Professional Documents
Culture Documents
SM - B90B - B100B - EN
SM - B90B - B100B - EN
MANUAL
SERVICE MANUAL
B90B
B90BLR
B90B
B90BLR B100B
B100B B100BLR
B100BLR
B110B B110B
B115B B115B
Loader Backholes
Loader Backholes
7
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 docu-
ments hereunder listed:
Z Operator’s Manual
Z 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 vol- tion to carry out service and repair on machine and
umes: on engine, necessary tools to carry out those op-
erations and information on service standard, on
Z B90B - B90BLR - B100B - B100BLR - B110B - procedures for connection, disconnection, disas-
B115B sembly and assembly of parts.
Service Manual for “Loader backhoe”
Z B90B - B90BLR - B100B - B100BLR - B110B - The complete Service Manual which covers the
B115B loader backhoe models B90B - B90BLR - B100B -
Service Manual “Engine” B100BLR - B110B - B115B consists of the follow-
ing volumes, which can be identified through their
print number as stated below:
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.
SWARNING
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.
LOADER BACKHOE MODELS
The complete range of Loader Backhoe models described in this manual are identified below:
SECTION 01 - MAINTENANCE
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 ON THE CHASSIS................................................................................ 10
2.5 MOUNTING SCREW TORQUE........................................................................................................... 12
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 4
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 7
3. LOADER ATTACHMENT SAFETY STRUT................................................................................................ 10
3.1 LOADER ATTACHMENT SAFETY STRUT (B90B - B100B - B110B)................................................. 10
3.2 LOADER ATTACHMENT SAFETY STRUT (B115B)........................................................................... 12
4. LOADER BUCKET REMOVAL ................................................................................................................... 13
4.1 LOADER BUCKET (B90B - B100B - B110B)....................................................................................... 13
4.2 LOADER BUCKET (B115) ................................................................................................................... 14
4.3 LOADER BUCKET WITH FORKS (OPTIONAL).................................................................................. 15
4.4 REPLACING LOADER BUCKET TEETH ............................................................................................ 16
5. LOADER REMOVAL................................................................................................................................... 17
5.1 LOADER ATTACHMENT (B90B - B100B - B110B) ............................................................................ 17
5.2 LOADER ATTACHMENT (B115B) ...................................................................................................... 19
SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION ............................................................ 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS VERSION ............................................................. 15
4. REMOVAL AND INSTALLATION ............................................................................................................... 17
4.1 CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY............................................................ 17
4.2 SIDESHIFT BACKHOE ATTACHMENT DISASSEMBLY.................................................................... 20
4.3 BACKHOE BUCKET REMOVAL ......................................................................................................... 22
4.4 BACKHOE BUCKET TEETH REPLACEMENT ................................................................................... 23
4.5 DIPPER REMOVE ............................................................................................................................... 24
5. TELESCOPIC DIPPER REVISION............................................................................................................. 27
6. TELESCOPIC DIPPER REVISION............................................................................................................. 27
7. REVISIONE DEL BRACCIO TELESCOPICO ............................................................................................ 27
B90B - B90BLR
B100B - B100BLR
B110B
B115B
TO PREVENT ACCIDENTS
Most accidents and personal injuries that occur in the work site 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 PRECAUTIONS
Z Carefully follow specified repair and maintenance Z For electrical heaters, battery-chargers and similar
procedures. equipment use exclusive auxiliary power supplies
Z 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 Z 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 Z Pay special attention to bystanders.
as: anti-slipping footwear, gloves, safety goggles, Z Never pour gasoline or diesel oil into open, wide
helmets, etc. and low containers.
Z Never carry out any repair on the machine if some- Z Never use gasoline, diesel oil or other flammable
one is sitting on the operator’s seat, except if they are liquids as cleaning agents. Use non-flammable
certified operators to assist in the operation to be car- non-toxic proprietary solvents.
ried out. Z Wear protection goggles with side guards when
Z Never operate the machine or use attachments cleaning parts using compressed air.
from a place other than sitting at the operator’s Z Do not exceed a pressure of 2.1 bar (30 psi), in ac-
seat. cordance with local regulations.
Z Never carry out any operation on the machine Z Do not run the engine in a closed building without
proper ventilation.
when the engine is running, except when specifi-
Z Do not smoke, use open flames, cause sparks in
cally indicated.
the nearby area when filling fuel or handling highly
Z Stop the engine and ensure that all pressure is re-
flammable liquids.
lieved from the hydraulic systems before removing
Z Do not use flames as light sources when working
caps, covers, valves, etc. on a machine or checking for leaks.
Z All repair and maintenance operations should be Z Move with caution when working under a Machine,
carried out with the greatest care and attention. and also on or near a Machine. Wear proper safety
Z Service stairs and platforms used in a workshop or accessories: helmets, goggles and special footwear.
in the field should be built in compliance with the Z During checks which should be carried out with the
safety rules in force. engine running, ask an assistant to sit at the oper-
Z Disconnect the batteries and label all controls to ator’s seat and keep the service technician under
warn that the Machine is being serviced. Block the visual control at any moment. In case of operations
machine and all equipment which should be outside the workshop, drive the machine to a flat
raised. area and block it. If working on an incline cannot be
Z Never check or fill fuel tanks and accumulator batter- avoided, first block the Machine carefully. Move it
ies, nor use starting liquid if you are smoking or near to a flat area as soon as possible with a certain ex-
open flames as such fluids are flammable. tent of safety.
Z Brakes are inoperative when they are manually re- Z Ruined or plied cables and chains are unreliable.
leased for maintenance purposes. In such cases, Do not use them for lifting or trailing. Always han-
the machine should be kept constantly under con- dle them wearing gloves of proper thickness.
trol using blocks or similar devices. Z Chains should always be safely fastened. Ensure that
Z The fuel filling gun should remain always in contact fastening device is strong enough to hold the load fore-
with the filler neck. seen. No persons should stop near the fastening point,
Maintain this contact until the fuel stops flowing into trailing chains or cables.
the tank to avoid possible sparks due to static elec- Z The working area should be always kept CLEAN
tricity buildup. and DRY. Immediately clean any spillage of water
Z Use exclusively specified towing points for towing or oil.
the machine. Connect parts carefully. Ensure that Z Do not pile up grease or oil soaked rags: they consti-
foreseen pins and/or locks are steadily fixed before tute a great fire hazard. Always place them into a met-
applying traction. al container. Before starting the Machine or its
Do not stop near towing bars, cables or chains attachments, check, adjust and block the operator’s
working under load. seat. Also ensure that there are no persons within the
Z To transfer a failed machine, use a trailer or a low Machine or attachment operating range.
loading platform trolley if available. Z Do not keep in your pockets any object which might fall
Z To load and unload the machine from the transpor- unobserved into the Machine’s inner compartments.
tation mean, select a flat area providing a firm sup-
port to the trailer or truck wheels. Firmly tie the
machine to the truck or trailer platform and block
wheels as required by the forwarder.
SECTION 00 - SAFETY PRECAUTIONS 5
Z Whenever there is the possibility of being reached Z Always disconnect the batteries before performing
by ejected metal parts or similar, use protection any type of service on the electrical system.
eye mask or goggles with side guards, helmets, HYDRAULIC SYSTEMS
special footwear and heavy gloves. Wear suitable
protection such as tinted eye protection, helmets, Z Some fluid slowly coming out from a very small
special clothing, gloves and footwear whenever it port can be almost invisible and be strong enough
is necessary to carry out welding procedures. All to penetrate the skin. For this reason, use a piece
persons standing in the vicinity of the welding proc- of cardboard or a piece of wood for checking. NEV-
ess should wear tinted eye protection. NEVER ER USE YOUR HANDS TO CHECK FOR LEAKS.
LOOK AT THE WELDING ARC IF YOUR EYES If any fluid is injected into the skin, seek medical
ARE NOT SUITABLY PROTECTED. aid immediately. Lack of immediate medical atten-
Z Metal cables with the use get frayed. Always wear tion, serious infections or dermatitis may result.
adequate protections (heavy gloves, eye protec- Z Always take system pressure readings using the
tion, etc.). appropriate gauges.
Z Handle all parts with the greatest caution. Keep WHEELS AND TYRES
your hands and fingers far from gaps, moving
gears and similar. Always use approved protective Z Check that the tyres are correctly inflated at the
equipment, such as eye protection, heavy gloves pressure specified by the Manufacturer. Periodi-
and protective footwear. cally check possible damages to the rims and
tyres.
START UP
Z Keep off and stay at the tyre side when correcting
Z Never run the engine in confined spaces which are the inflation pressure.
not equipped with adequate ventilation for exhaust Z Check the pressure only when the machine is un-
gas extraction. loaded and tyres are cold to avoid wrong readings
Z Never bring your head, body, arms, legs, feet, due to over-pressure. Do not reuse parts of recov-
hands, fingers near fans or rotating belts. ered wheels as improper welding, brazing or heat-
ENGINE ing may weaken the wheel and make it fail.
Z Always loosen the radiator cap very slowly before Z Never cut, nor weld a rim with the inflated tyre as-
removing it to allow pressure in the system to dis- sembled.
sipate. Coolant should be topped up only when the Z To remove the wheels, block both front and rear
engine is stopped or idle if hot. Machine wheels. Raise the Machine and install
Z Do not fill up fuel tank when the engine is running, safe and stable supports under the Machine in ac-
mainly if it is hot, to avoid ignition of fires in case of cordance with regulations in force.
fuel spilling. Z Deflate the tyre before removing any object caught
Z Never check or adjust the fan belt tension when the into the tyre tread.
engine is running. Never adjust the fuel injection Z Never inflate tyres using flammable gases as they
pump when the machine is moving. may originate explosions and cause injuries to by-
Z Never lubricate the machine when the engine is standers.
running.
REMOVAL AND INSTALLATION
ELECTRICAL SYSTEMS
Z Lift and handle all heavy components using lifting
Z If it is necessary to use auxiliary batteries, cables equipment of adequate capacity. Ensure that parts
must be connected at both sides as follows: (+) to are supported by appropriate slings and hooks.
(+) and (-) to (-). Avoid short-circuiting the termi- Use lifting eyes provided to this purpose. Take
nals. GAS RELEASED FROM BATTERIES IS care of the persons near the loads to be lifted.
HIGHLY FLAMMABLE. During charging, leave the Z Handle all parts with great care. Do not place your
battery compartment uncovered to improve venti- hands or fingers between two parts. Wear ap-
lation. Avoid checking the battery charge by
proved protective clothing such as safety goggles,
means of “jumpers” made by placing metallic ob-
gloves and footwear.
jects across the terminals. Avoid sparks or flames
Z Do not twist chains or metal cables. Always wear
near the battery area. Do not smoke to prevent ex-
protection gloves to handle cables or chains.
plosion hazards.
Z Prior to any service, check for fuel or coolant leaks.
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-
dental explosion hazard due to build-up of gasses
relieved during charging.
6 SECTION 00 - SAFETY PRECAUTIONS
Helpful hints
Z Avoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
Z 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.
Z Modern oils contain additives. Do not burn contam-
inated fuels and/or waste oils in ordinary heating
systems.
Z 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.
Z 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.
Z 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.
Z Repair any leaks or defects in the engine cooling or
hydraulic system immediately.
Z Do not increase the pressure in a pressurized sys-
tem as this may lead to a catastrophic failure of the
system components.
Z Protect hoses during welding as penetrating weld
chips may burn a hole or weaken them, causing
the loss of oils, coolant, etc.
B90B - B90BLR
B100B - B100BLR
B110B
B115B
SECTION 01 - MAINTENANCE
2 SECTION 01 - MAINTENANCE
SECTION 01 - MAINTENANCE 3
All maintenance and repair operations described in hoses must never be allowed to touch each other or
this manual should be carried out exclusively by related working surfaces. This causes chafing which
authorized workshops. All instructions detailed should reduces hose life.
be carefully observed and special equipment indicated
should be used if necessary. Everyone who carries out O-RING FLAT FACE SEAL FITTINGS
service operations described without carefully When repairing O-ring face seal connectors, the
observing these prescriptions will be directly following procedures should be observed.
responsible of deriving damages.
GENERAL SWARNING
Clean the exterior of all components before carrying Never disconnect or tighten a hose or tube that is
out any form of repair. Dirt and dust can reduce the under pressure, if in doubt, actuate the operating
efficient working life of a component and lead to levers several times with the engine switched off
costly replacement. prior to disconnecting a hose or tube.
Time spent on the preparation and cleanliness of
Release the fittings and separate the hose or tube
working surfaces will pay dividends in making the
assembly, then remove and discard the O-ring seal
job easier and safer and will result in overhauled
from the fitting. Dip a new O-ring seal into clean
components being more reliable and efficient in
hydraulic oil prior to installation. Install a new O-ring
operation. Use cleaning fluids which are known to
into the fitting and, if necessary, retain in position
be safe. Certain types of fluid can cause damage to
using petroleum jelly. Assemble the new hose or
O-rings and cause skin irritation. Solvents should be
tube assembly and tighten the fitting finger tight,
checked that they are suitable for the cleaning of
while holding the tube or hose assembly to prevent
components and also that they do not risk the
it from turning. Use two suitable wrenches and
personal safety of the user. Replace O-rings, seals
tighten the fitting to the specified torque according to
or gaskets whenever they are disturbed. Never mix
the size of the fitting.
new and old seals or O-rings, regardless of
condition. Always lubricate new seals and O-rings
NOTE: to ensure a leak-free joint is obtained, it is
with hydraulic oil before installation. When replacing
important that the fittings are not over or under
component parts, use the correct tool for the job.
torqued.
HOSES AND TUBES
Always replace hoses and tubes if the cone end or
the end connections on the hose are damaged. SHIMMING
When installing a new hose, loosely connect each At each adjustment, select adjusting shims,
end and make sure the hose takes up the designed measure them individually using a micrometre and
position before tightening the connection. Clamps then sum up recorded values.
should be tightened sufficiently to hold the hose Do not rely on measuring the whole shimming set,
without crushing and to prevent chafing. After hose which may be incorrect, or on rated value indicated
replacement to a moving component, check that the for each shim.
hose does not foul by moving the component
through the complete range of travel. Be sure any ROTATING SHAFT SEALS
hose which has been installed is not kinked or To correctly install rotating shaft seals, observe the
twisted. Hose connections which are damaged, following instructions:
dented, crushed or leaking, restrict oil flow and the Z let the seal soak into the same oil as it will seal for
productivity of the components being served. at least half an hour before mounting;
Connectors which show signs of movement from the Z thoroughly clean the shaft and ensure that the
original swagged position have failed and will shaft working surface is not damaged;
ultimately separate completely. A hose with a
chafed outer cover will allow water entry. Concealed
corrosion of the wire reinforcement will
subsequently occur along the hose length with
resultant hose failure. Ballooning of the hose
indicates an internal leakage due to structural
failure. This condition rapidly deteriorates and total
hose failure soon occurs. Kinked, crushed,
stretched or deformed hoses generally suffer
internal structural damage which can result in oil
restriction, a reduction in the speed of operation and
ultimate hose failure. Free-moving, unsupported
4 SECTION 01 - MAINTENANCE
Z place the sealing lip towards the fluid. In case of a NOTES FOR SPARE PARTS
hydrodynamic lip, consider the shaft rotation Only genuine parts guarantee same quality, life,
direction and orient grooves in order that they safety as original components as they are the same
deviate the fluid towards the inner side of the seal; as mounted in production. Only the genuine spare
Z 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 All spare parts orders should be complete with the
between the sealing lip and the dust lip of double following data:
lip seals; Z machine model (commercial name) and chassis
Z insert the seal into its seat and press it down using number;
a flat punch. Do not tap the seal with a hammer or Z engine type and number;
a drift; Z part number of the ordered part, which can be
Z take care to insert the seal perpendicularly to its seat found on the “Spare Parts Catalogue”, which is the
while you are pressing it. Once the seal is settled, base for order processing.
ensure that it contacts the thrust element if required;
Z to prevent damaging the sealing lip against the NOTES FOR EQUIPMENT
shaft, place a suitable protection during
installation. Equipment which proposes and shows in this
manual are as follows:
O-RINGS Z studied and designed expressly for use on
company machines;
Lubricate the O-rings before inserting them into their Z necessary to make a reliable repair;
seats. This will prevent the O-rings from rolling over Z accurately built and strictly tested to offer efficient
and twisting during mounting which will jeopardize and long-lasting working means.
sealing. We also remind the repair personnel that having
these equipment means:
BEARINGS
Z work in optimal technical conditions;
It is advisable to heat the bearings to 80 to 90 °C Z obtain best results;
before mounting them on their shafts and cool them Z save time and effort;
down before inserting them into their seats with Z work more safely.
external tapping.
CAUTION
SPRING PINS
Wear limits indicated for some details should be
When mounting split socket spring pins, ensure that intended as advised, but not binding values. The
the pin notch is oriented in the direction of the effort words “front”, “rear”, “right hand”, and “left hand”
to stress the pin. referred to the different parts should be intended as
Spiral spring pins should not be oriented during seen from the operator’s seat oriented to the normal
installation. sense of movement of the machine.
SECTION 02 - TECHNICAL
SPECIFICATIONS
1. MODELS....................................................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. SPECIFICATIONS ........................................................................................................................................ 6
3.1 DIESEL ENGINE ................................................................................................................................... 6
3.2 TRANSMISSION.................................................................................................................................... 8
3.3 AXLES ................................................................................................................................................... 9
3.4 BRAKES ................................................................................................................................................ 9
3.5 STEERING........................................................................................................................................... 10
3.6 HYDRAULIC SYSTEM ........................................................................................................................ 10
3.7 FRONT COUNTERWEIGHT ............................................................................................................... 10
3.8 NOISE AND VIBRATION LEVELS ...................................................................................................... 11
3.9 BUCKETS ............................................................................................................................................ 11
3.10 LOADER BUCKETS .......................................................................................................................... 11
3.11 TYRES ............................................................................................................................................... 12
4. DIMENSIONS AND PERFORMANCE........................................................................................................ 13
4.1 DIMENSIONS - 2WS SIDESHIFT ....................................................................................................... 13
4.2 DIMENSIONS - 2WS CENTER PIVOT................................................................................................ 14
4.3 DIMENSIONS - 4WS SIDESHIFT ....................................................................................................... 15
4.4 DIMENSIONS - 4WS CENTER PIVOT................................................................................................ 16
4.5 LOADER ATTACHMENT PERFORMANCE........................................................................................ 17
4.6 PERFORMANCE OF LOADER ATTACHMENT WITH FORKS .......................................................... 25
4.7 BACKHOE ATTACHMENT PERFORMANCE..................................................................................... 29
5. BACKHOE ATTACHMENT LIFTING CAPACITY ....................................................................................... 49
6. MAXIMUM LIFTING LOADS....................................................................................................................... 55
2 SECTION 02 - TECHNICAL SPECIFICATIONS
1.
SECTION 02 - TECHNICAL SPECIFICATIONS 3
1. MODELS
3. SPECIFICATIONS
3.1 DIESEL ENGINE
Supply
Type ............................................................................................................................................. direct injection
Injection pump............................................................................................. BOSCH ROTARY VE 4/12 F1100L
Injection sequence ...................................................................................................................................1-3-4-2
Cold-start device ..............................................................................................................“grid heater” (optional)
Cooling
Pump type .......................................................................................................................................... H2O pump
Pump drive ............................................................................................................................................belt drive
Temperature switch (opening start) ......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)
72 kW - 97 HP ENGINE (B100B)
Specifications (EEC 88/195) ................................................................................... 72 kW - 97 HP @ 2200 rpm
Model ..................................................................................................................................... F4HE0484G*J102
Type ......................................................................................................................................... diesel, electronic
No. of cylinders ................................................................................................................................................. 4
Valves per cylinder............................................................................................................................................ 4
Bore............................................................................................................................................... 104 mm (4 in)
Stroke......................................................................................................................................... 132 mm (5.2 in)
Displacement .................................................................................................................. 4485 cm3 (237.69 in3)
Compression ratio ..................................................................................................................................... 17.5:1
Maximum torque (EC) .......................................................................................453 Nm (334 lbf·ft) @ 1400 rpm
Low idle speed at no load .............................................................................................................. 950 ± 50 rpm
High idle speed at no load (engine not installed) ......................................................................... 2430 ± 50 rpm
High idle speed at no load (engine not installed on the vehicle) .................................................. 2380 ± 60 rpm
Maximum speed at full load ................................................................................................................. 2200 rpm
Air intake .................................................................................................... TAA (turbocharged with aftercooler)
Supply
Type .........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................. CP3 high-pressure pump
Control unit.................................................................................................................................................EDC7
Injection sequence ...................................................................................................................................1-3-4-2
Cold-start device ..............................................................................................................“grid heater” (optional)
SECTION 02 - TECHNICAL SPECIFICATIONS 7
Cooling
Pump type.......................................................................................................................................... H2O pump
Pump drive............................................................................................................................................ belt drive
Temperature switch (opening start) ......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)
Supply
Type ......................................................................................................................... high-pressure, common rail
Injection pump............................................................................................................. CP3 high-pressure pump
Control unit................................................................................................................................................. EDC7
Injection sequence ................................................................................................................................... 1-3-4-2
Cold-start device ..............................................................................................................“grid heater” (optional)
Cooling
Pump type.......................................................................................................................................... H2O pump
Pump drive............................................................................................................................................ belt drive
Temperature switch (opening start) ......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)
8 SECTION 02 - TECHNICAL SPECIFICATIONS
3.2 TRANSMISSION
3.3 AXLES
FRONT AXLES
REAR AXLES
3.4 BRAKES
Service brake
Type ........................................................................................................ wet multi-discs, 8 x axle (4 x half axle)
Braking surface .................................................................................................................... 1440 cm2 (223 in2)
Parking brake
Type ......................................................................................................................... single disc on transmission
BRAKES (B115B)
Service brake
Type ........................................................................................................ wet multi-discs, 6 x axle (3 x half axle)
Braking surface .................................................................................................................... 1440 cm2 (223 in2)
Parking brake
Type ......................................................................................................................... single disc on transmission
10 SECTION 02 - TECHNICAL SPECIFICATIONS
3.5 STEERING
POWER STEERING
2WS
Model ......................................................................................................................... DANFOSS OSPC 125 LS
Displacement ............................................................................................................ 125 cm3/rev (7.63 in3/rev)
Shock valve adjustment ......................................................................................................... 225 bar (3262 psi)
Pressure relief valve adjustment ............................................................................................ 170 bar (2465 psi)
4WS
Model ......................................................................................................................... DANFOSS OSPC 160 LS
Displacement ............................................................................................................ 160 cm3/rev (9.76 in3/rev)
Shock valve adjustment ......................................................................................................... 225 bar (3262 psi)
Pressure relief valve adjustment ............................................................................................ 170 bar (2465 psi)
HYDRAULIC PUMP
COUNTERWEIGHT - 2WS
Standard................................................................................................................................... 125.5 kg (276 lb)
Medium .................................................................................................................................... 366.5 kg (806 lb)
Big ............................................................................................................................................. 475 kg (1045 lb)
Extra (optional)............................................................................................................................ 125 kg (275 lb)
COUNTERWEIGHT - 4WS
Standard................................................................................................................................... 125.5 kg (276 lb)
Medium ....................................................................................................................................... 333 kg (733 lb)
Extra (optional)............................................................................................................................ 125 kg (275 lb)
SECTION 02 - TECHNICAL SPECIFICATIONS 11
NOISE LEVEL
Certified by the Manufacturer.
In compliance with European Directive 2000/14/EC - Stage II.
Internal noise level (LpA) ........................................................................................................................... 77 db
External noise level (LwA) (B90B - B100B) ............................................................................................. 102 db
External noise level (LwA) (B110B - B115B) ........................................................................................... 103 db
3.9 BUCKETS
LOADER BUCKETS
0.88 m3
Type 1 m3 (35.3 ft3) 4x1 6x1 (with forks)
(31.1 ft3) standard
standard
0.88 m3
2WS Heaped capacity 1.0 m3 (35.3 ft3) 1.0 m3 (35.3 ft3) 1.0 m3 (35.3 ft3)
(31.1 ft3)
Weight 310 kg (682 lb) 400 kg (880 lb) 750 kg (1650 lb) 950 kg (2090 lb)
Weight - 415 kg (913 lb) 770 kg (1694 lb) 970 kg (2134 lb)
BACKHOE BUCKETS
3.10 TYRES
TYRE TYPES
Tyres - 2WS
Tyres - 4WS
16.9/24 R4 12PR
16.9/28 R4 12PR
NUT TORQUES
Front nuts (2WS)................................................................................................................... 330 Nm (243 lbf·ft)
Rear nuts (2WS) ................................................................................................................... 540 Nm (398 lbf·ft)
Front and rear nuts (4WS) .................................................................................................... 700 Nm (516 lbf·ft)
SECTION 02 - TECHNICAL SPECIFICATIONS 13
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 4281 (168.54) 4345 (171.06) 4335 (170.66) 4342 (170.94)
B 3424 (134.80) 3488 (137.32) 3478 (136.92) 3485 (137.20)
C 2613 (102.87) 2677 (105.39) 2667 (105) 2674 (105.27)
D 181 (7.12) 117 (4.60) 127 (5) 120 (4.72)
E 728 (28.66) 665 (26.18) 662 (26.06) 661 (26.02)
F 1340 (52.75) 1234 (48.58) 1238 (48.74) 1232 (48.50)
G 1280 (50.39) 1217 (47.91) 1214 (47.79) 1213 (47.75)
H 1415 (55.70) 1307 (51.45) 1311 (51.61) 1305 (51.37)
α 44.2° 43.9° 44° 43.9°
β 59.6°
χ 50.3°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 23
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 4413 (173.74) 4477 (176.25) 4467 (175.86) 4474 (176.14)
B 3269 (128.7) 3333 (131.22) 3323 (130.82) 3330 (131.10)
C 2583 (101.69) 2647 (104.21) 2637 (103.81) 2644 (104.09)
D 208 (8.18) 144 (5.66) 154 (6.06) 147 (5.78)
E 893 (35.15) 830 (32.67) 827 (32.55) 826 (32.51)
F 1449 (57.04) 1344 (52.91) 1348 (53.07) 1342 (52.83)
G 1381 (54.36) 1318 (51.88) 1315 (51.77) 1314 (51.73)
H 1534 (60.39) 1427 (56.18) 1431 (56.33) 1425 (56.10)
α 44.3° 44° 44° 44°
β 59.6°
χ 42.3°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 25
B115B
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A (standard bucket) 3424 (134.80) 3488 (137.32) 3478 (136.92) 3485 (137.20)
A (6x1 bucket) 3424 (134.80) 3488 (137.32) 3478 (136.92) 3485 (137.20)
B (standard bucket) 3036 (119.52) 3100 (122.04) 3090 (121.65) 3097 (121.92)
B (6x1 bucket) 3032 (119.37) 3096 (121.88) 3086 (121.49) 3093 (121.77)
C (standard bucket) 428 (16.85)
C (6x1 bucket) 432 (17)
D (standard bucket) 2282 (89.84) 2219 (87.36) 2216 (87.24) 2215 (87.20)
D (6x1 bucket) 2255 (88.77) 2192 (86.29) 2189 (86.18) 2188 (86.14)
E (standard bucket) 2593 (102.08) 2493 (98.14) 2496 (98.26) 2491 (98.07)
E (6x1 bucket) 2568 (101.10) 2468 (97.16) 2471 (97.28) 2466 (97.08)
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 29
RETRACTED DIPPER
Front tyres 12.5/80-18 12.5/80-18 12.5/80-18 320/80 12.5-18 12.5-18
11L-16 F3 11L-16 F3
I3 I3 I3 R18 IT520 SLR4 SLR4
Rear tyres 18.4-26 18.4-26 16.9-28 480/80 18.4-26 16.9-28 18.4-26 16.9-28
R4 R1 R4 R26 IT520 R4 R4 SLR4 SLR4
5613 5605 5610 5603 5729 5721 5562 5594
A
(220.98) (220.66) (220.86) (220.59) (225.55) (255.23) (218.97) (220.23)
3751 3743 3748 3741 3864 3856 3702 3732
B
(147.67) (147.36) (147.55) (147.28) (152.12) (151.81) (145.74) (146.92)
4521 4528 4523 4530 4410 4417 4567 4538
C
(177.99) (178.26) (178.07) (178.34) (173.62) (173.89) (179.80) (178.66)
4142 4149 4145 4152 4037 4044 4187 4159
D
(163.07) (163.34) (163.18) (163.46) (158.93) (159.21) (164.84) (163.74)
1772 1778 1774 1774 1599 1606 1829 1802
E
(69.76) (70) (69.84) (69.84) (62.95) (63.22) (72) (70.94)
1180 1185 1182 1182 1067 1072 1218 1200
F
(46.45) (46.65) (46.53) (46.53) (42) (42.20) (47.95) (47.24)
5326 5327 5327 5327 5320 5320 5330 5327
G
(209.68) (209.72) (209.72) (209.72) (209.44) (209.44) (209.84) (209.72)
α 204°
mm (in)
EXTENDED DIPPER
Front tyres 12.5/80-18 12.5/80-18 12.5/80-18 320/80 12.5-18 12.5-18
11L-16 F3 11L-16 F3
I3 I3 I3 R18 IT520 SLR4 SLR4
Rear tyres 18.4-26 18.4-26 16.9-28 480/80 18.4-26 16.9-28 18.4-26 16.9-28
R4 R1 R4 R26 IT520 R4 R4 SLR4 SLR4
6291 6282 6288 6281 6431 6422 6233 6268
A
(247.67) (247.32) (247.44) (247.28) (253.18) (252.83) (245.39) (246.77)
4422 4413 4419 4412 4562 4554 4364 4399
B
(174.09) (173.74) (173.97) (173.7) (179.60) (179.29) (171.81) (173.18)
5559 5566 5561 5568 5452 5460 5603 5575
C
(218.85) (219.13) (218.93) (219.21) (214.64) (214.96) (220.59) (219.48)
5247 5254 5249 5256 5146 5153 5290 5262
D
(206.57) (206.85) (206.65) (206.92) (202.59) (202.87) (208.26) (207.16)
1988 1993 1990 1990 1851 1857 2033 2011
E
(78.26) (78.46) (78.34) (78.34) (72.87) (73.11) (80) (79.17)
2579 2587 2581 2581 2383 2391 2644 2613
F
(101.53) (101.85) (101.61) (101.61) (93.81) (94.13) (104.09) (102.87)
6276 6277 6276 6277 6270 6271 6279 6277
G
(247.08) (247.12) (247.08) (247.12 (246.85) (246.88) (247.20) (247.12)
α 204°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 35
RETRACTED DIPPER
Front tyres 12.5/80-18 12.5/80-18 12.5/80-18 320/80 12.5-18 12.5-18
11L-16 F3 11L-16 F3
I3 I3 I3 R18 SLR4 SLR4
Rear tyres 18.4-26 18.4-26 16.9-28 480/80 18.4-26 16.9-28 18.4-26 16.9-28
R4 R1 R4 R26 R4 R4 SLR4 SLR4
5698 5690 5696 5689 5819 5811 5646 5679
A
(224.33) (224.01) (224.25) (223.97) (229.09) (228.77) (222.28) (223.58)
3837 3829 3834 3827 3954 3947 3787 3818
B
(151.06) (150.74) (150.94) (150.66) (155.66) (155.39) (149.09) (150.31)
4670 4677 4672 4679 4560 4567 4716 4687
C
(183.85) (184.13) (183.93) (184.21) (179.52) (179.80) (185.66) (184.52)
4300 4307 4303 4310 4195 4203 4345 4316
D
(169.29) (169.56) (169.40) (169.68) (165.15) (165.47) (171.06) (169.92)
1905 1912 1908 1908 1730 1737 1964 1936
E
(74.99) (75.27) (75.11) (75.11) (68.11) (68.38) (77.32) (76.22)
1302 1306 1303 1303 1186 1190 1341 1322
F
(51.25) (51.41) (51.29) (51.29) (46.89) (46.85) (52.79) (52.04)
5456 5456 5456 5457 5449 5450 5459 5457
G
(214.80) (214.80) (214.80) (215.23) (214.52) (214.56) (214.92) (214.84)
α 204°
mm (in)
EXTENDED DIPPER
Front tyres 12.5/80-18 12.5/80-18 12.5/80-18 320/80 12.5-18 12.5-18
11L-16 F3 11L-16 F3
I3 I3 I3 R18 IT520 SLR4 SLR4
Rear tyres 18.4-26 18.4-26 16.9-28 480/80 18.4-26 16.9-28 18.4-26 16.9-28
R4 R1 R4 R26 IT520 R4 R4 SLR4 SLR4
6364 6355 6361 6354 6512 6503 6303 6339
A
(250.55) (250.19) (250.43) (250.15) (256.37) (256.02) (248.14) (249.56)
4503 4494 4500 4493 4647 4638 4443 4479
B
(177.28) (176.92) (177.16) (176.88) (182.95) (182.59) (174.92) (176.33)
5707 5714 5709 5716 5601 5609 5751 5722
C
(224.68) (224.96) (224.76) (225.03) (220.51) (220.82) (226.41) (225.27)
5400 5407 5402 5409 5299 5307 5443 5415
D
(212.59) (212.87) (212.67) (212.95) (208.62) (208.93) (214.29) (213.18)
2717 2725 2720 2720 2519 2527 2784 2751
E
(106.96) (107.28) (107.08) (107.08) (99.17) (99.48) (109.60) (108.30)
2114 2119 2116 2116 1975 1980 2160 2138
F
(83.22) (83.42) (83.30) (83.30) (77.75) (77.95) (85.03) (84.17)
5707 5714 5709 5716 5601 5609 5751 5722
G
(224.68) (224.96) (224.76) (225.03) (220.51) (220.82) (226.41) (25.27)
α 204°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 37
RETRACTED DIPPER
Front tyres 12.5/80-18 12.5/80-18 12.5/80-18 320/80 12.5-18 12.5-18
11L-16 F3 11L-16 F3
I3 I3 I3 R18 IT520 SLR4 SLR4
Rear tyres 18.4-26 18.4-26 16.9-28 480/80 18.4-26 16.9-28 18.4-26 16.9-28
R4 R1 R4 R26 IT520 R4 R4 SLR4 SLR4
5724 5716 5721 5714 5830 5674 5705
A 5838
(225.35) (225.03) (225.23) (224.96) (229.94) (223.38) (224.60)
3863 385 3860 3853 3973 3966 3814 3845
B
(152.086) (171.77) (151.96) (151.69) (156.41) (156.14) (150.15) (151.37)
4644 4651 4647 4654 4541 4548 4688 4654
C
(182.83) (183.11) (182.95) (183.22) (178.77) (179.05) (184.56) (133.22)
4275 4282 4277 4284 4177 4184 4317 4290
D
(168.30) (168.58) (168.38) (168.66) (164.44) (164.72) (169.96) (168.89)
1905 1912 1908 1908 1730 1737 1964 1936
E
(74.99) (75.27) (75.11) (75.11) (68.11) (68.38) (77.32) (76.22)
1302 1306 1303 1303 1186 1190 1341 1322
F
(51.25) (51.41) (51.29) (51.29) (46.69) (46.85) (52.79) (52.04)
5453 5454 5453 5454 5447 5448 5456 5454
G
(214.68) (214.72) (214.68) (214.72) (214.44) (214.48) (214.80) (214.72)
α 204°
mm (in)
EXTENDED DIPPER
Front tyres 12.5/80-18 12.5/80-18 12.5/80-18 320/80 12.5-18 12.5-18
11L-16 F3 11L-16 F3
I3 I3 I3 R18 IT520 SLR4 SLR4
Rear tyres 18.4-26 18.4-26 16.9-28 480/80 18.4-26 16.9-28 18.4-26 16.9-28
R4 R1 R4 R26 IT520 R4 R4 SLR4 SLR4
6389 6381 6387 6380 6531 6522 6330 6366
A
(251.53) (251.22) (251.45) (251.18) (257.12) (256.77) (249.21) (250.62)
4528 4520 4525 4518 4666 4657 4471 4506
B
(178.26) (177.95) (178.14) (177.87) (183.7) (183.34) (176.02) (177.40)
5681 5688 5683 5690 5583 5590 5723 5696
C
(223.66) (223.93) (223.73) (224.01) (219.80) (220.07) (225.31) (224.25)
5374 5381 5377 5384 5281 5288 5415 5389
D
(211.57) (211.85) (211.69) (211.96) (207.91) (208.18) (213.18) (212.16)
2717 2725 2720 2720 2519 2527 2784 2752
E
(106.96) (107.18) (107.08) (107.08) (99.17) (99.48) (109.60) (108.34)
2114 2119 2116 2116 1975 1980 2160 2138
F
(83.22) (83.42) (83.30) (83.30) (77.75) (77.95) (85.03) (84.17)
6407 6408 6407 6408 6402 6403 6410 6408
G
(252.43) (252.28) (252.24) (252.28) (252.04) (252.08) (252.36) (252.28)
α 204°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 41
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 5753 (226.49) 5817 (229.01) 5807 (228.62) 5814 (228.89)
B 3887 (153.03) 3951 (155.55) 3941 (155.15) 3948 (155.43)
C 4609 (181.45) 4545 (178.93) 4555 (179.33) 4548 (179.05)
D 4240 (166.92) 4176 (164.40) 4186 (164.80) 4179 (164.52)
E 1857 (73.11)
F 1296 (51.02)
G 5444 (214.33) 5436 (214.01) 5437 (214.05) 5437 (214.05)
α 206.9°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 43
RETRACTED DIPPER
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 5747 (226.25) 5815 (228.93) 5805 (228.54) 5812 (228.81)
B 3889 (153.11) 3953 (155.62) 3943 (155.23) 3950 (155.51)
C 4617 (181.77) 4553 (179.25) 4563 (179.64) 4556 (179.37)
D 4247 (167.20) 4183 (164.68) 4193 (165.07) 4186 (164.80)
E 1912 (75.27)
F 1306 (51.41)
G 5450 (214.56) 5442 (214.25) 5443 (214.29) 5442 (214.25)
α 204°
mm (in)
EXTENDED DIPPER
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 6415 (252.55) 6479 (255.07) 6469 (254.68) 6476 (254.96)
B 4554 (179.29) 4618 (181.81) 4608 (181.41) 4615 (181.69)
C 5653 (222.55) 5589 (220.03) 5599 (220.43) 5592 (220.15)
D 5347 (210.51) 5283 (207.99) 5293 (208.38) 5286 (208.11)
E 2725 (107.28)
F 2119 (83.42)
G 6404 (252.12) 6398 (251.88) 6399 (251.92) 6398 (251.88)
α 204°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 45
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 5782 (227.63) 5846 (230.15) 5836 (229.76) 5843 (230.03)
B 3913 (154.05) 3977 (156.57) 3967 (156.18) 3974 (156.45)
C 4584 (180.47) 4520 (177.95) 4530 (178.34) 4523 (178.07)
D 4214 (165.90) 4415 (173.81) 4160 (163.77) 4153 (163.90)
E 1857 (73.11)
F 1335 (52.55)
G 5400 (212.59) 5392 (212.18) 5393 (212.32) 5393 (212.32)
α 204.1°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 47
RETRACTED DIPPER
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 5776 (227.40) 5840 (229.92) 5830 (229.52) 5837 (229.80)
B 3915 (154.13) 3979 (156.65) 3969 (156.25) 3976 (156.53)
C 4591 (180.74) 4527 (178.22) 4537 (178.62) 4530 (178.34)
D 4221 (166.18) 4157 (163.66) 4167 (164.05) 4160 (163.77)
E 1912 (75.27)
F 1306 (51.41)
G 5447 (214.44) 5438 (214.09) 5440 (214.17) 5439 (214.13)
α 204°
mm (in)
EXTENDED DIPPER
Front tyres
16.9-24 R4 16.9-28 R4 440/80 R28 IT530 440/80 R28 IT520
Rear tyres
A 6441 (253.58) 6505 (256.10) 6495 (255.70) 6502 (255.98)
B 4580 (180.31) 4644 (182.83) 4634 (182.44) 4641 (182.71)
C 5628 (221.57) 5564 (219.05) 5574 (219.44) 5567 (219.17)
D 5319 (209.40) 5255 (206.88) 5265 (207.28) 5258 (207)
E 2725 (107.28)
F 2119 (83.42)
G 6402 (252.04) 6395 (251.77) 6396 (251.81) 6395 (251.77)
α 204°
mm (in)
SECTION 02 - TECHNICAL SPECIFICATIONS 49
2WS
4WS
56 SECTION 02 - TECHNICAL SPECIFICATIONS
2WS
4WS
SECTION 02 - TECHNICAL SPECIFICATIONS 57
NEW QUANTITY
RECOMMENDED FLUIDS AND INTERNATIONAL
HOLLAND MODELS
APPLICATION Specifications Litres Gal
Specifications
ENGINE - OIL
Ambra Master Gold HSP (15W40) NH 330 H API CH-4, ACEA E5 2WS - with filter 14 3.70
4WS - with filter 12.8 3.40
COOLING SYSTEM
Ambra Agriflu NH 900 A CUNA NC 956-16 ALL 24 6.30
antifreeze 50% water 50%
HYDRAULIC SYSTEM
Ambra Multi G NH 410 B API GL4 ISO VG 32/46 ALL 118 31.10
31.10
Hydrosystem biodegradable 46 BIO- NH 464 HBS ISO VG 46 ALL 118
S DIN 51524 - part II 4.70
POWERSHUTTLE TRANSMISSION
Ambra Multi G NH 410 B API GL4 ISO VG 32/46 ALL 18 3.70
POWERSHIFT TRANSMISSION
Ambra Hydrodex 3 NH 530 B ATF DEXRON III ALL 14 0.10
FRONT AXLE (2WS) 1.70
Ambra Mastertran NH 410 C ISO VG 46, 10W-20 2WD (each) 0.2
Differential 6.5 0.20
AIR CONDITIONING
COMPRESSOR ALL 240 cm3 Gal
PAG SP 20 oil
58 SECTION 02 - TECHNICAL SPECIFICATIONS
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
1.2 SPECIFICATIONS
Hydraulic tests
Tachometer setting .............................................................................................................................. 2000 rpm
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 (198-220 psi)
Torque converter..............................................................................................................7-11 bar (101-159 psi)
1.3 OVERHAUL
1.4 INSPECTION
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 flowing
to the other components which results in torque multiplication. This element can be compared to a centrifugal
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 causes the converter to multiply torque. The torque multiplication depends on the
regularity of certain elements (fan, turbine and stator) and on the output speed of the converter (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 multiplication
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.
TORQUE CONVERTER AND LUBRICATION PRESSURE TEST PORTS
2.2 SPECIFICATIONS
Hydraulic tests
Tachometer setting .............................................................................................................................. 2200 rpm
Test temperature, oil ........................................................................................................ 82-93 °C (180-200 °F)
Torque converter relief valve ..................................................................................................... 10 bar (145 psi)
Oil temperature converter out:
Normal operating range ........................................................................................ 80-90 °C ( 175-193 °F)
Maximum temperature.................................................................................................... 120 °C ( 284 °F)
2.3 OVERHAUL
2.4 INSPECTION
DISASSEMBLY
Remove the drive plate screws.
ASSEMBLY
Install the converter assembly on the input shaft.
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
SECTION 21 - TRANSMISSION
1.1 SPECIFICATIONS
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 (1.656 in)
4 SECTION 21 - TRANSMISSION
END FLOAT
Input forward Primary Shaft ......................................................................0.0508-0.41 mm (0.002 in - 0.016 in)
Input reverse Primary Shaft ......................................................................0.0508-0.41 mm (0.002 in - 0.016 in)
Output shaft................................................................................ 1st Gear - 0.33-0.508 mm (0.013 in - 0.020 in)
..................................................................................................2nd Gear - 0.35-0.558 mm (0.014 in - 0.022 in)
.................................................................................................. 3rd Gear - 0.38-0.838 mm (0.015 in - 0.033 in)
...................................................................................................4th Gear - 0.20-0.558 mm (0.008 in - 0.022 in)
4WD Shaft................................................................................................... 0.050-0.28 mm (0.002 in - 0.011 in)
Bearing End Floats.................................................................................... 0.025-0.076 mm (0.001 in - 0.003 in)
Bearing End Float Shims available ................................................... 0.050/0.076/0.127/0.177/0.381/0.508 mm
............................................................................................................(0.002/0.003/0.005/0.007/0.015/0.020 in)
HYDRAULIC TESTS
Tachometer setting .............................................................................................................................. 2000 rpm
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 (198 - 220 psi)
Torque Converter ...........................................................................................................7-11 bar (101 - 159 psi)
Reverse Clutch.......................................................................................................13.7-15.2 bar (198 - 220 psi)
Forward Clutch.......................................................................................................13.7-15.2 bar (198 - 220 psi)
4WD Supply ...........................................................................................................13.7-15.2 bar (198 - 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
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 gearshift lever
(1) or by pushing button (5), placed on the loader
control lever (3).
S 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.
Gearshift lever
The single gearshift lever (1) is used to select any
one of the four gear ratios. The transmission discon-
nect button (2) is depressed and held as the lever is
shifted from one gear to another and then released
to re-connect transmission drive.
8 SECTION 21 - TRANSMISSION
Transmission disconnection
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.
S 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
S 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.
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.
S 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
F29967
Pressure oil
Disengaged
Lubrication
SECTION 21 - TRANSMISSION 13
1 2 3 4 5
16
F R
15
6
14
13
12
11 10 9 8
F29968
1 2 3 4 5
16
F R
15
6
14
13
12
11 10 9 8
F29969
4 3 F29973
4 3
F29974
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 1
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.
3
F29975
3
F29977
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 9. Oil flow IN from cooler
26 bar ( 377 psi ) reference only 10. Torque converter pressure regulating valve
2. Forward travel solenoid valve 7-11 bar (198 - 220 psi )
13.7-15.2 bar (198 - 220 psi ) 11. Oil in from cooler, test port
3. Test port for reverse clutch pack 3.5 bar (50 psi)
13.7-15.2 bar (198 - 220 psi ) 12. Backhoe boom lock supply
4. Test port for forward clutch pack 13.7-15.2 bar (198 - 220 psi )
13.7-15.2 bar (198 - 220 psi ) 13. System pressure test point
5. System pressure sequencing valve 13.7-15.2 bar (198 - 220 psi )
13.7-15.2 bar (198 - 220 psi ) 14. Converter pressure oil test port
6. Oil flow OUT to cooler 7-11 bar (101 - 159 psi )
7. Oil OUT to cooler, test port 15. Front wheel drive solenoid
6.5 bar (94 psi ) 13.7-15.2 bar (198 - 220 psi )
8. Front wheel drive test point 16. Oil filter
13.7-15.2 bar (198 - 220 psi ) 17. Reverse solenoid valve
13.7-15.2 bar (198 - 220 psi )
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.
F29980
Input Output
Intermediate
SECTION 21 - TRANSMISSION 21
F27510
24 SECTION 21 - TRANSMISSION
F27511
SECTION 21 - TRANSMISSION 25
F27512
SECTION 21 - TRANSMISSION 27
28 SECTION 21 - TRANSMISSION
118.Oil seal
119.Sealing cap
120.Suction strainer
121.O-ring suction strainer
122.Support washer
123.Strainer cover plate
124.Adjuster screw
125.Breather
126.O-ring
127.O-ring
128.Expansion plug
129.Brake caliper nut
130.Pump mounting stud
131.Oil filter housing
132.Filter housing gasket
133.Screw
134.O-ring
135.Cold start spring
136.Ball
137.Adjuster screw
138.Adjuster screw
139.Copper washer
140.Screw
141.Remote test port assembly
142.Remote test port pipe
143.Remote test port pipe
144.Pump mounting stud nut
145.4WD gear bearing
146.Spacer 4WD gear bearings
30 SECTION 21 - TRANSMISSION
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 gearshift lever as-
sembly.
Invert the shaft and refit the 3rd gear, the synchro
hub and the circlip.
SECTION 21 - TRANSMISSION 55
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 (15
to 18 lbs.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 to 18 lbs.ft ). Hold the forks
and rail in place on the output shaft then refit the
complete 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 ( 9.6 to 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 lbs.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 (13-23 lbs.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.
Refit the 4WD solenoid coil and nut. (Only with 4WD
models).
Tighten to a torque of 5.4 Nm ( 4 lbf.ft ) maximum.
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
1 2 A
A. Adjust the two mounting bolts and locknuts to
leave a 0.25/1.50 mm (0.01/0.06 in) gap be-
tween the locknut and sleeve.
Then torque locknuts against mounting surface
to 155 Nm (110 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 (45-55
lbf.ft).
B 4
F27714
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 (0.37 in).
The maximum total wear limit for the disk is
1.524 mm (0.09 in).
Based on the nominal thickness of 9.5 mm (0.37 in)
this would give a minimum thickness of 7.976 mm
(0.31 in).
SECTION 21 - TRANSMISSION 89
PROBLEM 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 seal rings.
Pressure relief solenoid valve faulty.
Direction control solenoid valve inoperative.
Blockage of restricted flow in oil ports.
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 control solenoid valve or coil faulty.
Mechanical failure in transmission.
Blockage of restricted flow in oil ports.
Worn or broken input shaft seal ring.
Delay in taking up drive Low converter pressure.
Low oil level.
Low clutch pressure.
Faulty modulation in direction control solenoid valve.
Blocked direction control solenoid valve.
Blockage of restricted flow in oil ports.
No drive from 4WD 4WD solenoid valve or coil not operating.
Mechanical failure in transmission.
Low 4WD clutch pack pressure.
Worn 4WD clutch pack.
Transmission overheating Oil level too high or low.
Cooler flow restricted.
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 travel clutch pack pressurised when not selected.
Direction control solenoid valve faulty.
Input shaft seal rings leaking.
Mechanical failure in transmission.
Forward or reverse travel clutch pack not releasing due to a 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.
Wrong torque converter installed.
Low stall speed Poor engine performance.
Torque converter faulty.
Wrong torque converter installed.
SECTION 21 - TRANSMISSION 91
PROBLEM CAUSE
Noise Vehicle driveline problem:
Axles, propshafts, engine, engine mounts.
Misalignment of transmission/engine.
Worn or damaged bearings.
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.
Gearshift 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.
SECTION 21 - TRANSMISSION 93
A B
1
F27718
2.1 SPECIFICATIONS
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 (22.1-28 lbf.ft)
Control valve, connector nut to cover.............................................................................. 6 - 8 Nm (4.4-5.9 lbf.ft)
ELECTRICAL SPECIFICATIONS
Solenoid (forward reverse, high/low, 2nd/1st,
modulation, disconnect) ................................................................................................28 Ω ± 2 Ω 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 (0-0.01 in)
SECTION 21 - TRANSMISSION 95
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 LEDs T and N turn on 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.
Neutral state
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 turning the knob counterclockwise (+) in a single
movement. If the knob is held in this position, the
processor will upshift from the second to the fourth
gear in intervals of 1.8 seconds.
Downshifting
S WARNING
If descending down a steep slope, select the second
gear, upshifting only when it is safe to do so. You
cannot downshift to reduce speed if the machine
speed is above 15 km/h.
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
Powershift transmission
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 the 4th forward gear with the powershift lever;
then, with the parking brake disengaged, press the
accelerator pedal. 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 transmission will automatically
downshift through 4th, 3rd and 2nd gear as the ma-
chine speed decreases. Once stopped, engage the
parking brake; now the neutral position will be select-
ed by the microprocessor. To start travelling again,
simply twist the handgrip to select the 4th gear and,
with the parking brake disengaged, press the accel-
erator pedal.
Kickdown
The kickdown 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 gearshift from 2nd to 1st by the use of the
button (1) without the need to use the twist grip on
the powershift lever.
Transmission disconnection
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 gearshifts take place.
This effectively protects the transmission from ex-
cess forces, should gearshifts 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 the details regarding upshifting
and downshifting.
2.3 LUBRICATION
Daily
Check oil level daily with engine running at idle
(600 rpm) and oil at 82 - 93 °C (180-200 °F).
Maintain oil level at full mark.
Normal operating temperature 70 - 120 °C (158-248 Filter by-pass valve set to 4.1 - 5 bar (*) (59-73 psi).
°F) measured at temperature check port to cooler.
Lube pressure (*) 0.3 - 0.5 bar (4.3-7.3 psi) at 47 l/
Maximum allowed transmission temperature 120 °C min (12.4 GPM) pump flow (±1800 rpm).
(248 °F).
Internal leakage (*) 1.5 - 3.0 l/min (0.4-0.8 GPM) for
Transmission regulator pressure (*) - (neutral 2nd each clutch.
speed). Maximum total leakage 6.8 l/min (1.8 GPM) (clutch
Z at 600 rpm: 16.5 bar (239 psi). leakage + range + converter leak + valve leak) with-
Z at 2200 rpm: 19.6 - 23.1 bar (248-335 psi). out disconnect clutch.
Pump delivery (*): Safety valve: cracking pressure (*) 9.5 - 10.5 bar
Z at 2200 rpm in neutral 2nd speed: 64.9 l/min (17.1 (138-152 psi).
GPM) minimum.
Z at 2200 rpm in reverse 1st, 2nd, forward 1st, 2nd To cooler (converter out) pressure (*) 2 bar (29 psi)
maximum 3 l/min (0.8 GPM) less than in neutral minimum at 2000 rpm and maximum 5 bar (73 psi)
2nd. at no load governed speed.
Z at 2200 rpm in forward 3rd and 4th: maximum
5 l/min (1.3 GPM) less than in neutral 2nd. Converter by-pass valve set to 5 - 7 bar (*) (73-102
psi).
Clutch pressures (*) at 2200 rpm:
Z 18.1 - 21.5 bar (263-312 psi) clutch activated. (*) All pressures and flows to be measured with oil
Z 0 - 0.2 bar (0-3 psi) clutch released. temperature of 82 - 93 °C (180-200 °F).
A B
1
F27718
C D
13 14
11
10
12
F27719
E F
15
16
17
F27720
F27721
1
5
2 3
34 32 AA 33
bar 4 bar °C bar
7
71
°C
6
9
8
23 24 25 26 27 28
10 17
31
bar
20
11 12
35 18
bar
19 46
bar
45
bar
44
bar
42
bar
41
bar
47
bar
13
14 21 29 30 31 32 33 34
15
22
16
F27722
X
bar
Pressure check port
X
°C
Temperature check port
1. Operator’s compartment 18. Accumulator
2. Pressure gauge 19. Pressure booster 0 - 5.5 to 0 - 20 bar (0-80 to 0-
3. Thermometer 290 psi)
4. Torque converter 20. Electronic controlled modulation valve 5.5 to
5. Torque converter (pressure difference 4 bar (58 0 bar (80 to 0 psi)
psi)) by-pass valve 21. Modulated pressure 0 to 20 bar (0 to 290 psi)
6. Radiator 22. Clutch pressure 20 bar (290 psi)
7. Lubrication 23. Solenoid N/forward
8. Safety valve 10 bar (145 psi) cracking pressure 24. Solenoid N/reverse
9. Solenoid pressure 5 bar (73 psi) 25. High/low solenoid
10. Pressure regulator valve 20 bar (290 psi) 26. Solenoid 2nd/1st
11. By-pass valve pressure difference 4.3 bar (32 27. Solenoid range modulation
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
110 SECTION 21 - TRANSMISSION
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 system. A safety valve is fitted between the pressure regulator
and converter.
The valve will open if pressure in this system 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. 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).
SECTION 21 - TRANSMISSION 111
F27723
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.
114 SECTION 21 - TRANSMISSION
F27726
F27727
F27729 F27730
F27731 F27132
F27733 F27734
F29986
F29987
F29988
F29989
F29990
F29991
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 (62.4 psi)
7. System pressure test port 20 bar (290 psi)
8. System pressure regulating valve 20 bar (290 psi)
9. Oil to converter system
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 129
Control valve operation forward, second gear with four wheel drive engaged
F29992
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 (62.4 psi)
7. System pressure test port
8. System pressure regulating valve 20 bar (290 psi)
9. Oil to converter system
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 131
Control valve operation forward, third gear with four wheel drive disengaged
F29993
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 (62.4 psi)
7. System pressure test port 20 bar (290 psi)
8. System pressure regulating valve 20 bar (290 psi)
9. Oil to converter system
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 133
F29994
Suction oil
High pressure oil
Torque converter and lubrication oil
Return to oil tank
Pilot pressure
Modulated pilot oil
134 SECTION 21 - TRANSMISSION
t
Ou
In
t
Ou
F27735
Forward low
Forward high
Reverse and 1st
2nd
Disconnect
Input shaft
136 SECTION 21 - TRANSMISSION
REMOVAL
S WARNING
Before performing any service or maintenance on the machine ensure the wheels are chocked/blocked to pre-
vent 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. Engage the parking brake and block the wheels.
2. Stop the 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 the air filter assembly.
11. Disconnect all electrical connections.
12. Disconnect hydraulic pipe clamps.
13. Disconnect the fuel tank feed and return pipes.
14. Disconnect the foot throttle cable at the fuel injection pump.
15. Remove the cab mat.
16. Remove the cab floor access panel.
SECTION 21 - TRANSMISSION 137
F27736
F27737
F27739
2
F27740
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 139
INPUT SHAFT, TORQUE CONVERTER, PUMP DRIVE, INTERNAL CHARGING PUMP AND DRIVE PLATE
18
17
5
4
2 3
1
16
15
14
13
12
11
10
9
8
7
6 32
31
30
29
28
27
26
25
50
24
49
23 48
22 47
46
21
20 45
19
44
43
42
41
40
39
38
37
36
34 35
33
F27746
9
8
7
6
5
4
2 3
18
1 16 17
15
14 32
13
12
11
31
10
30
29
27 28
26
47
25
46
24 45
23 44
22 43
21
42
20
19
41
40
39
37 38
36
34 35
33
F27747
SECTION 21 - TRANSMISSION 149
2ND SHAFT
7
6
5
4
3
2
15
14
1 13
12
11
10
9
8
23
22
21
20
31
19
30
18 29
17
28
16
27
26
25
24
F27748
152 SECTION 21 - TRANSMISSION
13
12
11
10
8
7
5
4
22
3 21
2
1 20
19
18
17
16
15
32
31
30
29
28
14
27
26
25
24
23
F27749
PARKING BRAKE
19
20
3
19
2 18
1
17
21
15
16
14
12 13
11
10
9
8
7
6
5
4
F27750
6 3
5 F27751
ASSEMBLY INSTRUCTIONS
1 10 6 7
3
14 6
15
2
4
5
10
2
13
15
2
10
10 3
16 11
12
3
15
11
3
8
F27752
F27753
160 SECTION 21 - TRANSMISSION
TRANSMISSION DISASSEMBLY
Remove the oil filter.
Remove the output shaft, the 2nd shaft and the oil
baffle at the same time.
172 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.
S WARNING
Be sure that bearing shield is on the outside.
SECTION 21 - TRANSMISSION 213
S 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. Use caution as not to damage the seal-
ing rings.
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.
260 SECTION 21 - TRANSMISSION
19
20
3
19
2 18
1
17
21
15
16
14
12 13
11
10
9
8
7
6
5
4
F27750
Z 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).
Z Collapse pad retraction spring (21) and remove from brake head assembly.
Z 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.
Z Install new pads assembly (17) in each torque plate (16 and 18).
Z Install pad retention spring (21) into brake head assembly. Be sure spring’s “feet” are positioned properly in
holes in both pads assembly (17).
Z 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.
Z Back off inner adjusting nut (5) and check that disc is free to move (total clearance 0.8 - 1.1 mm (0.031-0.043
in)).
Z 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 267
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
F N R T N
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 - F N R T N
Group A:
F28360
Key on power
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
Select neutral and push kickdown
button:
= LED 1 red
= LED 4 orange NO Other input fault
YES YES
voltage.
YES
Check speed sensor has it failed
NO
YES F28371
Replace sensor
If static is not 0.6 - 0.8 V
or 1.3 - 1.5 V
F28370
276 SECTION 21 - TRANSMISSION
Over voltage F N R T N
Even power supply levels up to 30 V will not damage Blinks Slower
F28362
+ 24 VDC F28363
1 2 3 4
- 8 VDC F28364
SECTION 21 - TRANSMISSION 277
Key on power
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
F28365
Gear shifts
low/high solenoid:
inactive = forward high is selected
active = forward low is selected
SHIFT
DIAGRAM - FORWARD REVERSE
SOLENOIDS
1 2 3 4 1 2
reverse/n X X
forward/n
low/high X X X X
1st/2nd X X X
SECTION 21 - TRANSMISSION 279
During the output test LEDs 1234567 one by one are used and by
colour identifies the possible component at fault. Green= No
Red = Short circuit NO
fault found
Yellow = open circuit or short to battery plus
YES YES
Identify component by LED Identify component by LED
1 - Forward solenoid 1 - Forward solenoid
2 - Reverse solenoid 2 - Reverse solenoid
3 - 1/2 Solenoid 3 - 1/2 Solenoid
4 - Forward low/high solenoid 4 - Forward low/high solenoid
5 - 4WD/RWD solenoid 5 - 4WD/RWD solenoid
6 - Direction modulation solenoid 6 - Direction modulation solenoid
7 - Range modulation solenoid 7 - Range modulation solenoid
YES YES
Example: LED 1(red) forward solenoid Example: LED 2 (orange) reverse
output shorted to ground or a solenoid output open circuit or shorted
component. to battery plus
Check component and continuity of the Check component and continuity of the
cables and connectors cables and connectors output test
Output test
280 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)
F4288
SECTION 21 - TRANSMISSION 281
Key on power
YES
T-LED Blinks Safety critical
NO output
N-LED Blinks Faster
YES
Other output fault
Select neutral and push kickdown button forced to plus (F6) NO
(F5) open circuit: 2 red - 4 orange NO
2 red - 4 red
YES YES
All LEDs green Perform output test - fault Other LEDs are
NO NO
and OK found? orange
YES YES YES
Led 1 orange Led 2 orange Proceed to F7,
YES YES F8, F9 or F10
Check the forward Check the reverse cable
cable of the of the powershift lever: is
powershift lever: is
Repair or YES it faulty? it faulty?
replace NO YES NO
Check internal wires in forward travel Check internal wires in reverse travel
Repair or YES solenoid: are they faulty? solenoid: are they faulty?
replace
NO YES NO
Replace the
powershift lever unit
F28372
282 SECTION 21 - TRANSMISSION
Key on power
YES
T-LED Blinks
NO Non critical output
N-LED Blinks in phase
fault
YES
Replace the
powershift lever unit
5
F28373
284 SECTION 21 - TRANSMISSION
F4296
SECTION 21 - TRANSMISSION 285
Key on power
YES
T-LED Blinks
N-LED Blinks in phase NO No fault
YES
Replace the
powershift lever unit
F28374
286 SECTION 21 - TRANSMISSION
Internal faults F N R T N
Blinks Slower
Key on power
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
F12
Key on power
YES
Perform input test and
analyse faults if possible
fault found
NO
Possible input switch faults:
4WD - Request
Repair or Brake - Request
replace YES
Declutch - Request
Direction - Request
Speed/Temp sensor
F13
Key on power
YES
Perform output test and check range
modulation LED 7 (wire E08)
Repair or Green = Okay
replace YES Orange = Open circuit
Red = Short circuit
SECTION 21 - TRANSMISSION 289
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
TYPE
Front steering axle, model 26.00
F27349
4 SECTION 25 - FRONT AXLES
DESCRIPTION POSITION
Oil level plug 1
Air breather 2
Level, fill and drain plug for reduction gear oil 3
Oil drain plug 4
Greasing points 5
SECTION 25 - FRONT AXLES 5
SWARNING
Risk of violent oil ejection.
To drain the oil remove the level plug (1) and the
drain plug (4).
SWARNING
Risk of violent oil ejection.
1
7
6 2 9
4
5
8
15 3
13
1
11
10
14
12
8
F27351
Disassembly
10
F27352
SECTION 25 - FRONT AXLES 7
11
10
F27353
12
10
8
9
F27354
10
F27355
F27356
8 SECTION 25 - FRONT AXLES
Take the front support (2) out from the axle housing
(6).
2
6
F27357
2
8
3
9
F27358
Remove the bush (4) and the thrust washer (5) from
axle housing (6) only if necessary. 6 5
F27359
Assembly
F27356
SECTION 25 - FRONT AXLES 9
10
F27355
SWARNING
Align the bush hole with the bolt (8) hole.
F27360
11
10
F27353
SWARNING
Do not damage the O-ring when inserting the rear 10
support on the axle housing.
9 F27361
10 SECTION 25 - FRONT AXLES
F27359
F27362
Assemble the bush (3) into the front support (2) with
a suitable driver and a hammer.
S
WARNING
Align the bush hole with the bolt (8) hole.
2
8
Mount the bolt (8). 3
F27363
8
9
F27364
SECTION 25 - FRONT AXLES 11
STEERING CYLINDER
19
12
11
21 10
17
20
15
18
16 7
14 8 9
6
13
5
4
3
2 1
F27227
Disassembly
SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3
3 5
F27229
Assembly
16
14 20
13
18
17
15
F27231
17
15
19
F27232
SECTION 25 - FRONT AXLES 13
Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod 11
(17), then tighten to the requested torque.
6
12
4
10
7
17
3 5
F27233
F27504
8
F27235
Assemble the ball joint of the tie rod (3) into its hous-
ing in the swivel housing (2). 3
Assemble and tighten the locknut (1) to the specified
torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
1
F27236
14 SECTION 25 - FRONT AXLES
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been 11 12
carried out.
F27238
SECTION 25 - FRONT AXLES 15
WHEEL HUB
19
12
18
11
18
20
21
10
9 17
8
7 16
6
5
4 22
3 15
13 14
2 12
F27365
Disassembly
F27366
16 SECTION 25 - FRONT AXLES
F27368
F27255
S
WARNING 11 13
Before removing the king pins (11) and (13), secure
the swivel housing (10) to a rope or a hoist or to any
other supporting device; observe all current safety
10
regulations to guarantee the operator’s safety.
F27370
SECTION 25 - FRONT AXLES 17
10
F27371
18
17
16
F27372
Assembly
F37917
18
17
16
F27372
18 SECTION 25 - FRONT AXLES
22 21
13 11
F27374
F27371
Assemble the king pins, the lower (13) and the up-
per (11), and tighten the retaining screws (12) to the
requested torque.
12
11 13
F27375
F27376
SECTION 25 - FRONT AXLES 19
F27377
F27366
20 SECTION 25 - FRONT AXLES
11
1 2 3 11
3 2 1
5 5
4 4
F27339
Toe-in
S
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.
500 mm 500 mm
F27340
SECTION 25 - FRONT AXLES 21
F27341
M -05
F27342
F27343
22 SECTION 25 - FRONT AXLES
F27344
F27345
F27346
5 4
F27347
SECTION 25 - FRONT AXLES 23
F27348
24 SECTION 25 - FRONT AXLES
PROBLEM CAUSE
1 2 3 4 5 6 7 8 9
Wheel vibration; front tyre resistance; half shaft
breakage
Steering is difficult; vehicle goes straight while it’s
turning
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent noise
Vehicle’s accident
Load bump
Worn out or pitted bearings Insufficient lubrication Replace bearings.
Excessive use
Contaminated oil
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
TYPE
Front steering axle, model 26.16
F27203
3 5 1 4 5 3
5 2 5
5 4 5
F27205
DESCRIPTION POSITION
Oil level plug 1
Air breather 2
Level, fill and drain plug for reduction gear oil 3
Oil drain plug 4
Greasing points 5
28 SECTION 25 - FRONT AXLES
Before draining the oil from axle housing, use the oil
breather (2) to release possible internal pressure.
S
WARNING
Risk of violent oil ejection.
To drain the oil remove the level plug (1) and the
drain plug (4).
S
WARNING
Risk of violent oil ejection.
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.
Tighten the plug (3) to the requested torque.
30 SECTION 25 - FRONT AXLES
165 Nm
95 Nm 120 Nm 8 Nm 150 Nm 95 Nm 13 Nm
120 Nm
266 Nm 57 Nm
165 Nm
10 Nm 8 Nm 84 Nm 60 Nm 8 Nm 84 Nm
F27211
SECTION 25 - FRONT AXLES 31
21
18
20
15 17
16 19
14
12
9
6 8
3 5 13
11
10
7
4
2
1
F27212
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1) from the pinion shaft end (14).
14
1 2
F27213
32 SECTION 25 - FRONT AXLES
4
F27214
Remove the O-ring (6) from the bush (8) in rear sup-
port (5).
5
7
F27215
5 8
4
F27216
F27217
SECTION 25 - FRONT AXLES 33
11
F27218
Remove the O-ring (12) and the seal ring (13) from
the cover (11). 13
NOTE: destructive operation for the seal rings. 12
11
F27219
F27220
19
F27221
34 SECTION 25 - FRONT AXLES
19
F27222
17
F27223
Assembly
F27220
11
F27219
SECTION 25 - FRONT AXLES 35
11
F27218
F27217
SWARNING
Align the bush hole with the bolt (4) hole.
F27216
5
7
F27215
36 SECTION 25 - FRONT AXLES
S
WARNING
Do not damage the O-ring when inserting the rear
support on the central body. 5
4
F27214
14
1 2
F27213
F27223
20
F27224
SECTION 25 - FRONT AXLES 37
19
F27225
19
F27226
38 SECTION 25 - FRONT AXLES
STEERING CYLINDER
19
12
11
21 10
17
20
15
18
16 7
14 8 9
6
13
5
4
3
2 1
F27227
Disassembly
S
WARNING
Don’t beat on the threaded pin end of the tie rod (3). 3
Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the 11
conditions.
Unscrew the fastening screws (6) and take the
6
steering cylinder (7) out of its housing, if necessary 12
4
use a rubber hammer.
Remove only parts that need to be overhauled and/ 10
or replaced. 7
3 5
F27229
Assembly
16
14 20
13
18
17
15
F27231
17
15
19
F27232
40 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 11
(17), then tighten to the requested torque.
6
12
4
10
7
17
3 5
F27233
F27234
8
F27235
Assemble the ball joint of the tie rod (3) into its hous-
ing in the swivel housing (2). 3
Assemble and tighten the locknut (1) to the specified
torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
1
F27236
SECTION 25 - FRONT AXLES 41
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been 11 12
carried out.
F27238
42 SECTION 25 - FRONT AXLES
REDUCTION GEAR
10
9
8
7
6
5
4
2
1
3
F27239
Disassembly
F27240
SECTION 25 - FRONT AXLES 43
1
F27241
F27242
Assembly
F27246
1
F27241
F27247
SECTION 25 - FRONT AXLES 45
WHEEL HUB
28
19
27
18
24
14
22
13
12 26
25
23
11
10
9
8 15
7 21
4 16 20
3 17
2 5 6
F27248
Disassembly
SWARNING
Do not damage the cardan shaft.
14
F27249
46 SECTION 25 - FRONT AXLES
F27250
F27251
F27253
F27252
SECTION 25 - FRONT AXLES 47
F27254
F27255
F27256
14
F27257
48 SECTION 25 - FRONT AXLES
F27258
14 23
F27259
Assembly
20 21
F27260
Insert the bush (22) into the swivel housing (14) with
the special tool 380002660 and a hammer or a
23 14
press.
Insert the seal ring (23) into the swivel housing (14)
22
with the special tool 380002661 and a hammer.
Grease carefully the seal ring (23).
F27261
SECTION 25 - FRONT AXLES 49
F27258
F27262
F27257
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19
16 18
F27263
50 SECTION 25 - FRONT AXLES
F27264
F27265
F37835
F27267
SECTION 25 - FRONT AXLES 51
F27268
F27269
A= 11.975 ÷ 12.025 C A C
B= 52.229 ÷ 52.279
C= 20.000 ÷ 20.100
B
F27270
F27271
52 SECTION 25 - FRONT AXLES
F27250
SECTION 25 - FRONT AXLES 53
CARDAN SHAFTS
1 2
4
5
6
F27272
Disassembly
Remove the cardan shaft (6) from the axle shaft (1).
1
6
F27273
54 SECTION 25 - FRONT AXLES
S
WARNING
Be careful not to damage the bush seat.
5
F27274
Remove the upper king pin bush (2) and the bearing
cup (3) from the king pin seats using a suitable ex-
tractor only if wear conditions require it.
F27275
Assembly
Cool the upper king pin bush (2) and the bearing cup
(3) at a temperature lower than -100 °C (-148 °F) with
liquid nitrogen.
2
S
WARNING
Wear safety gloves.
Assemble the bush (2) on the upper king pin seat with
the special tool 380002664 and a hammer. 3
Assemble the bearing cup (3) on the lower king pin
seat with the special tool 380002662 and a hammer.
F27276
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
1
special tool 380002666 and a hammer.
4
NOTE: grease carefully the seal rings. 5
F27277
SECTION 25 - FRONT AXLES 55
SWARNING 5
Positioning the seal ring (5) as in figure.
F27278
Insert the cardan shaft (6) into the axle shaft (1).
SWARNING
Be careful not to damage the seal ring.
1
6
F27273
56 SECTION 25 - FRONT AXLES
DIFFERENTIAL SUPPORT
9 8 13
12
11
10
7
6
14
8
5
4
2 3
1
F27282
Disassembly
8 8
F27284
F27285
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
F27286
10
F27287
58 SECTION 25 - FRONT AXLES
F27288
Assembly
S
WARNING
Do not invert the bearing cones if the bearings are
not replaced. 4
6
5
F27289
S
WARNING
Check the correct assembly side of the ring gear.
F27290
10
F27291
SECTION 25 - FRONT AXLES 59
F27292
F27293
F27295
60 SECTION 25 - FRONT AXLES
F27293
S
WARNING
All preloadings must be measured without the seal
ring.
F27298
12
13
F27299
F27300
F27301
62 SECTION 25 - FRONT AXLES
F27302
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
1
F27304
SECTION 25 - FRONT AXLES 63
DIFFERENTIAL GROUP
Disassembly
12
F27306
64 SECTION 25 - FRONT AXLES
F27307
F27308
11
F27309
F27310
SECTION 25 - FRONT AXLES 65
Assembly
F27310
11
F27314
66 SECTION 25 - FRONT AXLES
1
F27316
F27315
12
F27317
F27318
SECTION 25 - FRONT AXLES 67
PINION GROUP
Disassembly
10
F27320
68 SECTION 25 - FRONT AXLES
Remove the ring nut (10) and collect its washer (9).
9
10
F27321
6
4
F27322
8
F27326
F27324
SECTION 25 - FRONT AXLES 69
SWARNING
The ring nut (10) and the spacer (5) must be re- 5
placed when reassembling the unit.
10
F27325
Assembly
8
F27326
F27327
10
F27328
70 SECTION 25 - FRONT AXLES
F27329
F27330
S = X-V mm
V
F27331
F27332
SECTION 25 - FRONT AXLES 71
10
F27328
F27334
F27335
9
10
F27321
72 SECTION 25 - FRONT AXLES
S
WARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
10
S
WARNING
All preloadings must be measured without the seal
ring. F27337
F27338
SECTION 25 - FRONT AXLES 73
11
1 2 3 11
3 2 1
5 5
4 4
F27339
Toe-in
SWARNING
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.
500 mm 500 mm
F27340
74 SECTION 25 - FRONT AXLES
F27341
M -05
F27342
F27343
SECTION 25 - FRONT AXLES 75
F27344
F27345
F27346
5 4
F27347
76 SECTION 25 - FRONT AXLES
F27348
SECTION 25 - FRONT AXLES 77
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 steer-
ing
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.
Fatigue failure of pinion teeth Use until worn Replace bevel gear set.
See if the fracture line is well Continuous overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage Crash load of differential compo- Check and/or replace other differen-
nents tial components.
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 a thickness by 0.1 mm
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.
80 SECTION 25 - FRONT AXLES
TYPE
Front steering axle, model 26.28
F27378
1 4
3 5 5 3
5 2 5
5 5
F27379
DESCRIPTION POSITION
Oil level plug 1
Air breather 2
Level, fill and drain plug for reduction gear oil 3
Oil drain plug 4
Greasing points 5
82 SECTION 25 - FRONT AXLES
S
WARNING
Risk of violent oil ejection.
To drain the oil remove the level plug (1) and the
drain plug (4).
S
WARNING
Risk of violent oil ejection.
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.
Tighten the plug (3) to the requested torque.
84 SECTION 25 - FRONT AXLES
21
18
22
17
15 16
19
23
7
6
8
5
11
1 14
3 10
4
9
12
13
2 F27380
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1).
1
3
2
F27381
SECTION 25 - FRONT AXLES 85
13
F27382
12
11
F27383
4
F27384
5
F37918
86 SECTION 25 - FRONT AXLES
8
5
4
9
F27386
F27217
10
F27387
19
F27388
SECTION 25 - FRONT AXLES 87
20
19
18
23
22
F27389
Remove the bush (17) and the washer (16) from the
axle housing (15) only if necessary. 17
15
NOTE: it is advisable to heat the bush (17) to make
easy this operation; this is a destructive operation
for the bush.
16
F27390
Assembly
10
F27387
F27217
88 SECTION 25 - FRONT AXLES
S
WARNING
Align the bush hole with the bolt (4) hole.
F27216
5
7
F27215
S
WARNING
Do not damage the O-ring when inserting the rear 5
support on the central body.
9
F27391
F27390
SECTION 25 - FRONT AXLES 89
20
F27224
SWARNING 20
Align the bush hole with the bolt (19) hole. 19
18
Mount the bolt (19). 22
Assemble O-ring (22).
F27393
23
F27394
12
11
F27383
90 SECTION 25 - FRONT AXLES
13
F27382
1
3
2
F27381
SECTION 25 - FRONT AXLES 91
STEERING CYLINDER
24
23
22
10
21
9
13 20
8
19
14 18
7
6
5
4
3
17 12
16 11
15
1
F27396
Disassembly
SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3
19
18 F27398
Assembly
24
17 22
16 21
20
19
18
F27392
22
20
18
F27399
SECTION 25 - FRONT AXLES 93
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. 10
9
8
7
6
5
4
3
F27400
11
F27402
Insert the ball joint of the tie rod (3) into its housing
in the swivel housing (2). 3
Assemble and tighten the locknut (1) to the specified
torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
1
F27236
94 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- 4 9 3 10
ried out.
F29526
SECTION 25 - FRONT AXLES 95
REDUCTION GEAR
11
9
10
8
7
6
5
1
3
2
F27404
Disassembly
F27240
96 SECTION 25 - FRONT AXLES
1
F27241
F27405
Assembly
F27405
F27407
F27408
98 SECTION 25 - FRONT AXLES
WHEEL HUB
19
26
18
24
27
14
22
13
12
25
11 23
10
9
8 15
7 21
4 16 20
3 17
2 5 6
F27409
Disassembly
S
WARNING
Do not damage the cardan shaft.
14
F27410
SECTION 25 - FRONT AXLES 99
F27250
F27251
F27253
F27252
100 SECTION 25 - FRONT AXLES
F27254
F27412
F27256
14
F27257
SECTION 25 - FRONT AXLES 101
26
25
F27413
14 23
F27259
Assembly
20 21
F27260
Insert the bush into the swivel housing (14) with the
special tool 380002668 and a hammer or a press.
23 14
Insert the seal ring (23) into the swivel housing (14)
with the special tool 380002669 and a hammer.
22
Grease carefully the seal ring (23).
F27261
102 SECTION 25 - FRONT AXLES
F27414
F27257
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19
16 18
F27263
F27525
SECTION 25 - FRONT AXLES 103
F27265
F37835
F27267
F27268
104 SECTION 25 - FRONT AXLES
F27269
14
F27410
3 2 1
F27416
SECTION 25 - FRONT AXLES 105
CARDAN SHAFTS
1
2
3
4
F27417
Disassembly
Remove the cardan shaft (4) from the axle shaft (1).
1
4
F27418
106 SECTION 25 - FRONT AXLES
Remove the seal rings (3) from the axle beam (1).
1
NOTE: destructive operation for the seal rings (3). 2
3
Remove the bush (2) from the axle beam (1) only if
the wear conditions require this.
S
WARNING
Be careful not to damage the bush seat.
3
F27419
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
1
special tool 380002670 and a hammer.
2
NOTE: grease carefully the seal rings. 3
F27420
F27421
Insert the cardan shaft (4) into the axle shaft (1).
S
WARNING
Be careful not to damage the seal ring.
1
6
F27273
SECTION 25 - FRONT AXLES 107
9 8 13
12
11
10
7
6
14
8
5
4
2 3
1
F27411
Disassembly
SWARNING
Support the differential support with a rope or other
appropriate means.
2
14
1
F27501
108 SECTION 25 - FRONT AXLES
8
8
F27395
F27422
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
F27423
10
F27424
SECTION 25 - FRONT AXLES 109
F27425
Assembly
SWARNING
Do not invert the bearing cones if the bearings are
not replaced. 4
6
5
F27289
SWARNING
Check the correct assembly side of the ring gear.
F27427
F27428
110 SECTION 25 - FRONT AXLES
Assemble the ring nuts (3) and (7) into the differen-
tial support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded.
Check that the differential bearings are well settled; 3
7
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.
F27429
F27293
F27295
SECTION 25 - FRONT AXLES 111
F27431
SWARNING
All preloadings must be measured without the seal
ring.
F27298
12
11
F27434
14
F27435
2
14
1
F27501
SECTION 25 - FRONT AXLES 113
F27302
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
1
F27304
114 SECTION 25 - FRONT AXLES
8
1
11
10
9
13
12
7
6
8
7
6
5
4
3
2
F27437
Disassembly
10
F27438
SECTION 25 - FRONT AXLES 115
F27307
F27308
11
F27309
F27439
116 SECTION 25 - FRONT AXLES
F27440
Remove the shaft (8), the gears (7) and the spheri-
cal washers (6).
6 6
7 7
F27441
13
F27442
Assembly
S
WARNING
Remove rests of dope.
F27443
SECTION 25 - FRONT AXLES 117
12
F27444
13
F27442
Position the shaft (8), the gears (7) and the spherical
washers (6).
6 6
7 7
F27441
F27440
118 SECTION 25 - FRONT AXLES
F27439
11
F27314
1
F27316
F27315
SECTION 25 - FRONT AXLES 119
10
F29010
F27318
120 SECTION 25 - FRONT AXLES
14
10
13
8
12
9
5
1
4
6
11
10
8
9
7
6
5
4
3
2
F27448
Disassembly
13
F27449
SECTION 25 - FRONT AXLES 121
F27307
F27446
14
F27450
F27451
122 SECTION 25 - FRONT AXLES
F27452
F27453
Remove the shaft (10), the gears (8) and the spher-
ical washers (9).
9 9
8 8
10
F27454
F27455
SECTION 25 - FRONT AXLES 123
4 5
F27456
Assembly
SWARNING
Remove rests of dope.
F27457
11
F27458
4 5
F27456
124 SECTION 25 - FRONT AXLES
F27455
Position the shaft (10), the gears (8) and the spher-
ical washers (9).
9 9
8 8
10
F27454
F37839
F27452
SECTION 25 - FRONT AXLES 125
F27451
14
F29320
1
F27316
F27315
126 SECTION 25 - FRONT AXLES
13
F27460
F27318
SECTION 25 - FRONT AXLES 127
PINION GROUP
1
2
3
4
5
6
7
8
9
10
F27461
Disassembly
F27462
128 SECTION 25 - FRONT AXLES
Remove the ring nut (10) and collect its washer (9).
9
10
F27463
6
4
F28106
8
F28107
F27324
SECTION 25 - FRONT AXLES 129
SWARNING
The ring nut (10) and the spacer (5) must be re- 5
placed when reassembling the unit.
10
F27325
Assembly
8
F28107
F28108
3
8
10
F28109
130 SECTION 25 - FRONT AXLES
F28110
F28111
S = X-V mm
V
F27331
F27332
SECTION 25 - FRONT AXLES 131
3
8
10
F28109
F27334
6
4
F28112
9
10
F27463
132 SECTION 25 - FRONT AXLES
S
WARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
10
S
WARNING
All preloadings must be measured without the seal
ring. F27432
F27338
SECTION 25 - FRONT AXLES 133
1 2 3 3 2 1
5 5
4 4
F28113
Toe-in
SWARNING
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.
500 mm 500 mm
F27340
134 SECTION 25 - FRONT AXLES
F27341
M -05
F27342
F27343
SECTION 25 - FRONT AXLES 135
F27344
F27345
F27346
5 4
F27347
136 SECTION 25 - FRONT AXLES
F27348
SECTION 25 - FRONT AXLES 137
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 steer-
ing
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.
Fatigue failure of pinion teeth Use until worn Replace bevel gear set.
See if the fracture line is well Continuous overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage Crash load of differential compo- Check and/or replace other differen-
nents tial components.
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 a thickness by 0.1 mm
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.
140 SECTION 25 - FRONT AXLES
4. SPECIAL TOOLS
S
WARNING
The differential lock fitted to this machine is operated
by oil pressure and controlled by an electrically
operated solenoid. The solenoid is energized when
the switch (1) mounted in the front console is
depressed.
SWARNING
Never use the differential lock at speeds above 8
km/h or when turning the machine. When engaged,
the differential lock prevents the machine from
turning: this could cause accidents.
F29549
6 SECTION 27 - REAR AXLE
1.2 SPECIFICATIONS
F29550
LUBRICATION
Oil capacity: 21.2 litres (5.6 US Gallons)
Oil specification: Ambra Mastertran NH 410 C + AoA Axle oil additive (0.8 litres (0.2 US Gallons))
SECTION 27 - REAR AXLE 7
2 11 3 4
8 9 10
F29551
1. Screw of half shaft: 554÷626 Nm (409÷462 lbf.ft) 5. Screw: 11÷14 Nm (8÷10 lbf.ft)
1. Screw of axle assy - rear RH or LH: 190÷231 Nm 6. Screw of block: 57÷76 Nm (42÷56 lbf.ft)
(140÷170 lbf.ft) 7. Screw of baffle oil: 43÷51 Nm (32÷38 lbf.ft)
2. 8. Plug: 27÷34 Nm (20÷25 lbf.ft)
3. Screw of front flange: 136÷170 Nm (100÷125 9. Screw: 32÷41 Nm (24÷30 lbf.ft)
lbf.ft) 10. Screw of housing rear brake: 204÷245 Nm
4. Screw to fixed rear axle to the chassis: 800 Nm (150÷189 lbf.ft)
(590 lbf.ft) 11. Right nut: 406 Nm (300 lbf.ft)
8 SECTION 27 - REAR AXLE
DIFFERENTIAL REMOVAL
2
F29552
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
gasket (4).
Remove the coupling (5).
14
F29553
Powershuttle
14
17
11
10
9 16
8 2
7 3
6 4
5 5
4 6
3 15 RH
2 13
1 12
LH
F29554
Powershift
18
19 1
20 2
15 3
6 4
5 6
4 5
3 7 RH
2 12
16 13
LH
F29555
17
12 13
8
F29556
F29557
3
F29558
22 SECTION 27 - REAR AXLE
VALUE “T”
SHIMS
mm in
0.034÷0.039 0.0013÷0.0015 81803515
0.040÷0.045 0.0016÷0.0018 81803516
T
F29559
0.046÷0.051 0.0018÷0.0020 81803517
0.052÷0.057 0.0020÷0.0022 81803518
0.058÷0.063 0.0023÷0.0025 81803519
0.064÷0.069 0.0025÷0.0027 81803520
0.070÷0.075 0.0028÷0.0030 81803521
0.076÷0.081 0.0030÷0.0032 81803522
Measuring of range between the face thrust block and the back face of differential
VALUE “S”
SHIMS
mm in
0.80÷0.89 0.031÷0.035 87346232 + 87346228
0.90÷0.99 0.035÷0.039 87346232 + 87346231
F29560
F29637
F29638
26 SECTION 27 - REAR AXLE
F29639
F29640
DESCRIPTION POSITION
Level and fill plug for differential oil 1
Air breather 2
Level, fill and drain plug for reduction gear oil 3
Differential oil drain plug 4
Greasing points 5
Brake bleed plug 6
Service brake oil inlet 7
30 SECTION 27 - REAR AXLE
F28005
4 1
F28006
F28007
F28008
SECTION 27 - REAR AXLE 31
6
F28009
32 SECTION 27 - REAR AXLE
FRONT FLANGE
7
6
5
4
1 2 3
F28010
Disassembly
F28011
SECTION 27 - REAR AXLE 33
F28012
Remove the seal ring (3), the O-ring (4), the gasket
(5), the O-ring (6) and the washer (7).
5
4
3
7
6
F29009
Assembly
7
6
F29322
F29323
34 SECTION 27 - REAR AXLE
Assemble the new O-ring (4) and the seal ring (3).
4
3
F29324
F28012
F28011
SECTION 27 - REAR AXLE 35
STEERING CYLINDER
4
5
7
3 10
11
12
2
6
8 13
9
14
15
16
17
18
19
20
21
22
23
24
F28013
Disassembly
SWARNING 3
Don’t beat on the threaded pin end of the tie rod (3).
1
2
NOTE: this is a destructive operation for the nut (1). F27228
3 6 8 9 13
F28014
Assembly
17
19
22
23
24
F28016
Assemble the tie rods (3) and (13), the ball joints (5)
and (11), the nuts (4) and (12) to the ends of the rod, 4
then tighten with a dynamometric wrench to the 5
requested torque.
7
10
11
12
13
F28017
SECTION 27 - REAR AXLE 37
14
F28020
Insert the ball joint of the tie rod (3) into its housing
in the swivel housing (2). 3
Assemble and tighten the locknut (1) to the specified
torque.
Repeat the whole sequence of the mentioned
operations to the other side.
1
F27236
38 SECTION 27 - REAR AXLE
REDUCTION GEAR
11
9
10
8
7
6
5
1
3
2
F27404
Disassembly
F27240
SECTION 27 - REAR AXLE 39
F28044
F27405
F28021
Remove the gear (7) from its seat, taking care not to
lose the rollers inside it. 7
Remove the shim (5).
5
F28022
40 SECTION 27 - REAR AXLE
F28023
Assembly
F28024
Insert all the rollers into the gears, then position the
two washers (8) and (9).
9
NOTE: the first washer must be aligned with the
dowel (10) pin. 10 8
F28025
F28026
SECTION 27 - REAR AXLE 41
F27405
F28044
F27408
42 SECTION 27 - REAR AXLE
WHEEL HUB
Disassembly
S
WARNING
Do not damage the cardan shaft.
14
F27410
SECTION 27 - REAR AXLE 43
F27250
F27251
F27253
F27252
44 SECTION 27 - REAR AXLE
F27254
F27412
F27256
14
F27257
SECTION 27 - REAR AXLE 45
28
23
F28046
14 23
F27259
Assembly
20 21
F27260
F28047
46 SECTION 27 - REAR AXLE
23
F28046
18 16
F28027
F27257
16 18
F27263
SECTION 27 - REAR AXLE 47
11 11
F28028
F27265
F37835
F27267
48 SECTION 27 - REAR AXLE
F27268
F27269
F27250
SECTION 27 - REAR AXLE 49
CARDAN SHAFTS
4
3
2
1
F27279
Disassembly
Remove the cardan shaft (1) from the axle shaft (4).
4
1
F27280
50 SECTION 27 - REAR AXLE
S
WARNING
Be careful not to damage the bush seat.
2
F27281
Assembly
F28029
F28048
Insert the cardan shaft (1) into the axle shaft (4).
S
WARNING
Be careful not to damage the seal ring.
4
1
F28049
SECTION 27 - REAR AXLE 51
F28030
Disassembly
F28031
52 SECTION 27 - REAR AXLE
2 1
F28033
S
WARNING 4
Once the axle shaft has been removed, the brake
disks are free. 1
F28034
F28035
Remove the O-ring (4) and (19) from its housing and
from oil pipe hole and check its conditions. 4
19
F28037
F27313
Take from the piston (14), the springs (13) and the
bushes (12) and (27) and spacer (26). 27
26
14
13
12
F28038
F28039
54 SECTION 27 - REAR AXLE
F28040
Assembly
F28040
Install the piston (14) into the brake flange (7) and
then a support flat disk on the piston and with a lever
14
anchored to an eyescrew, exert a pressure just
enough to insert the piston (14) into the brake flange
(7).
7
F28042
F28116
SECTION 27 - REAR AXLE 55
19
F28037
5 6
F28043
F28035
F28034
56 SECTION 27 - REAR AXLE
S
WARNING
Support the groups properly as already pointed out
for disassembly phase.
2 1
F28033
SECTION 27 - REAR AXLE 57
4
5
15
10
14
6
18
9
3 17
2 16
1
5 13
4 14
15
12
11
8
7
6 F28050
Disassembly
6
F28051
58 SECTION 27 - REAR AXLE
F28052
F28053
18
F28054
F28055
SECTION 27 - REAR AXLE 59
F28056
10
F28057
F28058
16
F28059
60 SECTION 27 - REAR AXLE
15 15
14 14
13
F28060
11
F28061
Assembly
S
WARNING
Remove rests of dope.
F28079
12
16
14
F28063
SECTION 27 - REAR AXLE 61
17
F28064
15 15
14 14
13
F28060
12
F28066
F28058
62 SECTION 27 - REAR AXLE
10
F28067
1
F27316
F27315
18
F28068
SECTION 27 - REAR AXLE 63
F28069
F28070
F28071
Insert and tighten the ring nuts (6), using the wrench
380002218 until the clearance of the bearings is 6
removed.
4
5
6
16 15
17 10
17
18
16
9
15 11
3 12
2
13
1
5 19
4 16
15
16
15
14
13
12
6 7 8 11
F28073
Disassembly
6
F28051
SECTION 27 - REAR AXLE 65
F28052
F28053
18
F28054
F28055
66 SECTION 27 - REAR AXLE
F28056
10
F28057
F28058
F28074
SECTION 27 - REAR AXLE 67
13
F28075
15 15
16 16
17
F28076
14
13
F28077
11 12
F28078
68 SECTION 27 - REAR AXLE
Assembly
S
WARNING
Remove rests of dope.
F28079
14
19
16
F28080
11 12
F28078
14
13
F28077
SECTION 27 - REAR AXLE 69
15 15
16 16
17
F28082
13
F28081
F28074
F28058
70 SECTION 27 - REAR AXLE
10
F28067
1
F27316
F27315
18
F28068
SECTION 27 - REAR AXLE 71
F28069
F28070
F28071
Insert and tighten the ring nuts (6), using the wrench
380002218 until the clearance of the bearings is 6
removed.
PINION GROUP
1
2
3
4
5
6
7
8
9
F28083
Disassembly
F29645
SECTION 27 - REAR AXLE 73
F28085
1
4
5
6
F28086
3 2
F28087
F28088
74 SECTION 27 - REAR AXLE
F28089
Assembly
F28090
F28091
F28092
SECTION 27 - REAR AXLE 75
F28093
C
X
C= (known value)= 50 mm (1.97 in)
A
B
(A+C) - B = X
F28094
F27331
F28095
76 SECTION 27 - REAR AXLE
Insert the shim (2) on the pinion (1) with the chamfer
against the gear.
Press the bearing (3) into the pinion, making sure 3
that it is well set.
1
F28096
Insert the shims (4) and (6) and the spacer (5) into
the pinion (1).
1
4
5
6
F28086
Insert the pinion (1) into its seat in the central body
housing and the bearing (7) into the pinion end.
1
F28097
F28084
SECTION 27 - REAR AXLE 77
F28098
78 SECTION 27 - REAR AXLE
1 2 3 3 2 1
5 5
4 4
F28099
Toe-in
S
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.
500 mm 500 mm
F27340
F27341
SECTION 27 - REAR AXLE 79
M -05
F27342
F27343
F27344
80 SECTION 27 - REAR AXLE
Steering angle
F27345
F27346
5 4
F27347
F27348
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.
Fatigue failure of pinion teeth Use until worn Replace bevel gear set.
See if the fracture line is well Continuous overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage Crash load of differential Check and/or replace other
components differential components.
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 or Insufficient lubrication Use correct lubrication and fill up to
scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with a thickness by 0.1 mm
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. SPECIFICATIONS ........................................................................................................................................ 3
2. PARKING BRAKE......................................................................................................................................... 6
2.1 PARKING 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. SPECIFICATIONS
2WS
4WS
2. PARKING BRAKE
The parking brake is fitted to all models and
incorporates 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.
19
20
3
19
2 18
1
17
21
15
16
14
12 13
11
10
9
8
7
6
5
4
F27750
Adjust the cable and lock the nut (1) to get 4-5 clicks
on the parking brake lever.
8 SECTION 33 - BRAKES SYSTEM
3. BRAKE CYLINDERS
Brake cylinders are accessible from the engine
compartment.
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
1 2 3 4 5 6
10
9 8 7
F29371
Trapped oil
Tank oil (no pressure)
1 2 3 4 5 6
10
9 8 7
F29372
1 2 3 4 5 6
10
9 8 7
F29373
5. BLEEDING PROCEDURE
1. Oil brake tank is full (1)
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
1. HYDRAULIC DIAGRAMS
1.1 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS
4 SECTION 35 - HYDRAULIC SYSTEM
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinders
4. Dipper cylinders
5. Boom cylinders
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer
12. Backhoe hammer
13. Hydraulic pump
14. Priority valve
15. Air filter
16. Hydraulic oil cooler
17. 4x1 bucket control valve
18. Oil filter
19. Return filter
20. Backhoe control valve
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Locking valve (optional)
25. Boom cylinder
26. Backhoe attachment travel lock cylinders
27. Telescopic cylinder
28. Stabilizer right cylinder
29. Stabilizer left cylinder
30. Check valve
31. Diagnostic
32. Bi-directional auxiliary
33. Locking valve (optional)
34. Backpressure valve
SECTION 35 - HYDRAULIC SYSTEM 5
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinders
4. Dipper cylinders
5. Boom cylinders
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer
12. Backhoe hammer
13. Hydraulic pump
14. Priority valve
15. Air filter
16. Hydraulic oil cooler
17. 4x1 bucket control valve
18. Oil filter
19. Return filter
20. Backhoe control valve
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Locking valve (optional)
25. Boom cylinder
26. Diagnostic
27. Telescopic cylinder
28. Stabilizer right cylinder
29. Stabilizer left cylinder
30. Check valve
31. Bi-directional auxiliary
32. Left-hand hydraulic control lever
33. Right-hand hydraulic control lever
34. Hydraulic control lever left-boom or dipper
35. Hydraulic control lever left-swing
36. Hydraulic control lever right-boom or dipper
37. Hydraulic control lever right-bucket
38. Backhoe attachment control valve solenoid valve
39. Backpressure valve
40. Backhoe attachment travel lock cylinders
41. Locking valve (optional)
SECTION 35 - HYDRAULIC SYSTEM 7
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinders
4. Dipper cylinders
5. Boom cylinders
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer
12. Backhoe hammer
13. Hydraulic pump
14. Priority valve
15. Air filter
16. Hydraulic oil cooler
17. 4x1 bucket control valve
18. Oil filter
19. Return filter
20. Backhoe control valve
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
26. Diagnostic
27. Telescopic cylinder
28. Stabilizer right cylinder
29. Stabilizer left cylinder
30. Check valve
31. Bi-directional auxiliary
32. Left-hand hydraulic control lever
33. Right-hand hydraulic control lever
34. Hydraulic control lever left-boom or dipper
35. Hydraulic control lever left-swing
36. Hydraulic control lever right-boom or dipper
37. Hydraulic control lever right-bucket
38. Backhoe attachment control valve solenoid valve
SECTION 35 - HYDRAULIC SYSTEM 9
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinders
4. Dipper cylinders
5. Boom cylinders
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer
12. Backhoe hammer
13. Hydraulic pump
14. Priority valve
15. Air filter
16. Hydraulic oil cooler
17. 4x1 bucket control valve
18. Oil filter
19. Return filter
20. Backhoe control valve
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Locking valve (optional)
25. Boom cylinder
26. Diagnostic
27. Telescopic cylinder
28. Stabilizer right cylinder
29. Stabilizer left cylinder
30. Check valve
31. Bi-directional auxiliary
32. Rear axle
33. 4WS steering control valve
34. Locking valve (optional)
35. Back pressure valve
36. Backhoe attachment travel lock cylinders
SECTION 35 - HYDRAULIC SYSTEM 11
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinders
4. Dipper cylinders
5. Boom cylinders
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer (optional)
12. Backhoe hammer (optional)
13. Hydraulic pump
14. Priority valve
15. Air filter
16. Hydraulic oil cooler
17. 4x1 bucket control valve
18. Oil filter
19. Return filter
20. Backhoe control valve
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Locking valve (optional)
25. Boom cylinder
26. Diagnostic
27. Telescopic cylinder
28. Stabilizer right cylinder
29. Stabilizer left cylinder
30. Check valve
31. Bi-directional auxiliary
32. Locking valve (optional)
33. Back pressure valve
34. Rear axle
35. 4WS steering control valve
36. Backhoe attachment travel lock cylinders
37. Left-hand hydraulic control lever
38. Right-hand hydraulic control lever
39. Hydraulic control lever left-boom or dipper
40. Hydraulic control lever left-swing
41. Hydraulic control lever right-boom or dipper
42. Hydraulic control lever right-bucket
43. Backhoe attachment control valve solenoid valve
SECTION 35 - HYDRAULIC SYSTEM 13
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinders
4. Dipper cylinders
5. Boom cylinders
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer (optional)
12. Backhoe hammer (optional)
13. Hydraulic pump
14. Priority valve
15. Air filter
16. Hydraulic oil cooler
17. 4x1 bucket control valve
18. Oil filter
19. Return filter
20. Backhoe control valve
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
26. Diagnostic
27. Telescopic cylinder
28. Stabilizer right cylinder
29. Stabilizer left cylinder
30. Check valve
31. Bi-directional auxiliary
32. Locking valve (optional)
33. Back pressure valve
34. Rear axle
35. 4WS steering control valve
36. Locking valve (optional)
37. Left-hand hydraulic control lever
38. Right-hand hydraulic control lever
39. Hydraulic control lever left-boom or dipper
40. Hydraulic control lever left-swing
41. Hydraulic control lever right-boom or dipper
42. Hydraulic control lever right-bucket
43. Backhoe attachment control valve solenoid valve
SECTION 35 - HYDRAULIC SYSTEM 15
2. HYDRAULIC PUMP
2.1 DESCRIPTION AND OPERATION
2.2 SPECIFICATIONS
HYDRAULIC DIAGRAM
18 SECTION 35 - HYDRAULIC SYSTEM
2 7
6
F29457
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).
2 7
6
F29458
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 displace- The loader control valve is mounted on the right
ment 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 con-
trol valves is independent of the load and it is there- Backhoe control valve
fore 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 sec- the stabilizers, the swing and telescopic arm (op-
tions in both the loader and backhoe control valve tional).
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 galler-
ies of the loader and backhoe control valves assem-
blies.
The flow coming from the rear section of the pump
passes through the load sensing flow divider valve
mounted on the pump and sends the priority flow to
the steering system, while the remaining flow adds
to the flow from the front pump, directed to the load-
er and backhoe attachment systems.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply system is controlled by the
pump flow balancer valve in accordance with the
pressure in the load sensing line.
Consequently, the higher the load sensing pressure
is, the less flow is returned to the tank, with a corre-
sponding increase in flow/pressure to the hydraulic
systems.
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 (3046
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 (3046 psi).
SECTION 35 - HYDRAULIC SYSTEM 27
1
2
5
7
6
F29287
1 2 3
4 4 4
F29288
1
2
5
7
6
F29289
1 2 3
4 4 4
F29290
1
2
5
7
6
F29291
1 2 3
4 4 4
F29292
Removal
Z Lower the loader to the ground, with the bucket
firmly placed on the ground.
Z Stop the engine and relieve any residual pressure
in the backhoe and loader attachment systems by
moving the relevant control levers through all
operating positions.
Z Disconnect the battery.
Z Clean the area around the control valve.
Z 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.
Z Unscrew and remove clamping screws to chassis.
Z Remove the valve assembly from the loader
backhoe.
Z 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 center pivot models 4. Bucket circuit relief valve (piston end) - 220 bar
W. Hydraulic diagram for sideshift models (3191 psi)
A. Right stabilizer section 5. Swing circuit relief valve (piston end) - 205 bar
B. Left stabilizer section (2973 psi)
C. Dipper section 6. Boom system relief valve (piston end) - 315 bar
D. Bucket section (4569 psi)
E. Swing section 7. Pump flow balancer - 15 bar (218 psi)
F. Lifting section 8. Load sensing return to tank
G. Telescopic dipper section 9. Swing circuit relief valve (rod end) - 205 bar
H. Backhoe attachment travel lock valve (sideshift) (2973 psi)
1. End cover 10. Boom relief valve (rod end) - 240 bar (3481 psi)
2. Inlet section 11. Telescopic relief valve (rod end) - 205 bar (2973
3. Backhoe bucket relief valve (piston end) - 240 bar psi)
(3481 psi) 12. Load sensing relief valve - 210 bar (3046 psi)
SECTION 35 - HYDRAULIC SYSTEM 37
Removal
Z Position the loader backhoe on a hard level sur-
face.
Z Lower the loader attachment to the ground.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Z Stop the engine and relieve any residual pressure in
the backhoe and loader attachment systems by mov-
ing the relevant control levers through all operating
positions.
Z Disconnect the battery.
Z Clean the area around the control valve.
Z Tag and identify the position of all hoses.
Z Disconnect and plug all the hoses.
Z Disconnect the levers of the manual control.
Z Unscrew and remove clamping screws to chassis.
Z Remove the valve assembly from the loader back-
hoe.
Z 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
Z Remove the screws (A), the boot along with its
plate (B) and the plate (C).
Z Remove the mounting screws (D) and the cover
(E).
Z Remove the spool (F) from the valve section.
Z Remove the lip seal (L).
Reassembly
Z Reassemble parts in reverse order after greasing
the spring.
Z Position the metal part of the lip seal (L) on the out-
side of the spool.
Z 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.
Z Slide the lip seal perpendicularly onto the spool.
Z Tighten the screws (A and D), the adapter (H) and
the tongue (M) from 9 to 11 Nm (6.6-8.1 lbf.ft).
SECTION 35 - HYDRAULIC SYSTEM 41
SWARNING
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
Z Remove the tongue and the cover sides.
Z Use a spool clamp (G) and a vice to secure the
spool.
Z Using a metal rod (minimum length = 80 mm (3.15
in), diameter 6) push the central ball (H) while ex-
tracting the detent bush (I).
Z Mark the orientation of the detent bush for the reas-
sembly.
Z Remove the balls (J) and the spring (K) from the
adapter (M).
Reassembly
Z Introduce the spring (K) into the adapter (M).
Z Place the 3 balls (J) into the radial holes of the
adapter (M) and use grease to prevent them from
falling.
Z Position the central ball (H) against the spring (K).
Z Slip the detent bush (I) onto a metal rod.
Z 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 relieve any residual pressure in
the backhoe and loader attachment systems by mov-
ing the relevant 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 back-
hoe.
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 center pivot models 4. Backhoe bucket relief valve (piston end) -
W. Hydraulic diagram for sideshift models 220 bar (3191 psi)
A. Right stabilizer section 5. Swing circuit relief valve (piston end) - 205 bar
B. Left stabilizer section (2973 psi)
C. Dipper section 6. Boom system relief valve (piston end) - 315 bar
D. Bucket section (4569 psi)
E. Swing section 7. Pump flow balancer valve - 15 bar (218 psi)
F. Lifting section 8. Load sensing return to tank
G. Telescopic dipper section 9. Swing circuit relief valve (rod end) - 205 bar
H. Backhoe attachment travel lock valve (sideshift) (2973 psi)
1. End cover 10. Boom relief valve (rod end) - 240 bar (3481 psi)
2. Inlet section 11. Telescopic relief valve (rod end) - 205 bar (2973
3. Dipper relief valve (piston end) - 240 bar (3481 psi)
psi) 12. Load sensing relief valve - 210 bar (3046 psi)
SECTION 35 - HYDRAULIC SYSTEM 47
Removal
Position the loader backhoe on a hard level surface.
Lower the loader attachment 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 relieve any residual pressure in
the backhoe and loader attachment systems by
moving the relevant control levers through all oper-
ating positions.
Disconnect the battery.
Clean the area around the control valve.
Tag and identify the position of all hoses and hydrau-
lic tubes.
Disconnect and plug all the hoses and all the hy-
draulic tubes.
Unscrew and remove clamping screws to chassis.
Remove the valve assembly from the loader back-
hoe.
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
Z Remove the screws (A), and the plate (B).
Z Extract the spring guides (C) and the springs (D).
Z Discard the seals (E).
Z Remove the spool (F) from the valve section.
Reassembly
Z Grease and install the spool (F) in the valve sec-
tion.
Z Install the springs (D) in the caps (B).
Z Install the spring guides (C) in the springs (D).
Z Install new seals (E).
Z Install the cap assemblies on the valve section, in-
stall and tighten the screws (A) to a torque of 9 to
11 Nm (6.8-8.1 lbf.ft).
3.3 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE (WITH
HYDRAULIC CONTROL)
REMOVAL
Z Position the loader backhoe on a hard level sur-
face.
Z Lower the loader attachment to the ground.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Z Stop the engine and relieve any residual pressure
in the backhoe and loader attachment systems by
moving the relevant control levers through all oper-
ating positions.
Z Disconnect the battery.
Z Clean the area around the solenoid valve.
Z Tag and identify the position of all hoses and hy-
draulic tubes.
Z Disconnect and plug all the hoses and all the hy-
draulic tubes.
Z Unscrew and remove clamping screws to chassis
supporting the operating levers.
Z Remove the solenoid from the loader backhoe.
Z Installation is removal procedure in reverse.
DISASSEMBLY
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).
SECTION 35 - HYDRAULIC SYSTEM 53
In case of necessity it is possible to disassemble the Check and eventually replace the O-rings (10).
various solenoid valves from the manifold blocks. Remove the check valve (11) and the orifice (12).
Loosen and remove the screws (6). Loosen and remove the solenoid valves (13).
Disassemble the solenoid valves (7). Check and eventually replace the O-rings (14).
Check and eventually replace the O-rings (8). Loosen and remove the solenoid valves (15).
Loosen and remove the valve (9). Check and eventually replace the O-rings (16).
54 SECTION 35 - HYDRAULIC SYSTEM
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston 7 6 5 4 F29541
Anti-cavitation operation
Relief valves with an anti-cavitation feature are fitted
in systems where a 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
low pressure (void) side.
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 auto-
matically 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.
2
1
5 4 F29542
7 6 5 4 F29543
6 5 2 F29544
6 5 2 F29545
Exhaust oil
High-pressure system oil
58 SECTION 35 - HYDRAULIC SYSTEM
Overhaul
1. Body 9. O-ring
2. Shutter 10. Nut
3. Spring 11. O-ring
4. Spring 12. Adjuster screw
5. O-ring 13. Spring
6. O-ring 14. Pilot valve
7. Valve 15. Poppet
8. Cover 16. Piston
SECTION 35 - HYDRAULIC SYSTEM 59
1. Body 6. Cover
2. Poppet 7. O-ring
3. Spring 8. Nut
4. Spring 9. O-ring
5. Shim 10. Adjuster screw
Technical specifications
Capacity (gas) ............................................................................................................. 2 litres (0.53 US Gallons)
Capacity (oil) .......................................................................................................... 1.84 litres (0.49 US Gallons)
Precharge.................................................................................................................. 30 ± 1 bar (435 ± 14.5 psi)
Maintenance
Z Check the gas pre-charge pressure regularly during the first few weeks of operation, and then at suitable in-
tervals afterwards based on this initial experience.
Z Carry out a visual examination of the accumulator periodically in order to detect any early signs of deteriora-
tion such as corrosion, deformation etc.
Z Comply with the regulatory provisions concerning the monitoring of operational equipment.
Z 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.
SECTION 35 - HYDRAULIC SYSTEM 63
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 attachment control neutral mid-way through a full power swing the sup-
valve, which contains pilot-operated pressure relief ply and exhaust ports in the main control valve are
valves with anti-cavitation feature to protect the sys- totally blocked.
tem and the cylinders, should an overload condition The momentum of the swinging backhoe assembly
occur. if not controlled will make the machine extremely un-
The diagram illustrates the operation of the swing stable.
circuit when retracting the right-hand cylinder (4) To prevent this from occurring, the system pressure
and extending the left-hand cylinder (5) in order to relief valves operate and drain the oil until an excess
swing the backhoe attachment to the right. pressure is detected. When the relief valve operates
When swinging the backhoe to the left the oil flows the cylinder rod will move and a void will be created
are reversed and exactly the same principle of oper- in the low pressure side of the cylinder. The anti-
ation applies. cavitation feature in the relief valves prevents the
Oil flow for a right hand swing is as follows: void from creating by transferring the drain oil from
When the swing control is operated the control valve the side of the system where an excess pressure
directs oil flow to the rod end of the right hand cylin- occurred to the low pressure side.
der.
The flow of oil at pump pressure lifts the one way re-
strictor (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 ex-
tend.
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 posi-
tion 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 re-
turn 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 opti-
mum 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 drained from the
cylinder. As the piston moves towards the end of its
stroke, the sliding restrictor is gently pushed down
towards the centre of the cylinder rod, allowing a
progressive and controlled stop of the swing cycle.
SECTION 35 - HYDRAULIC SYSTEM 67
7 2
6 3
5 4
F29480
5. HYDRAULIC CYLINDERS
2WS
1. Stroke
2. Completely retracted
4WS
1. Stroke
2. Completely retracted
70 SECTION 35 - HYDRAULIC SYSTEM
F28757
S
WARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal in-
jury may occur.
F28759
SWARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal in-
jury may occur.
F30318
3 4
F30320
SWARNING
Cylinder weight: 36 kg (79 lbs).
Only if necessary:
Z Remove the wiper ring (3), the seal rings (4) and
(5), the guide bush (6) and the back-up ring (9) with
the O-ring (10) from the cylinder head (7).
Z Remove the piston seal (12) and the piston guide
ring (13) from the piston (11).
SECTION 35 - HYDRAULIC SYSTEM 75
2WS
1. Stroke
2. Completely retracted
4WS
1. Stroke
2. Completely retracted
76 SECTION 35 - HYDRAULIC SYSTEM
Remove the ring (2) and the pin (3). Using a ham-
mer, extract the rod pin (4) and release the rod (5).
SECTION 35 - HYDRAULIC SYSTEM 77
1. Bushing 9. O-ring
2. Cylinder rod 10. Piston
3. Wiper ring 11. Piston gasket
4. Ring seal 12. Piston guide
5. Ring seal 13. Screw
6. Cylinder head 14. Cylinder tube
7. Snap ring 15. Bushing
8. Back-up ring
SWARNING
Cylinder weight (2WS): 24.6 kg (54.2 lbs)
Cylinder weight (4WS): 32.5 kg (71.6 lbs)
Only if necessary:
Z remove the wiper ring (3), the seal rings (4) and (5),
the back-up ring (8) with the O-ring (9) from the cyl-
inder head (6);
Z remove the piston seal (11) and the piston guide
ring (12) from the piston (10).
SECTION 35 - HYDRAULIC SYSTEM 81
CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket firmly on the ground.
Relieve the residual pressure in the system by mov-
ing the loader control lever through all operating po-
sitions.
82 SECTION 35 - HYDRAULIC SYSTEM
Remove the pin (2). Slide out the rod 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
backhoe on the ground. Support the backhoe ele-
ments for cylinder removal using a suitable stand.
S
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Loosen and remove the screw (1) and the nut (2).
Slide out the rod pin (3) with an hammer.
NOTE: the tube end of the dig cylinder and the rod
end of the boom cylinder use a common pin (3).
S
WARNING
Cylinder weight(with short dipper): 80.3 kg (177 lbs).
Cylinder weight (with long dipper): 93.4 kg (206 lbs).
Only if necessary:
Z remove the wiper ring, the seal rings (5) and (6),
the guide bush (7) and the back-up ring (10) with
the O-ring (11) from the cylinder head (9);
Z remove the piston guide ring (13) and the piston
seal (12) from the piston (14).
88 SECTION 35 - HYDRAULIC SYSTEM
(1) Stroke
(2) Completely retracted
with long dipper
with short dipper
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe ele-
ments for cylinder removal using a suitable stand.
S
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Loosen and remove the nut (1) and the screw (2).
Slide out the rod pin (3) with an hammer.
If necessary, use hydraulic power to very slowly re-
tract the cylinder. In this way, the rod moves away
from the attaching point.
SECTION 35 - HYDRAULIC SYSTEM 89
S
WARNING
Short dipper cylinder weight: 71.7 kg (158 lbs).
Long dipper cylinder weight: 72.3 kg (159 lbs).
Only if necessary:
Z remove the seal rings (5) and (6), the guide bush
(7) and the back-up ring (10) with the O-ring (11)
from the cylinder head (9);
Z remove the piston guide ring (13) and the piston
seal (12) from the piston (14).
92 SECTION 35 - HYDRAULIC SYSTEM
1. Stroke
2. Completely retracted
S
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Remove the stop ring (1) and the shim (2). Slide out
the pin (3) with an hammer and pay attention to le-
vers.
If necessary use hydraulic power to very slowly re-
tract the cylinder.
SECTION 35 - HYDRAULIC SYSTEM 93
S
WARNING
Cylinder weight: 64 kg (141 lbs).
Only if necessary:
Z remove the wiper ring (4), the seal rings (5) and (6),
the guide bush (7) and the back-up ring (10) with the
O-ring from the cylinder head (9);
Z remove the piston guide ring (13) and the piston
seal (12) from the piston (14).
96 SECTION 35 - HYDRAULIC SYSTEM
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe ele-
ments for cylinder removal using a suitable stand.
S
WARNING
Always support the structural members so that they
will be stable and safe to work around.
S
WARNING
Cylinder weight (with short telescopic): 41.5 kg (91.5
lbs).
Cylinder weight (with long telescopic): 45 kg (99 lbs).
Only if necessary:
Z remove the seal rings (3) and (4), the guide bush
(5), the O-ring (9) with the back-up ring (8) from the
cylinder head (7);
Z remove the piston guide ring (11) and the piston
seal (10) from the piston (12).
100 SECTION 35 - HYDRAULIC SYSTEM
(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.
S
WARNING
Cylinder weight: 43.5 kg (96 lbs).
Only if necessary:
Z remove the seal rings (3) and (4), the guide bush
(5), the O-ring (9) with the back-up ring (8) from the
cylinder head (8);
Z remove the piston guide ring (11) and the piston
seal (10) from the piston (12).
104 SECTION 35 - HYDRAULIC SYSTEM
1. Stroke
2. Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
bucket on the ground.
S
WARNING
Cylinder weight: 33.7 kg (74.3 lbs).
Only if necessary:
Z remove the wiper ring (2), the seal rings (3) and (4)
and the back-up ring (7) with the O-ring (8) from the
cylinder head (5);
Z remove the piston guide ring (10) and the piston
seal (11) from the piston (9).
108 SECTION 35 - HYDRAULIC SYSTEM
1. Stroke
2. Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe at-
tachment elements for cylinder removal using a suit-
able stand and a hoist.
S
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Loosen and remove the nut (1). Slide out the screw
(2) from the opposite side. Now the pin (3) can come
out and release the rod cylinder. If necessary ham-
mer to help the pin (3) to come out.
SECTION 35 - HYDRAULIC SYSTEM 109
S
WARNING
Cylinder weight: 31 kg (68 lbs).
Only if necessary:
Z remove the wiper ring (4), the seal rings (5) and (6),
the guide bush (7) and the back-up ring (12) with
the O-ring (11) from the king pin (10).
Z remove the piston seal (13) and the piston guide
ring (14) from the piston (15).
CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket on the ground.
Position the backhoe support in the centre of the ma-
chine and lower the backhoe on the ground.
Lower the stabilizers to the ground.
Relieve the residual pressure in the system by mov-
ing the control levers through all operating positions.
Disassembly
Release the pressure from the hydraulic systems us-
ing the following procedure: turn the starter switch
key to ON but do not start the engine. Turn pilot con-
trol cancellation switch to the ON position. Move the
hydraulic control levers through all positions. Turn
the starter switch key to OFF. Disconnect the nega-
tive battery cable(s).
Z Mark the position of the lever parts (see the
exploded view on previous pages).
Z Remove the knob (P) and the support (S).
Z Remove the bracket (O) with the relevant screws
(with left hydraulic control lever).
Z Lift the rubber boot (RL) for left control lever and
the rubber boot (RR) for right control lever.
120 SECTION 35 - HYDRAULIC SYSTEM
Reassembly
To reassemble the control levers, proceed in the re-
verse order to that of removal.
Follow the marks made during disassembly, and
tighten the nut (4) to a torque of 36 to 44 Nm (27-32
lbf.ft).
SECTION 35 - HYDRAULIC SYSTEM 121
P. Supply
T. Return to tank
Disassembly
1. Mark the direction of installation of all 15. Separate the upper (4) and lower (19) bodies
disassembled parts. and replace the seal rings (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 seal that of removal.
rings (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 spring guide (9), the spring (10) those in place.
and the 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 cover (12) and remove the safety ring 4. Install a 2 mm (0.08 in) shim (3), check that the
(13). recessing of the push-rods is less than 0.2 mm
10. Remove the spring (14) and the spool (15). (0.008 in), modify the shimming to more or less
11. Remove and note the thickness of the shims if required.
(16). 5. Assemble the new seal rings (6), (7) and O-rings
12. Proceed in the same manner for the other rods. (18), (20) and (21).
13. Secure the upper body (4) in a vice. 6. Lubricate the moving parts.
14. Loosen and remove the screw (17) using a key 7. Apply brake thread fluid on the threads of the U/
and replace the O-ring (18). J cam (1) and the screw (17).
8. Tighten the cam (1) to 50 Nm (37 lbf.ft) and the
screw (17) to 50 Nm (37 lbf.ft).
124 SECTION 35 - HYDRAULIC SYSTEM
7. FAULT FINDING
7.1 PRELIMINARY CHECKS
GENERAL
Restricted pump suction line Inspect the suction line and the tank and
repair as necessary.
Slow operation or loss of power in Worn pump Perform pump performance test and
all systems replace/reseal as necessary.
LOADER
PROBLEM CAUSE CORRECTION
The lifting system fails to operate, Valve spool leakage Examine lift section of loader control
is slow or loses power valve assembly for wear or scoring.
BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. This chart should
only be referred to if the supply system is operating normally, thereby confirming that the hydraulic supply sys-
tems and the pump are correctly operating. See also “Fault finding hydraulic pump”.
PROBLEM CAUSE CORRECTION
The lifting system is inoperative, is Lifting system relief valve stuck Test the pressure of the lifting system
too slow, loses power or does not open, set too low or seat leaking relief valve.
hold
Valve spool leakage
Examine lift section of backhoe control
valve assembly for wear and scoring.
SWING
HYDRAULIC PUMP
PROBLEM CAUSE CORRECTION
System noisy Worn or damaged pump gears or Make a hydraulic pump performance
pressure plates test.
Wrong type oil being used Check the hydraulic oil operating
temperature.
Contaminated oil Drain the tank and refill with clean oil.
SECTION 39 - CHASSIS
ENGINE
Supported by 2 rubber silent blocks and held in po- To remove the engine/transmission from the ma-
sition by 2 support brackets. The brackets, which chine it will be necessary to remove or disconnect
are welded to the frame one either side of the en- the following:
gine are positioned just ahead of the loader posts.
Remove:
S
WARNING Air filter
The engine and transmission bolted together act as Engine guard
a one piece unit. If separated in the machine they Radiator’s and related hoses (Or pivot forward
are not self supporting and will collapse causing in- where possible)
jury or damage to the machine. Front support cowling (if required)
Disconnect:
TORQUE CONVERTOR Fuel pump throttle cable and electric shut off
Engine harness
Fitted between the engine and the transmission can Fuel tank connection and leak off return pipes
only be removed when the engine/transmission as- Hydraulic pump and related pipework (plug all ports
sembly are separated. as required)
Transmission Lever
TRANSMISSION
Transmission harness connectors
Attached to the rear of the engine and supported in Engine supports (with engine supported by hoist)
rubber silent blocks in fixed brackets and held within Transmission supports
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.
SECTION 39 - CHASSIS 7
COUNTERWEIGHT
2WS (A):
1. Standard counterweight ...........125 kg (276 lbs)
2. Medium counterweight .............362 kg (798 lbs)
3. Big counterweight ..................475 kg (1047 lbs)
4. Extra counterweight (optional) .125 kg (276 lbs)
4WS (B):
5. Medium counterweight .............125 kg (276 lbs)
6. Big counterweight ....................333 kg (734 lbs)
7. Extra counterweight (optional) .125 kg (276 lbs)
SECTION 39 - CHASSIS 9
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/Transmission bolts 95 Nm (70 lbf.ft)
Retaining bolts air filter-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 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 (52 lbf.ft)
COMPONENTS TORQUES
Front axle retaining bolts (2WS) 500 Nm (369 lbf.ft)
Front axle retaining bolts (4WS) 500 Nm (369 lbf.ft)
Rear axle retaining bolts (2WS) 800 Nm (590 lbf.ft)
Rear axle retaining bolts (4WS) 900 Nm (664 lbf.ft)
HYDRAULIC SYSTEM
COMPONENTS TORQUES
Power steering hoses to support frame 55 Nm (41 lbf.ft)
Backhoe control valve to frame bolts 90 Nm (90 lbf.ft)
Loader control pipes clamp to frame 25 Nm (18 lbf.ft)
TANKS
COMPONENTS TORQUES
Oil tank bolts 85 Nm (63 lbf.ft)
Fuel tank bolts 85 Nm (63 lbf.ft)
SECTION 39 - CHASSIS 13
LOADER
COMPONENTS TORQUES
Loader control pipe bracket to frame 25 Nm (18 lbf.ft)
BACKHOE
COMPONENTS TORQUES
Retaining clamps of backhoe-to-frame hoses 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)
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 (133 lbf.ft)
WHEELS
COMPONENTS TORQUES
Front/rear wheels (4WS) 700 Nm (369 lbf.ft)
Front wheel (2WS) 330 Nm (243 lbf.ft)
Rear wheel (2WS) 540 Nm (398 lbf.ft)
14 SECTION 39 - CHASSIS
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
F29379
F29384
T3
P3
A3 B3
A2 B2
P2
T2
F29529
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.
Z a gear wheel assembly with fixed stator (with inner Z A cardan shaft, mechanically tied to gear wheel as-
teeth) and a rotor (with outer teeth). sembly and to outer sleeve, allows the movement
Z A 4 ways rotary distributor consisting of an outer transmission.
sleeve and an inner selection rotor. Z Set of centering springs between outer sleeve and
The selection rotor is connected to the steering inner rotor.
3.1 SPECIFICATIONS
HYDRAULIC DIAGRAM
3.2 COMPONENTS
DISASSEMBLY
To gain access to the power steering, remove the
hood and the air filter.
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.
Extract the ring (7), the races and the bearing (6)
from the sleeve and the spool. The outer (thin) bear-
ing race can sometimes “stick” in the housing, there-
fore check that is has come out.
Press out the cross pin (8). Use the special screw
(17). 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, remember to leave a mark of
your own on sleeve and spool before the neutral po-
sition springs are dismantled.
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 (2) into the sleeve (1). Make sure
that spool and sleeve are placed correctly in relation
to each other.
SECTION 41 - STEERING SYSTEM 23
1. Spool
2. Sleeve
6. Bearing - needle
6A. Outer bearing race
6B. Needle bearing
6C. Inner bearing race
The spool set will push out the assembly tool guide.
The O-ring is 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. Distributor plate surface
C. Pin axis
D. Housing surface
E. Rotor gear
F. Cardan shaft
Screw plug with seal ring into the two shock valves
and tighten them with a torque of 30 ± 10 Nm (22 ±
7.3 lbf.ft).
Install the seal ring into the housing using the special
tool and a plastic hammer.
SECTION 41 - STEERING SYSTEM 33
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
1. SPECIFICATIONS ........................................................................................................................................ 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING .................................................................................................................................. 13
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 13
3.2 SAFETY PRECAUTIONS .................................................................................................................... 17
3.3 DESCRIPTION AND OPERATION...................................................................................................... 18
3.4 FAULT FINDING AND TESTING......................................................................................................... 27
3.5 FLUSHING THE SYSTEM................................................................................................................... 45
3.6 EVACUATING THE SYSTEM.............................................................................................................. 47
3.7 CHARGING THE SYSTEM.................................................................................................................. 48
3.8 COMPONENTS OVERHAUL .............................................................................................................. 49
3.9 COMPRESSOR ................................................................................................................................... 54
3.10 SPECIAL TOOLS............................................................................................................................... 68
2 SECTION 50 - CAB HEATING AND AIR CONDITIONING
SECTION 50 - CAB HEATING AND AIR CONDITIONING 3
1. SPECIFICATIONS
HEATING
ENGINE RADIATOR COOLANT
Antifreeze - Ambra Agriflu 12 litres (3.2 US Gallons)
Water 12 litres (3.2 US Gallons)
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 (0.39-0.63 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 (3.3-6.6-9.9 ft/s)
Condensation temperature 58 °C (136.4°F)(absolute 16 bar(232 psi))
Undercooling 2 °C (35.6°F)
4 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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.
Temperature control
The temperature of the air from the radiator is adjust-
ed by rotation of the control knob (2) which opens or
closes the radiator valve increasing or decreasing
the water flow as required. Turn the control clock-
wise to increase the temperature of air from the
heater and counter clockwise to reduce the temper-
ature.
SWARNING
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.
6 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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 conditioning (optional) is fitted.
8 SECTION 50 - CAB HEATING AND AIR CONDITIONING
3 4
2
6
5
F30058
4
1 2
F30059
SWARNING
5
Once this operation is complete, reset pin (A) in the
correct start position.
6
Reinstall the heater valve, repeating the previous
operation in the reverse order.
A
F30060
10 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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 the 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 the temperature control knob
fully counterclockwise for maximum
cooling.
OVERHAUL
F28674
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 taking care not to damage the radi-
ator 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.
12 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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.
F32411
SECTION 50 - CAB HEATING AND AIR CONDITIONING 13
3. AIR CONDITIONING
F28681
F28682
14 SECTION 50 - CAB HEATING AND AIR CONDITIONING
F28683
SECTION 50 - CAB HEATING AND AIR CONDITIONING 15
EXPANSION
VALVE
LOW
TEMPERATURE
LIQUID ATOMIZED HIGH PRESSURE
AT A LOWER LIQUID FILTERED
TEMPERATURE 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-
Z Refrigerant nents of an air conditioning system.
Z Compressor Refrigerant is drawn into the compressor as a cool,
Z Condenser low pressure vapour which is compressed and then
Z Receiver dryer pumped out as a hot, high pressure vapour to the
Z Expansion valve condenser.
Z 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.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 17
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 the cab blower motor. The refrigerant now changes
pressure to the receiver dryer where it is stored until from a cold low pressure atomized liquid to a warm
released to the evaporator by the temperature low pressure vapour and leaves the evaporator
sensing expansion valve. outlet, moving to the suction (low pressure) side of
As liquid refrigerant passes through the metered the compressor to repeat the cycle.
orifice in the expansion valve the refrigerant As this heat loss is taking place, moisture (humidity)
changes from a high pressure liquid to a low in the cab air will condense on the outside of the
pressure atomized 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.
CONTROLS (B90B)
The air conditioning control can be adjusted to obtain
the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the warning lamp (3) turns on. The
selector (1) allows choosing the ideal temperature
according to your requirements. Positioning selector
(1) to “0” and turning selector (2) you will obtain more
or less cold according to the selector (2) position. By
positioning selector (1) to any other position different
from “0”, you will obtain instead a mixture of warm
and cold air and the desired climate inside the cab.
SWARNING
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.
COOLANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air condition- SWARNING
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, cover the area loosely with a bandage to pro-
The refrigerant used in the air conditioning system is tect affected area against infection and consult a
refrigerant HFC 134a. doctor immediately.
If refrigerant should contact the eyes wash immedi-
NOTE: to help protect the environment legislation ately in cold clean water for at least 5 minutes and
has been introduced in most territories banning the 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.
S
WARNING
Coolant HFC 134a is not compatible with coolant R-
12. Do not try to replace coolant HFC 134a with
coolant R-12 or to test the system using instruments
or attachments previously used with R12, as the
system could get damaged.
S
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 21
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.
During the upward stroke, the piston compresses the
refrigerant and expels it through another reed valve
into an inner gallery in the cylinder and, from here,
out into the coolant system.
The compressor is lubricated with a Polyalklene Gly-
col (PAG) oil Type SP20. This oil can be mixed with
coolant and is carried around in the coolant system
itself.
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:
Z temperature control
Z low pressure cut-out switch
22 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 is located underneath the
evaporator in the pressure line leading from the re-
ceiver/dryer and performs the following functions:
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- 2
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- 1
tor’s feet.
F29327
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 27
1 2
7 3
6 4
9 8
F37888
Attaching the gauge set to the loader backhoe 2. Re-check that both the high and low side shut off
valves on the manifold gauge set are fully closed.
SWARNING 3. Run the engine at 1000-1200 rpm.
To avoid personal injury, stop the loader backhoe en- 4. Turn off the heater temperature control.
gine 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 stabi-
1. Check that the gauge set shut off valves are lize all components.
closed (turned fully clockwise). 6. Check the manifold low pressure gauge reading
2. Connect the high side gauge hose (normally red) is within the specified range of approximately
to the high pressure (discharge) side service 0.28-2.48 bar (4-36 psi).
valve and the low side gauge hose (normally 7. Check the manifold high pressure gauge reading
blue) to the low pressure (suction) side service and compare the reading to the pressure indicat-
valve on the loader backhoe. Ensure the hose ed on the pressure temperature chart below.
connections are fully tightened. 8. Measure and compare the temperature of condi-
tioned air entering the cab through the louvered
IMPORTANT: prior to connection of the manifold air vents with the ambient air at the air intake fil-
gauge set, identify the suction (low pressure) and dis- ters on the outside of the cab.
charge (high pressure) service gauge ports. The high If the system is operating correctly the condi-
pressure service valve is always in the line from the tioned air entering the cab should be 6-9 °C
compressor to the condenser. (42.8-48.2 °F) cooler than the ambient tempera-
ture of the outside air.
The high and low pressure service valves on the 9. If it is confirmed that the system is not operating
loader backhoe are spring loaded valve and will be correctly refer to the fault diagnostic charts and
automatically opened when the test hose is connect- performance test gauge reading examples on the
ed. following pages for possible corrective action.
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 the system.
Replace the expansion valve.
Evacuate the system.
Charge the system.
Re-test.
7 1
6 2
5 4 3
F28697
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Repair leaks. (Discharge and recover the refrig-
erant from the system; replace lines or compo-
nents).
34 SECTION 50 - CAB HEATING AND AIR CONDITIONING
7 1
6 2
5 4 3
F28698
PROBLEM DIAGNOSIS
Insufficient cooling. System refrigerant is extremely low. A serious leak
is indicated.
CAUSE
Refrigerant excessively low. NOTE: * test procedure based upon ambient temper-
ature of 35 °C (95°F).
CONDITIONS* For proper high side gauge reading for other ambient
Low side pressure very low. temperatures, refer to the pressure temperature chart.
Gauge should read 1-2 bar (14.5-29 psi).
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 35
7 1
6 2
5 4 3
F28699
7 1
6 2
5 4 3
F28700
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 temper-
2 bar (14.5-29 psi). ature of 35 °C (95°F).
For proper high side gauge reading for other ambient
High side pressure too low. Gauge should read temperatures, refer to the pressure temperature chart.
13.3-14.8 bar (193-215 psi).
7 1
6 2
5 4 3
F28701
PROBLEM At this point, operate the system and check its per-
Little or no cooling. Engine overheats in some cas- formance. If still unsatisfactory, proceed as follows:
es. 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-
CONDITIONS* denser appears to be unduly dirty or plugged,
Low side pressure too high. Gauge should read 1- replace it.
2 bar (14.5-29 psi). 6. Replace receiver/drier.
High side pressure too high. Gauge should read 7. Evacuate the system, and recharge it with the
13.3-14.8 bar (193-215 psi). correct quantity of refrigerant.
Liquid line hot. 8. Performance test the system.
Evaporator air warm.
DIAGNOSIS
High pressure switch cutting out.
Lack of cooling caused by pressure that is too high
CORRECTIVE PROCEDURES on the high side, resulting from improper operation
1. Check belt. Loose or worn drive belts could of condenser. (Refrigerant charge may be normal or
cause excessive pressures in the compressor excessive).
head.
2. Look for clogged passages between the con- NOTE: * test procedure based upon ambient temper-
denser fins and coil, or other obstructions that ature of 35 °C (95°F).
could reduce condenser airflow. For proper high side gauge reading for other ambient
3. If engine is overheating replace engine thermo- temperatures, refer to the pressure temperature chart.
stat and radiator pressure cap.
38 SECTION 50 - CAB HEATING AND AIR CONDITIONING
7 1
6 2
5 4 3
F28701
Evaporator air not cold. NOTE: * test procedure based upon ambient temper-
ature of 35 °C (95°F).
For proper high side gauge reading for other ambient
temperatures, refer to the pressure temperature chart.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 39
7 1
6 2
5 4 3
F28704
Evaporator air warm. NOTE: * test procedure based upon ambient temper-
ature of 35 °C (95°F).
Evaporator and suction hose (to compressor) sur- For proper high side gauge reading for other ambient
faces show considerable moisture. 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.
40 SECTION 50 - CAB HEATING AND AIR CONDITIONING
7 1
6 2
5 4 3
F28705
7 1
6 2
5 4 3
F28706
7 B A 1
6 2
5 4 3
F28707
CORRECTIVE PROCEDURES
1. Stop engine and shut off A/C.
2. Replace thermostatic switch with switch of same
type.
3. Make sure the switch’s temperature sensor is in-
stalled in the same position and depth (in evap-
orator core) as previous.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 43
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. F28708
F28709
44 SECTION 50 - CAB HEATING AND AIR CONDITIONING
4 3 2
F37889
7 1
6 2
5 4 3
F28711
F28712
SECTION 50 - CAB HEATING AND AIR CONDITIONING 47
NOTE: for every 305 m (1000 ft) above sea level, the
vacuum gauge reading must be corrected by adding
2.54 cm (1 inch) of mercury to compensate for the
change in atmospheric pressure.
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 27.
to the loader backhoe air conditioning system in
accordance with the manufacturers instructions. NOTE: after charging a system use the following start
2. If a charging unit, in conjunction with the mani- up procedure to ensure the lubricating oil is properly
fold gauge set is used, open the high and low dispersed around the system.
side hand valves on the manifold.
3. Charge the system with 0.75 kg (1.65 lbs) of re- Z Ensure air conditioning is switched OFF.
frigerant as per the manufacturers instructions. Z Start the engine and bring speed down to idle.
4. If the charging rate becomes very slow close Z 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
4 3 2
F37889
GENERAL
SWARNING
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- F28714
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.
52 SECTION 50 - CAB HEATING AND AIR CONDITIONING
CONDENSER
1. Unscrew and remove the fastening screws (2).
Remove the front grill (1).
3.9 COMPRESSOR
SPECIFICATIONS
Belt tension
Measure at the widest gap ... 10 mm ( 0.40 in) deflection with 1 kg (2.2 lbs) 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±2.1)
Cylinder head bolts, M8 34.3±4.9 (25.3±3.6)
Clutch dust cover screw, M5 9±2 (6.6±1.5)
Oil filler plug 19.6±4.9 (14.5±3.6)
SECTION 50 - CAB HEATING AND AIR CONDITIONING 55
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.
13
10
7
12
11 1
7 2
5
8
14
9
1 3 6 5
F28721
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 57
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.
Z Torque the fixing bolts to 40-51 Nm (29-38 lbf.ft).
the compressor.
Z Reconnect the hoses to the compressor and tight-
en all bolts and hoses.
F28725
58 SECTION 50 - CAB HEATING AND AIR CONDITIONING
F28726
OVERHAUL COMPRESSOR
Before any internal repair is done, drain the oil from
the compressor:
Z Remove the oil plug and drain as much oil as pos-
sible into a suitable container.
Z Remove the caps (if present) from suction and dis-
charge ports.
Z 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. CC
F28727
F28728
SECTION 50 - CAB HEATING AND AIR CONDITIONING 59
CLUTCH
1 2 3 4 5 6 7 8 9 10
F28729
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. 4
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).
F28730
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 F28731
Remove the snap ring (7), remove the shaft key and
lift the pulley assembly from the compressor.
F28732
F28733
F28734
F28735
SECTION 50 - CAB HEATING AND AIR CONDITIONING 61
Lift the coil (10) from the housing and replace as re-
quired. 10
F28736
Assembly
Install the coil (10), making sure that the wire is lo-
cated behind the clip on the outside of the body and
that the snap ring (9) is located in the groove. 10
F28737
F28738
F28732
62 SECTION 50 - CAB HEATING AND AIR CONDITIONING
F28730
8
F28741
F28742
SECTION 50 - CAB HEATING AND AIR CONDITIONING 63
COMPRESSOR
5 6 7 8 9 10
1 3
2 4
F28743
Removal
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior
to replacing the shaft seal.
Z Remove the armature plate, as detailed in the
steps of clutch disassembly.
Z Remove the shaft key (1), shims and ring (2) to ex-
pose the snap ring (3). 3
Z Remove the snap ring (3).
F28744
F37893
64 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.
F28746
F37894
Install the snap ring (3). If the snap ring has a bevel-
led edge this should face outwards.
F28744
F28713
SECTION 50 - CAB HEATING AND AIR CONDITIONING 65
Position the shims over the shaft and refit the shaft
key.
Reinstall the plate as described in clutch reassem-
bly.
F28911
66 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 10 9
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.
F28747
F28748
Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage. 7
F28749
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.
F28750
SECTION 50 - CAB HEATING AND AIR CONDITIONING 67
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 V battery, test the current absorption
of the field coil: it must be between 3.6 and 4.2
A.
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 F28751
F28752
68 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.
1. GENERALITIES............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 6
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B90B) ............................................................ 6
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B90B)............................................................. 24
2.3 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B100B - B110B)............................................. 44
2.4 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (B110B)................................................................. 60
2.5 ELECTRICAL DIAGRAMS - 4WS CAB ............................................................................................... 76
3. CONTROLS AND INSTRUMENTS ............................................................................................................ 93
3.1 FRONT INSTRUMENT CLUSTER PANEL ......................................................................................... 93
3.2 CALIBRATION OF SPEEDOMETER .................................................................................................. 95
3.3 SIDE INSTRUMENT CLUSTER PANEL (B90B) ................................................................................. 96
3.4 SIDE INSTRUMENT CLUSTER PANEL (B100B - B110B - B115B) ................................................... 98
3.5 SIDE INSTRUMENT CLUSTER (B90B) ............................................................................................ 100
3.6 SIDE INSTRUMENT CLUSTER (B100B - B110B - B115B) .............................................................. 102
3.7 ANTI-START SYSTEM ...................................................................................................................... 104
4. DIAGNOSTIC DISPLAY (B100B-B110B-B115B) ..................................................................................... 105
4.1 SYMBOLS.......................................................................................................................................... 107
4.2 SETUP MENU ................................................................................................................................... 108
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 109
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 110
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 111
4.6 WORK HOURS.................................................................................................................................. 112
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 113
4.8 MAINTENANCE................................................................................................................................. 119
4.9 WARNING MESSAGES .................................................................................................................... 120
2 SECTION 55 - ELECTRICAL SYSTEM
1. GENERALITIES
1.1 TEMPORARY WIRING HARNESS REPAIR
Clean and tighten connections Check the electrolyte level and den-
Sulphated batteries sity.
Battery Isolator switch turned off Restore the battery isolator switch.
Main machine fuse link blown Find the reason of the failure and
replace the connection fuse.
Starter motor speed too low, the Loose or corroded connections Clean and tighten loose connec-
engine cranks slowly tions.
Low battery output voltage Check that the battery voltage with
open circuit is at least 12.6 V.
Check the electrolyte level and den-
sity.
Incorrect viscosity of the engine oil Use an oil with correct viscosity for
the temperature conditions.
Starter motor inoperative Transmission shift lever in gear Move gearshift lever to neutral.
2. ELECTRICAL DIAGRAMS
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B90B)
NAME DESCRIPTION
X600 Load sensing solenoid valve - 2-way
connector
XC1 Control unit - 11-way connector
XC2 Control unit - 7-way connector
XC3 Control unit - 21-way connector
XC4 Control unit - 21-way connector
XC5 Control unit - 17-way connector
XC6 Control unit - 13-way connector
XD Engine stop diode - 2-way connector
XX Diodes - 5-way connector
XY Seat safety switch - 2-way connector
10 SECTION 55 - ELECTRICAL SYSTEM
CONTROLLER
1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82
G1
R1
N1
M1
N1
S1
B-N1
V-B1
L-N1
1 2
X83 X83
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER
RELAY
TO ENGINE LINE
F27176
SECTION 55 - ELECTRICAL SYSTEM 19
Calibrations
Gage type Input Reading Pointer Input tolerance Calibration
tolerance direction
0 HZ 0 rpm ±3° N/A Descending
Speedometer 307 HZ 1000 rpm N/A ± 60 rpm Ascending
736 HZ 2400 rpm N/A ± 60 rpm Ascending
240 OHMS Empty +0/-6° 230-240 OHMS Descending
(REF)
Level fuel
102 OHMS 1/2 Tank ±3° (REF) 98-108 OHMS Descending
33 OHMS Full +4/-2° 33-42 OHMS Ascending
900 OHMS Point B +0/-6° N/A Descending
Transmission
temperature 114 OHMS 106 °C (Red/green ±5° 111-117 OHMS (REF) Ascending
line)
700 OHMS Point A +0/-5° N/A Descending
Coolant
temperature 95 HMS 106 °C (Red/green ±3° 93-97 OHMS (REF) Ascending
line)
11V Red/green left line ±3° 10.7-11.3 V (REF) Descending
VOLT 15.9V Red/green right ±5° 15.0-15.6 V (REF) Ascending
line
20 SECTION 55 - ELECTRICAL SYSTEM
Connections
PIN # NAME FUNCTION WARNING
LAMP No.
1 Ignition 10V-16V INPUT
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Parking brake Low side switch input LP3
5 Alternator Alternator D+ input LP4
6 Not used
7 Crab steer Low side switch input LP6
8 Neutral High side switch input
9 Seat switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
12 Driving lights High side switch input LP9
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
20 Fuel level sender Speed sensor input LP27
21 Water temperature sender Speed sensor input
22 Transmission temperature sender Speed sensor input
23 Not used
24 Driving lights High side switch input LP8
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Transmission oil temperature Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Horn Open collector output
36 Ground Ground
SECTION 55 - ELECTRICAL SYSTEM 21
Other calibrations:
FRONT INSTRUMENT
NAME DESCRIPTION
X58 Flasher control unit - 13-way connector
X59 Right light - 5-way connector
X60 Left light / horn - 7-way connector
X61 Light / windshield wiper control lever
X62 Gearshift lever - 6-way connector
X63 Number plate light - 2-way connector
X64 Air conditioning compressor - 1-way con-
nector
X65 “Grid heater” switch - 1-way connector
X67 Alternator - 3-way connector
X68 Engine water temperature switch - 3-way
connector
X69 Air conditioning pressure switch - 2-way
connector
X70 Front instrument cluster - 12-way connector
X71 Start switch - 10-way connector
X72 Pilot control line - 1-way connector
X73 Engine oil low pressure switch - 1-way con-
nector
X80 Beacon lamp - 2-way connector
X81 Beacon lamp - 2-way connector
X82 Control unit - 10-way connector
X83 Relay - 2-way connector
X89 Left light - 6-way connector
X110 Air conditioner - 2-way connector
X111 Air conditioner - 9-way connector
XA Horn - 2-way connector
XC1 Control unit - 11-way connector
XC2 Control unit - 7-way connector
XC3 Control unit - 21-way connector
XC4 Control unit - 21-way connector
XC5 Control unit - 17-way connector
XC6 Control unit - 13-way connector
XD Engine stop diode - 2-way connector
XX Diodes - 5-way connector
XY Seat safety switch - 2-way connector
28 SECTION 55 - ELECTRICAL SYSTEM
R/N1 4.1
R/N1
M-V1
2 6 1 5 9 1 9 I II F N R NO
1 1 0 I
2 0 II F
0
R
S2
4 8 3 7 10
S3
5 10
+ + NI
S40
M/B1
1 2 3 4 5 6
X62
N1
N1
C1
M-N1
M-V1
M-B1
R-N1
L/G1
C1 4.4
N1 4.1
R-N1 5.1
3
X9
C1
M-N1
M-V1
M-B1
M/B1
H-N1
L/G1
7 2 6 11 5 9 3 1
XC4 XC2 XC2 XC4 XC1 XC1 XC1 XC1
1.4
3
F6C
7,5A
+15 +15
+15
F4B F4A
10A 5A
1.4
1
K10 K11
K1 86 87a 87
K4 86 87a 87 86 87a 87 86 87a 87
K2 86 87a 87
85 30 85 30 85 30 85 30 85 30
KC
1 6 9 19 16 8 5 8 1 11
XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC6 XC6 XC3
M-N1
1.2
M-B1 1.2
R-V1 R-V1 3.5
M-N1
M-V1
M-B1
H-N1
A-G1
H-R1
C-N1
B-R1
A-R1
B-R1
A-R1
R-V1
18 6 7 8 24 9 11 29 14 10 4 17 20
X1 X1 X10 X10 X10 X10 X10 X10 X10 X10 X1 X1 X10
M-B1
M-B1
H-N1
A-G1
H-R1
B-R1
A-R1
B-R1
A-R1
R-V1
M-N1
M-V1
C-N1
M-B1
M-B1
A-G1
H-R1
B-R1
A-R1
B-R1
A-R1
R-V1
2 1 1 2 1 2 1 2 C A B 1 2 1 2 2 1 2 2 1
X8 X8 X35 X35 X28 X28 X23 X23 X26 X26 X26 X29 X29 X7 X7 X19 X6 X6 X27 X27
EV2
EV8 S27 S26 S28 EV6 EV9 HA1 EV10
1
2
1
N2.5
N2.5
X19
N1
N1
N1
N1
N1
N1
N1
N1
1.5
31 31 3.1
F27169
30 SECTION 55 - ELECTRICAL SYSTEM
V1
1 0
1 9
1 0
1 9
1 0
1 9
1 0
1 7 9
H1
S4 5 10
S5 5 10
S7 5 10
S8 5 10
A-N1
B-N1
L-G1
N1
N1 6.1
L/G1
C-B1
6 9 5 15 16 8
X15 X14 X15 X16 X16 X14
V1
A-N1
B-N1
C-B1
L-G1
L/G1
1.2
L-G1
2.5
R-V1
R-V1
18
23 16 27 X10 24 15
X10 X10 X10 X10 X10
V1
R-V1
2 1
X31 X31
2
X36
S30
B-N1
A-N1
C-B1
L-G1
1
X36
ST3
R-V1
EV12 1 2
1 2 1 2 X24 X24 1 2 1 2
X30 X30 X34 X34 X25 X25 X32 X32
EV4 EV5 EV3
EV1
EV11
1
1
N1
C
2
2
N1
N1
N1
N1
N1
31 31
2.5 4.1
F27464
SECTION 55 - ELECTRICAL SYSTEM 31
2.5
R-N1
S32 S33
4.5
L1
4.5
A1
R1
G1
A1
A1
G-N1
R-N1
R-N1
L1
L1
B/R1
19 17 7 8 9 6 8 2 7 17
XC4 XC4 XC5 XC5 XC5 XC5 XC1 XC1 XC1 XC5
F1C
10A
+15
4.2
11
4.2
10 52 8.3
KC
2 13 12 20 21
XC3 XC3 XC3 XC3 XC3
G1
A1
R-N1
L1
G1 8.3
G1
G1
N1
N1
N1
N1
A1
A1
A1
G-N1
G-N1
G-N1
R-N1
R-N1
R-N1
R-N1
L1
L1
L1
5 2 6 4 3 9 8 10 7 1 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X18 X52 X48 X42 X37
G1
N1
N1
N1
A1
G-N1
G-N1
R-N1
R-N1
L1
N1
G-N1
2 1
X63 X63
H4 H6
H5
R
59c
59c
L
58
58
31
31
N1
N1
4.5
31 31 6.1
F27466
SECTION 55 - ELECTRICAL SYSTEM 33
3.5
R-N1 R-N1 R-N1 7.1
3.5
C/N1 C/N1 C/N1 7.1
3.5
C/B1
1 6 8 9 1 6 8 9
0 1 2 0 1 2
S11 3 2 10
S12 3 2 10
3.5
N1 N1 N1 7.1
G-V1
S-G1
A-V1
Z-N1
C/B1
3 1 3 5 14
X15 X15 X16 X16 X16
G-V1
S-G1
A-V1
Z-N1
C/B1
3 14 4 12 14 13 15 11 18
XC3 XC5 XC3 XC5 XC3 XC5 XC3 XC5 XC3
F4C
10A
H1
V1
H-N1
V-N1
+30 +30 +30 +30
+15
K6 86 87a 87
K8 86 87a 87
K7 86 87a 87
K9 86 87a 87
85 30 85 30 85 30 85 30
KC
N1
H1
N1
H1
N1
N1
V1
H-N1
H-N1
V-N1
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X51 X50 X44 X45 X47 X46 X38 X40
5.5
31 31 7.1
F27173
34 SECTION 55 - ELECTRICAL SYSTEM
6.5
R-N1 R-N1 R-N1 8.1 4.5
R/N1
6.5
C/N1
S14 3 5 10
S15 5 10
A-V1.5
1 2 3 4 5 6 7 8 9 10 11 12 - l - l
X61 X80 X80 X81 X81
V-N1.5
G/R1
A/N1
A/R1
L-G1
A-V1
A/B1
L-N1
N1
M1
6.5
L1
4.5
A-V1
4.5
L-N1
1 2 3 4
L-G1
A-G1.5
4.5 X43
4.5
G/R1
4.5
V-N1.5
C/N1
A/N1
A/R1
A/B1
L-B1
L/B1
13 2 1 12 1 4
X16 X16 X16 X16 X9 X16
A-G1.5
A-G1.5
A-V1.5
Z1
Z1
R/N1
C/N1
A/N1
A/R1
A/N1
A/B1
A/B1
4 1 3 14 15 12 1 1 16 5 7 4 7
XC5 XC5 XC5 XC4 XC4 XC4 XC4 XC2 XC5 XC2 XC2 XC2 XC3
F7C
6A A.R. F6A F3C
7,5A 10A
+15
F1A
15A
4.4
50
KC
17
XC3
A/N1
A/N1
A/R1
A/B1
L-B1
L/B1
5 6 5 4 1 2 3
X10 X10 X12 X12 X12 X12 X12
R/N1
A/N1
A/N1
A/R1
A/N1
A/B1
A/B1
L-B1
L/B1
- l 4 1 2 3 - l - l 6 3 4 1
X41 X41 X39 X57 X57 X56 X56 X49
M4 M6 M7 M5
M9 53a 53a
53 M 53b M M 53 M 53b
31b 31b
31 31
N1.5
N1.5
N1.5
N1
N1
N1
N1
N1
N1
6.5
31 31 8.1
F27467
SECTION 55 - ELECTRICAL SYSTEM 35
CONTROLLER
1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82
G1
R1
N1
M1
N1
S1
B-N1
V-B1
L-N1
1 2
X83 X83
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER
RELAY
TO ENGINE LINE
F27176
SECTION 55 - ELECTRICAL SYSTEM 37
Calibrations
Gage type Input Reading Pointer Input tolerance Calibration
tolerance direction
0 HZ 0 rpm ±3° N/A Descending
Speedometer 307 HZ 1000 rpm N/A ± 60 rpm Ascending
736 HZ 2400 rpm N/A ± 60 rpm Ascending
240 OHMS Empty +0/-6° 230-240 OHMS Descending
(REF)
Level fuel
102 OHMS 1/2 Tank ±3° (REF) 98-108 OHMS Descending
33 OHMS Full +4/-2° 33-42 OHMS Ascending
900 OHMS Point B +0/-6° N/A Descending
Transmission
temperature 114 OHMS 106 °C (Red/green ±5° 111-117 OHMS (REF) Ascending
line)
700 OHMS Point A +0/-5° N/A Descending
Coolant
temperature 95 HMS 106 °C (Red/green ±3° 93-97 OHMS (Ref) Ascending
line)
11V Red/green left line ±3° 10.7-11.3 V (Ref) Descending
VOLT 15.9V Red/green right ±5° 15.0-15.6 V (Ref) Ascending
line
38 SECTION 55 - ELECTRICAL SYSTEM
Connectors:
PIN # NAME FUNCTION WARNING
LAMP No.
1 Ignition 10V-16V INPUT
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Parking brake Low side switch input LP3
5 Alternator Alternator D+ input LP4
6 Not used
7 Crab steer Low side switch input LP6
8 Neutral High side switch input
9 Seat switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
12 Driving lights High side switch input LP9
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
20 Fuel level sender Speed sensor input LP27
21 Water temperature sender Speed sensor input
22 Transmission temperature sender Speed sensor input
23 Not used
24 Driving lights High side switch input LP8
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Transmission oil temperature Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Horn Open collector output
36 Ground Ground
SECTION 55 - ELECTRICAL SYSTEM 39
Other calibrations:
FRONT INSTRUMENT
TO SOLENOID
VALVES LINE
SAFETY
SWITCH
LVC RIGHT
JOYSTICK
LEFT
JOYSTICK
1 A B
X72 X23 X23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 1 2
X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X14 X14 X14 X14 X14 X14 X4 X4
N1
M-N1
G-R1
G-N1
M-B1
G-V1
B-G1
C-N1
A-R1
A-N1
B-R1
L-G1
V-N1
L-R1
Z-B1
V-B1
H1.5
N1.5
L-B1
H-G1.5
A1
L1
H-N1.5
K1 86 87a 87
85 30
N1
H-N1
H-R1.5
1 2 3 4 5 1 2 1 2 1 2 1 2 1 2 1 2 1 2 A B C A B C 1 2 1 2 A B A B 1 2
X13 X13 X13 X13 X13 X17 X17 YP4 YP4 YP3 YP3 YP6 YP6 YP5 YP5 YP7 YP7 YP8 YP8 XL XL XL XR XR XR X11 X11 X12 X12 X1 X1 X2 X2 X27 X27
CONNECTION
PRESS. SW
PRESS. SW
RETRACT
EXTEND
RH DOWN
JOYSTICK
PATTERN
JOYSTICK
PATTERN
LH DOWN
HORN JUMPER
RH STAB.
RH STAB.
LH STAB.
LH STAB.
VALVE 1
VALVE 2
PLUG 4
PLUG 3
PLUG 6
P5 PLUG 5
PLUG 7
PLUG 8
MAINFOLD
RH UP
LH UP
POWER
P4
P3
P6
P7
P8
R
L
2
B-R1
B-R1
H1.5
H-G1.5
H-N1.5
H-R1.5
N1
N1
N1
N1
1 2 3 4 5 6 1 2 1 2
X24 X24 X24 X24 X24 X24 YP9 YP9 YP10 YP10
AUX FORWARD
P10 PLUG 10
AUX REVERSE
LEFT
PLUG 9
N1
JOYSTICK
P9
2 5 3 6 7 8 2 3 7
S1 S1 S1 S1 S1 S1 S2 S2 S2
31 31
F27182
SECTION 55 - ELECTRICAL SYSTEM 43
NAME DESCRIPTION
K1 Safety relay
S1 Pilot ON/OFF switch - 8-way connector
S2 Pattern change switch - 8-way connector
X1 Valve configuration “1” - 2-way connector
X2 Valve configuration “2” - 2-way connector
X4 Left hydraulic control lever - 2-way con-
nector
X11 Left stabilizer pressure switch - 2-way
connector
X12 Right stabilizer pressure switch - 2-way
connector
X13 Right line - 5-way connector
X14 Right hydraulic control lever - 6-way con-
nector
X17 Manifold power - 2-way connector
X20 LVC control unit - 23-way connector
X23 Safety switch - 2-way connector
X24 Left stabilizer control lever - 6-way con-
nector
X27 Horn jumper connection - 2-way connec-
tor
X72 Pilot control cable - 1-way connector
XL Left stabilizer control lever - 3-way con-
nector
XR Right stabilizer control lever - 3-way con-
nector
YP3 Left bottom plug 3 - 2-way connector
YP4 Left bottom plug 4 - 2-way connector
YP5 Right bottom plug 5 - 2-way connector
YP6 Right bottom plug 6 - 2-way connector
YP7 Extension plug 7 - 2-way connector
YP8 Retraction plug 8 - 2-way connector
YP9 Reverse travel auxiliary speed plug 9 - 2-
way connector
YP10 Auxiliary forward travel plug 10 - 2-way
connector
44 SECTION 55 - ELECTRICAL SYSTEM
NAME DESCRIPTION
X144 2-way connector
X201.P Pilot control - 1-way connector
X201.S Pilot control - 1-way connector
X202 Backhoe attachment travel lock solenoid
valve - 2-way connector
X203 Backhoe attachment travel lock solenoid
valve - 2-way connector
X204 Horn switch - 2-way connector
X206 Bucket level - 2-way connector
XC207 Optional speed control solenoid valve - 2-
way connector
X208 Loader attachment - 2-way connector
X209 Rear hammer solenoid valve - 2-way con-
nector
X210 Transmissione disconnect - 2-way connec-
tor
X124 Quick coupler
X128 Optional
XX From pilot control cable
XC1 Fuse and relay control unit line interface -
general line - 11-way connector
XC2 Fuse and relay control unit line interface -
general line - 7-way connector
XC3 Fuse and relay control unit line interface -
general line - 21-way connector
XC4 Fuse and relay control unit line interface -
general line - 21-way connector
XC5 Fuse and relay control unit line interface -
general line - 17-way connector
XC6 Fuse and relay control unit line interface -
general line - 13-way connector
XST1 Side instrument cluster - 20-way connector
XST2 Front instrument cluster - 20-way connector
Y6 Forward speed solenoid valve
Y7 Reverse travel solenoid valve
Y8 4WD solenoid
Y12 4x1 bucket solenoid valve (optional)
Y24 Backhoe attachment travel lock solenoid
valve
Y25 Backhoe attachment travel lock solenoid
valve
Y30 Speed control solenoid valve (optional)
Y32 Rear hammer solenoid valve (optional)
Y34 Ride control solenoid valve (optional)
Y35 Hand hammer solenoid valve
48 SECTION 55 - ELECTRICAL SYSTEM
1
3
87a
30
86
87
85
M
- +
10 11
9
Off
Off
Off
4
L M H
4
I H ML C
A S
12
5
F27181
FRONT INSTRUMENT
Calibrations
Connectors
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used 1 Keep alive power Need to fuse at 1
2 Key on power Wake up ampere without dis-
3 In gear input Digital input connect
4 Driving lights Digital input 2 Not used
5 Front work lights Digital input 3 Can bus input Twisted pair with
120 OHM terminal
6 Rear work lights Digital input
4 Can bus input Twisted pair with
7 Not used
120 OHM terminal
8 Not used
5 Not used
9 Not used
6 Audible alarm Floyd bell under
10 Air conditioning Digital input buzzer 80 mA
system pressure
7 Starter motor inter- 40 OHM relay =
11 Display input Digital input lock 300 mA
switch
8 Not used
12 Enter input switch Digital input
9 Not used
13 Up input switch Digital input
10 Not used
14 Down input switch Digital input
11 Not used
15 Cranking Digital input
12 Not used
16 Air filter restriction Digital input
13 Fuel level gauge Variable resistance
17 Not used
14 Transmission tem- Thermistor
18 Parking brake Digital input perature
19 Not used 15 Not used
20 Idle validation Digital input 16 Foot accelerator 0.5-4.5 V
switch
17 Accelerator knob 0.5-4.5 V
21 Decelerator button Digital input
18 Foot accelerator Output monitored
22 Not used for diagnostics
23 Not used 19 Accelerator knob Output monitored
24 Not used for diagnostics
25 Transmission oil Digital input 20 Foot accelerator
pressure 21 Accelerator knob
26 Not used 22 Not used
23 Not used
24 Alternator excita- Low alternator out-
tion put signals fault
25 Not used
26 Ground Digital input
60 SECTION 55 - ELECTRICAL SYSTEM
NAME DESCRIPTION
X202 Backhoe attachment travel lock solenoid
valve - 2-way connector
X203 Backhoe attachment travel lock solenoid
valve - 2-way connector
X204 Horn switch - 2-way connector
X205 Transmission disconnect switch and horn
switch
X205a Front horn button
X205b Transmission disconnect button
X206 Bucket level - 2-way connector
X205b Front right light - 4-way connector
X207 Optional speed control solenoid valve - 2-
way connector
X208 Loader attachment - 2-way connector
X209 Rear hammer solenoid valve - 2-way con-
nector
X210 Transmissione disconnect - 2-way connec-
tor
XC1 Fuse and relay control unit line interface -
11-way connector
XC2 Fuse and relay control unit line interface - 7-
way connector
XC3 Fuse and relay control unit line interface -
21-way connector
XC4 Fuse and relay control unit line interface -
21-way connector
XC5 Fuse and relay control unit line interface -
17-way connector
XC6 Fuse and relay control unit line interface -
13-way connector
XST1 Side instrument cluster - 20-way connector
XST2 Front instrument cluster - 20-way connector
XX From pilot control cable
Y8 Differential lock solenoid valve
Y12 4x1 bucket solenoid valve (optional)
Y24 Backhoe attachment travel lock solenoid
valve
Y25 Backhoe attachment travel lock solenoid
valve
Y30 Speed control solenoid valve (optional)
Y32 Rear hammer solenoid valve (optional)
Y34 Ride control solenoid valve (optional)
Y35 Hand hammer solenoid valve
Y206 Bucket level solenoid valve
64 SECTION 55 - ELECTRICAL SYSTEM
1
3
87a
30
86
87
85
M
- +
10 11
9
Off
Off
Off
4
L M H
4
I H ML C
A S
12
5
F27181
FRONT INSTRUMENT
Calibrations
Connectors
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used 1 Keep alive power Need to fuse at 1
2 Key on power Wake up ampere without dis-
3 In gear input Digital input connect
4 Driving lights Digital input 2 Not used
5 Front work lights Digital input 3 Can bus input Twisted pair with
120 OHM terminal
6 Rear work lights Digital input
4 Can bus input Twisted pair with
7 Not used
120 OHM terminal
8 Not used
5 Not used
9 Not used
6 Audible alarm Floyd bell under
10 Air conditioning Digital input buzzer 80 mA
system pressure
7 Starter motor inter- 40 OHM relay =
11 Display input Digital input lock 300 mA
switch
8 Not used
12 Enter input switch Digital input
9 Not used
13 Up input switch Digital input
10 Not used
14 Down input switch Digital input
11 Not used
15 Cranking Digital input
12 Not used
16 Air filter restriction Digital input
13 Fuel level gauge Variable resistance
17 Not used
14 Transmission tem- Thermistor
18 Parking brake Digital input perature
19 Not used 15 Not used
20 Idle validation Digital input 16 Foot accelerator 0.5-4.5 V
switch
17 Accelerator knob 0.5-4.5 V
21 Decelerator button Digital input
18 Foot accelerator Output monitored
22 Not used for diagnostics
23 Not used 19 Accelerator knob Output monitored
24 Not used for diagnostics
25 Transmission oil Digital input 20 Foot accelerator
pressure 21 Accelerator knob
26 Not used 22 Not used
23 Not used
24 Alternator excita- Low alternator out-
tion put signals fault
25 Not used
26 Ground Digital input
76 SECTION 55 - ELECTRICAL SYSTEM
1
3
87a
30
86
87
85
M
- +
10 11
9
Off
Off
Off
4
L M H
4
I H ML C
A S
12
5
F27181
FRONT INSTRUMENT
Calibrations
Connectors
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used 1 Keep alive power Need to fuse at 1
2 Key on power Wake up ampere without dis-
3 In gear input Digital input connect
4 Driving lights Digital input 2 Not used
5 Front work lights Digital input 3 Can bus input Twisted pair with
120 OHM terminal
6 Rear work lights Digital input
4 Can bus input Twisted pair with
7 Not used
120 OHM terminal
8 Not used
5 Not used
9 Not used
6 Audible alarm Floyd bell under
10 Air conditioning Digital input buzzer 80 mA
system pressure
7 Starter motor inter- 40 OHM relay =
11 Display input Digital input lock 300 mA
switch
8 Not used
12 Enter input switch Digital input
9 Not used
13 Up input switch Digital input
10 Not used
14 Down input switch Digital input
11 Not used
15 Cranking Digital input
12 Not used
16 Air filter restriction Digital input
13 Fuel level gauge Variable resistance
17 Not used
14 Transmission tem- Thermistor
18 Parking brake Digital input perature
19 Not used 15 Not used
20 Idle validation Digital input 16 Foot accelerator 0.5-4.5 V
switch
17 Accelerator knob 0.5-4.5 V
21 Decelerator button Digital input
18 Foot accelerator Output monitored
22 Not used for diagnostics
23 Not used 19 Accelerator knob Output monitored
24 Not used for diagnostics
25 Transmission oil Digital input 20 Foot accelerator
pressure 21 Accelerator knob
26 Not used 22 Not used
23 Not used
24 Alternator excita- Low alternator out-
tion put signals fault
25 Not used
26 Ground Digital input
SECTION 55 - ELECTRICAL SYSTEM 93
1
1. DIRECTION INDICATOR LAMP 4. MAIN BEAM INDICATOR LAMP
This lamp turns on when the direction indicators This indicator lamp turns on when the main
are working. beams are on.
2. BRAKE LIQUID LEVEL WARNING LAMP 5. “FOUR WHEEL STEER” (4WS) STEER INDI-
This lamp turns on and the audible alarm CATOR LAMP
sounds when the brake liquid is at minimum lev- This lamp turns on when 4 wheel steer mode is
el. selected and phased.
3. SIDE LIGHT AND LOW BEAM INDICATOR 6. “ROAD” (4WS) STEER INDICATOR LAMP
LAMP This lamp turns on when 2 wheel steer mode is
This indicator lamp turns on when the side lights selected and phased.
or the low beams are on.
94 SECTION 55 - ELECTRICAL SYSTEM
F28666
POWERSHUTTLE
POWERSHIFT
2
1. FRONT WORK LIGHT SWITCH over protection device by pressing the switch
This switch has three positions: (ON position and lamp turned on).
- The first position is OFF. In this condition, the audible alarm will sound by
- Second position, the two front external work means of the buzzer when the pressure switch,
lights turn on. installed on the backhoe attachment boom cyl-
- Third position, the two front internal work lights inder, detects a pressure exceeding the follow-
turn on. ing values:
The light switch turns on only in the second 2WS = 116 bar (17 psi)
and third position. 4WS = 126.5 bar (18 psi)
2. HYDRAULIC SPEED CONTROL SWITCH (If 4. “GLIDE RIDE” SWITCH (Optional)
fitted) The “glide ride” system control improves the ma-
This switch enables an increase in the moving chine comfort during travel, regardless of the
speed of the loader and backhoe attachment. type of terrain and with the loader bucket full or
3. ROLL-OVER PROTECTION SWITCH (Option- empty. It reduces forward and rearward pitching
al) when moving to the rear or forwards and when
This switch is used to engage or disengage the carrying loads, at the same time increasing pro-
roll-over protection device. When the operator is ductivity and operator comfort. It also reduces
about to start working with the backhoe attach- impact forces to the machine during operation.
ment in conditions which could cause the ma- Do not use this system while operating the load-
chine to roll over, he/she must activate the roll- er attachment.
SECTION 55 - ELECTRICAL SYSTEM 97
S WARNING S
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.
1. FRONT WORK LIGHT SWITCH over protection device by pressing the switch
This switch has three positions: (ON position and lamp turned on).
- The first position is OFF. In this condition, the audible alarm will sound by
- Second position, the two front external work means of the buzzer when the pressure switch,
lights turn on. installed on the backhoe attachment boom cyl-
- Third position, the two front internal work lights inder, detects a pressure exceeding the follow-
turn on. ing values:
The light switch turns on only in the second 2WS = 116 bar (17 psi)
and third position. 4WS = 126.5 bar (18 psi)
2. HYDRAULIC SPEED CONTROL SWITCH (If 4. “GLIDE RIDE” SWITCH (Optional)
fitted) The “glide ride” system control improves the ma-
This switch enables an increase in the moving chine comfort during travel, regardless of the
speed of the loader and backhoe attachment. type of terrain and with the loader bucket full or
3. ROLL-OVER PROTECTION SWITCH (Option- empty. It reduces forward and rearward pitching
al) when moving to the rear or forwards and when
This switch is used to engage or disengage the carrying loads, at the same time increasing pro-
roll-over protection device. When the operator is ductivity and operator comfort. It also reduces
about to start working with the backhoe attach- impact forces to the machine during operation.
ment in conditions which could cause the ma- Do not use this system while operating the load-
chine to roll over, he/she must activate the roll- er attachment.
SECTION 55 - ELECTRICAL SYSTEM 99
S WARNING S
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.
4
1. ENGINE OIL PRESSURE WARNING LAMP 5. AIR FILTER RESTRICTION WARNING LAMP
This warning lamp turns on and the audible This warning lamp turns on when the air filter el-
alarm sounds when the engine oil pressure is ement needs to be cleaned or replaced.
too low. 6. TRANSMISSION OIL PRESSURE WARNING
If the lamp turns on while the machine is work- LAMP
ing, move the machine to a safe place, immedi- This lamp turns on and the audible alarm
ately stop the engine, remove the starter switch sounds when the transmission oil pressure is
key and find the cause of the problem. too low. If the lamp turns on while the machine
2. “GRID HEATER” INDICATOR LAMP (If fitted) is working, move the machine to a safe place,
If the machine is equipped with a “grid heater”, immediately stop the engine, remove the starter
wait for the indicator lamp to turn off before start- switch key and find the cause of the problem.
ing the engine. 7. LOW FUEL LEVEL WARNING LAMP
3. BATTERY CHARGE WARNING LAMP This warning lamp turns on when the fuel level
This warning lamp turns on when the alternator/ is low. You have approximately an hour to fill the
fan belt is broken or when the alternator is not fuel tank.
charging the battery.
If the lamp turns on while the machine is work- NOTE: when the starter switch key is in the ON po-
ing, move the machine to a safe place, immedi- sition, all lamps turn on and the instrument buzzer
ately stop the engine, remove the starter switch sounds for 5 seconds. Afterwards, the lamps turn off
key and find the cause of the problem. and only lamp (2) remains on. The gauges (9) and
4. PARKING BRAKE INDICATOR LAMP (10) set to position.
This indicator lamp turns on when the parking
brake lever is in the raised position (wheels
braked).
SECTION 55 - ELECTRICAL SYSTEM 101
5
1. CAUTION MASTER LAMP 5. PARKING BRAKE INDICATOR LAMP
This lamp signals a not critical caution. This indicator lamp turns on when the parking
When this caution is active, it is necessary to brake lever is in the raised position (wheels
change the operating mode, plan a down time to braked).
carry out maintenance or, if the fault continues, 6. AIR FILTER RESTRICTION WARNING LAMP
consult your dealer. This warning lamp turns on when the air filter el-
This lamp turns on at the same time of lamps ement needs to be cleaned or replaced.
(2), (4), (6), (7) and (9). 7. TRANSMISSION OIL PRESSURE WARNING
2. ENGINE OIL PRESSURE WARNING LAMP LAMP
This warning lamp turns on and the audible This lamp turns on and the audible alarm
alarm sounds when the engine oil pressure is sounds when the transmission oil pressure is
too low. too low.
3. STOP MASTER LAMP 8. AIR CONDITIONER INDICATOR LAMP (Op-
The stop master lamp signals a critical caution. tional)
When this lamp turns on, stop the machine im- This lamp turns on when the air conditioner is
mediately and shut off the engine. working.
If this is not the case, the machine can get dam- 9. “GRID HEATER” INDICATOR LAMP (If fitted)
aged or accidents may occur. If the machine is equipped with a “grid heater”,
4. BATTERY CHARGE WARNING LAMP wait for the indicator lamp to turn off before start-
This warning lamp turns on when the alternator/ ing the engine.
fan belt is broken or when the alternator is not
charging the battery.
SECTION 55 - ELECTRICAL SYSTEM 103
F28667
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
3 (-31) Negative power supply Connected to the vehicle negative at two independent
points
5-6 Immobilization relay No. 2 Connected in line with the wire controlling the starter
motor relay/solenoid - Minimum 500 mA maximum 10 A
capacity
7 - 8 - 9 Immobilization relay No. 1 Connected in line with the cable controlling the ignition
or the fuel system - minimum capacity 500 mA, maxi-
mum capacity 10 A
SECTION 55 - ELECTRICAL SYSTEM 105
4.1 SYMBOLS
1000
500
n/min
Dimmer
Increase O
Decrease P
Increase
Decrease
Service
interval
Increase
Decrease
Stored error
code
“Grid heater”
presence Select / Deselect
HARDWARE
P/N Increase O
Hardware code
ID Decrease P
VER
SOFTWARE
OPress Enter to make the value flash and then set
Software code P/N up
ID
VER PPress Enter to make the value stop flashing
SECTION 55 - ELECTRICAL SYSTEM 109
Go to menu
Maximum accelerator knob: 125/120
X.X.
field
Normal “Key ON” Z Minimum accelerator knob: X.X.
Z
Initiate Self test
Accelerator pedal %: XXX 113/122
Any of the keys above and with “Key ON”
Accelerator knob %: XXX field
Check:
100 mA < Current draw < 1amp
Step 1: Lamps switch on at full intensity.
Step 5: Lamps switch off after 2 seconds. 10 mA < Current draw < 100
mA Voltage: XX.X
116/124
Transmission oil field
Step 6: Wait 2 seconds. temperature: XX
Step 7: Sweep all 5 gauges to maximum angle.
Makes sure that needles can
move freely and have proper Brakes: XXX 102/92
position Engine rpm: XXXX field
Step 8: 2 seconds after maximum angle sweep to red border.
Step 9: 2 seconds after red-green border is reached move to Makes sure that needles are
properly calibrated to
second red border for voltage. applique
Radiator water
temperature XXX 107/123
Step 10: Park all gauges and start LCD test. field
Air temperature XXX
Step 11: When LCD test is complete sound alarm for 2 seconds.
MAIN SCREEN
↵
Z
Z Page 1/6
CODE 3059 3-second scroll unless
the up/down button is
↵ OCCURRENCE 3 pressed
TIME 1004.5
Page 2/6
CODE 3009
OCCURRENCE 2
TIME 1010.6
Page 3/6
CODE 1018
Occurrence counter will be incremented on transition from OCCURRENCE 1
inactive to active status. Status has to be stored in EEPROM
TIME 1024.5
and checked at key on. Only the hour count of the last
occurrence will be stored per SAE convention.
Page 4/6
CODE 3022
OCCURRENCE 1
HOUR 969 .4
Page 5/6
CODE 3113
OCCURRENCE 2
TIME 1050.6
Page 6/6
CODE 1003
OCCURRENCE 3
TIME 1076.4
SECTION 55 - ELECTRICAL SYSTEM 111
A proper and uniform backlighting for matrix, gauge The dot matrix visualization will be as follows:
pointer and symbols shall be provided.
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- Z once in the adjustment mode the meaning of the
hicle hours of operation, it will not be necessary to arrow UP switch is “increase hourmeter value”,
have the key. By pressing the enter/display/up/ and the meaning of arrow DOWN switch is “de-
down switch, with the key turned to OFF, the instru- crease hourmeter value”. Single switch pressure
ment cluster panel will activate and display the serv- will increase or decrease the value of one unit
ice hours for 10 seconds. (6 min). Continuous switch pressure will increase
The hourmeter increments when the engine is run- or decrease the value continuously (1 every 300
ning (rpm> 600). The hours are visualized starting milliseconds): when the value reaches a multiple of
from 0.0 until 210554060.7 using a step of 6 min- 10, the increment/decrement rate is 10 units every
utes. In case of battery disconnection, the cluster 300 ms; when the value reaches a multiple of 100,
can lose 0.1 hour or 6 minutes max. the rate is 100 units every 300 ms; when the value
reaches a multiple of 1000, the rate is 1000 units
WORK HOURS SETTING every 300 ms.
In order to allow service to install a new Vehicle
Control Module (VCM) on an old vehicle, it is possi- During continuous setting the value stops flashing.
ble to increase (no decrease will be allowed) the Once the operator has reached the desired value
hour to the same setting as the original. press and hold down the arrow UP and display
To modify the hourmeter value, execute the follow- switches for 15 seconds to end setting procedure. It
ing procedure: is not possible to set a value lower than the current
Z select the hourmeter function on the display; one, and the procedure can be repeated three times
Z press and hold depressed for 15 seconds “arrow in the cluster life.
UP” and “display” until the value shown on display
starts to blink (1 Hz, duty 50%);
Work hours
Value may only increase for the hourmeter. 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. Press-
ing DISPLAY will exit without saving. ENTER must be pressed to store the modified value in
protected memory.
SECTION 55 - ELECTRICAL SYSTEM 113
Auto wake up at every 600 ms for sensing a change With the key OFF, all indicators set to the parking
in ENTER, DISPLAY, UP or DOWN switch status position. The parking position is hard to obtain with
will be provided. Upon sensing of one of those in- the internal stops of the stepper motor. With the key
puts transition, the cluster has to wake up. ON, follow the procedure below.
As a general rule, at engine start-up, it is necessary
to deactivate all alarms and instrument gauges, un-
less an error is detected on the starting line.
Needle collision
control at key-on
Vibration, service,
transport or If RTZ is observed TRUE
battery loss can on all 5 gauges
generate a FALSE
FALSE
Drive gauges:
- engine coolant
- fuel level
TACHOMETER - ENGINE SPEED GAUGE An audible alarm must sound when the engine tem-
The tachometer accuracy should be less than or perature exceeds 106 °C (223 °F).
equal ±50 rpm. The above-specified tolerances If the sender is disconnected, the instrument must
must be respected in all operating ranges (tempera- go to 65 °C (149 °F). Once the sensor is connected
ture, voltage, etc.). A stepper motor will drive the ta- again, the instrument must return to the correct po-
chometer. Needle calibration has never to be lost for sition. 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
Green field 0 - 2500 rpm VOLTMETER GAUGE
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
Z The bottom of the scale is 9 V.
signal is a function of the engine controller the ap-
Z Low voltage range 11 V or less. The pointer will be
propriate warning lamp and lamp will be illuminated.
±3° of the bold centerline indicating 11 V.
During cranking, the needle movement shall be fro-
Z The normal operating range will vary between 11
zen in order to inhibit any spurious movement of it.
and 16 V.
ENGINE COOLANT TEMPERATURE GAUGE Z High voltage range 16 V or more. The pointer will
be ±3° of the bold centerline indicating 16 V.
A stepper motor will drive coolant temperature Z The top of the scale will be 18 V.
gauge. The gauge accuracy should be less than or A stepper motor will drive the voltmeter gauge. The
equal 3%. Needle calibration has never to be lost for gauge accuracy should be less than or equal 3%.
any external condition. Needle calibration has never to be lost for any exter-
Gauge Temperature nal condition. Loss of voltmeter sensor will be the
loss of the internal VCM A/D converter. During
Gauge indication range +65 to +112 °C cranking, the needle movement shall be frozen in
(149-234 °F) order to inhibit any spurious movement of it.
Green field +65 to +106 °C A/D accuracy is specified as ±180 mV during self
(149-221 °F) test operation.
Z 5 V = 75 °C (167 °F).
The CL of the pointer will be ±2 angular degrees of
the centerline of the tick mark that indicates this
temperature.
Z 2.6 V = 93.3 °C (200 °F).
The CL of the pointer will be ±3 angular degrees of
the centerline of the tick mark that indicates this
temperature.
Z 2.05 V = 115.5 °C (240 °F).
The CL of the pointer will be ±2 angular degrees of
the centerline of the tick mark that indicates this
temperature.
ALARM ACTIVATION
Non Critical A failure is present but the operator can continue his work: the purpose is to warn him
regarding the presence of the fault. This will be a 1 second beep every 30 seconds.
Critical A serious fault that can affect either the safety of the operator or the damage of the
loader backhoe is present: the operator shall stop the loader backhoe. This will be a
continuous alarm.
Action required The system is asking for a certain maneuver from the operator in order to return to the
normal functionality. This will be a continuous alarm.
Safety The system purpose is to warn the operator regarding the presence of a dangerous
situation for his safety. This will be a continuous alarm.
General sound There are certain conditions in which it is necessary to activate an audible alarm. This
is a one second beep to draw the operators attention to the cluster.
4.9 MAINTENANCE
DISPLAY FUNCTION
3 seconds
LIGHT
3 seconds
500
GREEN AMBER
Audible alarm for 1 second when displaying either service interval for the first time
3 seconds
HEAVY
3 seconds
1000
GREEN AMBER
Audible alarm for 1 second when displaying either service interval for 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
120 SECTION 55 - ELECTRICAL SYSTEM
Display
Function Lamp Alarm Lamp Condition DTC SA Description Priority Color
lamp
Coolant Coolant
Engine STOP above temperature
coolant too Continuous 1002 VCM 1 Red
112 °C for 5 signal - Above
high
seconds normal
Oil pressure
Engine oil Pressure
STOP sensor -
pressure too Continuous < 26 bar 3028 ECU 1 Red
pressure too
low 500> rpm
low
The engine
Switch
Transmission STOP 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 STOP Continuous without 1051 ECU 1 Red
message
message
25 seconds
Timeout of
Malfunction STOP Continuous without 1053 ECU 1 Red
message
message
Timeout of
5 seconds
STOP message
Malfunction Continuous without 1054 VCM 1 Red
engine
message
temperature
5 seconds Timeout of
Malfunction STOP Continuous without 1055 VCM message inlet/ 1 Red
message exhaust
5 seconds Timeout of
Malfunction STOP Continuous without 1056 VCM message 1 Red
message engine fluid
Timeout of
5 seconds
STOP message
Malfunction Continuous without 1057 VCM 1 Red
vehicle
message
electrical
5 seconds Timeout of
Malfunction STOP Continuous without 1059 VCM message 1 Red
message display
Transmission Transmission Transmission
oil STOP oil above oil
Continuous 1009 VCM 1 Red
temperature 115 °C for 5 temperature
too high seconds limit reached
SECTION 55 - ELECTRICAL SYSTEM 121
Display
Function Lamp Alarm Lamp Condition DTC SA Description Priority Color
lamp
General Only display
DTC’s 3000 -
display STOP Continuous STOP with display 1 Red
3366
message request
Display
Function Lamp Alarm Lamp Condition DTC SA Description Priority Color
lamp
Foot Foot
One second Voltage over
accelerator accelerator
alarm every 4.75 V for 5 1011 VCM 2 Amber
signal out of sensor -signal
30 seconds seconds
range above range
Foot Foot
One second Voltage
accelerator accelerator
alarm every under 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 123
Display
Function Lamp Alarm Lamp Condition DTC SA Description Priority Color
lamp
Hand Hand
One second Voltage over
accelerator accelerator
alarm every 4.75 V for 5 1035 VCM 2 Amber
signal out of sensor -signal
30 seconds seconds
range above range
Hand Hand
One second Voltage
accelerator accelerator
alarm every under 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
124 SECTION 55 - ELECTRICAL SYSTEM
Display
Function Lamp Alarm Lamp Condition DTC SA Description Priority Color
lamp
Boost
Engine over
Boost air One second temperature
operating
temperature alarm every over 1018 VCM 3 Amber
boost air
too high 30 seconds 88 °C for 5
temperature
seconds
Coolant Engine over
Engine One second
above operating
coolant too alarm every 1019 VCM Amber
106 °C for 5 coolant
high 30 seconds
seconds temperature
Coolant
Engine One second
temperature
coolant too alarm every 3007 ECU 3 Amber
signal source
high 30 seconds
high
Coolant
Transmission One second Transmission
above
oil above alarm every 1020 VCM over operating 3 Amber
105 °C for 5
105 °C 30 seconds temperature
seconds
Fuel One second Fuel over Fuel over
temperature alarm every 82 °C for 5 1021 VCM operating 3 Amber
too high 30 seconds seconds temperature
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
Air One second
closed to conditioning
conditioning alarm every 1003 VCM 4 Amber
Vbat for 5 system
not functional 30 seconds
seconds pressure
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 125
Display
Function Lamp Alarm Lamp Condition DTC SA Description Priority Color
lamp
Fuel sender
One second Fuel sender
Fuel level shorted high -
alarm every above 9 V for 1043 VCM 4 Amber
sensor instrument in
30 seconds 5 seconds
stand-by
Fuel sender
One second Fuel sender
Fuel level shorted low -
alarm every below 0.5 V 1044 VCM 4 Amber
sensor instrument in
30 seconds for 5 seconds
stand-by
Input is Fuel sender
One second
Fuel level switched open circuit -
alarm every 1045 VCM 4 Amber
sensor battery for 5 instrument in
30 seconds
seconds stand-by
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
126 SECTION 55 - ELECTRICAL SYSTEM
5. STARTING SYSTEM
5.1 DESCRIPTION AND OPERATION
The motor does not start when the starter switch key is operated and the transmission is in the neutral position.
NO
Is the starter motor seized? Repair or replace the starter motor
YES
NO
Operate the starter switch key. Is Does the solenoid Windings, brush or starter
there a voltage of +12 V on the make a “clicking” YES motor mechanism possi-
(white) input wire of the starting sole- YES
sound? bly defective.
noid valve (terminal 30)?
NO
NO
Check the starter motor relay (K01). Can you Solenoid possibly defec-
hear the relay operate after operating the starter tive. Remove the starter
switch key? motor and inspect
NO
Remove the connector from the relay (K01). Is there a voltage of +12 V
at terminal 86 (white/black) after the starter switch key is operated? YES Replace the relay
NO
Check the starter motor safety relay (K3). Can one hear the relay
operate after operating the reverse travel lever?
NO
YES
Check the main power sup-
Are the indicators on the instrument panel correctly lighted ply between the battery
after operating the key switch? NO
and the starter motor key.
YES Pin 2 (red wire) of the igni-
tion key connector.
Are the cable wires of the key switch connected correctly?
YES NO
SPECIFICATIONS
Manufacturer .............................................................................................................................................Denso
Voltage .........................................................................................................................................................12 V
Rated power........................................................................................................................ 2.7 kW (2000 ft.lb/s)
Starting system .......................................................................................................................................Positive
Operating time.............................................................................................................................................. 30 s
Direction of rotation .................................................................................... Clockwise seen from the pinion side
Weight ....................................................................................................................................... 8.4 kg (18.5 lbs)
Maximum consumption without load at 11 V and 3000 rpm minimum ...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm (14.5 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 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 131
132 SECTION 55 - ELECTRICAL SYSTEM
1. Shim
2. Bearing
3. Armature
4. Bearing
5. Coils housing
6. Protection
7. Brush spring
8. Brush assembly
9. Disc
10. Cover
11. Screw
12. Screw
13. Drain
14. Screw
15. Protection
16. Gasket
17. Washer
18. Nut
19. Rod
20. Connection assembly
21. Screw
22. Connection assembly
23. Nut
24. Ring
25. Roller
26. Cage
27. Pinion
28. Ball
29. Spring
30. Drain
31. Screw
32. Washer
33. O-ring
34. Flange
35. Pinion, rings and spring assembly
36. O-ring
37. Bearing
38. Bearing
39. Spring
40. Shaft
41. Body
42. Clutch assembly
SECTION 55 - ELECTRICAL SYSTEM 133
Armature
Z 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.
Z After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in
gasoline.
Field coils
Z 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).
Z 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.
Z If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Drive pinion
Z 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 the clutch and the ring gear.
tooth tips
Field coil loss Pinion gear disengagement fault Replace the magnetic switch.
caused by a coil short circuit in
Magnetic switch coil burnt, etc. the magnetic switch.
136 SECTION 55 - ELECTRICAL SYSTEM
6. ALTERNATOR
6.1 SPECIFICATIONS
Manufacturer .............................................................................................................................................Denso
Rated voltage ...............................................................................................................................................12 V
Polarity .................................................................................................................... Negative terminal grounded
Current ........................................................................................................................................................90 A
Minimum charging speed ..................................................................................................................... 1400 rpm
Maximum speed................................................................................................................................... 9000 rpm
Operating temperature ........................................................................................-30 °C to 90 °C (-22 to 194 °F)
Direction of rotation .................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 °C (77 °F) .............................................................14.2 - 14.8 V
Maximum load that can be applied at terminal L.............................................. 12 V, 3.4 W x 6 (2519 ft.lb/s x 6)
1. Alternator
2. Output winding of the rotor
3. Rectifier
4. Regulator
5. Starter motor
6. Battery
7. Key switch
8. Charge indicator
9. Speedometer
138 SECTION 55 - ELECTRICAL SYSTEM
6.3 COMPONENTS
6.4 REMOVAL
PRELIMINARY CHECKS
Before undertaking an electrical inspection, check
the charging system and the electrical system care-
fully.
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 system components; these
tests help check the following items:
Z Connections of the alternator cables
Z Charging current and regulated voltage of the alter-
nator
Z Voltage drops in the alternator charging system
Z Maximum flow of the alternator
Required devices:
Z Voltmeter (0-30 V, moving coil)
Z Millivoltmeter (0-1 V)
Z Ammeter (0-110 A, moving coil)
Z Variable resistance of 1.5 Ohm, 110 A
Required devices:
Z 12 V battery
Z Multimeter
Z 2.2 W test lamp
7. BATTERY
For the loader backhoe models two different kinds of installation are provided:
Z with one battery.
Z with two batteries (for cold climates).
7.1 SPECIFICATIONS
Single battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):..........................................................................................................................................95 Ah
Discharge current:......................................................................................................................................900 A
Weight with electrolyte: ................................................................................................................. 25 kg (55 lbs)
Double battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):..........................................................................................................................................60 Ah
Discharge current:......................................................................................................................................600 A
Weight with electrolyte: .............................................................................................................. 17 kg (37.5 lbs)
S WARNING
A spark or flame can cause the electrolyte in a bat-
tery to explode. To prevent any risk of explosion, ob-
serve the following instructions:
Z Place the battery master switch to OFF (discon-
nected).
Z When disconnecting the battery cables, always dis-
connect the negative cable (-) first.
Z When reconnecting the battery cables, always con-
nect the negative (-) cable last.
Z Never short-circuit the battery terminals with metal
objects.
Z Do not weld, grind or smoke near a battery.
S 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.
152 SECTION 55 - ELECTRICAL SYSTEM
S WARNING
Before carrying out any welding on the machine or
repair work on the electrical system, disconnect the
battery and disconnect the B+ and D+ wires on the
alternator. When reconnecting, check the wire mark-
ings.
S WARNING
Always store batteries in a safe place, out of the
reach of children.
S WARNING
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
S 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 153
7.4 MAINTENANCE
DRY CHARGED
Z Remove the battery cell vent plugs. S WARNING
Z Fill each cell to the recommended level with elec- When a battery is being charged an explosive gas is
trolyte of 1.260 specific gravity. produced. Do not smoke or use an exposed flame
Dry charged batteries must be prepared for service when checking the electrolyte level and ensure the
as follows: charger is switched off before connecting or
disconnecting to avoid sparks which could ignite the
NOTE: the electrolyte must be diluted sulphuric acid gas.
preferably at a temperature of 21-32 °C (69.8-
89.6 °F). RECHARGING DEEPLY DISCHARGED
The recommended method to recharge a mainte-
Z After filling, allow the battery to stand for 15 min- nance free Pb-Ca battery is to use a constant volt-
utes then re-check the electrolyte level and top up age charger. For deeply discharged batteries a 48
if necessary. hours charging period at 16 V is recommended, with
Z Charge the battery for 4 hours at a rate of 5-8 am- current limitation, (47.5 A for 95 Ah).
peres and check that all cells are gassing freely. This system is self regulating: high current is deliv-
Z Install the battery cell vent plugs. ered at the beginning (when battery voltage is low),
lower and lower current is then absorbed when bat-
CHARGING THE BATTERY tery reaches full charge (and its voltage is high).
Before charging a battery: If only constant current chargers are available it is
Z Thoroughly clean the battery casing and cell cov- recommended to use the current levels and times. If
ers with dilute ammonia or hot water and clean the the battery is only 50% discharged use one half of
terminals. the time listed (slow charge programs). For other
Z Check the level of the electrolyte in each cell and, states of discharge reduce proportionally the time of
if below plates, add distilled water to bring above charge. Whenever possible use the slowest charge
plate level. program to increase the battery’s life.
If when charging the battery, violent gassing or
NORMAL (TOP-UP) CHARGING spewing of electrolyte occurs, or the battery case
Z With a slow charger use a rate of 3 to 6 amperes feels hot (50 °C (122 °F) or greater), reduce or tem-
for the time necessary to bring the battery to full porarily halt charging to avoid damaging the battery.
charge. This may take 36 hours or more if the bat-
tery is heavily discharged. A severely sulphated
battery might not accept a charge. When the bat-
tery is fully charged the cells will gas freely and the
specific gravity will remain constant. Remove the
charger after three consecutive hydrometer read-
ings taken at hourly intervals indicate that the spe-
cific gravity has stopped rising.
Z When using a fast or high rate of charge carefully
follow the manufacturers instructions. High rate
charging raises the temperature of the electrolyte
and unless the charger is equipped with an auto-
matic time or temperature device, the electrolyte
temperature could exceed 50 °C (122 °F), which
may cause violent battery gassing and damage to
internal components.
Z Re-check the level of electrolyte in each cell and
add distilled water as necessary.
SECTION 55 - ELECTRICAL SYSTEM 155
7.5 TESTS
Before commencing battery tests check the battery 4. If the specific gravity is 1.280 or more the battery
for clogged vents, corrosion, raised vent plugs or a is fully charged and in good operating condition.
cracked case. 5. Should the corrected specific gravity be below
Test equipment required: 1.280, charge the battery and inspect the charg-
Z Hydrometer. ing system to determine the cause of the low
Z Battery starter tester (high rate discharge tester). battery charge.
Z Thermometer.
Z Battery Charger. NOTE: if distilled water has recently been added the
battery should be recharged for a short period oth-
SPECIFIC GRAVITY erwise accurate hydrometer readings will not be ob-
This test will determine the state of battery charge. tained.
1. With the float in the vertical position take the
reading. If the battery has been charged under static condi-
2. Adjust the hydrometer reading for electrolyte tions, denser electrolyte will accumulate at the bot-
temperature variations by subtracting 4 points tom of the cells. The battery should be shaken
(0.004 specific gravity) for every 5.5 °C (41.9 °F) periodically to mix the electrolyte, this will improve
below the temperature at which the hydrometer the charge rate and provide a more accurate hy-
is calibrated and by adding 4 points (0.004 spe- drometer reading when tested.
cific gravity) for every 5.5 °C (41.9 °F) above this
PERFORMANCE TEST
temperature.
The following examples are calculated using a hy- The performance test is to determine if the battery
drometer calibrated at 30 °C (86 °F). has adequate capacity to turn the engine. The volt-
age reading obtained is used to determine the bat-
Example 1: tery condition. Prior to testing, ensure the electrolyte
Temperature below 30 °C (86 °F) level is correct and the open circuit voltage is 12.5 V
Electrolyte temperature....................19 °C (66.2 °F) or more. The battery may be tested on or off the
Hydrometer reading ........................................1.270 loader backhoe.
Subtract (11.0 / 5.5) x 0.004 ...........................0.008 1. Set the current control switch of the battery
Corrected specific gravity................................1.262 starter tester (high rate discharge tester) to OFF
and the voltage selector switch equal to, or
Example 2: slightly higher than, the rated battery voltage.
Temperature above 30 °C Connect the tester positive leads to the battery
Electrolyte temperature.....................40 °C (104 °F) positive terminal and the negative leads to the
Hydrometer reading ........................................1.220 negative battery terminal.
Add (10.0 / 5.5) x 0.004 ..................................0.007 2. Turn the current control knob until the ammeter
Corrected specific gravity................................1.227 reading is half the CCA rating of the battery and
3. Use the following table to determine the state of take the voltage reading.
charge. Z If the reading is 9.6 V or more after 15 seconds, the
battery has an acceptable output capacity and will
State of Corrected Corrected Average readily accept a normal charge.
Charge specific specific battery Z If however the reading is below 9.6 V, the battery
gravity @ gravity @ voltage is considered unsatisfactory for service and should
15 °C 25 °C be test charged as described below.
(59 °F) (77 °F)
100% 1.295 1.287 2.76 S CAUTION
75% 1.253 1.246 12.52 Do not leave the high discharge load on the battery
50% 1.217 1.210 12.30 for periods longer than 15 seconds.
25% 1.177 1.170 12.06
Discharged 1.137 1.130 11.84
S 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.
S WARNING
Connecting jumper cables wrongly or short-circuiting
battery terminals can cause an accident. Connect
the jumper cables following the instructions in this
manual.
Z Open the battery box and then remove the tool box.
Z Remove the terminal covers.
Z Connect the positive (+) jumper cable to the posi-
tive (+) terminal of the machine’s battery.
Z Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Z Start the engine
Z First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Z Install the terminal covers.
Z Install the tool box and close the battery box.
S 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.
158 SECTION 55 - ELECTRICAL SYSTEM
8. COMPONENT TESTING
8.1 GENERAL INTRODUCTION
The wiring harnesses contain wires which are colour Z Check polarity of the battery before connecting
coded for identification. power to the harness.
Each harness can be removed and replaced, but Z When it is necessary to remove or partially discon-
certain precautions must be observed: nect a wiring harness, label each connector before
Z Disconnect or isolate the battery, negative terminal removal from its mating instrument.
first, prior to disconnection or removal of any wiring
harness.
Z Prior to removal, note the harness routing, clamp-
ing positions and terminal connections.
Z On replacement, be sure that the harness routing
is not in contact with sharp edges, the exhaust sys-
tem or moving parts.
Z Check connections for wire colour matching.
Z Use a light coating of di-electrical grease on the
connector pins to prevent corrosion.
Z Be sure that all connectors are fully engaged and
no conductor is exposed.
Z Tape back unused connectors.
Z Be sure that ground connections are clean with
metal-to-metal contact. Use toothed lock washers
for good ground connections.
Z Be sure that fuses are of the specified rating.
Z Check the system amperage before applying pow-
er to the wiring.
SECTION 55 - ELECTRICAL SYSTEM 159
F32641
F28380
F28381
SECTION 55 - ELECTRICAL SYSTEM 161
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
162 SECTION 55 - ELECTRICAL SYSTEM
8.5 ALTERNATOR
F28384
F28388
8.6 TRANSMISSIONS
Test procedure
Continuity should be found between pin 1 and pin 2 X23
when switch is operated.
2: RM:A-R:1
1: RM:B-R:1
X28
2: RM:A-R:1
4: RM:C-N:1
1: RM:B-R:1
3: RM:N:1
F28391
Test Procedure
Test procedure of the speed sensor refer to the next
page.
SECTION 55 - ELECTRICAL SYSTEM 163
Test Procedure
Test between pin indicated in the left hand column
and either pin H or M as detailed in the table below.
F28394
DESCRIPTION
Pin
H M
No.
A 27.5 Ω -
B 27.5 Ω -
C 27.5 Ω -
D 27.5 Ω -
E 27.5 Ω -
F 27.5 Ω - F28395
G - 14 Ω
K - 31 Ω
F28394
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.
F28397
Description
A Speed sensor +
B FWD request
C Disconnect request input A
B M
D Speedometer output
C N L
E Diagnostic link input P U
F Analogue Input 1 D V K
G Analogue Input 0 R T
H - E S J
J - F H
G
K PWM solenoid supply
L Solenoid 3
M PWM 1 F28398
N Range solenoid 27
P Forward solenoid
R Solenoid 2
S Solenoid 1
T VCS
U Ground
V Battery +
SECTION 55 - ELECTRICAL SYSTEM 165
Test procedure
Continuity should be found between pin 1 and pin 2
when switch is operated.
7: Z/N1
5: N1
F28400
F28402
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 Z-B:1
No.
1 12 V at low pressure 0.3 Ω N:1
F28403
166 SECTION 55 - ELECTRICAL SYSTEM
F28404
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 Z-B:1
No.
1 12 V at low pressure 0.3 Ω N:1
F28403
Test procedure
Brake engaged:
switch closed warning light illuminated.
S18
Brake disengaged:
switch open warning light off. 1: FM:G-R:1
1: FM:N:1
F28407
SECTION 55 - ELECTRICAL SYSTEM 167
8.8 CAB
FRONT INSTRUMENT
The front instrument cluster receives signals from
the brake oil level sender, the transmission speed
sensor, the light switch and the indicator switch.
Behind the instrument there are connectors at-
tached to the vehicle wiring.
These connectors and functions are listed on the fol-
lowing pages.
Connectors
SECTION 55 - ELECTRICAL SYSTEM 169
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.
F28419
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
1: R:1 1: R:1
0 V pedal released
Red - Black wire 12 V pedal depressed 2: R-N:1 2: B/R:1
0 V pedal released
F28420
SECTION 55 - ELECTRICAL SYSTEM 173
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 1: G-R:1
Red/Black terminal.
2: R/N:1
F28422
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.
F28417
174 SECTION 55 - ELECTRICAL SYSTEM
Test procedure
7 - to pins 2/3/5
F28428
XC1 XC2
F1/C F2/C
Continuity
F28431
SECTION 55 - ELECTRICAL SYSTEM 175
Switch Continuity
All Wiper
Pin Windshield Indicator Beam
switches seal
No. washer
OFF Left Right Low High On
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
2: L-B:1
12 4: G/R:1
12
5: V/N:1.5
6: A/B:1
7: A/N:1
8: A/R:1 1 7
9: L:1
10: A-V:1 6
11: L-N:1
F28433
Test procedure
Test procedure
With ignition ON
B L-R
C-G
A
F28438
SECTION 55 - ELECTRICAL SYSTEM 177
Buzzer operation
The buzzer operation depends on the adjustment of
pin 2 of the 12-way connector:
Z Pin 2 not connected (North America only). If 12 km/h
is exceeded in crab mode, the buzzer sounds.
Z Pin 2 grounded (Outside of N/America). If 12 km/h
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; steering mode
change is not possible when this speed is exceed-
ed.
F28443
F28444
F28445
F28446
180 SECTION 55 - ELECTRICAL SYSTEM
F28447
1: RM:L/R:1
2: RM:N:1
1: RM:S/N:1
2: RM:N:1
F28449
1: RM:H/N:1
2: RM:N:1
1: RM:M/B:1
2: RM:N:1
F28450
SECTION 55 - ELECTRICAL SYSTEM 181
Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity shoud be found between pins 1 and 5.
1: M/B1
5: C-B1
F28452
EV7
Pin No. Solenoid Resistance X8
1 0V 5.0 Ω
1: RM:CL:1
2: RM:N:1
F28453
182 SECTION 55 - ELECTRICAL SYSTEM
8.23 LOADER
S WARNING
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF.
Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity shoud be found between pins 1 and 5.
1: C/N1
5: A-N1
F28456
EV11
X34
Pin No. Solenoid Resistance
1 0V 5.0 Ω
1: RM:A-N:1
2: RM:N:1
F28457
SECTION 55 - ELECTRICAL SYSTEM 183
F28417
1: RM:N:1
2: RM:C-L:1
F28461
Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity shoud be found between pins 1 and 5.
1: C/N1
5: L-G1
F28464
1: RM:N:1
2: RM:C-L:1
Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity shoud be found between pins 1 and 5.
1: C/B1
5: B-N1
F28468
SECTION 55 - ELECTRICAL SYSTEM 185
1: RM:A-N:1
2: RM:N:1
1: RM:N:1
2: RM:C-L:1
F28469
Test procedure
(Switch Off) - X25
Continuity shoud be found between pins 1 and 5.
(Switch On)
Continuity shoud be found between pins 5 and 7.
1: C-B1
7: L/G1
5: C/B1
F28472
EV5
1: R-V:1
2: N:1
F28473
186 SECTION 55 - ELECTRICAL SYSTEM
2: R-V
1: R-V:1
F28476
1: R-V:1
2: N:1
F28473
SECTION 55 - ELECTRICAL SYSTEM 187
1: C-B1
5: C/B1
F28479
1: H-N
2: N:1
F28480
188 SECTION 55 - ELECTRICAL SYSTEM
1: C/N1
5: V1
F28483
M/B
N
F28488
SECTION 55 - ELECTRICAL SYSTEM 189
Test procedure
Approximate resistance:
F28490
190 SECTION 55 - ELECTRICAL SYSTEM
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
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:
Z 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.
Z 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.
Z Securely tighten the lock nuts on a vertical tie 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 re-
turn to dig system is activated, and the solenoid valve
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 re-
turn to dig system is activated, and the solenoid valve
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
Completely raise the loader attachment. Stop the en-
gine and remove the starter switch key.
Remove the split pin (1) and the lock pin (2).
Place the strut (3) on the cylinder rod and install the
pin (2) and the split pin (1) back into the holes in the
strut.
S
WARNING
It is mandatory to install the safety strut when carry-
ing out any operation requiring the loader attachment
to be in the raised position.
UNLOCKED POSITION
Remove the split pin (1) and the lock pin (2).
SECTION 82 - LOADER 11
LOCKED POSITION
Completely raise the loader attachment, stop the en-
gine and remove the starter switch key.
Remove the split pins (1) and the safety strut (2) from
the arm. Put the split pins back in place.
S
WARNING
It is mandatory to install the safety strut when carry-
ing out any operation requiring the loader attachment
to be in the raised position.
UNLOCKED POSITION
Remove the flip (3) and the strut (2) from the cylinder
rod.
REMOVAL
Move the machine to a level and firm 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 from the bucket system.
Remove the fastening screws, then remove the pins
(1).
SWARNING
Always wear eye protection when using a tool which
might project metal particles. Use a hammer with a
soft face, such as copper, for pins assembly/disas-
sembly.
INSTALLATION
Make sure all bushings are completely clean. Re-
move 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 pins (1) and then install the rel-
evant retaining bolts.
Use the bucket controls to align the connecting rod
orifices with the bucket lugs.
Stop the engine and remove the starter switch key.
(4x1 bucket) release the pressure from the bucket
system.
Install the rod/bucket pins (2), and then install the rel-
evant retaining bolts.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic lines.
14 SECTION 82 - LOADER
REMOVAL
Move the machine to a level and firm 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 from the bucket system.
S
WARNING
Always wear eye protection when using a tool which
might project metal particles. Use a hammer with a
soft face, such as copper, for pins assembly/disas-
sembly.
INSTALLATION
Make sure all bushings are completely clean. Re-
move any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Reinstall the arm/bucket pins (1) and then install the
relevant retaining pins and rings.
Use the bucket controls to align the connecting rod
holes (3) with the bucket lugs.
Stop the engine and remove the starter switch key.
(4x1 bucket) release the pressure from the bucket
system.
Install the rod/bucket pins (2) and then install the rel-
evant retaining pins and rings.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic lines.
SECTION 82 - LOADER 15
SWARNING
The forks are heavy, so use great care when swing-
ing them into their working and stowage position.
SWARNING
When using the forks with a 4x1 bucket, never at-
tempt to use the bucket jaw opening function.
16 SECTION 82 - LOADER
Reinstall the pin (1) and the safety pin into their hous-
ing.
5. LOADER REMOVAL
5.1 LOADER ATTACHMENT (B90B - B100B - B110B)
INSTALLATION
Installation is removal procedure in reverse. When
installing the retaining bolts tighten them to 500 Nm.
Remove the safety rings (2) and the pins and then
drive out the pins (1). Lower the lift cylinders carefully
onto the chassis.
20 SECTION 82 - LOADER
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).
SECTION 82 - LOADER 21
INSTALLATION
Installation is removal procedure in reverse.
22 SECTION 82 - LOADER
NOTES:
B90B - B90BLR
B100B - B100BLR
B110B
B115B
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
CROSS-PATTERN CONFIGURATION
S
WARNING
Before leaving the operator’s compartment, under-
taking any road travel or working with the backhoe
attachment, place the pin in locking position.
SECTION 84 - BACKHOE 15
STABILIZER CONTROLS
These controls are located on the left-hand hydraulic
control lever and may be operated independently or
simultaneously.
SWARNING
Always support the structural members so that they
will be stable and safe to work around.
Loosen and remove the nut (4) and the screw (5).
Extract the pin (6) of the swing cylinder.
Repeat the operation with both swing cylinders.
Loosen and remove the nut (7) and the screw (8).
Extract the lower pin (9) from the swing support using
a hammer.
SECTION 84 - BACKHOE 19
S
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Loosen and remove the nut (4) and the screw (5).
Extract the pin (6) of the swing cylinder.
Repeat the operation with both swing cylinders.
Loosen and remove the nut (7) and the screw (8).
Extract the lower pin (9) from the swing support using
a hammer.
REMOVAL
Move the machine to a level and firm ground.
Lower the stabilizers until they are resting on the
ground.
Place the bucket on the ground.
Stop the engine and remove the starter switch key.
Remove the lock rings and pins and the rod/bucket
link pin (1).
S
WARNING
Always wear eye protection when using a tool which
might project metal particles.
INSTALLATION
Start the engine.
Extend the bucket cylinder rod to bring the connect-
ing rod to their housing.
Reinstall the rod/bucket link pin (1), then install the
lock rings and pins.
Slightly raise the attachment, then operate the buck-
et and dipper control to align the dipper hole with the
bucket lugs.
Reinstall the arm/bucket link pin (2), then install the
lock rings and pins.
SECTION 84 - BACKHOE 23
S
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
NOTES: