feet” are positioned properly in
holes in both pads assembly (17).
Tighten inner adjusting nut (5) until firm contact is made with the disc by the pads. Torque to 11 Nm (8 lbf·ft)
make certain lever is in proper operating position for application.
Back off inner adjusting nut (5) and check that disc is free to move (total clearance 0.8 - 1.1 mm (0.6 -
0.8 lbf·ft)).
Tighten outer locking nut (4) against inner adjusting nut to lock adjustment bolt in place. Torque to 61 - 75 Nm
(45 - 55 lbf·ft).
SECTION 21 - TRANSMISSION 261
STALL TEST
Use a stall test to identify transmission, converter, or
engine problems.
HYDRAULIC CHECK
Also, before checking the transmission clutches,
torque converter, charging pump, and hydraulic cir-
cuit for pressure and rate of oil flow, it is important to
make the following transmission fluid check:
Check oil level in the transmission. The transmis-
sion fluid must be at the correct (full level). All clutch-
es and the converter and its fluid circuit lines must
be fully charged (filled) at all times. See note below.
LED display.
INDICATION OF FAULTS
In case a fault is present during normal operation
and is detected by the microprocessor, both the T-
LED and N-LED may be blinking in some way as
Ú Ò Î Ì Ò
shown in the table below.
FAULT GROUP
The faults are displayed using 2 LEDs on the 8 LED
display. Faults are displayed as 3 subgroups - Ú Ò Î Ì Ò
Group A:
ß Þ
Within each group several faults are possible. The Úîèíëç
Úîèíêð
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
age.
YES
Check speed sensor has it failed
NO
YES Úîèíéï
Replace sensor
If static is not 0.6 - 0.8 V
or 1.3 - 1.5 V
Úîèíéð
270 SECTION 21 - TRANSMISSION
Over voltage Ú Ò Î Ì Ò
Even power supply levels up to 30 V will not damage Þ´·²µ- Í´±©»®
Þ´·²µ
circuit components.
Above a power supply of 17 Vdc: Þ´·²µ-
Þ´·²µ-
Group Fault 1 - Fault code 7.
ï î í ì ë ê é è
NOTE: the speed sensor circuit will not operate
when an over voltage is present. ï î í ì
Úîèíêî
õ îì ÊÜÝ Úîèíêí
ï î í ì
ó è ÊÜÝ Úîèíêì
SECTION 21 - TRANSMISSION 271
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
Úîèíêë
Gear Shifts
low/high solenoid:
inactive = forward high is selected
active = forward low is selected
During the output test LEDs 1234567 one by one are used and by
colour identifies the possible component at fault. Green= No fault
Red = short circuit NO
found
Yellow = open circuit or short to battery plus
YES YES
Output test
274 SECTION 21 - TRANSMISSION
COLOUR STATUS
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)
Úìîèè
SECTION 21 - TRANSMISSION 275
Key start ON
YES
T-LED Blinks
NO Safety critical output
N-LED Blinks Faster
YES
Replace the
Powershift lever unit
Úîèíéî
276 SECTION 21 - TRANSMISSION
Key start ON
YES
T-LED Blinks
NO Non critical output
N-LED Blinks in phase
fault
YES
Replace the
Powershift lever unit
ë
Úîèíéí
278 SECTION 21 - TRANSMISSION
Úìîçê
SECTION 21 - TRANSMISSION 279
Key start ON
YES
T-LED Blinks
NO No fault
N-LED Blinks in phase
YES
NO
Replace the
Powershift lever unit
Úîèíéì
280 SECTION 21 - TRANSMISSION
Internal faults Ú Ò Î Ì Ò
Þ´·²µ- Í´±©»®
Þ´·²µ
At power up a series of integrity checks is done.
If a fault is detected: Þ´·²µ-
Þ´·²µ-
and the fault prevent operation as a transmission
ï î í ì ë ê é è
controller: the microprocessor locks itself in a reset
state.
and controlling the transmission is still possible: the ï î í ì
microprocessor reverts to limp home mode.
Úîèíêç
Limp Home mode
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks slower
YES
F12
Key start ON
YES
Perform input test and
analyse faults if
possible fault found
NO
F13
Key start ON
YES
Perform output test and
check range modulation
Repair or LED 7 (wire E08)
replace YES Green = Okay
Orange = Open circuit
Red = Short circuit
SECTION 21 - TRANSMISSION 283
Úïïèíì
Úïïèíë
NOTE:
B110
B115
TYPE
Front steering axle, model 26.16
Úîéîðí
Úîéîðì
í ë ï ì ë í
ë î ë
ë ì ë
Úîéîðë
DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
6 SECTION 25 - FRONT AXLES
Before draining the oil from axle housing, use the oil
breather (2) to release possible internal pressure. î
WARNING
Risk of violent oil ejection.
Úîéîðê
To drain the oil remove the level plug (1) and the
drain plug (4).
WARNING
Risk of violent oil ejection.
ï ì
Úîéîðé
ï
Úîéîðè
Úîéîðç
SECTION 25 - FRONT AXLES 7
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. í
Tighten the plug (3) to the requested torque.
Úîéîïð
8 SECTION 25 - FRONT AXLES
TIGHTENING TORQUES
ïêë Ò³
çë Ò³ ïîð Ò³ è Ò³ ïëð Ò³ çë Ò³ ïí Ò³
ïîð Ò³
îêê Ò³ ëé Ò³
ïêë Ò³
ïð Ò³ è Ò³ èì Ò³ êð Ò³ è Ò³ èì Ò³
Úîéîïï
SECTION 25 - FRONT AXLES 9
îï
ïè
îð
ïë ïé
ïê ïç
ïì
ïî
ç
ê è
í ë ïí
ïï
ïð
é
ì
î
ï
Úîéîïî
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1) from the pinion shaft end (14).
ïì
ï î
Úîéîïí
10 SECTION 25 - FRONT AXLES
ì
Úîéîïì
Remove the O-ring (6) from the bush (8) in rear sup-
port (5).
ë
é
Úîéîïë
ë è
ì
Úîéîïê
Úîéîïé
SECTION 25 - FRONT AXLES 11
ïï
Úîéîïè
Remove the seal rings (12) and (13) from the cover
(11). ïí
NOTE: destructive operation for the seal rings. ïî
ïï
Úîéîïç
Úîéîîð
ïç
Úîéîîï
12 SECTION 25 - FRONT AXLES
ïç
Úîéîîî
ïé
Úîéîîí
Assembly
Úîéîîð
ïï
Úîéîïç
SECTION 25 - FRONT AXLES 13
ïï
Úîéîïè
Úîéîïé
WARNING
Align the bush hole with the bolt (4) hole.
Úîéîïê
ë
é
Úîéîïë
14 SECTION 25 - FRONT AXLES
WARNING
Do not damage the O-ring when inserting the rear
support on the central body. ë
ì
Úîéîïì
ïì
ï î
Úîéîïí
Úîéîîí
îð
Úîéîîì
SECTION 25 - FRONT AXLES 15
ïç
Úîéîîë
ïç
Úîéîîê
16 SECTION 25 - FRONT AXLES
STEERING CYLINDER
ïç
ïî
ïï
îï ïð
ïé
îð
ïë
ïè
ïê é
ïì è ç
ê
ïí
ë
ì
í
î ï
Úîéîîé
Disassembly
WARNING
Don’t beat on the threaded pin end of the tie rod (3). í
Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the ïï
conditions.
Unscrew the fastening screws (6) and take the
ê
steering cylinder (7) out of its housing, if necessary ïî
ì
use a rubber hammer.
Remove only parts that need to be overhauled and/ ïð
or replaced. é
í ë
Úîéîîç
Assembly
ïê
ïì îð
ïí
ïè
ïé
ïë
Úîéîíï
ïé
ïë
ïç
Úîéîíî
18 SECTION 25 - FRONT AXLES
Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod ïï
(17), then tighten to the requested torque.
ê
ïî
ì
ïð
é
ïé
í ë
Úîéîíí
Úîéîíì
è
Úîéîíë
Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). í
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
ï
Úîéîíê
SECTION 25 - FRONT AXLES 19
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been ïï ïî
carried out.
Úîéîíè
20 SECTION 25 - FRONT AXLES
ïð
ç
è
é
ê
ë
ì
î
ï
í
Úîéîíç
Disassembly
Úîéîìð
SECTION 25 - FRONT AXLES 21
ï
Úîéîìï
Úîéîìî
Assembly
Úîéîìê
ï
Úîéîìï
Úîéîìé
SECTION 25 - FRONT AXLES 23
WHEEL HUB
îè
ïç
îé
ïè
îì
ïì
îî
ïí
îê
ïî
îë
îí
ïï
ïð
ç
è ïë
é îï
ì ïê îð
í ïé
î ë ê
Úîéîìè
Disassembly
WARNING
Do not damage the double U-Joint.
ïì
Úîéîìç
24 SECTION 25 - FRONT AXLES
Úîéîëð
Úîéîëï
Úîéîëí
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). è
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- ê
cial tool 380002223.
é
Úîéîëî
SECTION 25 - FRONT AXLES 25
Úîéîëì
Úîéîëë
ïì
Úîéîëé
26 SECTION 25 - FRONT AXLES
Úîéîëè
ïì îí
Úîéîëç
Assembly
îð îï
Úîéîêð
Insert the bush (22) into the swivel housing (14) with
the special tool 380002660 and a hammer or a
îí ïì
press.
Assemble the seal ring (23) on the swivel housing
îî
(14) with the special tool 380002661 and a hammer.
Grease carefully the seal ring (23).
Úîéîêï
SECTION 25 - FRONT AXLES 27
Úîéîëè
Úîéîêî
Úîéîëé
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
ïé ïç
ïê ïè
Úîéîêí
28 SECTION 25 - FRONT AXLES
ïï ïï
NOTE: do not lubricate the seal ring (13).
Úîéîêì
Úîéîêë
Úîéîêê
Úîéîêé
SECTION 25 - FRONT AXLES 29
Úîéîêè
Úîéîêç
Úîéîéð
Úîéîéï
30 SECTION 25 - FRONT AXLES
Slide the thrust washers (2) and (3) onto the double
U-Joint shaft end. í î
Insert the lock ring (1) at the end of the splined hub
and push it into its seat.
Úîéîëð
SECTION 25 - FRONT AXLES 31
DOUBLE U-JOINTS
ï î
ì
ë
ê
Úîéîéî
Disassembly
ï
ê
Úîéîéí
32 SECTION 25 - FRONT AXLES
Remove the seal rings (5) from the axle beam (1).
WARNING
Be careful not to damage the bush seat.
ë
Úîéîéì
Remove the upper king pin bush (2) and the ball
bearing cup (3) from the king pin seats using a suit-
able extractor only if the wear conditions require
this.
Úîéîéë
Assembly
Cool the upper king pin bush (2) and the ball bearing
cup (3) at a temperature lower than -100 °C (-148 °F)
with liquid nitrogen.
î
WARNING
Wear safety gloves.
Assemble the bush (4) on the axle beam (1) with the
special tool 380002665 and a hammer.
Assemble the seal ring (5) on the axle beam with the
ï
special tool 380002666 and a hammer.
ì
NOTE: grease carefully the seal rings. ë
Úîéîéé
SECTION 25 - FRONT AXLES 33
WARNING ë
Positioning the seal ring (5) as in figure.
Úîéîéè
WARNING
Be careful not to damage the seal ring.
ï
ê
Úîéîéí
34 SECTION 25 - FRONT AXLES
DIFFERENTIAL SUPPORT
ç è ïí
ïî
ïï
ïð
é
ê
ïì
è
ë
ì
î í
ï
Úîéîèî
Disassembly
è è
Úîéîèì
Úîéîèë
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
Úîéîèê
ïï
ïð
Úîéîèé
36 SECTION 25 - FRONT AXLES
Úîéîèè
Assembly
WARNING
Do not invert the bearings if they are not replaced.
ì
ê
ë
Úîéîèç
WARNING
Check the right side of the bevel crown assembly.
Úîéîçð
ïð
Úîéîçï
SECTION 25 - FRONT AXLES 37
Úîéîçî
Úîéîçí
Úîéîçë
38 SECTION 25 - FRONT AXLES
Úîéîçí
WARNING
All preloadings must be measured without seal ring.
Úîéîçè
ïî
ïí
Úîéîçç
Úîéíðð
Úîéíðï
40 SECTION 25 - FRONT AXLES
Úîéíðî
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
ï
Úîéíðì
SECTION 25 - FRONT AXLES 41
DIFFERENTIAL GROUP
Disassembly
ïî
Úîéíðê
42 SECTION 25 - FRONT AXLES
Úîéíðé
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîéíðè
ïï
Úîéíðç
Úîéíïð
SECTION 25 - FRONT AXLES 43
Assembly
Úîéíïð
Úîéíïì
44 SECTION 25 - FRONT AXLES
ï
Úîéíïê
Úîéíïë
ïî
Úîéíïé
Úîéíïè
SECTION 25 - FRONT AXLES 45
PINION GROUP
Disassembly
ïð
Úîéíîð
46 SECTION 25 - FRONT AXLES
ç
ïð
Úîéíîï
WARNING
Take care not to lower the bevel pinion (1). ë
ï
Collect the washers (4) and (6), the collapsible
spacer (5) and the bearing (8).
ê
ì
Úîéíîî
è
Úîéíîê
Úîéíîì
SECTION 25 - FRONT AXLES 47
WARNING
The ring nut (10) and the collapsible spacer (5) must ë
be replaced when reassembling the unit.
ïð
Úîéíîë
Assembly
è
Úîéíîê
Úîéíîé
ïð
Úîéíîè
48 SECTION 25 - FRONT AXLES
Úîéíîç
Úîéííð
S = X-V mm
Ê
Úîéííï
Úîéííî
SECTION 25 - FRONT AXLES 49
ïð
Úîéíîè
Úîéííì
Úîéííë
Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
ç
ïð
Úîéíîï
50 SECTION 25 - FRONT AXLES
WARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
ïð
P = 9.2÷13.7 daN
(P = 20.7÷30.8 lbf)
WARNING
Úîéííé
All preloadings must be measured without the seal
ring.
Úîéííè
SECTION 25 - FRONT AXLES 51
ïï
ï î í ïï
í î ï
ë ë
ì ì
Úîéííç
Toe-in
WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
ëðð ³³ ëðð ³³
Úîéíìð
52 SECTION 25 - FRONT AXLES
Úîéíìï
Ó óðë
Úîéíìî
Úîéíìí
SECTION 25 - FRONT AXLES 53
Úîéíìì
Úîéíìë
Úîéíìê
ë ì
Úîéíìé
54 SECTION 25 - FRONT AXLES
Úîéíìè
SECTION 25 - FRONT AXLES 55
PROBLEM CAUSE
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
10. Incorrect adjustment of the bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm (0.004 in)
thickness lower than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
58 SECTION 25 - FRONT AXLES
TYPE
Front steering axle, model 26.28
Úîéíéè
ï ì
í ë ë í
ë î ë
ë ë
Úîéíéç
DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
60 SECTION 25 - FRONT AXLES
WARNING
Risk of violent oil ejection.
Úîéîðê
To drain the oil remove the level plug (1) and the
drain plug (4).
WARNING
Risk of violent oil ejection.
ï ì
Úîéîðé
ï
Úîéîðè
Úîéîðç
SECTION 25 - FRONT AXLES 61
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. í
Tighten the plug (3) to the requested torque.
Úîéîïð
62 SECTION 25 - FRONT AXLES
îï
ïè
îî
ïé
ïë ïê
ïç
îí
é
ê
è
ë
ïï
ï ïì
í ïð
ì
ç
ïî
ïí
î Úîéíèð
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1).
ï
í
î
Úîéíèï
SECTION 25 - FRONT AXLES 63
ïí
Úîéíèî
ïî
ïï
Úîéíèí
ì
Úîéíèì
ë
Úîéíèë
64 SECTION 25 - FRONT AXLES
è
ë
ì
ç
Úîéíèê
Úîéîïé
ïð
Úîéíèé
ïç
Úîéíèè
SECTION 25 - FRONT AXLES 65
îð
ïç
ïè
îí
îî
Úîéíèç
Remove the bush (17) and the washer (16) from the
axle housing (15) only if necessary. ïé
ïë
NOTE: it is advisable to heat the bush (17) to make
easy this operation; this is a destructive operation
for the bush.
ïê
Úîéíçð
Assembly
ïð
Úîéíèé
Úîéîïé
66 SECTION 25 - FRONT AXLES
WARNING
Align the bush hole with the bolt (4) hole.
Úîéîïê
ë
é
Úîéîïë
WARNING
Do not damage the O-ring when inserting the rear ë
support on the central body.
ç
Úîéíçï
Úîéíçð
SECTION 25 - FRONT AXLES 67
îð
Úîéîîì
WARNING
îð
Align the bush hole with the bolt (19) hole. ïç
ïè
Mount the bolt (19).
îî
Assemble O-ring (22).
Úîéíçí
îí
Úîéíçì
ïî
ïï
Úîéíèí
68 SECTION 25 - FRONT AXLES
ïí
Úîéíèî
ï
í
î
Úîéíèï
SECTION 25 - FRONT AXLES 69
STEERING CYLINDER
îì
îí
îî
ïð
îï
ç
ïí îð
è
ïç
ïì ïè
é
ê
ë
ì
í
ïé ïî
ïê ïï
ïë
ï
Úîéíçê
Disassembly
WARNING
Don’t beat on the threaded pin end of the tie rod (3). í
Remove the tie rods (3) and (10) by loosing the nuts
(4) and (9) with a suitable wrench, then check the ïí
ïí
conditions.
Unscrew the fastening screws (13) and take the ïð
ïì
steering cylinder (7). ç
Remove only parts that need to be overhauled and/ è
ïë
or replaced. é
ê
ë
ì
í
Úîéíçé
ïç
ïè Úîéíçè
Assembly
îì
ïé îî
ïê îï
îð
ïç
ïè
Úîéíçî
îî
îð
ïè
Úîéíçç
SECTION 25 - FRONT AXLES 71
Assemble the tie rods (3) and (8), the ball joints (3)
and (10), the nuts (4) and (9) to the ends of the rod,
then tighten with a dynamometric wrench to the re-
quested torque. ïð
ç
è
é
ê
ë
ì
í
Úîéìðð
ïï
Úîéìðî
Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). í
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
ï
Úîéîíê
72 SECTION 25 - FRONT AXLES
Screw the locknuts (4) and (9) of the tie rods (3) and
(10) only when the toe-in adjustment has been car- ì ç í ïð
ried out.
Úîçëîê
SECTION 25 - FRONT AXLES 73
ïï
ç
ïð
è
é
ê
ë
ï
í
î
Úîéìðì
Disassembly
Úîéîìð
74 SECTION 25 - FRONT AXLES
ï
Úîéîìï
Úîéìðë
Assembly
Úîéìðë
Úîéìðé
Úîéìðè
76 SECTION 25 - FRONT AXLES
WHEEL HUB
ïç
îê
ïè
îì
îé
ïì
îî
ïí
ïî
îë
ïï îí
ïð
ç
è ïë
é îï
ì ïê îð
í ïé
î ë ê
Úîéìðç
Disassembly
WARNING
Do not damage the double U-Joint.
ïì
Úîéìïð
SECTION 25 - FRONT AXLES 77
Úîéîëð
Úîéîëï
Úîéîëí
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). è
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- ê
cial tool 380002667.
é
Úîéîëî
78 SECTION 25 - FRONT AXLES
Úîéîëì
Úîéìïî
ïì
Úîéîëé
SECTION 25 - FRONT AXLES 79
îê
îë
Úîéìïí
Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.
ïì îí
Úîéîëç
Assembly
îð îï
Úîéîêð
Úîéîêï
80 SECTION 25 - FRONT AXLES
Úîéìïì
Úîéîëé
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
ïé ïç
ïê ïè
Úîéîêí
Úîéëîë
SECTION 25 - FRONT AXLES 81
Úîéîêë
Úîéîêê
Úîéîêé
Úîéîêè
82 SECTION 25 - FRONT AXLES
Úîéîêç
ïì
Úîéìïð
í î ï
Úîéìïê
SECTION 25 - FRONT AXLES 83
DOUBLE U-JOINTS
ï
î
í
ì
Úîéìïé
Disassembly
ï
ì
Úîéìïè
84 SECTION 25 - FRONT AXLES
Remove the seal rings (3) from the axle beam (1).
ï
NOTE: destructive operation for the seal rings (3). î
í
Remove the bush (2) from the axle beam (1) only if
the wear conditions require this.
WARNING
Be careful not to damage the bush seat.
í
Úîéìïç
Assembly
Assemble the bush (2) on the axle beam (1) with the
special tool 380002226 and a hammer.
Assemble the seal ring (3) on the axle beam with the
ï
special tool 380002670 and a hammer.
î
NOTE: grease carefully the seal rings. í
Úîéìîð
Úîéìîï
WARNING
Be careful not to damage the seal ring.
ï
ê
Úîéîéí
SECTION 25 - FRONT AXLES 85
ç è ïí
ïî
ïï
ïð
é
ê
ïì
è
ë
ì
î í
ï
Úîéìïï
Disassembly
WARNING
Support the differential support with a rope or other
appropriate means.
î
ïì
ï
Úîéëðï
86 SECTION 25 - FRONT AXLES
è
è
Úîéíçë
Úîéìîî
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
Úîéìîí
ïð
Úîéìîì
SECTION 25 - FRONT AXLES 87
Úîéìîë
Assembly
WARNING
Do not invert the bearings if they are not replaced.
ì
ê
ë
Úîéîèç
WARNING
Check the right side of the bevel crown assembly.
Úîéìîé
ïð
Úîéìîè
88 SECTION 25 - FRONT AXLES
Úîéìîç
Úîéîçí
Úîéîçë
SECTION 25 - FRONT AXLES 89
Úîéìíï
WARNING
All preloadings must be measured without seal ring.
Úîéîçè
ïî
ïï
Úîéìíì
ïì
Úîéìíë
î
ïì
ï
Úîéëðï
SECTION 25 - FRONT AXLES 91
Úîéíðî
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
ï
Úîéíðì
92 SECTION 25 - FRONT AXLES
è
ï
ïï
ïð
ç
ïí
ïî
é
ê
è
é
ê
ë
ì
í
î
Úîéìíé
Disassembly
ïð
Úîéìíè
SECTION 25 - FRONT AXLES 93
Úîéíðé
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîéíðè
ïï
Úîéíðç
Úîéìíç
94 SECTION 25 - FRONT AXLES
Úîéììð
ê ê
é é
Úîéììï
ïí
Úîéììî
Assembly
WARNING
Remove rests of dope.
Úîéììí
SECTION 25 - FRONT AXLES 95
ïî
Úîéììì
ïí
Úîéììî
ê ê
é é
Úîéììï
Úîéììð
96 SECTION 25 - FRONT AXLES
Úîéìíç
Úîéíïì
ï
Úîéíïê
Úîéíïë
SECTION 25 - FRONT AXLES 97
ïð
Úîçðïð
Úîéíïè
98 SECTION 25 - FRONT AXLES
ïì
ïð
ïí
è
ïî
ç
ë
ï
ì
ê
ïï
ïð
è
ç
é
ê
ë
ì
í
î
Úîéììè
Disassembly
ïí
Úîéììç
SECTION 25 - FRONT AXLES 99
Úîéíðé
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîéììê
ïì
Úîéìëð
Úîéìëï
100 SECTION 25 - FRONT AXLES
Úîéìëî
Úîéìëí
ç ç
è è
ïð
Úîéìëì
Úîéìëë
SECTION 25 - FRONT AXLES 101
ì ë
Úîéìëê
Assembly
WARNING
Remove rests of dope.
Úîéìëé
ïï
Úîéìëè
ì ë
Úîéìëê
102 SECTION 25 - FRONT AXLES
Úîéìëë
ç ç
è è
ïð
Úîéìëì
Úîéìëç
Úîéìëî
SECTION 25 - FRONT AXLES 103
Úîéìëï
ïì
Úîçíîð
ï
Úîéíïê
Úîéíïë
104 SECTION 25 - FRONT AXLES
ïí
Úîéìêð
Úîéíïè
SECTION 25 - FRONT AXLES 105
PINION GROUP
ï
î
í
ì
ë
ê
é
è
ç
ïð
Úîéìêï
Disassembly
ïð
Úîéìêî
106 SECTION 25 - FRONT AXLES
ç
ïð
Úîéìêí
WARNING
Take care not to lower the bevel pinion (1).
ë
Collect the washers (4) and (6), the collapsible ï
spacer (5) and the bearing (8).
ê
ì
Úîèïðê
è
Úîèïðé
Úîéíîì
SECTION 25 - FRONT AXLES 107
WARNING
The ring nut (10) and the collapsible spacer (5) must ë
be replaced when reassembling the unit.
ïð
Úîéíîë
Assembly
è
Úîèïðé
Úîèïðè
í
è
ïð
Úîèïðç
108 SECTION 25 - FRONT AXLES
Úîèïïð
Úîèïïï
S = X-V mm
Ê
Úîéííï
Úîéííî
SECTION 25 - FRONT AXLES 109
í
è
ïð
Úîèïðç
Úîéííì
ê
ì
Úîèïïî
Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
ç
ïð
Úîéìêí
110 SECTION 25 - FRONT AXLES
WARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
ïð
P = 9.2÷13.7 daN
(P = 20.7÷30.8 lbf)
WARNING
Úîéìíî
All preloadings must be measured without the seal
ring.
Úîéííè
SECTION 25 - FRONT AXLES 111
ï î í í î ï
ë ë
ì ì
Úîèïïí
Toe-in
WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
ëðð ³³ ëðð ³³
Úîéíìð
112 SECTION 25 - FRONT AXLES
Úîéíìï
Ó óðë
Úîéíìî
Úîéíìí
SECTION 25 - FRONT AXLES 113
Úîéíìì
Úîéíìë
Úîéíìê
ë ì
Úîéíìé
114 SECTION 25 - FRONT AXLES
Úîéíìè
SECTION 25 - FRONT AXLES 115
PROBLEM CAUSE
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all com-
ponents. Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
10. Incorrect adjustment of the bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm (0.004 in)
thickness lower than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
118 SECTION 25 - FRONT AXLES
3. SPECIAL TOOLS
ELECTRO-HYDRAULIC DIFFERENTIAL
LOCKING OPERATION (only Powershift)
WARNING
The differential lock fitted to this machine is operated
by oil pressure and controlled by an electrically op-
erated solenoid. The solenoid is energized when the
switch (1) mounted in the front console is de-
pressed.
WARNING
Never use the differential lock at speeds above 8
km/h (5 mph) or when turning the machine. When
engaged the lock will prevent the machine turning
and personal injury could result.
Úîçëìç
6 SECTION 27 - REAR AXLE
Úîçëëð
LUBRICATION
Oil capacity: 21.2 litres
Oil specification: Ambra Mastertran NH 410 C + AoA Axle oil additive (0.8 litres)
SECTION 27 - REAR AXLE 7
TIGHTENING TORQUES
î ïï í ì
è ç ïð
Úîçëëï
1. Screw of half shaft: 554÷626 Nm (408÷461 lbf·ft) 6. Screw of block: 57÷76 Nm (42÷56 lbf·ft)
2. Screw of axle assy - rear RH or LH: 190÷231 Nm 7. Screw of baffle oil: 43÷51 Nm (31÷37 lbf·ft)
(140÷170 lbf·ft) 8. Plug: 27÷34 Nm (20÷25 lbf·ft)
3. Screw of front flange: 136÷170 Nm (100÷125 lbf·ft) 9. Screw: 32÷41 Nm (23÷30 lbf·ft)
4. Screw to fixed rear axle to the chassis: 800 Nm 10. Screw of housing rear brake: 204÷245 Nm
(590 lbf·ft) (150÷180 lbf·ft)
5. Screw: 11÷14 Nm (8÷10 lbf·ft) 11. Right nut: 406 Nm (299 lbf·ft)
8 SECTION 27 - REAR AXLE
DIFFERENTIAL REMOVAL
î
Úîçëëî
DIFFERENTIAL DISASSEMBLY
PINION REMOVAL
Remove the lock pin (2) to unlock the ring nut (1).
SECTION 27 - REAR AXLE 13
Remove the ring nut (1), the washer (3) and the gas-
ket (4).
Remove the coupling (5).
Remove the snap ring (14) from the axle inner cen-
tral body.
Using an rubber hammer, take out the pinion (12). ïî
ïì
Úîçëëí
Powershuttle
ïì
ïé
ïï
ïð
ç ïê
è î
é í
ê ì
ë ë
ì ê
í ïë ÎØ
î ïí
ï ïî
ÔØ
Powershift
ïè
ïç ï
îð î
ïë í
ê ì
ë ê
ì ë
í é ÎØ
î ïî
ïê ïí
ÔØ
Úîçëëë
ïé
ïî ïí
è
Úîçëëê
Úîçëëé
í
Úîçëëè
22 SECTION 27 - REAR AXLE
VALUE “T”
SHIMS
mm (in)
0.034 ÷ 0.039 (0.00134 ÷ 0.00154) 81803515
0.040 ÷ 0.045 (0.00157 ÷ 0.00177) 81803516
Ì
0.046 ÷ 0.051 (0.00181 ÷ 0.00201) 81803517 Úîçëëç
Measuring of range between the face thrust block and the back face of differential
VALUE “S”
SHIMS
mm (in)
0.80 ÷ 0.89 87346232 + 87346228
(0.0315 ÷ 0.0350)
0.90 ÷ 0.99 87346232 + 87346231
Úîçëêð
(0.0354 ÷ 0.0389)
1.00 ÷ 1.10 87346232 + 87346427
(0.0393 ÷ 0.0433)
Úîçêíé
Úîçêíè
26 SECTION 27 - REAR AXLE
Úîçêíç
Úîçêìð
Úîèððí
í ë é ï ê ê ï é î
ì
Úîèððì
DESCRIPTION POSITION
Differential oil filling and level plug 1
Oil breather 2
Fill / drain and level plug of epicyclic reduction gear oil 3
Differential oil drain plug 4
Greasing points 5
Brake bleed plug 6
Service brake oil port 7
30 SECTION 27 - REAR AXLE
Úîèððë
ì ï
Úîèððê
Úîèððé
Úîèððè
SECTION 27 - REAR AXLE 31
ê
Úîèððç
32 SECTION 27 - REAR AXLE
FRONT FLANGE
é
ê
ë
ì
ï î í
Úîèðïð
Disassembly
Úîèðïï
SECTION 27 - REAR AXLE 33
Úîèðïî
Remove the seal (3), the O-ring (4), the gasket (5),
the O-ring (6) and the washer.
ë
ì
í
é
ê
Úîçððç
Assembly
é
ê
Úîçíîî
Úîçíîí
34 SECTION 27 - REAR AXLE
ì
í
Úîçíîì
Úîèðïî
Úîèðïï
SECTION 27 - REAR AXLE 35
STEERING CYLINDER
ì
ë
é
í ïð
ïï
ïî
î
ê
è ïí
ç
ïì
ïë
ïê
ïé
ïè
ïç
îð
îï
îî
îí
îì
Úîèðïí
Disassembly
WARNING
Don’t beat on the threaded pin end of the tie rod (3). í
Remove the tie rods (3) and (13) by loosing the nuts
(4) and (12) with a suitable wrench, then check the ì
conditions. ë
é
Unscrew the fastening screws (6) and (9) and take ïð
the steering cylinder (7) out of its housing, if neces- ïï
ïî
sary use a rubber hammer.
Remove only parts that need to be overhauled and/
or replaced.
í ê è ç ïí
Assembly
ïé
ïç
îî
îí
îì
Úîèðïê
Assemble the tie rods (3) and (13), the ball joints (5)
and (11), the nuts (4) and (12) to the ends of the rod, ì
then tighten with a dynamometric wrench to the re- ë
é
quested torque. ïð
ïï
ïî
ïí
SECTION 27 - REAR AXLE 37
ïì
Úîèðîð
Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). í
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
ï
Úîéîíê
38 SECTION 27 - REAR AXLE
ïï
ç
ïð
è
é
ê
ë
ï
í
î
Úîéìðì
Disassembly
Úîéîìð
SECTION 27 - REAR AXLE 39
Úîèðìì
Úîéìðë
Úîèðîï
Úîèðîî
40 SECTION 27 - REAR AXLE
Úîèðîí
Assembly
Úîèðîì
Úîèðîë
Úîèðîê
SECTION 27 - REAR AXLE 41
Úîéìðë
Úîèðìì
Úîéìðè
42 SECTION 27 - REAR AXLE
WHEEL HUB
Disassembly
WARNING
Do not damage the double U-Joint.
ïì
Úîéìïð
SECTION 27 - REAR AXLE 43
Úîéîëð
Úîéîëï
Úîéîëí
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). è
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- ê
cial tool 380002667.
é
Úîéîëî
44 SECTION 27 - REAR AXLE
Úîéîëì
Úîéìïî
ïì
Úîéîëé
SECTION 27 - REAR AXLE 45
îè
îí
Úîèðìê
Turn the swivel housing and take the bush (26) out,
using a suitable drift and a hammer.
ïì îí
Úîéîëç
Assembly
îð îï
Úîéîêð
Force the bush (26) into the swivel housing (14) with
the special tool 380002668 and a hammer.
Assemble the seal ring (22) on the swivel housing
(14) with the special tool 380002669 and a hammer. ïì
Grease carefully the seal ring (22). îê
îî
Úîèðìé
46 SECTION 27 - REAR AXLE
îí
Úîèðìê
Úîèðîé
Úîéîëé
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
ïé ïç
ïê ïè
Úîéîêí
SECTION 27 - REAR AXLE 47
ïï ïï
Úîèðîè
Úîéîêë
Úîéîêê
Úîéîêé
48 SECTION 27 - REAR AXLE
Úîéîêè
Úîéîêç
Úîéîëð
SECTION 27 - REAR AXLE 49
DOUBLE U-JOINTS
ì
í
î
ï
Úîéîéç
Disassembly
ì
ï
Úîéîèð
50 SECTION 27 - REAR AXLE
Remove the seal rings (2) from the axle beam (4).
WARNING
Be careful not to damage the bush seat.
î
Úîéîèï
Assembly
Úîèðîç
Úîèðìè
WARNING
Be careful not to damage the seal ring.
ì
ï
Úîèðìç
SECTION 27 - REAR AXLE 51
Úîèðíð
Disassembly
Úîèðíï
52 SECTION 27 - REAR AXLE
î ï
Úîèðíí
WARNING ì
Once the axle beam trumpet has been removed, the
brake disks are free. ï
Úîèðíì
Úîèðíë
Remove the O-ring (4) and (19) from its housing and
from oil pipe hole and check its conditions. ì
ïç
Úîèðíé
Úîéíïí
Take from the piston (14), the springs (13) and the
bushes (12) and (27) and spacer (26). îé
îê
ïì
ïí
ïî
Úîèðíè
Úîèðíç
54 SECTION 27 - REAR AXLE
Úîèðìð
Assembly
Úîèðìð
Install the piston (14) into the brake flange (7) and
then a support flat disk on the piston and with a lever
ïì
anchored to an eyescrew, exert a pressure just
enough to insert the piston (14) into the brake flange
(7).
é
Úîèðìî
Úîèïïê
SECTION 27 - REAR AXLE 55
ïç
Úîèðíé
ë ê
Úîèðìí
Úîèðíë
Úîèðíì
56 SECTION 27 - REAR AXLE
WARNING
Support the groups properly as already pointed out
for disassembly phase.
î ï
Úîèðíí
SECTION 27 - REAR AXLE 57
ì
ë
ïë
ïð
ïì
ê
ïè
ç
í ïé
î ïê
ï
ïí
ë
ì ïì
ïë
ïî
ïï
è
é
ê Úîèðëð
Disassembly
ê
Úîèðëï
58 SECTION 27 - REAR AXLE
Úîèðëî
Úîèðëí
ïè
Úîèðëì
Úîèðëë
SECTION 27 - REAR AXLE 59
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîèðëê
ïð
Úîèðëé
Úîèðëè
ïê
Úîèðëç
60 SECTION 27 - REAR AXLE
ïë ïë
ïì ïì
ïí
Úîèðêð
ïï
Úîèðêï
Assembly
WARNING
Remove rests of dope.
Úîèðéç
ïî
ïê
ïì
Úîèðêí
SECTION 27 - REAR AXLE 61
ïé
Úîèðêì
ïë ïë
ïì ïì
ïí
Úîèðêð
ïî
Úîèðêê
Úîèðëè
62 SECTION 27 - REAR AXLE
Úîèðêé
ï
Úîéíïê
Úîéíïë
ïè
Úîèðêè
SECTION 27 - REAR AXLE 63
Úîèðêç
Úîèðéð
Úîèðéï
ì
ë
ê
ïê ïë
ïé ïð
ïé
ïè
ïê
ç
ïë ïï
í
ïî
î
ïí
ï
ë ïç
ì ïê
ïë
ïê
ïë
ïì
ïí
ïî
ê é è ïï
Úîèðéí
Disassembly
ê
Úîèðëï
SECTION 27 - REAR AXLE 65
Úîèðëî
Úîèðëí
ïè
Úîèðëì
Úîèðëë
66 SECTION 27 - REAR AXLE
WARNING ï
This operation makes both differential half housings
free, so take care not to lower the inner compo-
nents.
Úîèðëê
ïð
Úîèðëé
Úîèðëè
Úîèðéì
SECTION 27 - REAR AXLE 67
ïí
Úîèðéë
ïë ïë
ïê ïê
ïé
Úîèðéê
ïì
ïí
Úîèðéé
ïï ïî
Úîèðéè
68 SECTION 27 - REAR AXLE
Assembly
WARNING
Remove rests of dope.
Úîèðéç
ïì
ïç
ïê
Úîèðèð
ïï ïî
Úîèðéè
ïì
ïí
Úîèðéé
SECTION 27 - REAR AXLE 69
ïë ïë
ïê ïê
ïé
Úîèðèî
ïí
Úîèðèï
Úîèðéì
Úîèðëè
70 SECTION 27 - REAR AXLE
Úîèðêé
ï
Úîéíïê
Úîéíïë
ïè
Úîèðêè
SECTION 27 - REAR AXLE 71
Úîèðêç
Úîèðéð
Úîèðéï
ï
î
í
ì
ë
ê
é
è
ç
Úîèðèí
Disassembly
Úîçêìë
SECTION 27 - REAR AXLE 73
Úîèðèë
Remove the washer (6), the ring (5) and the shims
(4) from the bevel pinion (1).
ï
ì
ë
ê
Úîèðèê
í î
Úîèðèé
Úîèðèè
74 SECTION 27 - REAR AXLE
Úîèðèç
Assembly
Úîèðçð
Úîèðçï
Úîèðçî
SECTION 27 - REAR AXLE 75
Úîèðçí
Úîèðçì
Úîéííï
Úîèðçë
76 SECTION 27 - REAR AXLE
Insert the shim (2) on the bevel pinion (1) with cham-
fer against the gear.
Press the bearing (3) into the pinion, making sure í
that it is well set.
ï
Úîèðçê
Insert the shims (4) and (6) and the ring (5) into the
bevel pinion (1).
ï
ì
ë
ê
Úîèðèê
Insert the bevel pinion (1) unit into the central body
housing and the bearing (7) into the pinion end.
ï
Úîèðçé
Úîèðèì
SECTION 27 - REAR AXLE 77
Úîèðçè
78 SECTION 27 - REAR AXLE
ï î í í î ï
ë ë
ì ì
Úîèðçç
Toe-in
WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
ëðð ³³ ëðð ³³
Úîéíìð
Úîéíìï
SECTION 27 - REAR AXLE 79
Ó óðë
Úîéíìî
Úîéíìí
Úîéíìì
80 SECTION 27 - REAR AXLE
Steering angle
Úîéíìë
Úîéíìê
ë ì
Úîéíìé
Úîéíìè
SECTION 27 - REAR AXLE 81
PROBLEMS CAUSE
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
10. Incorrect adjustment of the bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0.1 mm (0.004 in)
thickness lower than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
84 SECTION 27 - REAR AXLE
3. SPECIAL TOOLS
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. HAND BRAKE............................................................................................................................................... 6
2.1 HAND BRAKE ADJUSTMENT .............................................................................................................. 7
3. BRAKE CYLINDERS .................................................................................................................................... 8
4. OIL BRAKE TANK ...................................................................................................................................... 13
5. BLEEDING PROCEDURE .......................................................................................................................... 13
2 SECTION 33 - BRAKES SYSTEM
SECTION 33 - BRAKES SYSTEM 3
1. TECHNICAL SPECIFICATIONS
2WS
4WS
2. HAND BRAKE
The hand brake is fitted to all models and incorpo-
rates two free floating friction pads.
When operated the cam (1) forces the friction pads
against the disc (2), effecting a braking action on the
output shaft from the transmission, locking the drive
shaft to the rear and front axles.
ïç
îð
í
ïç
î ïè
ï
ïé
îï
ïë
ïê
ïì
ïî ïí
ïï
ïð
ç
è
é
ê
ë
ì
Úîééëð
Adjust the cable clevis and lock the nut (1) to get 4 to
5 clicks on the hand brake lever.
8 SECTION 33 - BRAKES SYSTEM
3. BRAKE CYLINDERS
Brake cylinders are accessible from the engine com-
partment.
The brake cylinders are linked by a balancing pipe
(12) situated below the cylinders to maintain equal oil
pressure between the two cylinders.
1. Fitting 7. Seal
2. Pressure switch 8. Clevis
3. Fitting 9. Seals
4. Body 10. Secondary spool
5. Primary spool 11. Spring
6. Bottom 12. Balancing pipe
SECTION 33 - BRAKES SYSTEM 9
ï î í ì ë ê
ïð
ç è é
Úîçíéï
Trapped oil
Tank oil (no pressure)
ï î í ì ë ê
ïð
ç è é
Úîçíéî
ï î í ì ë ê
ïð
ç è é
Úîçíéí
5. BLEEDING PROCEDURE
1. Oil brake tank is full (1)
NOTE:
B110
B115
2. HYDRAULIC PUMP
2.1 DESCRIPTION AND OPERATION
TIGHTENING TORQUES
HYDRAULIC DIAGRAM
SECTION 35 - HYDRAULIC SYSTEM 17
î é
ê
Úîçìëé
The pressure on (CF) increases until the pressure value (standby pressure) is sufficient to move the spool valve
in a way to divert the flow toward (EF).
î é
ê
Úîçìëè
2.4 REMOVAL
2.5 COMPONENTS
3. CONTROL VALVES
3.1 CONTROL VALVES “REXROTH” (MECHANICAL MODELS)
The hydraulic circuit is a load sensing flow sharing Loader control valve
system working in conjunction with a fixed The loader control valve is mounted on the right
displacement gear type hydraulic pump. hand side of the machine adjacent to the pump.
This system has the advantage that at any time the The valve assembly consists of a maximum of three
distribution of flow to the services being operated is spool operated sections and provides oil flow to the
in proportion to the openings of the control valve loader boom, bucket and auxiliary services where
spools. fitted.
The flow distribution to the backhoe and loader
control valves is independent of the load and it is Backhoe control valve
therefore possible to operate two or more spools The backhoe control valve is located at the rear of
satisfactorily at the same time. the chassis.
The principal components of the load sensing flow The control valve consists of a maximum of seven
sharing system are the pressure compensator sections of spool control valves and provides the oil
valves in each control valve section, together with flow for operating the lifting, the digging, the bucket,
the load sense line which connects all the spool the stabilizers, the swing and telescopic arm
sections in both the loader and backhoe control (optional).
valve assemblies.
Because the hydraulic pump is a fixed displacement
gear type pump it should be noted that the load
sense line only connects the loader and backhoe
control valve assemblies and does not have any
connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and flow
from the front pump is directed to the centre
galleries of the loader and backhoe control valves
assemblies.
Flow from the rear section of the pump passes
through the load sensing flow divider valve mounted
on the pump and gives priority flow to the steering
circuit with remaining flow directed to supplement
the flow from the front pump for the loader and
backhoe circuits.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply circuit is controlled by the
pump flow balancer valve in accordance with the
pressure in the load sense line.
Consequently the higher the load sense pressure
the less flow is returned to tank with corresponding
increase in flow/pressure to the hydraulic circuits.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure
in the load sense line when it reaches 210 bar
(3045 psi).
Because the pump flow balancer valve is influenced
by load sense pressure the valve diverts sufficient
flow back to tank to maintain the maximum system
pressure of 210 bar (3045 psi).
26 SECTION 35 - HYDRAULIC SYSTEM
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Removal
Lower the loader to the ground, with the bucket
firmly placed on the ground.
Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Unscrew and remove clamping screws to chassis.
Remove the control valve assembly from the loader
backhoe.
Installation is the reverse of the removal procedure.
Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 ± 2 Nm (20 ± 1.5 lbf·ft). Slide out the three
tie bars (2).
K. Hydraulic diagram for centre pivot models 4. Bucket circuit relief valve (piston end) - 220 bar
W. Hydraulic diagram for sideshift models (3190 psi)
A. Right stabilizer section 5. Swing circuit relief valve (piston end) - 205 bar
B. Left stabilizer section (2972 psi)
C. Dipper section 6. Boom circuit relief valve (piston end) - 315 bar
D. Bucket section (4567 psi)
E. Swing section 7. Pump flow balancer - 15 bar (218 psi)
F. Boom section 8. Load sensing return to tank
G. Telescopic dipper section 9. Swing circuit relief valve (rod end) - 205 bar
H. Sideshift clamps valve (2972 psi)
1. End cover 10. Boom circuit relief valve (rod end) - 240 bar
2. Inlet section (3480 psi)
3. Dipper circuit relief valve (piston end) - 240 bar 11. Telescopic circuit relief valve (rod end) - 205 bar
(3480 psi) (2972 psi)
12. Load sensing relief valve - 210 bar (3045 psi)
36 SECTION 35 - HYDRAULIC SYSTEM
Removal
Position the loader backhoe on a hard level
surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Disconnect the battery.
Clean the area around the control valve.
Tag and identify the position of all hoses.
Disconnect and plug all the hoses.
Disconnect the levers of the manual control.
Unscrew and remove clamping screws to chassis.
Remove the control valve assembly from the
loader backhoe.
Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm (20 ± 1.5 lbf·ft).
Slide out the three tie bars (2).
Disassembly
Remove the screws (A), the boot along with its
plate (B) and the plate (C).
Remove the mounting screws (D) and the cover
(E).
Remove the spool (F) from the valve section.
Remove the lip seal (L).
Reassembly
Reassemble parts in reverse order after greasing
the spring.
Position the metal part of the lip seal (L) on the
outside of the spool.
The lip seal must be fitted on the end of the spool
so that it is not damaged by the spool grooves (N)
and its tightness is not damaged.
Slide the lip seal perpendicularly onto the spool.
Tighten the screws (A and D), the adapter (H) and
the tongue (M) from 9 to 11 Nm (6.6 to 8.1 lbf·ft).
40 SECTION 35 - HYDRAULIC SYSTEM
WARNING
The lip seal must be fitted on the end of the spool so
that it is not damaged by the spool grooves (N) and
its tightness is not damaged.
Disassembly
Remove the tongue and the cover sides.
Use a spool clamp (G) and a vice to secure the
spool.
Using a metal rod (minimum length = 80 mm
(3.15 in), diameter 6) push the central ball (H) while
extracting the detent bush (I).
Mark the orientation of the detent bush for the
reassembly.
Remove the balls (J) and the spring (K) from the
adapter (M).
Reassembly
Introduce the spring (K) into the adapter (M).
Place the 3 balls (J) into the radial holes of the
adapter (M) and use grease to prevent them from
falling.
Position the central ball (H) against the spring (K).
Slip the detent bush (I) onto a metal rod.
Using the metal rod, press the central ball (H) into
the adapter (M), then slide the detent bush (I) onto
the adapter, making sure that the 3 balls are still in
place.
Removal
Lower the loader to the ground, with the bucket firmly
placed on the ground.
Stop the engine and eliminate any residual pressure
in the backhoe and loader circuits by moving the
loader and backhoe control levers through all
operating positions.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Unscrew and remove clamping screws to chassis.
Remove the valve assembly from the loader
backhoe.
Installation is the reverse of the removal procedure.
Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 ± 2 Nm (20 ± 1.5 lbf·ft). Slide out the three
tie bars (2).
K. Hydraulic diagram for centre pivot 5. Swing circuit relief valve (piston end) - 205 bar
W. Sideshift (2972 psi)
A. Right stabilizer section 6. Boom circuit relief valve (piston end) - 315 bar
B. Left stabilizer section (4567 psi)
C. Dipper section 7. Pump flow balancer valve - 15 bar (218 psi)
D. Bucket section 8. Load sensing return to tank
E. Swing section 9. Swing circuit relief valve (rod end) - 205 bar
F. Boom section (2972 psi)
G. Telescopic dipper section 10. Boom circuit relief valve (rod end) - 240 bar
H. Sideshift clamps (3480 psi)
1. End cover 11. Telescopic circuit relief valve (rod end) - 205 bar
2. Inlet section (2972 psi)
3. Dipper circuit relief valve (piston end) - 240 bar 12. Load sensing relief valve - 210 bar (3045 psi)
(3480 psi)
4. Bucket circuit relief valve (piston end) - 220 bar
(3190 psi)
46 SECTION 35 - HYDRAULIC SYSTEM
Removal
Position the loader backhoe on a hard level surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Stop the engine and eliminate any residual pressure
in the backhoe and loader circuits by moving the
loader and backhoe control levers through all
operating positions.
Disconnect the battery.
Clean the area around the control valve.
Tag and identify the position of all hoses and
hydraulic tubes.
Disconnect and plug all the hoses and all the
hydraulic tubes.
Unscrew and remove clamping screws to chassis.
Remove the control valve assembly from the loader
backhoe.
Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm (20 ± 1.5 lbf·ft).
Slide out the three tie bars (2).
Disassembly
Remove the screws (A), and the plate (B).
Extract the spring guides (C) and the springs (D).
Discard the seals (E).
Remove the spool (F) from the valve section.
Reassembly
Grease and install the spool (F) in the valve
section.
Install the springs (D) in the caps (B).
Install the spring guides (C) in the springs (D).
Install new seals (E).
Install the cap assemblies on the valve section,
install and tighten the screws (A) to a torque of 9 to
11 Nm (6.6 to 8.1 lbf·ft).
3.3 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE (WITH
HYDRAULIC CONTROL)
REMOVAL
Position the loader backhoe on a hard level
surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Disconnect the battery.
Clean the area around the solenoid valve.
Tag and identify the position of all hoses and
hydraulic tubes.
Disconnect and plug all the hoses and all the
hydraulic tubes.
Unscrew and remove clamping screws to chassis
supporting the operating levers.
Remove the solenoid from the loader backhoe.
Installation is removal procedure in reverse.
DISASSEMBLY
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).
52 SECTION 35 - HYDRAULIC SYSTEM
In case of necessity it is possible to disassemble the Check and possibly replace the O-rings (10).
various solenoid valves from the manifold blocks. Remove the check valve (11) and the orifice (12).
Untighten and remove screws (6). Untighten and remove the solenoid valves (13).
Disassemble the solenoid valves (7). Check and possibly replace the O-rings (14).
Check and possibly replace the O-rings (8). Untighten and remove the solenoid valves (15).
Untighten and remove the valve (9). Check and possibly replace the O-rings (16).
SECTION 35 - HYDRAULIC SYSTEM 53
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston é ê ë ì Úîçëìï
Anti-cavitation operation
Circuit relief valves with an anti-cavitation feature
are fitted in circuits where rapid extension of the
cylinder could create a void condition and permit the
transfer of oil from the high pressure side of a
cylinder to the lower pressure (void) end of the
cylinder.
When for example the boom is rapidly lowered and
the cylinder rod end circuit relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is
automatically replenished by the anti-cavitation
device in the opposite circuit relief valve as follows:
The void creates a pressure lower in the cylinder
supply gallery and back pressure in the control valve
exhaust gallery acts on the outer face of the sleeve
poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.
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Exhaust oil
High pressure circuit oil
SECTION 35 - HYDRAULIC SYSTEM 57
Overhaul
1. Body 9. O-ring
2. Poppet 10. Locknut
3. Spring 11. O-ring
4. Spring 12. Adjuster
5. O-ring 13. Spring
6. O-ring 14. Pilot valve
7. Fitting 15. Piston
8. Cap 16. Poppet valve
58 SECTION 35 - HYDRAULIC SYSTEM
1. Body 6. Cap
2. Poppet 7. O-ring
3. Spring 8. Locknut
4. Spring 9. O-ring
5. Shim 10. Adjuster screw
Technical specifications
Capacity (gas) ...........................................................................................................................2 litres (0.52 gal)
Capacity (oil) ........................................................................................................................1.84 litres (0.50 gal)
Precharge .................................................................................................................... 30 ± 1 bar (435 ± 15 psi)
Maintenance
Check the gas pre-charge pressure regularly during the first few weeks of operation, and then at suitable
intervals afterwards based on this initial experience.
Carry out a visual examination of the accumulator periodically in order to detect any early signs of
deterioration such as corrosion, deformation etc.
Comply with the regulatory provisions concerning the monitoring of operational equipment.
Before removal, it is vital to ensure that there is no residual hydraulic pressure in the accumulator. Discharge
the gas side of the accumulator using a Parker UCA charging and gauging assembly before carrying out any
maintenance operations
Safety
Charging must be carried out by qualified personnel.
Before taking any readings or pressurizing with nitrogen, the accumulator must be isolated from the hydraulic
system and the fluid side discharged in order to depressurize it.
Use only nitrogen (N2) to pressurize the accumulator.
Warning - Stabilization
The process of charging or discharging an accumulator with nitrogen causes a temperature change which is
transmitted to the surrounding air as the temperature of the accumulator stabilizes. To allow for the effects of
temperature transfer, the accumulator should be allowed to stand for a minimum of 15 minutes before a final
reading of the precharge pressure is taken.
62 SECTION 35 - HYDRAULIC SYSTEM
A. Inflation valve
B. Bleed valve
1. UCA
2. Adapter (long)
3. Adapter (short)
4. Adapter (insert)
5. Pressure gauge
6. Protective cap - gauge port
7. Collar - gas port
8. Knurled protective cap - filling port
9. Hose (G1/4 fitting, 60° cone) with O-ring
10. Valve
Hydraulic feed to the swing cylinders is controlled by If the swing control valve is suddenly returned to
the swing section of the backhoe control valve which neutral mid-way through a full power swing the
contains pilot operated relief valves with anti supply and exhaust ports in the main control valve
cavitation feature to protect the circuit and cylinders are totally blocked.
should an overload condition occur. The momentum of the swinging backhoe assembly
The diagram illustrates operation of the swing circuit if not controlled will make the machine extremely
when retracting the right hand cylinder (4) and unstable.
extending the left hand cylinder (5) in order to swing To prevent this from occurring the circuit relief
the backhoe to the right. valves operate and dumps oil to exhaust until the
When swinging the backhoe to the left the oil flows excess pressure is relieved. When the relief valve
are reversed and exactly the same principle of operates the cylinder rod will move and a void will be
operation applies. created in the low pressure side of the cylinder. The
Oil flow for a right hand swing is as follows: anti-cavitation feature in the relief valves prevent the
When the swing control is operated the control valve void from occurring by transferring exhaust oil from
directs oil flow to the rod end of the right hand the excess pressure side of the circuit to the low
cylinder. pressure side.
The flow of oil at pump pressure lifts the one way
restrictor (2) of its seat allowing the flow to continue
unrestricted to the inlet port of the piston end of the
left hand cylinder.
System pressure increases causing the right hand
cylinder to retract and the left hand cylinder to
extend.
As the cylinders move, displaced oil on the piston
side of the left hand cylinder flows towards the one
way restrictor (7) in the inlet port on the rod end of
the right hand cylinder.
The oil flow moves the restrictor to the restrict
position which limits the flow of oil and creates a
back pressure (1st stage restricted return oil) in the
right hand cylinder.
The restricted flow of oil passes through restrictor
(7) into the rod end of the left hand cylinder before
returning to the control valve and back to tank.
The spool in the swing control valve assembly (1) is
designed such that during operation oil can flow
freely through the port directing oil flow to the swing
cylinders but restricts the flow returning oil back to
tank.
This restriction is achieved using metering lands
machined into the lands of the spool and creates a
secondary back pressure (2nd stage restricted
return oil) in the rod end of the cylinder.
By allowing oil to flow unrestricted to the power side
of the cylinder and be restricted on the exhaust side
a smooth controlled swing of the backhoe at
optimum speed is achieved.
When the swing system reaches the last 20-25° of
travel the sliding restrictor in the end of the piston
rod touches the outlet port in the cylinder barrel.
This further restricts the flow of oil exhausted from
the cylinder and as the piston moves towards the
end of its stroke the sliding restrictor is gently
pushed down the centre of the cylinder rod allowing
a progressive and controlled halt to the swing cycle.
66 SECTION 35 - HYDRAULIC SYSTEM
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5. HYDRAULIC CYLINDERS
1. Loader cylinder
2. Loader bucket cylinder
3. 4x1 bucket cylinder
4. Backhoe boom cylinder
5. Backhoe dipper cylinder
6. Backhoe bucket cylinder
7. Telescopic cylinder
8. Swing backhoe cylinder
9. Stabilizer cylinder (centre pivot models)
10. Stabilizer cylinder (sideshift models)
11. Backhoe sideshift locking cylinder (sideshift models)
68 SECTION 35 - HYDRAULIC SYSTEM
4WS
1. Stroke
2. Completely retracted
2WS
1. Stroke
2. Completely retracted
SECTION 35 - HYDRAULIC SYSTEM 69
Úîèéëé
WARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal
injury may occur.
Úîèéëç
WARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal
injury may occur.
Úíðíïè
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Úíðíîð
WARNING
Cylinder weight: 36 kg (79 lb).
Only if necessary:
Remove from the cylinder head (7), the wiper ring
(3), the seal (4), the seal (5), the bearing sleeve (6)
and the back-up ring (9) with O-ring (10).
Remove from the piston (11) the seal (12) and the
ring guide (13).
74 SECTION 35 - HYDRAULIC SYSTEM
4WS
1. Stroke
2. Completely retracted
2WS
1. Stroke
2. Completely retracted
SECTION 35 - HYDRAULIC SYSTEM 75
Remove the ring (2) with the dowel (3). Remove the
pin (4) using an hammer to release the rod (5).
76 SECTION 35 - HYDRAULIC SYSTEM
1. Bushing 9. O-ring
2. Cylinder rod 10. Piston
3. Wiper ring 11. Piston seal
4. Seal 12. Piston ring guide
5. Seal 13. Screw
6. Cylinder head 14. Cylinder tube
7. Safety ring 15. Bushing
8. Back-up ring
WARNING
Cylinder weight: 32.5 kg (72 lb).
Only if necessary:
remove from the cylinder head (6), the wiper ring
(3), the seal (4), the seal (5), the back up ring (8)
with the O-ring (9);
remove from the piston (10) the piston seal (11)
and the ring guide (12).
80 SECTION 35 - HYDRAULIC SYSTEM
CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket firmly on the ground.
Relieve the residual pressure in the system by
moving the loader control lever through all operating
positions.
SECTION 35 - HYDRAULIC SYSTEM 81
Remove the pin (2). Slide out the pin (1) with an
hammer.
Unscrew and remove the nut (6) and the dowel (5).
Slide out the lower pin (7) with an hammer.
DISASSEMBLY CYLINDER
(1) Stroke
(2) Completely retracted
with long dipper
with short dipper
CYLINDER REMOVAL
Park the machine on a flat surface and position the
bucket on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
NOTE: the tube end of the dig cylinder and the rod
end of the boom cylinder use a common attaching
pin (2).
WARNING
Cylinder weight (with short dipper): 77.5 kg (171 lb).
Cylinder weight (with short dipper): 80.5 kg (177 lb).
Pull out the cylinder head (7) from the cylinder tube
(16) by tapping with a rubber hammer. Remove the
cylinder rod (3) and the cylinder head (7).
Only if necessary:
remove from the cylinder head (7), the wiper ring
(4),O-ring (5), the guide bush (6), and the back-up
ring (8) with O-ring (9);
remove from the piston (12), the piston ring guide
(10) and the piston gaskets (11) and (13).
SECTION 35 - HYDRAULIC SYSTEM 87
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Untighten and remove the nut (1) and the dowel (2).
Slide out the rod pin (3) with an hammer.
If necessary use hydraulic power to very slowly
retract the cylinder so that the rod comes clear of the
attaching point.
WARNING
Cylinder weight: 64 kg (141 lb).
Pull out the cylinder head (7) from the cylinder tube
(15) by tapping with a rubber hammer. Remove the
cylinder rod (3) and the cylinder head (7).
Only if necessary:
remove from the cylinder head (7), the wiper ring
(4), O-ring (5), the guide bush (6), and the back-up
ring (8) with O-ring (9);
remove from the piston (12) the piston ring guides
(10) and the piston gasket (11).
SECTION 35 - HYDRAULIC SYSTEM 91
(1) Stroke
(2) Completely retracted
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Remove the stop ring (1) with the shim (2). Slide out
the pin (3) with an hammer and pay attention to
levers.
If necessary use hydraulic power to very slowly
retract the cylinder.
WARNING
Cylinder weight: 64 kg (141 lb).
Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a rubber hammer. Remove the
cylinder rod (3) and the cylinder head (7).
Only if necessary:
remove from the cylinder head (7), the wiper seal
(4), O-ring (5), the bearing sleeve (6), and the back-
up ring (8) with the O-ring (9);
remove from the piston (12) piston the ring guide
(11) and the piston gasket (10).
SECTION 35 - HYDRAULIC SYSTEM 95
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
WARNING
Cylinder weight (with short telescopic): 41.5 kg
(91 lb).
Cylinder weight (with long telescopic): 45 kg (99 lb).
Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a rubber hammer. Remove the
cylinder rod (1) and the cylinder head (7).
Only if necessary:
remove from the cylinder head (7), the wiper ring
(2), the seal (3), the seal (4), the guide bush (5), the
O-ring (9) with the back-up ring (8);
remove from the piston (12) the piston ring guide
(11) and the piston gasket (10).
SECTION 35 - HYDRAULIC SYSTEM 99
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Make sure that the backhoe loader is locked in the
transfer position or parked in a safety work position.
Lower the stabilizers to the ground.
WARNING
Cylinder weight: 43.5 kg (96 lb).
Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a plastic hammer. Remove the
cylinder rod (1) and the cylinder head (7).
Only if necessary:
remove from the cylinder head (7), the wiper ring
(2), the seal (3), the seal (4), the guide bush (5), the
O-ring (9) with the back-up ring (8);
remove from the piston (12) the piston ring guide
(11) and the piston gasket (10).
SECTION 35 - HYDRAULIC SYSTEM 103
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
bucket on the ground.
WARNING
Cylinder weight: 33.7 kg (74 lb).
Pull out the cylinder head (5) from the cylinder tube
(13) by tapping with a rubber hammer. Remove the
cylinder rod (1) and the cylinder head (5).
Only if necessary:
remove from the cylinder head (5), the wiper ring
(2), the seal (3), the seal (4), and the back-up ring
(7) with O-ring (8);
remove from the piston (9) the piston ring guide
(10) and the piston gasket (11).
SECTION 35 - HYDRAULIC SYSTEM 107
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
WARNING
Cylinder weight: 31 kg (68 lb).
Only if necessary:
remove from the trunnion (10), the wiper ring (4),
the rod seal (5), the buffer seal (6), the guide bush
(7) and the back-up ring (12) with O-ring (11).
remove from the piston (15) the piston seal (13)
and the ring piston guide (14).
CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket on the ground.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Úíðíîï
Úíðíîî
112 SECTION 35 - HYDRAULIC SYSTEM
Úíðíîí
WARNING
Before moving machine forward check that backhoe
is still fully supported by the hoist and remains
stable.
Úíðíîì
í ì
Úíðíîë
SECTION 35 - HYDRAULIC SYSTEM 113
Disassembly
Release pressure in the hydraulic circuits using the
following procedure: turn key switch “ON”, but do not
start the engine. Turn pilot control cancellation
switch to the “ON” position. Move both joysticks in all
directions. Turn key switch “OFF”. Disconnect the
negative battery cable(s).
Mark the position of the lever parts (see the
exploded view on previous pages).
Remove the knob (P) and the support (S).
Remove the bracket (O) with the relevant screws
(with left hydraulic control lever).
Reassembly
To reassemble the hydraulic control levers, proceed
in the reverse order to that of removal.
Follow the marks made during disassembly, and
tighten the nut (4) to a torque of 36 to 44 Nm (26 to
32 lbf·ft).
SECTION 35 - HYDRAULIC SYSTEM 121
P. Supply
T. Tank return
Disassembly
1. Mark the direction of installation of all 15. Separate the upper (4) and lower (19) bodies
disassembled parts. and replace the seals (20) and (21).
2. Remove the U/J cam (1) using a key.
3. Remove the plate (2). Reassembly
4. Remove the shim (3) from the upper body (4). 1. To reassemble, proceed in the reverse order to
5. Extract the rod guide (5) and replace the seals that of removal.
(6) and (7). 2. In the case of reassembly without changing the
6. Drift the rod (8) out. U/J cam (1), put the same value of shims (3) as
7. Remove the bearing (9), the spring (10) and the those in place.
shims (11). 3. After changing the U/J cam (1) adjust the
8. Extract the spool assembly. pressure of the cam on the rods.
9. Hold the cup (12) and remove the lock ring (13). 4. Install a 2 mm shim (3), check that the recessing
10. Remove the spring (14) and the spool (15). of the push-rods is less than 0.2 mm, modify the
11. Remove and note the thickness of the shims shimming to more or less if required.
(16). 5. Install new seals (6), (7), (18), (20) and (21).
12. Proceed in the same manner for the other rods. 6. Lubricate the moving parts.
13. Secure the upper body (4) in a vice. 7. Apply brake thread fluid on the threads of the U/
14. Loosen and remove the screw (17) using a key J cam (1) and the screw (17).
and replace the seal (18). 8. Tighten the U/J cam (1) to 50 Nm (36 lbf·ft) and
the screw (17) to 50 Nm (36 lbf·ft).
124 SECTION 35 - HYDRAULIC SYSTEM
GENERAL
Restricted pump suction line Inspect suction line and tank, repair
as necessary.
Slow operation or loss of power in Pump worn Perform pump performance test and
all circuits replace/reseal as necessary.
Restricted pump suction line Inspect suction line and tank, repair
as necessary.
LOADER
BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. The backhoe chart
should only be referred to if the supply circuit is performing normally, thereby confirming that the pump and
hydraulic supply circuits are functioning to specification. See also “Fault finding hydraulic pump”.
SWING
HYDRAULIC PUMP
Setting of relief valve too high or Drain tank and refill with clean oil.
too low Test relief valves.
Oil in system too light Drain tank and refill with correct
viscosity oil.
SECTION 39 - CHASSIS
ENGINE
Supported by 2 rubber silent blocks and held in po- Remove:
sition by 2 support brackets. The brackets, which Air Cleaner bowl
are welded to the frame one either side of the en- Engine guard and panels
gine are positioned just ahead of the loader posts. Radiator’s and related hoses (Or pivot forward
where possible)
WARNING Front support cowling (if required)
The engine and transmission bolted together act as
a one piece unit. If separated in the machine they Disconnect:
are not self supporting and will collapse causing in- Fuel pump accelerator cable and electric shut off
jury or damage to the machine. Engine harness
Fuel tank connection and leak off return pipes
Hydraulic pump and related pipework (plug all ports
TORQUE CONVERTOR as required)
Transmission Lever
Fitted between the engine and the transmission can
Transmission harness connectors
only be removed when the engine/transmission as-
Engine supports (with engine supported by hoist)
sembly are separated.
Transmission supports
TRANSMISSION
Attached to the rear of the engine and supported in
rubber silent blocks in fixed brackets and held within
the frame just at the rear of the loader post.
To make repairs that require disassembly of the
transmission or engine it will be necessary to re-
move the engine/transmission as a complete unit
from the chassis.
To remove the engine/transmission from the ma-
chine it will be necessary to remove or disconnect
the following:
SECTION 39 - CHASSIS 7
COUNTERWEIGHT
TANKS
Attached to the chassis below the cab are the tanks
for hydraulic oil (1) mounted to the right hand side of
the machine and the fuel tank (2) mounted to the left
hand side of the machine.
Both tanks when drained of their contents can be re-
moved from the machine by removal of the attach-
ing pipe work and supporting bolts.
CAB
In the following table are the torques for the various assemblies that should be removed to affect repair.
IMPORTANT: always ensure prior to carrying out repairs on the machine that the vehicle parking brake is on
and the wheels are chocked.
ENGINE/TRANSMISSION
ù
COMPONENTS TORQUES
Engine/Transmission retaining bolts and nuts 95 Nm (70 lbf·ft)
Engine coolant tank retaining bolts 25 Nm (18 lbf·ft)
Engine/Transmission bolts 95 Nm (70 lbf·ft)
Air cleaner retaining bolts to frame 25 Nm (18 lbf·ft)
Coolant radiator bolts to frame 95 Nm (70 lbf·ft)
Radiator retaining bolts to frame 95 Nm (70 lbf·ft)
Front panel cowling to frame 214 Nm (157 lbf·ft)
Front bonnet to frame 170 Nm (125 lbf·ft)
Upper and front panel to frame 80 Nm (59 lbf·ft)
Front cardan joint to axle 38 Nm (28 lbf·ft)
Front cardan joint to transmission 38 Nm (28 lbf·ft)
Rear cardan joint to axle 38 Nm (28 lbf·ft)
Rear cardan joint to transmission (PS) 38 Nm (28 lbf·ft)
Rear cardan joint to transmission (PT) 70 Nm (51 lbf·ft)
FRONT/REAR AXLE
COMPONENTS TORQUES
Front axle retaining bolts (2WS) 500 Nm (368 lbf·ft)
Front axle retaining bolts (4WS) 500 Nm (368 lbf·ft)
Rear axle retaining bolts (2WS) 800 Nm (590 lbf·ft)
Rear axle retaining bolts (4WS) 900 Nm (663 lbf·ft)
HYDRAULIC SYSTEMS
COMPONENTS TORQUES
Power steering hoses to support frame 55 Nm (40 lbf·ft)
Backhoe control valve to frame bolts 90 Nm (66 lbf·ft)
Loader control pipes clamp to frame 25 Nm (18 lbf·ft)
TANK
COMPONENTS TORQUES
Oil tank bolts 85 Nm (63 lbf·ft)
Fuel tank bolts 85 Nm (63 lbf·ft)
SECTION 39 - CHASSIS 13
FRONT COUNTERWEIGHTS
COMPONENTS TORQUES
Weight 700 Nm (516 lbf·ft)
LOADER
COMPONENTS TORQUES
Loader control pipe bracket to frame 25 Nm (18 lbf·ft)
BACKHOE
COMPONENTS TORQUES
Backhoe to frame hose retaining clamps 52 Nm (38 lbf·ft)
Fastening pin of boom to swing bracket 320 Nm (236 lbf·ft)
Stabilizers upper pins retaining bolt 80 Nm (59 lbf·ft)
Fastening pin of boom cylinder 320 Nm (236 lbf·ft)
Fastening pin of dipper cylinder 320 Nm (236 lbf·ft)
Fastening pin of bucket cylinder 320 Nm (236 lbf·ft)
CAB
COMPONENTS TORQUES
Cab support 450 Nm (332 lbf·ft)
Front cab retaining bolts 210 Nm (155 lbf·ft)
Rear cab retaining bolts 180 Nm (132 lbf·ft)
WHEELS
COMPONENTS TORQUES
Front/rear wheels (4WS) 700 Nm (516 lbf·ft)
Front wheel (2WS) 330 Nm (243 lbf·ft)
Rear wheel (2WS) 540 Nm (398 lbf·ft)
14 SECTION 39 - CHASSIS
NOTE:
B110
B115
Úîçíéç
Úîçíèì
Ìí
Ðí
ßí Þí
ßî Þî
Ðî
Ìî
Úîçëîç
X = Energized
O = Not Energized
3a 3b 2a 2b
2WS O X O X
2WS X O O X
4WS O X X O
CRAB X O X O
12 SECTION 41 - STEERING SYSTEM
3. POWER STEERING
The steering unit consists of a metering pump that wheel, through column, that can be of two types:
includes: fixed or adjustable.
a gear wheel assembly with fixed stator (with inner A cardan shaft, mechanically tied to gear wheel as-
teeth) and a rotor (with outer teeth). sembly and to outer sleeve, allows the movement
A 4 ways rotary distributor consisting of an outer transmission.
sleeve and an inner selection rotor. Set of centering springs between outer sleeve and
The selection rotor is connected to the steering inner rotor.
TIGHTENING TORQUES
3/4 - 16 UNF Nm (lbf·ft) 60 (44)
7/16 - 20 UNF Nm (lbf·ft) 20 (15)
Steering wheel nut Nm (lbf·ft) 55 (40)
Steering motor to steering column bracket Nm (lbf·ft) 23 (17)
Power steering end cover Nm (lbf·ft) 30 (22)
Power steering pipe connection Nm (lbf·ft) 45 (33)
Power steering pipe adaptors Nm (lbf·ft) 55 (40)
Check valve bolt Nm (lbf·ft) 30 (22)
Shock valve (4WS) Nm (lbf·ft) 30 (22)
14 SECTION 41 - STEERING SYSTEM
HYDRAULIC DIAGRAM
1. Power steering diagram 4. Anti-shock valve set at 240 ÷ 260 bar (3480 ÷
2. Power steering control valve 3769 psi)
3. Check valve 5. Anticavitation valve
SECTION 41 - STEERING SYSTEM 15
3.2 COMPONENTS
DISASSEMBLY
To gain access to the power steering the bonnet and
air cleaner should be removed.
Screw out the screws (18), the screw (17) and the
washers (16) from the end cover (15).
SECTION 41 - STEERING SYSTEM 17
Shake out the check valve ball (3) and the suction
valve pins (21) and the balls (20). Replace the pins
(21) prior to the reassembly.
Take the ring (7), the bearing cups and the needle
bearing (6) from sleeve and spool. The outer (thin)
bearing race can sometimes “stick” in the housing,
therefore check that is has come out.
Press out the cross pin (8). Use the special screw
(17) from the end cover. A small mark has been
made with a pumice stone on both spool and sleeve
close to one of the slots for the neutral position
springs (see drawing). If the mark is not visible, re-
member to leave a mark of your own on sleeve and
spool before the neutral position springs are disman-
tled.
Shake out the two springs and two valve balls into
your hand. The valve seats are bonded into the
housing and cannot be removed.
CLEANING
Clean all parts carefully.
LUBRICATION
Before assembly, lubricate all parts with hydraulic
oil.
22 SECTION 41 - STEERING SYSTEM
ASSEMBLY
Guide the spool (1) into the sleeve (2). Make sure
that spool and sleeve are placed correctly in relation
to each other.
SECTION 41 - STEERING SYSTEM 23
1. Spool
2. Sleeve
6. Needle bearings
6A. Outer bearing race
6B. Needle bearing
6C. Inner bearing race
Lubricate the lip seal (24) with hydraulic oil and place
it on the assembly tool.
Press and turn the lip seal into place in the housing.
The spool set will push out the assembly tool guide.
The O-ring and Roto Glyd are now in position.
Guide the cardan shaft (9) down into the bore so that
the slot is parallel with the connection flange.
SECTION 41 - STEERING SYSTEM 29
A. Rotor/stator surface
B. Plate surface
C. Pin axis
D. Housing surface
E. Inner gear case
F. Cardan shaft
Fit the special screw (17) with washer (16) and place
it in the hole shown.
SECTION 41 - STEERING SYSTEM 31
Fit the six screws (18) with washers (16) and insert
them. Cross-tighten all the screws and the rolled pin
with a torque of 30 ± 6 Nm (22 ± 4 lbf·ft) in the se-
quence shown, initial torque of 10.8 Nm (8 lbf·ft).
Screw plug with seal ring into the two shock valves
and tighten them with a torque of 30 ± 10 Nm (22 ±
7 lbf·ft).
Fit the dust seal ring in the housing using the special
tool and a plastic hammer.
PRESSURE TESTING
Connect a suitable pressure gauge capable of read-
ing up to 200 bar (2900 psi) to the connector inside
the left hand loader support.
Start engine. A standby pressure of 6-7 bar (87-
102 psi) should be observed.
Turn steering to the left or right to the stop. A max-
imum pressure of 180 bar (2610 psi) should be
seen.
NOTE:
B110
B115
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING .................................................................................................................................. 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 DESCRIPTION AND OPERATION...................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 25
3.5 FLUSHING THE SYSTEM................................................................................................................... 43
3.6 EVACUATING THE SYSTEM.............................................................................................................. 45
3.7 CHARGING THE SYSTEM.................................................................................................................. 46
3.8 COMPONENTS OVERHAUL .............................................................................................................. 47
3.9 COMPRESSOR ................................................................................................................................... 52
3.10 SPECIAL TOOLS............................................................................................................................... 66
2 SECTION 50 - CAB HEATING AND AIR CONDITIONING
SECTION 50 - CAB HEATING AND AIR CONDITIONING 3
1. TECHNICAL SPECIFICATIONS
HEATING
ENGINE RADIATOR COOLANT
Antifreeze - Ambra Agriflu 12 litres (3.20 gal)
Water 12 litres (3.20 gal)
System type Pressurized FULL FLOW by-pass with
expansion chamber
FAN BELT DEFLECTION
Naturally aspired 13 - 19 mm (0.51 - 0.75 in)
Turbocharged 10 - 16 mm (0.40 - 0.63 in)
THERMOSTAT
Start to open at 82 °C (179.6 °F)
Fully open at 95 °C (203 °F)
Radiator cap 0.90 bar (13 psi)
TORQUE VALUES
Coolant/hot water hose connections 5 Nm (3.7 lbf·ft)
Air hose ducting connections 5 Nm (3.7 lbf·ft)
Heater housing to floor mounting bolts 6.2 Nm (4.6 lbf·ft)
CHECK CONDITIONS
Air inlet temperature 37.8 °C (100 °F)
Rated air inlet moisture 40%
Evaporation temperature 0 °C (32 °F)
Overheating 5 °C (41 °F)
Inlet air speed 1.0 - 2.0 - 3.0 m/s (3.3 - 6.5 - 9.8 ft/s)
Condensation temperature 58 °C (136 °F) (absolute 16 bar (13 psi))
Undercooling 2 °C (35.6 °F)
4 SECTION 50 - CAB HEATING AND AIR CONDITIONING
PERFORMANCE CALCULATED AT 2.0 m/s (6.5 ft/s) (383.4 m3/h (13539.6 ft3/h))
Exchanged warmth 9.29 kW 7998.69 kcal/h
Air outlet temperature 10.30 °C (50.54 °F)
Air side load loss 9.34 daPa 0.95 mmH20
PERFORMANCE CALCULATED AT 3.0 m/s (9.8 ft/s) (575.1 m3/h (20309.5 ft3/h))
Exchanged warmth 12.00 kW 10332.00 kcal/h
Air outlet temperature 13.70 °C (56.66 °F)
Air side load loss 18.30 daPa 1.87 mmH20
2. CAB HEATING
2.1 DESCRIPTION AND OPERATION
Cab heating
The cab is heated by a radiator mounted below the
cab seat, which is supplied hot water from the engine
coolant system. A blower motor mounted behind the
cab radiator is used to transfer the heat into the cab.
WARNING
The cab air filters are designed to remove dust from
the air but may not exclude chemical vapour. When
working in an enclosed area ensure there is ade-
quate ventilation as exhaust fumes can suffocate
you.
Heater radiator
The heater radiator (1) is fitted in a housing under
the cab seat for central displacement of warm or cold
air flow.
NOTE: the vents (B) and (F) are mounted only when
air conditioned (optional) is fitted.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 7
í ì
î
ê
ë
Úíððëè
ì
ï î
Úíððëç
WARNING
ë
Once this operation is complete, reset pin (A) in the
correct start position.
ê
Reinstall the heater valve, repeating the previous
operation in the reverse order.
ß
Úíððêð
SECTION 50 - CAB HEATING AND AIR CONDITIONING 9
FAULT FINDING
Excessive air leak (s) around doors Repair and Seal air leak(s).
and windows
Blower motor air flow low Blocked filter or recirculation filter Clean or replace filter(s).
Heater hose from engine to cab Ensure water flow to heater radiator
radiator, kinked or blocked is adequate and not restricted.
Cab does not cool Heater control turned on Turn temperature control knob fully
counterclockwise for maximum
cooling.
OVERHAUL
Úîèêéì
Heater radiator
With the system drained remove the heater radiator
hose connections, attaching bolts and remove from
the vehicle.
Inspect the heater radiator (3).
Check water flow through the heater pipe which
should be free running; if not, clear any blockage.
Fins should be free of all debris and not damaged;
clean and or repair.
Clean the heater radiator using compressed air not
exceeding 7 bar (102 psi) taking care not to damage
the radiator fins.
Ensure the radiator is not leaking under pressure;
repair or replace as required.
Clean the chamber with a damp, cloth and re-as-
semble the housing filter element with the seal fac-
ing the inside of the cover.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 11
Blower motor
The blower motor (1) can be removed by removal of
the attaching hardware and disconnection of the wir-
ing connector.
Check the blower is working, if not check fuse and
continuity of blower motor. If defective replace the
blower unit as an assembly.
Úíîìïï
12 SECTION 50 - CAB HEATING AND AIR CONDITIONING
3. AIR CONDITIONING
Úîèêèï
Úîèêèî
SECTION 50 - CAB HEATING AND AIR CONDITIONING 13
Úîèêèí
14 SECTION 50 - CAB HEATING AND AIR CONDITIONING
EXPANSION
VALVE
LOW
LOWER TEMPERATURE
TEMPERATURE HIGH PRESSURE
LOW PRESSURE LIQUID FILTERED
ATOMIZED LIQUID AND MOISTURE
REMOVED
RECEIVER DRYER
LOWER
TEMPERATURE
EVAPORATOR
HIGH PRESSURE
LIQUID
CONDENSER
WARM LOW
PRESSURE
VAPOUR
HIGH
TEMPERATURE
HIGH PRESSURE
VAPOUR
COMPRESSOR
It can now be seen that the principal components of The figure in the this page shows in schematic form
an air conditioning system are: the flow of refrigerant through the five major compo-
Refrigerant nents of an air conditioning system.
Compressor Refrigerant is drawn into the compressor as a cool,
Condenser low pressure vapour which is compressed and then
Receiver dryer pumped out as a hot, high pressure vapour to the
Expansion valve condenser.
Evaporator As the hot, high pressure vapour passes through the
The figure in the previous page uses the examples condenser core it gives off heat to the cooler outside
above to illustrate the air conditioning cycle. air, being drawn past the fins by the engine cooling
fan.
16 SECTION 50 - CAB HEATING AND AIR CONDITIONING
By giving off heat to the outside air, the vapour is the cab warm air blown across the coils and fins by
condensed to a liquid which moves under high pres- the cab blower motor. The refrigerant now changes
sure to the receiver dryer where it is stored until re- from a cold low pressure atomized liquid to a warm
leased to the evaporator by the temperature low pressure vapour and leaves the evaporator out-
sensing expansion valve. let, moving to the suction (low pressure) side of the
As liquid refrigerant passes through the metered or- compressor to repeat the cycle.
ifice in the expansion valve the refrigerant changes As this heat loss is taking place, moisture (humidity)
from a high pressure liquid to a low pressure atom- in the cab air will condense on the outside of the
ized liquid with a lower temperature. evaporator and drain off as water through the drain
This low pressure, low temperature, atomized liquid hoses attached to the evaporator drain pan, thereby
enters the evaporator coils and absorbs heat from reducing the humidity level of the cab.
WARNING
The air filter is designed to remove dust from the air
but may not exclude chemical vapour. Refer to
chemical manufacturers directions regarding protec-
tion from dangerous chemicals.
REFRIGERANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air condition- WARNING
ing system, requires the use of a suitable “refriger- If refrigerant should contact the skin use the same
ant” a liquid that has a relatively low temperature treatment as for frostbite.
boiling point, plus certain desirable safety and sta- Warm the area with your hand or lukewarm water
bility features. 32 °C (89 °F), cover the area loosely with a band-
The refrigerant used in the air conditioning system is age to protect affected area against infection and
refrigerant HFC 134a. consult a doctor immediately.
If refrigerant should contact the eyes wash imme-
NOTE: to help protect the environment legislation diately in cold clean water for at least 5 minutes
has been introduced in most territories banning the and consult a doctor immediately.
release into the atmosphere of refrigerants, includ-
ing HFC 134a. All service procedures contained in
this manual can be carried out without the need to
release refrigerant into the atmosphere.
WARNING
HFC 134a refrigerant is not compatible with R-12
refrigerant. Do not attempt to replace HFC 134a re-
frigerant with R-12 refrigerant or test the system us-
ing gauges or equipment previously used with R12
as damage to the system will result.
WARNING
HFC 134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
explosion, and the production of phosgene gas.
Never disconnect or disassemble any part of the air-
conditioning system as escaping refrigerant can
cause frostbite.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 19
COMPRESSOR
The air conditioning compressor is mounted on the
left hand side of the engine and is belt driven from
the crankshaft pulley.
The compressor separates the low and high pres-
sure sides of the system and has two functions:
1. To raise the refrigerant temperature by com-
pression to a higher degree of temperature than
the ambient (outside air) temperature.
2. To circulate the required volume of refrigerant
through the system.
The refrigerant compressor is a seven cylinder wob-
ble plate unit housed in a die cast aluminium hous-
ing.
Drive to the wobble plate is from the pulley, through
the electro-magnetic clutch to the main driveshaft.
Attached to the driveshaft is a cam rotor which oscil-
lates the wobble plate. The wobble plate is prevent-
ed from rotating by a static gear engaging with teeth
formed in the face of the plate. The seven pistons are
connected to the wobble plate by rods located in ball
sockets.
Refrigerant is drawn in on the downward stroke of a
piston through the reed valves located either end of
the cylinder assembly. Refrigerant enters the cylin-
der assembly through a gallery in the outer circum-
ference of the cylinder assembly.
The upwards stroke of the piston compresses the re-
frigerant and expels it through another reed valve
into an inner gallery in the cylinder assembly and out
into the refrigerant circuit.
The compressor is lubricated with a Polyalklene Gly-
col (PAG) oil Type SP20. This oil is miscible with the
refrigerant and is carried around the refrigerant cir-
cuit.
The compressor is activated by an electro-magnetic
clutch which functions to engage or disengage the
compressor as required in the operation of the air
conditioning system.
The clutch is primarily activated by the:
Temperature control
Low pressure cut-out switch
20 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Temperature control
The air conditioner temperature control switch is
mounted on the blower motor assembly.
The switch is a device which turns the compressor
clutch on and off to maintain a constant average
evaporator temperature and senses the evaporator
temperature using a thermistor (1).
The temperature control switch compares the volt-
age of the thermistor, which is dependent on the
temperature of the evaporator, with the voltage
across the potentiometer of the “in cab” temperature
control switch.
The switch upon comparing the two voltages deter-
mines whether the compressor clutch should be
switched “on” or “off” in order to maintain the desired
in cab temperature control.
CONDENSER
The condenser (1), located at the front of the ma-
chine in front of the engine radiator consists of a
number of turns of continuous coil mounted in a se-
ries of thin cooling fins to provide a maximum of heat
transfer in a minimum amount of space.
RECEIVER DRYER
The receiver/dryer (2) situated behind the battery
stores the liquid refrigerant to be sure a steady flow
to the thermostatic expansion valve is maintained
under widely different operating conditions.
The drier section contains a desiccant (Molecular
sieve) to absorb any moisture within the system and
a filter prevents the entry of foreign particles.
EXPANSION VALVE
The expansion valve (1) is located underneath the
evaporator in the pressure line leading from the re-
ceiver/ dryer and performs the following unctions:
1. METERING ACTION
A metered orifice changes the liquid refrigerant
from a high pressure low temperature liquid to a
low pressure, lower temperature atomized liq-
uid.
2. MODULATING ACTION
A thermostatically controlled valve within the ex-
pansion valve body controls the volume of liquid
refrigerant passing through the orifice and
makes sure the refrigerant is fully vaporized
within the evaporator. Liquid refrigerant at would
damage the compressor reed valves or freeze
the pistons.
3. CONTROLLING ACTION
The valve responds to changes in the cooling re-
quirements. When increased cooling is required,
the valve opens to increase the refrigerant flow
and when less cooling is required the valve clos-
es and decreases the refrigerant flow.
EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature refrigerant in the evaporator ab-
sorbs heat from the hotter air in the operator’s com-
partment, thereby cooling the air.
Air Recirculation
An intake grille is located on the left side of the seat
base. A portion of the air flow will recirculate through
the evaporator.
Filter General
The blower fan, draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recircula- î
tion grille (1). The air passes over the evaporator
then into the cab through the six louvered vents.
Two vents are located on the front instrument panel
to direct air onto the windshield. Two are located at
the base of the rear posts to direct air onto the rear
window. Two additional vents are located at the front
and rear of the seat base to direct air at the opera- ï
tor’s feet.
Úîçíîé
Blower Fan
The blower motor is controlled by a three-speed
switch (3) which uses a variable resistor to change
the fan speed.
High blower speed provides the greatest volume of
circulated air, however, a slower speed will allow the
air to contact the cooling fins and coils of the evapo-
rator for a longer period resulting in the warm air giv-
ing up more heat to the cooler refrigerant. Therefore,
the coldest air temperature is obtained when the
blower fan is operated at the lowest speed.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 25
ï î
é í
ê ì
ç è
Úîèêçê
NOTE: for Dealers who posses the latest design In the closed position, refrigerant circulates around
level of refrigerant recovery, recycling and recharg- the valve stems to the gauges. Therefore, when the
ing station, these gauges are an integral part of the manifold gauge set is connected into a system,
machine. pressure is registered on both gauges.
NEVER open the HIGH SIDE shut off valve when
The following instructions for performance testing the system is operating.
the air conditioning system is based on the use of ALWAYS open the LOW SIDE shut off valve when
the gauge set shown. The principal of operation is adding refrigerant.
however similar when testing the system using a re-
covery and recharging station with integral gauges.
When using this type of equipment always consult
the manufacturers operating instructions.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 27
Attaching The Gauge Set To The Loader Back- 2. Re-check that both the high and low side shut
hoe off valves on the manifold gauge set are fully
closed.
WARNING 3. Run the engine at 1000-1200 rev/min.
To avoid personal injury, stop the loader backhoe 4. Turn the heater temperature control “off”.
engine during connection of the manifold gauge set. 5. Operate the system at maximum cooling, with
the blower fan at high speed for 10 minutes to
1. Check that the gauge set shut off valves are stabilize all components.
closed (turned fully clockwise). 6. Check the manifold low pressure gauge reading
2. Connect the high side gauge hose (normally is within the specified range of approximately
red) to the high pressure (discharge) side serv- 0.28-2.48 bar (4-36 psi).
ice valve and the low side gauge hose (normally 7. Check the manifold high pressure gauge read-
blue) to the low pressure (suction) side service ing and compare the reading to the pressure in-
valve on the loader backhoe. Ensure the hose dicated on the pressure temperature chart
connections are fully tightened. below.
8. Measure and compare the temperature of con-
IMPORTANT: prior to connection of the manifold ditioned air entering the cab through the lou-
gauge set, identify the suction (low pressure) and vered air vents with the ambient air at the air
discharge (high pressure) service gauge ports. The intake filters on the outside of the cab.
high pressure service valve is always in the line from If the system is operating correctly the condi-
the compressor to the condenser. tioned air entering the cab should be 6-9 °C (42-
48 °F) cooler than the ambient temperature of
The high and low pressure service valves on the the outside air.
loader backhoe are spring loaded valve and will be 9. If it is confirmed that the system is not operating
automatically opened when the test hose is con- correctly refer to the fault diagnostic charts and
nected. performance test gauge reading examples on
the following pages for possible corrective ac-
NOTE: the test hose must incorporate a valve de- tion.
pressor to actuate this type of valve.
WARNING
The service valves have a protective cap. This cap A significant amount of refrigerant vapour may have
must be removed for test gauge connections and re- condensed to a liquid at the service fitting at the high
placed when service operations are completed. side of the compressor. Use a cloth or other protec-
tive material when disconnecting the manifold hose
Test Procedure
from this fitting to prevent personal injury to hands
After the manifold gauge set has been connected
and face.
and before pressure tests can be made, the system
must be stabilized as follows:
1. Apply the parking brake, check the gear shift le-
vers are in neutral and close the cab windows
and doors.
Evacuate system.
Evacuate system.
High pressure switch cutting Overcharged with refrigerant Check for overcharge as follows:
out
Air in system Stop the engine. Recover and
recycle the charge using correct
recovery equipment.
Recharge the system with the
correct quantity of refrigerant,
replacing any lost lubricant. Recheck
performance of air conditioning
system.
Evaporator air not cold Expansion valve allowing too much Check expansion valve as follows:
refrigerant to flow through the
evaporator Set for maximum cooling.
Low pressure gauge should lower
slowly.
If expansion valve is defective:
Discharge System.
Replace Expansion Valve.
Evacuate System.
Charge System.
Re-test.
é ï
ê î
ë ì í
Úîèêçé
é ï
ê î
ë ì í
Úîèêçè
PROBLEM DIAGNOSIS
Insufficient cooling. System refrigerant is extremely low. A serious leak
is indicated.
CAUSE
Refrigerant excessively low. NOTE: * test procedure based upon ambient tem-
perature of 35 °C (95 °F).
CONDITIONS* For proper high side gauge reading for other ambi-
Low side pressure very low. ent temperatures, refer to the pressure temperature
Gauge should read 1-2 bar (15-23 psi). chart.
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Discharge and recover the refrigerant from the
system.
3. Repair leaks.
4. Check compressor oil to ensure no loss.
5. Evacuate the system.
6. Charge the system.
7. Performance test the system.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 33
é ï
ê î
ë ì í
Úîèêçç
é ï
ê î
ë ì í
Úîèéðð
CAUSE DIAGNOSIS
Compressor malfunction. Internal leak in compressor caused by worn or
scored pistons, rings, or cylinders.
CONDITIONS*
Low side pressure too high. Gauge should read 1- NOTE: * test procedure based upon ambient tem-
2 bar (15-23 psi). perature of 35 °C (95 °F).
For proper high side gauge reading for other ambi-
High side pressure too low. Gauge should read ent temperatures, refer to the pressure temperature
13.3-14.8 bar (193-215 psi). chart.
é ï
ê î
ë ì í
Úîèéðï
PROBLEM At this point, operate the system and check its per-
Insufficient or no cooling. Engine overheats in some formance. If still unsatisfactory, proceed as follows:
cases. 4. Discharge and recover the refrigerant from the
system.
CAUSE 5. Remove the condenser and clean and flush it to
Condenser not functioning properly. ensure a free flow of refrigerant. Or, if the con-
denser appears to be unduly dirty or plugged,
CONDITIONS* replace it.
Low side pressure too high. Gauge should read 1- 6. Replace the receiver/dryer.
2 bar (15-23 psi). 7. Evacuate the system, and recharge it with the
High side pressure too high. Gauge should read correct quantity of refrigerant.
13.3-14.8 bar (193-215 psi). 8. Performance test the system.
Liquid line hot.
Evaporator air warm. DIAGNOSIS
High pressure switch cutting out. Lack of cooling caused by pressure that is too high
on the high side, resulting from improper operation
CORRECTIVE PROCEDURES of condenser. (Refrigerant charge may be normal or
1. Check belt. Loose or worn drive belts could excessive).
cause excessive pressures in the compressor
head. NOTE: * test procedure based upon ambient tem-
2. Look for clogged passages between the con- perature of 35 °C (95 °F).
denser fins and coil, or other obstructions that For proper high side gauge reading for other ambi-
could reduce condenser airflow. ent temperatures, refer to the pressure temperature
3. If engine is overheating replace engine thermo- chart.
stat and radiator pressure cap.
36 SECTION 50 - CAB HEATING AND AIR CONDITIONING
é ï
ê î
ë ì í
Úîèéðï
Evaporator air not cold. NOTE: * test procedure based upon ambient tem-
perature of 35 °C (95 °F).
For proper high side gauge reading for other ambi-
ent temperatures, refer to the pressure temperature
chart.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 37
é ï
ê î
ë ì í
Úîèéðì
Evaporator air warm. NOTE: * test procedure based upon ambient tem-
perature of 35 °C (95 °F).
Evaporator and suction hose (to compressor) sur- For proper high side gauge reading for other ambi-
faces show considerable moisture. ent temperatures, refer to the pressure temperature
chart.
CORRECTIVE PROCEDURES
1. Check for sticking expansion valve as follows:
Operate the system at maximum cooling.
Check the low side gauge. The pressure should
lower slowly.
38 SECTION 50 - CAB HEATING AND AIR CONDITIONING
é ï
ê î
ë ì í
Úîèéðë
é ï
ê î
ë ì í
Úîèéðê
é Þ ß ï
ê î
ë ì í
Úîèéðé
CORRECTIVE PROCEDURES
1. Stop the engine and shut off A/C system.
2. Replace thermostatic switch with switch of same
type.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 41
Leak Testing
To perform a leak test if refrigerant leakage is sus-
pected, use a leak detector following the manufac-
turer’s instructions.
Leak detectors use light or sound dependent upon
the type used to alert the operator of a leak. If the
leak detector’s sensitivity is adjustable, be sure you
calibrate the detector according to the manufactur-
er’s instructions before use.
When using a leak detector, keep in mind that a very
slight amount of leakage in the compressor pulley
area is normal and does not necessarily indicate a
repair is required. Úîèéðè
Úîèéðç
42 SECTION 50 - CAB HEATING AND AIR CONDITIONING
ì í î
Úîèéïð
Other recovery systems are available where the loader backhoe air conditioning system. The hose
manifold gauges are not an integral part of the ma- from the recovery unit is then connected to the man-
chine. When this type of equipment is used a sepa- ifold centre port.
rate manifold gauge set must be used.
The following is a summary of the steps for dis- 3. To recover refrigerant, open both high and low
charging the system using a recovery/recycling unit. side valves on the control panel or the valves on
the manifold gauge set if being used.
WARNING 4. Open the valves labelled “gas” and “liquid” on
Never discharge refrigerant gas into the atmos- the recovery unit refrigerant tank.
phere. Always wear safety goggles and gloves 5. Plug in the unit’s power cord.
when working with refrigerant. Only use authorized 6. Operate the recovery system in accordance with
refrigerant tanks. the manufacturers instructions.
The compressor will shut off automatically when the
recovery is complete.
IMPORTANT: always follow the manufactures in-
structions when operating recovery equipment.
é ï
ê î
ë ì í
Úîèéïï
Úîèéïî
SECTION 50 - CAB HEATING AND AIR CONDITIONING 45
3.7 CHARGING THE SYSTEM pull the remainder of the refrigerant into the sys-
tem.
5. If the refrigerant charge will not completely
IMPORTANT: be sure there are no leaks in the sys- transfer to the air conditioning system, recover
tem and the system has been fully evacuated. Ob- and recharge the system.
serve all safety recommendations when handling 6. Close the high and low side valves on the units
refrigerant HFC 134a, see “Precautions when Han- control panel, or manifold gauge set if being
dling Refrigerant HFC 134a” in this Section. used and test the air conditioning as detailed in
Performance testing the air conditioning system
1. Ensure the charging unit is correctly connected on page 25.
to the loader backhoe air conditioning system in
accordance with the manufacturers instructions. NOTE: after charging a system use the following
2. If a charging unit, in conjunction with the mani- start up procedure to ensure the lubricating oil is
fold gauge set is used, open the high and low properly dispersed around the system.
side hand valves on the manifold.
3. Charge the system with 0.75 kg (2 lb) of refrig- Ensure air conditioning is switched OFF.
erant as per the manufacturers instructions. Start the engine and bring speed down to idle.
4. If the charging rate becomes very slow close Turn the air conditioning ON and allow system to
the high side valve carefully, start the loader operate for at least one minute before increasing
backhoe and set engine speed to idle. Turn ON engine speed.
the air conditioning so that the compressor can
ì í î
Úîèéïð
GENERAL
WARNING
Before disconnecting components in the air condi-
tioning system the refrigerant gas must be dis-
charged and recovered using a certified recovery
system. Refer to Discharging the system. Do Not
discharge the gas into the atmosphere.
EXPANSION VALVE
The expansion valve is not a serviceable item and
must be replaced if defective.
1. Fully discharge the air conditioning system.
2. Remove the seat to gain access to the valve.
3. To gain access to the expansion valve partially
lift the evaporator core from its position in the
cab floor.
4. Remove the screw securing the inlet and outlet
connections to the valve and pull valve from tub-
ing.
5. Replace the O-ring seals and lubricate with re-
frigerant oil prior to installing the valve using dis- Úîèéïì
EVAPORATOR
1. Discharge and reclaim refrigerant gas using cer-
tified recovery systems.
2. Remove the seat and cover plate to reveal evap-
orator assembly (1).
3. Remove temperature cycling control thermocou-
ple.
4. Disconnect tubing to expansion valve.
5. Remove evaporator.
6. Check the evaporator assembly fins for damage.
Straighten fins if necessary.
7. Clean the evaporator core of all foreign material
to be sure it is free of obstructions.
8. Check the evaporator assembly for indications
of refrigerant leakage. If damage or leaks are ev-
ident, replace the evaporator core.
If a new evaporator is to be installed drain the refrig-
erant oil in the evaporator into a clean calibrated
container. Measure the quantity of oil obtained and
add the same quantity of new refrigerant oil directly
into the replacement evaporator core.
Install evaporator using disassembly procedure in
reverse.
Evacuate, leak test and recharge the system.
RECEIVER DRYER
The receiver/dryer (3) cannot be overhauled and
must be replaced as an assembly. The receiver/dry-
er assembly should be replaced if it is suspected that
moisture is in the system.
The receiver dryer must also be replaced if the sys-
tem has been discharged and the air conditioning
joints disconnected.
1. Discharge and reclaim refrigerant gas using cer-
tified recovery systems.
2. Disconnect the hoses and switch and remove
the dryer from the loader backhoe.
3. Drain the refrigerant oil from the receiver dryer
into a clean calibrated container. Measure the
quantity of oil obtained and add the same quan-
tity of new refrigerant oil directly into the new
item.
4. Cap and plug all fittings to prevent any dirt enter-
ing the system.
5. Install a new receiver dryer.
50 SECTION 50 - CAB HEATING AND AIR CONDITIONING
CONDENSER
1. Remove the front grill (1). Unscrew and remove
the fixing nuts (2).
3.9 COMPRESSOR
TECHNICAL SPECIFICATIONS
Belt tension
Measure at the widest gap ............10 mm (0.4 in) deflection with 1 kg (2 lb) force applied midway between the pulleys
Speed rating
MAXIMUM RPM
Constant Downshift
6000 8000
Tightening torques
COMPONENT Nm (lbf·ft)
Armature retaining nut, M8 17.7±2.9 (13±2.1)
Cylinder head bolts, M6 13.7±2.9 (10.1±2.1)
Cylinder head bolts, M8 34.3±4.9 (25.3±3.6)
Clutch dust cover screw, M5 9±2 (6.6±1.4)
Oil filler plug 19.6±4.9 (14.4±3.6)
SECTION 50 - CAB HEATING AND AIR CONDITIONING 53
FAULT FINDING
During diagnosis follow the inspections procedures in the sequence shown until a default is found. Then per-
form the repair in the “Cause and Remedy” section. If this repair does not fully solve the problem, proceed to
the next inspection step.
ïí
ïð
é
ïî
ïï ï
é î
ë
è
ïì
ç
ï í ê ë
Úîèéîï
Removal
Discharge the air conditioning system. Disconnect
the electrical harness of the compressor (12) from
the electrical harness of the engine. Disconnect tub-
ing to compressor. Remove the washer (7) and the
screw (1). Remove the protective guard (13). Re-
move the bolt (11). Remove the nut (14) and the
screw (9).
SECTION 50 - CAB HEATING AND AIR CONDITIONING 55
Remove the washers (5), the nut (6), the screw (2)
and the block (8). Remove the screw (1), the wash-
ers (3) and the belt tensioner (4). Remove the screw
(10), the washers (2) and the compressor (12).
Installation
Installation is the reversal of the removal but the fol-
lowing points should be noted:
Torque the fixing bolts to 40-51 Nm (29.5-
37.6 lbf·ft).
Úîèéîë
56 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Úîèéîê
OVERHAUL COMPRESSOR
Before any internal repair is done, drain the oil from
the compressor:
Remove the oil plug and drain as much oil as pos-
sible into a suitable container.
Remove the caps (if present) from suction and dis-
charge ports.
Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retain-
ing nut.
Úîèéîé
Úîèéîè
SECTION 50 - CAB HEATING AND AIR CONDITIONING 57
CLUTCH
ï î í ì ë ê é è ç ïð
Úîèéîç
Disassembly
All clutch servicing should be done with the com-
pressor removed from the vehicle. Support the com-
pressor. If using a vice, do not hold on to the
housing. If dust cover (2) is present, remove the 3 or
6 bolts (1) holding it in place and remove cover. If
auxiliary sheet metal pulley is present, remove the
screws holding it in place. Then remove pulley. ì
Attach tool to the cover on the front of the clutch
plate and placing a socket and ratchet through the
tool remove the cover attaching nut (3).
Úîèéíð
Using the front plate tool and a tommy bar hold the
clutch plate stationary.
Place the bolt into the tool and by tightening the bolt
onto the end of the shaft the front plate will be ex-
tracted from the shaft.
If shims (5) are above shaft key, remove them now.
If shims (5) are below shaft key, the key and bearing
dust cover (if present) must be removed before
shims can be removed.
Remove dust cover (6) (if present). Use caution to
prevent distorting cover when removing it.
Remove shaft key by tapping loose with a flat blade
screwdriver and hammer. Remove shims (5). Use a Úîèéíï
Remove the snap ring (7), remove the shaft key and
lift the pulley assembly from the compressor.
Úîèéíî
Úîèéíí
Úîèéíì
Úîèéíë
SECTION 50 - CAB HEATING AND AIR CONDITIONING 59
Lift the coil (10) from the housing and replace as re-
quired. ïð
Úîèéíê
Assembly
Install the field coil (10), ensuring that the wire is lo-
cated back at cable clip on the outside of the body
and snap ring (9) is placed in the groove. ïð
Úîèéíé
Úîèéíè
Úîèéíî
60 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Úîèéíð
è
Úîèéìï
Úîèéìî
SECTION 50 - CAB HEATING AND AIR CONDITIONING 61
COMPRESSOR
ë ê é è ç ïð
ï í
î ì
Úîèéìí
Removal
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior
to replacing the shaft seal.
Remove the armature plate, as detailed in the
steps of clutch disassembly.
Remove the shaft key (1), shims and ring (2) to ex-
pose the snap ring (3). í
Remove the snap ring (3).
Úîèéìì
Úîèéìë
62 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Installation
Thoroughly clean the seal cavity in the hub. Use “lint
free” cloth only.
Ensure the new shaft seal O-ring is installed onto
the seal assembly. Dip the new seal assembly in
clean refrigerant oil and attach to the seal remover/
installer tool.
Úîèéìê
Úîèéïç
Install the snap ring (3). If the snap ring has a bevel-
led edge this should face outwards.
Úîèéìì
Úîèéïí
SECTION 50 - CAB HEATING AND AIR CONDITIONING 63
Position the shims over the shaft and refit the shaft
key.
Reinstall the plate as described in clutch reassem-
bly.
Úîèçïï
64 SECTION 50 - CAB HEATING AND AIR CONDITIONING
CYLINDER HEAD
Disassembly
Drain the refrigerant oil from the compressor into a
clean calibrated container. Measure and record the ïð ç
quantity of oil obtained. This information is required
during installation of the new or overhauled unit.
Remove the six cylinder head bolts (10) and using a
hide mallet, gently tap the cylinder head (9) free.
The use of a gasket scraper may also be required to
free the cylinder head from the compressor body.
Úîèéìé
Úîèéìè
Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage. é
Úîèéìç
Reassembly
Coat the top of the valve plate with clean refrigerant
oil and reassemble the cylinder head using the re-
verse of the disassembly procedure.
When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins
in the cylinder block.
Install the cylinder head bolts and tighten using the
sequence shown. Torque initially to 20 Nm
(14.7 lbf·ft).
When the overhaul is complete add to the compres-
sor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.
Úîèéëð
SECTION 50 - CAB HEATING AND AIR CONDITIONING 65
Preliminary Inspection
1. Rotate the compressor shaft. Use a suitable
socket on the hub centre bolt or by hand using
the rubber dampers.
If severe roughness is felt while rotating the hub,
the compressor should be disassembled.
2. Using a 12 volt battery check current drawn by
the field coil which should be between 3.6-
4.2 Amps.
Very high current readings indicate a short cir-
cuit in the field coil and no current reading indi-
cate an open circuit. Replace coil with either
fault. Resistance of the coil using an ohmmeter Úîèéëï
Úîèéëî
66 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Only certified refrigerant recovery, recycling and recharge equipment suitable for the type of refrigerant gas
HFC 134a should be used on these vehicles when servicing the air conditioning system.
This special equipment is available through recognized suppliers of air conditioning equipment. Refer to the
“Tool supplier” for details on the latest equipment available for servicing the air conditioning system.
1. GENERALITIES ............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB ........................................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB ............................................................................... 22
2.3 ELECTRICAL DIAGRAMS - 4WS........................................................................................................ 39
3. CONTROLS AND INSTRUMENTS ............................................................................................................ 57
3.1 FRONT INSTRUMENT PANEL ........................................................................................................... 57
3.2 CALIBRATION OF SPEEDOMETER .................................................................................................. 59
3.3 SIDE INSTRUMENT PANEL ............................................................................................................... 60
3.4 IMMOBILISER CIRCUIT...................................................................................................................... 64
4. DIAGNOSTICS DISPLAY ........................................................................................................................... 65
4.1 SYMBOL .............................................................................................................................................. 66
4.2 SETUP MENU ..................................................................................................................................... 67
4.3 SETUP MENU ..................................................................................................................................... 68
4.4 PROCEDURE ABOUT SELF TEST .................................................................................................... 69
4.5 ON BOARD ERROR CODE RETRIEVAL ........................................................................................... 70
4.6 BACKLIGHTING AND DIMMING......................................................................................................... 71
4.7 WORK HOURS.................................................................................................................................... 72
4.8 FUNCTIONAL DESCRIPTION ............................................................................................................ 73
4.9 MAINTENANCE................................................................................................................................... 79
4.10 WARNING MESSAGES .................................................................................................................... 80
5. STARTING SYSTEM .................................................................................................................................. 86
5.1 DESCRIPTION AND OPERATION...................................................................................................... 86
5.2 FAULT FINDING.................................................................................................................................. 87
5.3 STARTER MOTOR.............................................................................................................................. 90
2 SECTION 55 - ELECTRICAL SYSTEM
6. ALTERNATOR ............................................................................................................................................ 96
6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 96
6.2 DESCRIPTION AND OPERATION...................................................................................................... 96
6.3 COMPONENTS ................................................................................................................................... 98
6.4 REMOVAL............................................................................................................................................ 99
6.5 PRELIMINARY CHECK AND TESTS ................................................................................................ 100
6.6 FAULT FINDING ................................................................................................................................ 109
7. BATTERY.................................................................................................................................................. 110
7.1 TECHNICAL SPECIFICATIONS........................................................................................................ 110
7.2 DESCRIPTION AND OPERATION.................................................................................................... 110
7.3 BATTERY REPLACEMENT............................................................................................................... 111
7.4 MAINTENANCE ................................................................................................................................. 113
7.5 TESTS................................................................................................................................................ 115
7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 117
7.7 BATTERY MASTER SWITCH ........................................................................................................... 117
8. COMPONENT TESTING .......................................................................................................................... 118
8.1 GENERAL INTRODUCTION ............................................................................................................. 118
8.2 COMPONENT TESTING ................................................................................................................... 119
8.3 GROUND POINTS............................................................................................................................. 119
8.4 KEY-START AND STOP SWITCH .................................................................................................... 121
8.5 ALTERNATOR ................................................................................................................................... 122
8.6 TRANSMISSIONS ............................................................................................................................. 122
8.7 PARKING BRAKE SWITCH............................................................................................................... 126
8.8 CAB.................................................................................................................................................... 127
8.9 4WD SWITCH .................................................................................................................................... 132
8.10 BRAKE PEDAL SWITCHES ............................................................................................................ 132
8.11 BRAKE OIL LEVEL SWITCH........................................................................................................... 133
8.12 FRONT WORK LAMP SWITCH (1) - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH.... 133
8.13 HAZARD SWITCH ........................................................................................................................... 134
8.14 FLASHER MODULE ........................................................................................................................ 134
8.15 MULTI FUNCTION SWITCH............................................................................................................ 135
8.16 FRONT WIPER MOTOR (1) - REAR WIPER MOTOR - (2) ............................................................ 135
8.17 4WS -STEERING SELECTOR SWITCH ......................................................................................... 136
8.18 STEERING CONTROL UNIT........................................................................................................... 137
8.19 4WS REAR AXLE STEERING SENSOR......................................................................................... 139
8.20 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 139
8.21 STEERING SOLENOIDS................................................................................................................. 140
8.22 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 141
8.23 LOADER .......................................................................................................................................... 142
8.24 BACKHOE........................................................................................................................................ 144
8.25 REVERSING BUZZER..................................................................................................................... 149
8.26 FUEL LEVEL SENDER.................................................................................................................... 149
SECTION 55 - ELECTRICAL SYSTEM 3
1. GENERALITIES
1.1 TEMPORARY WIRING HARNESS REPAIR
Charge indicator lamp stays on Malfunctioning battery Check battery open circuit voltage
with engine running for 12.6 volts minimum.
Check electrolyte level and specific
gravity.
2. ELECTRICAL DIAGRAMS
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB
NAME DESCRIPTION
Rear windshield wiper and rear windshield washer
F1A
(15 A)
Fuel shut off, (+15) antitheft, (+15) key switch, supply
F1B
(+15) ECU (7.5 A)
F1C Stop lights switch (10 A)
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat (15 A)
F2B Conditioner (15 A)
F2C Pilot control (15 A)
Rear right/front left side lights, instruments illumination
F3A
(3 A)
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, Ride control, double delivery, 4x1 grab
F3C
switches (10 A)
Forward speed, reverse speed, reverse buzzer, speed
F4A
switch (5 A)
Rear hammer button, grab level valve and sensor,
F4B
clutch shut off buttons (10 A)
Rear excavator lock, rear translation lock, rear transport
F4C
lock (10 A)
F5A Front inner work lights (15 A)
F5B Traffic lights (10 A)
F5C Main beam (15 A)
F6A Beacon lamp (7.5 A)
F6B (+15) Flasher (7.5 A)
F6C Hand hammer, 4WD (7.5 A)
F7A (+30) Warning horn (10 A)
F7B Current intake, radio, roof lamp (10 A)
F7C Front windshield wiper (6 A)
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
6 SECTION 55 - ELECTRICAL SYSTEM
NAME DESCRIPTION
K1 Forward-reverse speed switch relay
K3 Starting relay
K4 Grab level solenoid valve relay
K5 Traffic and main beam lights relay
K6 Inner front work lights relay
K7 Inner rear work lights relay
K8 Outer front work lights relay
K9 Outer rear work lights relay
K10 Reverse speed relay
K11 Forward speed relay
K1A Flasher
SECTION 55 - ELECTRICAL SYSTEM 7
LIGHTS SCHEMATIC
14 SECTION 55 - ELECTRICAL SYSTEM
ï
í
Ó
ó õ
ïð ïï
ç
ì
Ô Ó Ø
î
× Ø ÓÔ Ý
ß Í
ïî
ë
Úîéïèï
FRONT INSTRUMENT
SIDE INSTRUMENT
Calibrations
CONNECTORS
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used Need to fuse at 1 A
1 Keep alive power
2 Key on power Wake up without disconnect
NAME DESCRIPTION
Rear windshield wiper and rear windshield washer
F1A
(15 A)
Fuel shut off, (+15) antitheft, (+15) key switch, supply
F1B
(+15) ECU (7.5 A)
F1C Stop lights switch (10 A)
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat (15 A)
F2B Conditioner (15 A)
F2C Pilot control (15 A)
Rear right/front left side lights, instruments illumination
F3A
(3 A)
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, Ride control, double delivery, grab 4x1
F3C
switches (10 A)
EGS power supply, clutch shut off button, 4WD switch
F4A
(7.5 A)
F4B Rear hammer button, grab level valve and sensor (10 A)
Rear excavator lock, rear translation lock, rear transport
F4C
lock (10 A)
F5A Front inner work lights (15 A)
F5B Traffic lights (10 A)
F5C Main beam (15 A)
F6A Beacon lamp (7.5 A)
F6B (+ 15) Flasher
F6C Hand hammer, differential lock (7.5 A)
F7A (+30) Warning horn (10 A)
F7B Current intake, radio, roof lamp (10 A)
F7C Front windshield wiper (6 A)
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
K3 Starting relay
K4 Grab level solenoid valve relay
K5 Traffic and main beam lights relay
K6 Inner front work lights relay
K7 Inner rear work lights relay
SECTION 55 - ELECTRICAL SYSTEM 23
NAME DESCRIPTION
K8 Outer front work lights relay
K9 Outer rear work lights relay
K10 Differential lock relay
K1A Flasher
24 SECTION 55 - ELECTRICAL SYSTEM
LIGHTS SCHEMATIC
SECTION 55 - ELECTRICAL SYSTEM 31
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ç
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Ô Ó Ø
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× Ø ÓÔ Ý
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FRONT INSTRUMENT
SIDE INSTRUMENT
Calibrations
CONNECTORS
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used Need to fuse at 1 A
1 Keep alive power
2 Key on power Wake up without disconnect
NAME DESCRIPTION
Rear windshield wiper and rear windshield washer
F1A
(15 A)
Fuel shut off, (+15) antitheft, (+15) key switch, supply
F1B
(+15) ECU (7.5 A)
Stop lights switch (15 A), steering unit, steering switch
F1C
(10 A)
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat, buzzer
F2B Conditioner (15 A)
F2C Pilot control, front tools (optional) (15 A)
Rear right/front left side lights, instruments illumination
F3A
(3 A)
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, Ride control, double delivery, 4x1 grab
F3C
switches (10 A)
EGS power supply, clutch shut off button, 4WD switches
F4A
(7.5 A)
F4B Rear hammer button, grab level valve and sensor (10 A)
Rear excavator lock, rear translation lock, rear transport
F4C
lock (10 A)
F5A Front inner work lights (15 A)
F5B Traffic lights (10 A)
F5C Main beam (15 A)
F6A Beacon lamp (7.5 A)
F6B (+15) Flasher (7.5 A)
F6C Hand hammer (7.5 A)
F7A (+30) Warning horn (10 A)
F7B Current intake, radio, roof lamp (10 A)
F7C Front windshield wiper (6 A)
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
40 SECTION 55 - ELECTRICAL SYSTEM
NAME DESCRIPTION
K3 Starting relay
K4 Grab level solenoid valve relay
K5 Traffic and main beam lights relay
K6 Inner front work lights relay
K7 Inner rear work lights relay
K8 Outer front work lights relay
K9 Outer rear work lights relay
K10 Optional relay
K1A Flasher
K1B Buzzer
SECTION 55 - ELECTRICAL SYSTEM 41
LIGHTS SCHEMATIC
48 SECTION 55 - ELECTRICAL SYSTEM
STEERING SCHEMATIC
52 SECTION 55 - ELECTRICAL SYSTEM
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Ô Ó Ø
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× Ø ÓÔ Ý
ß Í
ïî
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Úîéïèï
FRONT INSTRUMENT
SIDE INSTRUMENT
Calibrations
CONNECTORS
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used Need to fuse at 1 A
1 Keep alive power
2 Key on power Wake up without disconnect
Úîèêêê
POWERSHUTTLE
POWERSHIFT
WARNING
Never operate the glide ride system control when
the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The
machine could fall and cause serious or fatal injury.
SECTION 55 - ELECTRICAL SYSTEM 61
SIDE INSTRUMENT
Úîèêêé
Wire
Function Connection
No.
1 (+15) Key positive Connected to the + 12 V full ignition supply
2 (+30) Permanent + 12 V power supply Connected to the wire from the battery positive
Connected to the vehicle negative at two independent
3 (-31) Negative power supply
points
Connected in line with the wire controlling the starter
5-6 Immobilization relay No. 2 motor relay/solenoid - Minimum 500 mA maximum 10 A
capacity
Connect in line with the wire controlling the ignition or
7 - 8 - 9 Immobilization relay No. 1
fuel circuit - Minimum 500 mA maximum 10 A capacity
SECTION 55 - ELECTRICAL SYSTEM 65
4. DIAGNOSTICS DISPLAY
The diagnostics display (1) is located in the middle
of the side instrument panel (4).
The switches used to enter diagnostics are follow-
ing:
4.1 SYMBOL
Increment
Decrement
Enter to make the number stop flashing
Increment
Decrement
Service
interval
Increment
Decrement
Page#/total page
Stored error CODE
code OCCURRENCE
HOUR
Presence of grid
heater Select/Deselect
HARDWARE
Hardware part P/N
number ID Enter to make the number
VER flash then it can be adjusted
Increment
Decrement
Enter to make the number
HARDWARE stop flashing
Software part P/N
number ID
VER
SECTION 55 - ELECTRICAL SYSTEM 69
Go to menu
Hand max: X.X. 125/120
Normal “Key ON” Hand min: X.X. range
Check:
Step 1: Lamps switch on at full intensity. 100 mA < Current draw < 1amp
Requested
98/88
engine rpm:
Step 2: Lamps switch off after 2 seconds. range
XXX
10 mA < Current draw < 1 mA
Step 9: 2 seconds after red-green border is reached move Makes sure that needles are
to second red border for voltage. properly calibrated to applique
Coolant temp:
107/123
XXX
Step 10: Park all gauges and start LCD test. range
Air temp: XXX
Óß×Ò ÍÝÎÛÛÒ
Page 1/6
CODE 3059 3 second scroll unless
HOUR 1004.5
Page 2/6
CODE 3009
OCCURRENCE 2
HOUR 1010.6
Page 3/6
Occurrence counter will be incremented on transition from CODE 1018
inactive to active status. Status has to be stored in EEPROM and
checked at key on. Only the hour count of the last occurrence will OCCURRENCE 1
be stored per SAE convention. HOUR 1024.5
Page 4/6
CODE 3022
OCCURRENCE 1
HOUR 969.4
Page 5/6
CODE 3113
OCCURRENCE 2
HOUR 1050.6
Page 6/6
CODE 1003
OCCURRENCE 3
HOUR 1076.4
SECTION 55 - ELECTRICAL SYSTEM 71
DIMMING LAW
The dimming adjustment is done through the setup
menu, it can be used in single. In single step mode,
the luminance level go from min to max value in 10
steps.
In order to allow service or the customer to view ve- once in the adjustment mode the meaning of the
hicle hours of operation, it will not be necessary to arrow UP switch is “increase hour meter value”,
have the key. By pressing the enter/display/up/ and the meaning of arrow DOWN switch is “de-
down switch, with the key-off, the cluster must wake crease hour meter value”. Single switch pressure
up and display hours for 10 seconds. will increase or decrease the value of one unit
The hour meter increments when the engine is run- (6 min). Continuous switch pressure will increase
ning (rpm > 600). The hours are visualized starting or decrease the value continuously (1 every 300
from 0.0 until 210,554,060.7 using a step of 6 min- milliseconds): when the value reaches a multiple of
utes. In case of battery disconnection, the cluster 10, the increment/decrement rate is 10 units every
can lose 0.1 hour or 6 minutes max. 300 ms; when the value reaches a multiple of 100,
the rate is 100 units every 300 ms; when the value
WORK HOURS SETTING reaches a multiple of 1000, the rate is 1000 units
In order to allow service to install a new Vehicle every 300 ms.
Control Module (VCM) on an old vehicle, it is possi-
ble to increase (no decrease will be allowed) the During continuous setting the value stops flashing.
hour to the same setting as the original. Once the operator has reached the desired value
To modify the hour meter value, execute the follow- press and hold down the arrow UP and display
ing procedure: switches for 15 seconds to end setting procedure. It
select the hour meter function on the display; is not possible to set a value lower than the current
press and hold depressed for 15 seconds “arrow one, and the procedure can be repeated three times
UP” and “display” until the value shown on display in the cluster life.
starts to blink (1 Hz, duty 50%);
Service hours
Value may only increase for the hour counter. While setting the value it can be decreased due
to operator overshoot, but the value can not be stored if it is below the current stored value.
Pressing DISPLAY will exit without saving. ENTER must be pressed to store the modified value
in protected memory.
SECTION 55 - ELECTRICAL SYSTEM 73
Auto wake up at every 600 ms for sensing a change At key off all the needles have to be put into parking
in ENTER, DISPLAY, UP or DOWN switch status position. parking position will be hard against inter-
will be provided. Upon sensing of one of those in- nal stepper motor stops. At key on the following flow
puts transition, the cluster has to wake up. must be followed.
As a general rule, during cranking, all warnings ac-
tivation and all gauges movements have to be fro-
zen unless we detect an error on the cranking line.
Needle collision
control at key-on
Vibration, service,
transport or battery If RTZ is observed TRUE
loss can generate a on all 5 gauges
FALSE
FALSE
Drive gauges:
- engine coolant
- fuel level
TACHOMETER - ENGINE SPEED GAUGE Audible alarm output needs to be activated when
The tachometer accuracy should be less than or the engine temperature exceeds 106 °C (222.8 °F).
equal ±50 rpm. The above specified tolerances In case the sender is disconnected, the gauge has
must be respected in all operating ranges (tempera- to go to 65 °C (149 °F) position. Reconnecting the
ture, voltage, etc.). A stepper motor will drive the ta- sensor the gauge has to return to the correct posi-
chometer. Needle calibration has never to be lost for tion. Both the movements have to be uniform.
any external condition. The behavior of the gauge in case of faulty sensor
The message to be used is EEC1. will be to return to the parked position. Since this
signal is a function of the engine controller the ap-
EEC1 message Gauge position propriate warning lamp and lamp will be illuminated.
0000 0 rpm During cranking, the needle movement shall be fro-
zen in order to inhibit any spurious movement of it.
0001 => FFFD According to the value
VOLTMETER GAUGE
Green field 0 - 2500 rpm
The voltmeter will indicate the voltage of the vehicle
Red field 2500 - 3000 rpm
electrical system. This gauge will have three operat-
FFFF 0 rpm ing ranges: two reds and one green. One red range
will indicate low voltage. The other red will indicate
high voltage. The green range will indicate normal
The behavior of the gauge in case of faulty sensor
operating voltage.
will be to return to the parked position. Since this
signal is a function of the engine controller the ap- Bottom of the scale will be 9 volts.
propriate warning lamp and lamp will be illuminated. Low voltage range is 11 volts or less. The CL of the
During cranking, the needle movement shall be fro- pointer will be ±3° of the centerline of the tick mark
zen in order to inhibit any spurious movement of it. that indicates 11 volts.
The normal operating range will be 11 volts to
ENGINE COOLANT TEMPERATURE GAUGE 16 volts.
High voltage range is 16 volts or higher. The CL of
A stepper motor will drive coolant temperature the pointer will be ±3° of the centerline of the tick
gauge. The gauge accuracy should be less than or mark that indicates 16 volts.
equal 3%. Needle calibration has never to be lost for Top of the scale will be 18 volts.
any external condition. A stepper motor will drive the voltmeter gauge. The
Gauge Temperature gauge accuracy should be less than or equal 3%.
Needle calibration has never to be lost for any exter-
+65 to +112 °C nal condition. Loss of voltmeter sensor will be the
Gauge indication range
(+149 to +233.6 °F) loss of the internal VCM A/D converter. During
+65 to +106 °C cranking, the needle movement shall be frozen in
Green field order to inhibit any spurious movement of it.
(+149 to +222.8 °F)
A/D accuracy is specified as ±180 mV during self
+106 to +112 °C test operation.
Red field
(+222.8 to +233.6 °F)
ALARM ACTIVATION
A failure is present but the operator can continue his work: the purpose is to warn him
Non Critical
regarding the presence of the fault. This will be a 1 second beep every 30 seconds.
A serious fault that can affect either the safety of the operator or the damage of the
Critical loader backhoe is present: the operator shall stop the loader backhoe. This will be a
continuous alarm.
The system is asking for a certain maneuver from the operator in order to return to the
Action Required
normal functionality. This will be a continuous alarm.
The system purpose is to warn the operator regarding the presence of a dangerous
Safety
situation for his safety. This will be a continuous alarm.
There are some condition in which there is the need of an activation of the audible
General Sound
alarm. This is a one second beep to draw the operators attention to the cluster.
4.10 MAINTENANCE
In Amber backlighting
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ëðð
The interval can be set between 50 and 500 hours
In Amber backlighting in steps of 100 (0.0, 500, 600, 700, 800, 900, 1000).
The 0.0 setting turns the heavy maintenance feature
The interval can be set between 50 and 500 hours off.
in steps of 50 (0.0, 50, 100, 150, 200, 250, 300, 350,
400, 450, 500). The 0.0 setting turns the light main-
tenance feature off.
DISPLAY FUNCTIONALITY
3 seconds
Ô×ÙØÌ
3 seconds
ëðð
GREEN AMBER
Audible alarm for 1 second when displaying either service interval the first time
3 seconds
ØÛßÊÇ
3 seconds
ïððð
GREEN AMBER
Audible alarm for 1 second when displaying either service interval the first time
Since heavy maintenance contains light maintenance the following will be shown:
500 - Light
1000 - Heavy
1500 - Light
2000 - Heavy
The service indicator message will be cleared with a single key cycle
80 SECTION 55 - ELECTRICAL SYSTEM
Fault Display
Function Alarm Lamp Condition DTC SA Description Priority Color
lamp lamp
Coolant
Coolant
Engine ÍÌÑÐ above
temperature
coolant too Continuous 112 °C 1002 VCM 1 Red
signal - Above
high (233.6 °F) for
normal
5 seconds
Pressure Oil pressure
Engine oil ÍÌÑÐ < 26 bar sensor -
pressure too Continuous 3028 ECU 1 Red
(37.7 psi) pressure too
low
rpm>500 low
The engine
Switch
Transmission ÍÌÑÐ must be
closed to
oil pressure Continuous 1008 VCM running with 1 Red
ground for 25
too low switch closed
seconds
for 25 seconds
5 seconds
Timeout of
Malfunction ÍÌÑÐ Continuous without 1051 ECU 1 Red
message
message
25 seconds
Timeout of
Malfunction ÍÌÑÐ Continuous without 1053 ECU 1 Red
message
message
Timeout of
5 seconds
ÍÌÑÐ message
Malfunction Continuous without 1054 VCM 1 Red
engine
message
temperature
5 seconds Timeout of
Malfunction ÍÌÑÐ Continuous without 1055 VCM message inlet/ 1 Red
message exhaust
5 seconds Timeout of
Malfunction ÍÌÑÐ Continuous without 1056 VCM message 1 Red
message engine fluid
Timeout of
5 seconds
ÍÌÑÐ message
Malfunction Continuous without 1057 VCM 1 Red
vehicle
message
electrical
5 seconds Timeout of
Malfunction ÍÌÑÐ Continuous without 1059 VCM message 1 Red
message display
Transmission
Transmission Transmission
ÍÌÑÐ oil above
oil oil
Continuous 115 °C 1009 VCM 1 Red
temperature temperature
(239 °F) for 5
too high limit reached
seconds
SECTION 55 - ELECTRICAL SYSTEM 81
Fault Display
Function Alarm Lamp Condition DTC SA Description Priority Color
lamp lamp
General Only display
DTC’s 3000 -
display ÍÌÑÐ Continuous ÍÌÑÐ with display 1 Red
3366
message request
One touch
ßËÌÑ N/A VCM 1 Red
idle active
²ñ³·²
Fault Display
Function Alarm Lamp Condition DTC SA Description Priority Color
lamp lamp
Foot Foot
One second Accelerator
accelerator accelerator
alarm every above 4.75 V 1011 VCM 2 Amber
signal out of sensor -signal
30 seconds for 5 seconds
range above range
Foot Foot
One second Accelerator
accelerator accelerator
alarm every below 0.25 V 1012 VCM 2 Amber
signal out of sensor -signal
30 seconds for 5 seconds
range below range
Foot Foot
One second
accelerator accelerator
alarm every 1013 VCM 2 Amber
signal out of sensor -no
30 seconds
range signal
Foot
Foot
One second Voltage over accelerator
accelerator
alarm every 9 V for 5 1029 VCM sensor - 2 Amber
signal out of
30 seconds seconds shorted high to
range
Vbat
Foot
Foot
One second Voltage accelerator
accelerator
alarm every under 0.5 V 1030 VCM sensor - 2 Amber
signal out of
30 seconds for 5 seconds shorted low to
range
Vbat
Foot
Foot One second Voltage over
accelerator
accelerator alarm every 5.1 V for 5 1023 VCM 2 Amber
supply voltage
5 V supply 30 seconds seconds
too high
Foot
Foot One second Voltage
accelerator
accelerator alarm every under 4.9 V 1024 VCM 2 Amber
supply voltage
5 V supply 30 seconds for 5 seconds
too low
Foot
Foot One second Voltage over
accelerator
accelerator alarm every 9 V for 5 1025 VCM 2 Amber
supply shorted
5 V supply 30 seconds seconds
high to Vbat
Foot
Foot One second Voltage accelerator
accelerator alarm every under 0.5 V 1026 VCM supply shorted 2 Amber
5 V supply 30 seconds for 5 seconds low
to ground
SECTION 55 - ELECTRICAL SYSTEM 83
Fault Display
Function Alarm Lamp Condition DTC SA Description Priority Color
lamp lamp
Hand Hand
One second Accelerator
accelerator accelerator
alarm every above 4.75 V 1035 VCM 2 Amber
signal out of sensor -signal
30 seconds for 5 seconds
range above range
Hand Hand
One second Accelerator
accelerator accelerator
alarm every below 0.25 V 1036 VCM 2 Amber
signal out of sensor -signal
30 seconds for 5 seconds
range above range
Hand Hand
One second
accelerator accelerator
alarm every 1037 VCM 2 Amber
signal out of sensor - no
30 seconds
range signal
Hand
Hand
One second Voltage over accelerator
accelerator
alarm every 9 V for 5 1038 VCM sensor - 2 Amber
signal out of
30 seconds seconds shorted high to
range
Vbat
Hand
Hand
One second Voltage accelerator
accelerator
alarm every under 0.5 V 1039 VCM sensor - 2 Amber
signal out of
30 seconds for 5 seconds shorted low to
range
ground
Hand
Hand One second Voltage over
accelerator
accelerator alarm every 5.1 V for 5 1031 VCM 2 Amber
supply voltage
5 V supply 30 seconds seconds
too high
Hand
Hand One second Voltage
accelerator
accelerator alarm every under 4.9 V 1032 VCM 2 Amber
supply voltage
5 V supply 30 seconds for 5 seconds
too low
Hand
Hand One second Voltage over
accelerator
accelerator alarm every 9 V for 5 1033 VCM 2 Amber
supply shorted
5 V supply 30 seconds seconds
high
Hand
Hand One second Voltage
accelerator
accelerator alarm every under 0.5 V 1034 VCM 2 Amber
supply shorted
5 V supply 30 seconds for 5 seconds
low
Switch
This must
closed to
Seat not in have a
ground with
driving Continuous N/A VCM debounce time 2 Amber
vehicle in
position of less then
gear and no
500 ms
park brake
84 SECTION 55 - ELECTRICAL SYSTEM
Fault Display
Function Alarm Lamp Condition DTC SA Description Priority Color
lamp lamp
Boost
temperature Engine over
Boost air One second
over operating
temperature alarm every 1018 VCM 3 Amber
88 °C boost air
too high 30 seconds
(190 °F) for 5 temperature
seconds
Coolant
Engine over
Engine One second above
operating
coolant too alarm every 106 °C 1019 VCM Amber
coolant
high 30 seconds (222.8 °F) for
temperature
5 seconds
Coolant
Engine One second
temperature
coolant too alarm every 3007 ECU 3 Amber
signal source
high 30 seconds
high
Coolant
Transmission
One second above Transmission
oil above
alarm every 105 °C 1020 VCM over operating 3 Amber
105 °C
30 seconds (221 °F) for 5 temperature
(221 °F)
seconds
Fuel over
Fuel One second Fuel over
82 °C
temperature alarm every 1021 VCM operating 3 Amber
(179.6 °F) for
too high 30 seconds temperature
5 seconds
Fuel
Fuel One second
temperature
temperature alarm every 3015 ECU 3 Amber
signal source
too high 30 seconds
high
Fuel
Fuel One second
temperature
temperature alarm every 3016 ECU 3 Amber
signal no
too high 30 seconds
signal
Switch
One second
Air filter closed to Air filter
alarm every 1001 VCM 4 Red
restriction ground for 5 threshold
30 seconds
seconds
Switch
Air One second Air
closed to
conditioning alarm every 1003 VCM conditioning 4 Amber
Vbat for 5
not functional 30 seconds high pressure
seconds
Switch
Hydraulic One second
closed to Hydraulic filter
filter alarm every 1004 VCM 4 Red
ground for 5 threshold
restriction 30 seconds
seconds
Fuel One second
Display
contaminated alarm every 1022 VCM 4 Amber
message
with water 30 seconds
SECTION 55 - ELECTRICAL SYSTEM 85
Fault Display
Function Alarm Lamp Condition DTC SA Description Priority Color
lamp lamp
One second Fuel sender Fuel sender
Fuel level
alarm every above 9 V for 1043 VCM shorted high - 4 Amber
sensor
30 seconds 5 seconds park gauge
One second Fuel sender Fuel sender
Fuel level
alarm every below 0.5 V 1044 VCM shorted low - 4 Amber
sensor
30 seconds for 5 seconds park gauge
Input is
One second Fuel sender
Fuel level switched
alarm every 1045 VCM open circuit - 4 Amber
sensor battery for 5
30 seconds park gauge
seconds
Transmission
Transmission
Transmission One second temperature
temperature
temperature alarm every sender 1046 VCM 4 Amber
sender
sensor 30 seconds above 9 V for
shorted high
5 seconds
Transmission
Transmission
Transmission One second temperature
temperature
temperature alarm every sender below 1047 VCM 4 Amber
sender
sensor 30 seconds 0.5 V for 5
shorted low
seconds
Input is
Transmission One second Transmission
switched
temperature alarm every 1048 VCM temperature 4 Amber
battery for 5
sensor 30 seconds open circuit
seconds
Brake
Brake One second Sender over
temperature
temperature alarm every 1000 ohms 1049 VCM 4 Amber
sender out of
sensor 30 seconds for 5 seconds
range
General Only display
One second DTC’s 3000 -
display VCM with display 4 Amber
alarm 3366
message request
Low fuel -
Low fuel One second must stay on
VCM 5 Amber
warning alarm for remaining
key cycle
86 SECTION 55 - ELECTRICAL SYSTEM
5. STARTING SYSTEM
5.1 DESCRIPTION AND OPERATION
The motor does not start if the ignition key is operated and the transmission is in the neutral position.
Check the starter motor safety relay (K3). Can one hear the relay
operate after operating the reverse travel lever?
NO
Does the reverse travel lever switch operate correctly? NO Replace the switch
YES
Check the main power
Are the indicators on the instrument panel correctly lighted supply between the battery
after operating the key switch? NO
and the starter motor key
YES switch. Pin 2 (red wire) of
the ignition key connector
Are the cable wires of the key switch connected correctly?
YES NO
TECHNICAL SPECIFICATIONS
Manufacturer ............................................................................................................................................. Denso
Voltage ......................................................................................................................................................... 12 V
Rated power............................................................................................................................................. 2.7 kW
Starting system .......................................................................................................................................Positive
Operating time.............................................................................................................................................. 30 s
Direction of rotation .................................................................................... Clockwise seen from the pinion side
Weight ............................................................................................................................................ 8.4 kg (19 lb)
Maximum consumption without load at 11 V and 3000 rpm minimum ...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm (14.4 lbf·ft) at 8 V and 1130 rpm minimum . 600 A maximum
Maximum consumption when shimming at 3 V with a torque of 39.2 Nm (28.9 lbf·ft) minimum .1400 A maximum
MAIN COMPONENTS
1. Motor
2. Induction coils
3. Armature
4. Commutator
5. Brush assembly
6. Pinion gear
7. Intermediate pinion
8. Solenoid
9. Clutch
10. Drive pinion
SECTION 55 - ELECTRICAL SYSTEM 91
92 SECTION 55 - ELECTRICAL SYSTEM
1. Washer
2. Bearing
3. Armature
4. Bearing
5. Coils housing
6. Protection
7. Brush spring
8. Brush assembly
9. Brush bracket
10. Protective cover
11. Screw and washer
12. Screw
13. Drain
14. Screw and washer
15. Solenoid hood
16. Union
17. Spring washer
18. Nut
19. Push-rod
20. Connection assembly
21. Screw
22. Connection assembly
23. Nut
24. Retaining ring
25. Roller
26. Cage
27. Pinion
28. Ball
29. Spring
30. Drain
31. Screw
32. Flat washer
33. O-ring
34. Box
35. Pinion, rings and spring assembly
36. Union
37. Bearing
38. Bearing
39. Spring
40. Shaft pinion
41. Solenoid housing
42. Clutch assembly
SECTION 55 - ELECTRICAL SYSTEM 93
Armature
The surface of the commutator must be clean and
without traces of burns. If necessary, remove trac-
es of burns using fine sandpaper. Do not use em-
ery cloth. Then, clean the commutator with a cloth
soaked in gasoline.
After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in
gasoline.
Field coils
To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Drive pinion
The drive pinion must only rotate clockwise. If the
pinion is seized or turns in both directions or if its
teeth are damaged, change the complete drive as-
sembly.
FAULT FINDING
Wear on pinion gear or ring gear Replace clutch and ring gear.
teeth tips
6. ALTERNATOR
6.1 TECHNICAL SPECIFICATIONS
1. Alternator
2. Output winding of the rotor
3. Rectifier
4. Regulator
5. Starter motor
6. Battery
7. Key switch
8. Charge indicator
9. Tachometer
98 SECTION 55 - ELECTRICAL SYSTEM
6.3 COMPONENTS
6.4 REMOVAL
PRELIMINARY CHECKS
Before undertaking an electrical inspection, check
the charging circuit and the electrical circuit carefully.
Check the state of cables and the tightening of con-
nections.
PRELIMINARY TESTS
The preliminary tests may be carried out without re-
moving the charging circuit components, these tests
help check the following items:
Connections of the alternator cables
Charging current and regulated voltage of the alter-
nator
Voltage lowers in the alternator charging circuit
Maximum flow of the alternator
Required devices:
Voltmeter (0-30 V, moving coil)
Millivoltmeter (0-1 V)
Ammeter (0-110 A, moving coil)
Variable resistance of 1.5 Ohm, 110 A
Required devices:
12 V battery
Multimeter
2.2 W test lamp
7. BATTERY
For the loader backhoe models two different kinds of installation are provided:
with a battery.
with two batteries (for harsh climates).
Single battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):..........................................................................................................................................95 Ah
Discharge current:...................................................................................................................................... 900 A
Weight with electrolyte: ................................................................................................................... 25 kg (55 lb)
Double battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):..........................................................................................................................................60 Ah
Discharge current:...................................................................................................................................... 600 A
Weight with electrolyte: ................................................................................................................... 17 kg (37 lb)
WARNING
A spark or flame can cause the hydrogen in a battery
to explode. To prevent any risk of explosion, observe
the following instructions:
Place the battery master switch key in the OFF po-
sition (disconnected).
When disconnecting the battery cables, always dis-
connect the negative cable (-) first.
When reconnecting the battery cables, always con-
nect the negative (-) cable last.
Never short-circuit the battery terminals with metal
objects.
Do not weld, grind or smoke near a battery.
WARNING
Batteries produce explosive gases. Keep away any
flame, spark or cigarettes. Always provide good ven-
tilation when charging a battery or using a battery in
an enclosed space. Always protect your eyes when
working near a battery.
WARNING
Before carrying out any welding on the machine or
repair work on the electrical circuit, disconnect the
battery and disconnect the B+ and D+ wires on the
alternator. When reconnecting, check the wire mark-
ings.
WARNING
Always store batteries in a safe place, out of the
reach of children.
WARNING
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
112 SECTION 55 - ELECTRICAL SYSTEM
WARNING
Never reverse the battery terminals. Connect the
positive cable to the positive terminal (+) and the
negative cable to the negative terminal (-).
SECTION 55 - ELECTRICAL SYSTEM 113
7.4 MAINTENANCE
WARNING
When a battery is being charged an explosive gas is
produced. Do not smoke or use an exposed flame
when checking the electrolyte level and ensure the
charger is switched off before connecting or discon-
necting to avoid sparks which could ignite the gas.
SECTION 55 - ELECTRICAL SYSTEM 115
7.5 TESTS
Before commencing battery tests check the battery 5. Should the corrected specific gravity be below
for clogged vents, corrosion, raised vent plugs or a 1.280, charge the battery and inspect the charg-
cracked case. ing system to determine the cause of the low
Test equipment required: battery charge.
Hydrometer.
Battery starter tester (High rate discharge tester). NOTE: if distilled water has recently been added the
Thermometer. battery should be recharged for a short period oth-
Battery Charger. erwise accurate hydrometer readings will not be ob-
tained.
SPECIFIC GRAVITY
This test will determine the state of battery charge. If the battery has been charged under static condi-
1. With the float in the vertical position take the tions, denser electrolyte will accumulate at the bot-
reading. tom of the cells. The battery should be shaken
2. Adjust the hydrometer reading for electrolyte periodically to mix the electrolyte, this will improve
temperature variations by subtracting 4 points the charge rate and provide a more accurate hy-
(0.004 specific gravity) for every 5.5 °C (41.9 °F) drometer reading when tested.
below the temperature at which the hydrometer
PERFORMANCE TEST
is calibrated and by adding 4 points (0.004 spe-
cific gravity) for every 5.5 °C (41.9 °F) above this The performance test is to determine if the battery
temperature. has adequate capacity to turn the engine. The volt-
The following examples are calculated using a hy- age reading obtained is used to determine the bat-
drometer calibrated at 30 °C (86 °F). tery condition. Prior to testing, ensure the electrolyte
level is correct and the open circuit voltage is 12.5 V
Example 1: or more. The battery may be tested on or off the
Temperature below 30 °C (86 °F) loader backhoe.
Electrolyte temperature ....................19 °C (66.2 °F) 1. Set the current control switch of the battery
Hydrometer reading ........................................1.270 starter tester (high rate discharge tester) to the
Subtract (11.0 / 5.5) x 0.004 ...........................0.008 “off” position and the voltage selector switch
Corrected specific gravity................................1.262 equal to, or slightly higher than, the rated battery
voltage. Connect the tester positive leads to the
Example 2: battery positive terminal and the negative leads
Temperature above 30 °C (86 °F) to the negative battery terminal.
Electrolyte temperature .....................40 °C (104 °F) 2. Turn the current control knob until the ammeter
Hydrometer reading ........................................1.220 reading is half the CCA rating of the battery and
Add (10.0 / 5.5) x 0.004 ..................................0.007 take the voltage reading.
Corrected specific gravity................................1.227 If the reading is 9.6 volts or more after 15 seconds,
3. Use the following table to determine the state of the battery has an acceptable output capacity and
charge. will readily accept a normal charge.
If however the reading is below 9.6 volts, the bat-
State of Correcte Correcte Average tery is considered unsatisfactory for service and
Charge d specific d specific battery should be test charged as described below.
gravity @ gravity @ voltage
15 °C 25 °C CAUTION
(59 °F) (77 °F)
Do not leave the high discharge load on the battery
100% 1.295 1.287 2.76 for periods longer than 15 seconds.
75% 1.253 1.246 12.52
50% 1.217 1.210 12.30
25% 1.177 1.170 12.06
Discharged 1.137 1.130 11.84
WARNING
When the electrolyte of a battery is frozen, it can ex-
plode if you attempt to charge the battery or if you try to
start the engine using a booster battery. Always keep
the battery charged to prevent the electrolyte freezing.
WARNING
Connecting jumper cables wrongly or short-circuiting
battery terminals can cause an accident. Connect
the jumper cables following the instructions in this
manual.
Open the battery box and then remove the tool box.
Remove the terminal covers.
Connect the positive (+) jumper cable to the posi-
tive (+) terminal of the machine’s battery.
Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Start the engine.
First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Install the terminal covers.
Install the tool box and close the battery box.
WARNING
The battery master switch must be switched off at
the end of each working day, for machine service or
for any operations on the electrical system. It acts as
an anti-theft device when the cab doors and win-
dows are locked.
118 SECTION 55 - ELECTRICAL SYSTEM
8. COMPONENT TESTING
8.1 GENERAL INTRODUCTION
Úíîêìï
Úîèíèð
Úîèíèï
SECTION 55 - ELECTRICAL SYSTEM 121
Key start
1. Not used
2. Off
3. Ignition “ON”
4. Engine start
MAXIMUM MAXIMUM
CONTACTS CURRENT CURRENT TIME
12 V 24 V
30 - 58 8A 4A
30 - 15/54 35 A 17.5 A
70 A 40 A
30 - 50a 1 min
18 A 5A
122 SECTION 55 - ELECTRICAL SYSTEM
8.5 ALTERNATOR
Úîèíèì
Úîèíèè
8.6 TRANSMISSIONS
Test procedure
Continuity should be found between pin 1 and pin 2 Èîí
when switch is operated.
îæ ÎÓæßóÎæï
ïæ ÎÓæÞóÎæï
Èîè
îæ ÎÓæßóÎæï
ìæ ÎÓæÝóÒæï
ïæ ÎÓæÞóÎæï
íæ ÎÓæÒæï
Úîèíçï
Test procedure
Test procedure of the speed sensor refer to the next
page.
SECTION 55 - ELECTRICAL SYSTEM 123
Test procedure
Test between pin indicated in the left hand column
and either pin H or M as detailed in the table below.
Úîèíçì
DESCRIPTION
Pin
H M
No.
A 27.5 -
B 27.5 -
C 27.5 -
D 27.5 -
E 27.5 -
F 27.5 - Úîèíçë
G - 14
K - 31
Úîèíçì
Test procedure
Pin
V1 V2
No.
A 0.6 - 0.8 1.3 - 1.5
The special tool connects to pin A speed sensor plus
output, and pin J speed sensor/temperature sensor
ground.
Úîèíçé
Description
A Speed sensor +
B FWD request
C Disconnect request input ß
Þ Ó
D Speedometer output
Ý Ò Ô
E Diagnostic link input Ð Ë
F Analogue Input 1 Ü Ê Õ
G Analogue Input 0 Î Ì
H - Û Í Ö
J - Ú Ø
Ù
K PWM solenoid supply
L Solenoid 3
M PWM 1 Úîèíçè
N Range solenoid 27
P Forward solenoid
R Solenoid 2
S Solenoid 1
T VCS
U Ground
V Battery +
SECTION 55 - ELECTRICAL SYSTEM 125
Test procedure
Continuity should be found between pin 1 and pin 2
when switch is operated.
éæ ÆñÒï
ëæ Òï
Úîèìðð
Úîèìðî
Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
Pin
Sender Resistance ÆóÞæï
No.
1 12 V at low pressure 0.3 Òæï
Úîèìðí
126 SECTION 55 - ELECTRICAL SYSTEM
Úîèìðì
Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
Pin
Sender Resistance ÆóÞæï
No.
1 12 V at low pressure 0.3 Òæï
Úîèìðí
Test procedure
Brake engaged:
switch closed warning light illuminated.
Íïè
Brake disengaged:
switch open warning light off. ïæ ÚÓæÙóÎæï
ïæ ÚÓæÒæï
Úîèìðé
SECTION 55 - ELECTRICAL SYSTEM 127
8.8 CAB
SIDE PANEL
Calibrations
Connectors
SECTION 55 - ELECTRICAL SYSTEM 129
CN1
CN2
Test procedure
Continuity:
Brakes not applied: no continuity.
Brakes applied: continuity, between the two centre
pins of each switch.
Both brake pedals must be applied to allow 12 V to
relay.
Úîèìïç
Voltage:
Left switch:
White / red wire 12 V continuous with ignition ON
Red wire 12 V pedal depressed
0 V pedal released
Right switch:
Red wire 12 V pedal depressed
ïæ Îæï ïæ Îæï
0 V pedal released
Red - Black wire 12 V pedal depressed îæ ÎóÒæï îæ ÞñÎæï
0 V pedal released
Úîèìîð
SECTION 55 - ELECTRICAL SYSTEM 133
Test procedure:
Continuity:
With the fluid level correct there should be no conti-
nuity through the switch. Continuity should be seen
when the level is low or the test button pushed.
Voltage:
With the Ignition ON there should be 12 V at the ïæ ÙóÎæï
Red/Black terminal.
îæ ÎñÒæï
Úîèìîî
Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 3
and 2 and 8.
Úîèìïé
134 SECTION 55 - ELECTRICAL SYSTEM
Test procedure
7 - to pins 2/3/5
Úîèìîè
ÈÝï ÈÝî
ÚïñÝ ÚîñÝ
Continuity
Úîèìíï
SECTION 55 - ELECTRICAL SYSTEM 135
Switch Continuity
All Indicator Beam Wiper
Wind-
Pin switc
screen
No. hes Left Right Low High On
washer
OFF
1
2 pin 7
3 pin 4
4 pin 5 pin 3
5 pin 4
6 pin 8
7 pin 2 pin 8
8 pin 6 pin 7
9 pin 11
10 pin 11
11 pin 9 pin 10 îæ ÔóÞæï
ìæ ÙñÎæï
12 ïî
ëæ ÊñÒæïòë
êæ ßñÞæï
éæ ßñÒæï
èæ ßñÎæï ï é
çæ Ôæï
ïðæ ßóÊæï ê
ïïæ ÔóÒæï
Úîèìíí
Test procedure
Test procedure
With ignition ON
ÝóÙ
ß
Úîèìíè
SECTION 55 - ELECTRICAL SYSTEM 137
Buzzer operation
Buzzer operation depends on setting of pin 2 of the
12 way connector:
Pin 2 not connected (North America only). If 12 km/h
(7.45 mph) is exceeded in crab mode, the buzzer
sounds.
Pin 2 grounded (Outside of N/America). If 12 km/h
(7.45 mph) is exceeded in crab or 4WS mode, the
buzzer sounds.
Buzzer operation is intermittent, 250 ms on and
250 ms off.
The control unit is set at 9 km/h (5.59 mph); steering
mode change is not possible when this speed is ex-
ceeded.
Úîèììí
A - - -
B - - -
C 12 V 12 V 12 V ßæ ÎÓæÔñÒæï
Þæ ÎÓæÒæï
Ýæ ÎÓæÎñÒæï
Úîèììì
Úîèììë
A - - -
B - - -
C 12 V 12 V 12 V ßæ ÎÓæØóÔæï
Þæ ÎÓæÒæï
Ýæ ÎÓæßñÊæï
Úîèììê
140 SECTION 55 - ELECTRICAL SYSTEM
Úîèììé
TEST PROCEDURE
Èçï
Pin No. Solenoid Resistance
Èçî
1 0V 5.0
ïæ ÎÓæÔñÎæï
îæ ÎÓæÒæï
ïæ ÎÓæÍñÒæï
îæ ÎÓæÒæï
Úîèììç
TEST PROCEDURE
Èçí
Pin No. Solenoid Resistance
Èçì
1 0V 5.0
ïæ ÎÓæØñÒæï
îæ ÎÓæÒæï
ïæ ÎÓæÓñÞæï
îæ ÎÓæÒæï
Úîèìëð
SECTION 55 - ELECTRICAL SYSTEM 141
Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity should be found between pins 1 and 5.
ïæ ÓñÞï
ëæ ÝóÞï
Úîèìëî
TEST PROCEDURE
Èè
Pin No. Solenoid Resistance
1 0V 5.0
ïæ ÎÓæÝÔæï
îæ ÎÓæÒæï
Úîèìëí
142 SECTION 55 - ELECTRICAL SYSTEM
8.23 LOADER
WARNING
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF.
If the switch is ON, upon engine start up the vehicle
will fall to the ground without any control.
Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 5.
ïæ ÝñÒï
ëæ ßóÒï
Úîèìëê
TEST PROCEDURE
Èíì
Pin No. Solenoid Resistance
1 0V 5.0
ïæ ÎÓæßóÒæï
îæ ÎÓæÒæï
Úîèìëé
SECTION 55 - ELECTRICAL SYSTEM 143
Úîèìïé
Test procedure
ïæ ÎÓæÒæï
îæ ÎÓæÝóÔæï
Úîèìêï
Test procedure
(Switch off)
Continuity should not be found between any pins.
(Switch on)
Continuity should be found between pins 1 and 5.
ïæ ÝñÒï
ëæ ÔóÙï
Úîèìêì
ïæ ÎÓæÒæï
îæ ÎÓæÝóÔæï
Úîèìêï
8.24 BACKHOE
Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity should be found between pins 1 and 5.
ïæ ÝñÞï
ëæ ÞóÒï
Úîèìêè
SECTION 55 - ELECTRICAL SYSTEM 145
ïæ ÎÓæÒæï
îæ ÎÓæÝóÔæï
Úîèìêç
Test procedure
(Switch Off) - X25
Continuity should be found between pins 1 and 5.
(Switch On)
Continuity should be found between pins 5 and 7.
ïæ ÝóÞï
éæ ÔñÙï
ëæ ÝñÞï
Úîèìéî
ïæ ÎóÊæï
îæ Òæï
Úîèìéí
146 SECTION 55 - ELECTRICAL SYSTEM
îæ ÎóÊ
ïæ ÎóÊæï
Úîèìéê
ïæ ÎóÊæï
îæ Òæï
Úîèìéí
SECTION 55 - ELECTRICAL SYSTEM 147
ïæ ÝóÞï
ëæ ÝñÞï
Úîèìéç
ïæ ØóÒ
îæ Òæï
Úîèìèð
148 SECTION 55 - ELECTRICAL SYSTEM
ïæ ÝñÒï
ëæ Êï
Úîèìèí
îæ Êæï
ïæ Òæï
Úîèìèê
SECTION 55 - ELECTRICAL SYSTEM 149
ÓñÞ
Ò
Úîèìèè
Test procedure
Approximate resistance:
Úîèìçð
150 SECTION 55 - ELECTRICAL SYSTEM
NOTE:
B110
B115
SECTION 82 - LOADER
The loader assy consists essentially of an arm hinged to the loader backhoe chassis, on which is installed a
linkage moving the bucket frontally.
Two kinds of loader arm are provided:
Rotate the bell crank (1) till it touches the tube (2)
on the loader arm. Make sure the lower bell crank
arm is directing upwards.
Adjust the length of the vertical rod (3) so that when
re-connected, the end of the loader arm tube re-
mains in contact with the bell crank.
Securely tighten locknuts on vertical rod.
8 SECTION 82 - LOADER
2WS
Return to dig is an electrically activated feature
which enables the operator to automatically return
the bucket to a level digging position for a further
work cycle with one simple movement of the loader
control lever (3).
Whenever the bucket is rolled forward to dump the
return to dig electrical circuit is completed and the so-
lenoid on the bucket spool is energized.
When the loader bucket control lever (3) is moved di-
agonally left to the return to dig position (2) the elec-
tromagnet will hold the bucket spool in the roll back
position until the bucket is in the level digging posi-
tion at which time the indicator on the rod of the buck-
et self leveling linkage will pass in front of the sensor
which de-energizes the electromagnet on the bucket
spool enabling the spool to return to the neutral posi-
tion.
4WS
Return to dig is an electrically activated feature
which enables the operator to automatically return
the bucket to a level digging position for a further
work cycle with one simple movement of the loader
control lever (3).
Whenever the bucket is rolled forward to dump the
return to dig electrical circuit is completed and the so-
lenoid on the bucket spool is energized.
When the loader bucket control lever (3) is moved di-
agonally left to the return to dig position (2) the elec-
tromagnet will hold the bucket spool in the roll back
position until the bucket is in the level digging posi-
tion at which time the indicator on the rod of the buck-
et linkage will pass in front of the sensor which de-
energizes the electromagnet on the bucket spool en-
abling the spool to return to the neutral position.
LOCKED POSITION
Raise the loader attachment completely, stop the en-
gine and remove the starter switch key.
Remove the retaining pin and split pin.
Place the strut on the cylinder rod and install the pin
and split pin in the holes in the strut.
UNLOCKED POSITION
Remove the retaining pin and split pin.
Swing the strut against the lift arm and install the pin
and split pin in the holes in the strut and the retaining
lug.
Start the engine and lower the loader attachment.
LOCKED POSITION
Raise the loader attachment completely, stop the en-
gine and remove the starter switch key.
Remove the pins and the safety strut from the loader
arm. Put the pins back in place.
Place the strut on the cylinder rod and install the re-
taining strap.
UNLOCKED POSITION
Remove the strut from the cylinder rod.
Install the safety strut with the pins on the loader arm.
Start the engine and lower the loader attachment.
12 SECTION 82 - LOADER
REMOVAL
Park the machine on flat, level ground.
Lower the bucket to the ground in dump position (tilt-
ed completely forward).
Stop the engine and remove the starter switch key.
If the machine is fitted with a 4x1 bucket, release the
pressure in the bucket circuit.
Remove the linkage pin retaining bolts and then re-
move the linkage pins (1).
(4x1 bucket) disconnect and plug the hydraulic sup-
ply lines.
Start the engine.
Operate the attachment controls so as to release the
bucket.
Reverse the machine from the bucket.
INSTALLATION
Make sure all bushings are completely clean.
Remove any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Install the arm/bucket linkage pins (1) and then in-
stall the linkage pin retaining bolts.
Use the bucket controls to align the connecting rod
holes with the bucket lugs.
Stop the engine and remove the starter switch key.
(4x1 bucket) release the pressure in the bucket cir-
cuit.
Install the connecting rod/bucket linkage pins (1) and
then install the linkage pin retaining bolts.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic supply lines.
SECTION 82 - LOADER 13
REMOVAL
Park the machine on flat, level ground.
Lower the bucket to the ground in dump position (tilt-
ed completely forward).
Stop the engine and remove the starter switch key.
If the machine is fitted with a 4x1 bucket, release the
pressure in the bucket circuit.
Remove the snap rings and retaining pins and then
drive out the linkage pins (1).
(4x1 bucket) disconnect and plug the hydraulic sup-
ply lines.
Start the engine.
Operate the attachment controls so as to release the
bucket.
Reverse the machine from the bucket.
INSTALLATION
Make sure all bushings are completely clean.
Remove any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Install the arm/bucket linkage pins (1) and then in-
stall the retaining pins and snap rings.
Use the bucket controls to align the connecting rod
holes with the bucket lugs.
Stop the engine and remove the starter switch key.
(4x1 bucket) release the pressure in the bucket cir-
cuit.
Install the connecting rod/bucket linkage pins (1) and
then install the retaining pins and snap rings.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic supply lines.
14 SECTION 82 - LOADER
INSTALLATION
Installation follows removal procedure in reverse.
When installing the retaining bolts tighten them to
500 Nm (368.7 lbf·ft).
SECTION 82 - LOADER 17
Remove the safety rings (2) and the pins and then
drive out the pins (1). Lower the lift cylinders carefully
onto the chassis.
Remove the snap rings (3) and drive out the pins (4).
Lower the arms onto the lift cylinders.
Remove the safety ring and pins and then pull out the
pin (8).
INSTALLATION
Installation follows removal procedure in reverse.
B110
B115
SECTION 84 - BACKHOE
STANDARD CONFIGURATION
Backhoe boom and backhoe attachment swing left-
hand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (A): the backhoe boom lowers.
Position (B): the backhoe boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.
ISO CONFIGURATION
Lever 1: Lever 3:
Position (A): push the lever forward - dipper in. Position (E): push the lever forward - bucket curls in.
Position (B): push the lever back - dipper out. Position (F): push the lever back - bucket curls out.
Lever 2: Lever 4:
Position (C): push the lever forward - boom lifts. Position (G): push the lever forward - boom swings
Position (D): push the lever back - boom lowers. right.
Position (H): push the lever back - boom swings left.
SECTION 84 - BACKHOE 11
CROSS-PATTERN CONFIGURATION
STABILIZER CONTROLS
These controls are located on the left-hand control
arm and may be used to operate the stabilizers inde-
pendently or simultaneously.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Remove the snap ring (4), slide out the pin (5) and
with an hammer remove the pin (6) of the swing cyl-
inder.
Repeat the operation with both swing cylinders. Re-
move the snap ring (7).
Slide out the pin (8) and with an hammer remove the
lower pin (9) from the swing support.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Úíðííî
Remove the snap ring (4), slide out the pin (5) and
with an hammer remove the pin (6) of the swing cyl-
inder.
Repeat the operation with both swing cylinders. Re-
move snap ring (7).
Slide out the pin (8) and with an hammer remove the
lower pin (9) from the swing bracket.
DIPPER REMOVE
Park the machine on a level, firm surface and posi-
tion the backhoe on the ground.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
- Standard dipper
Procedure No. 1
Procedure No. 2