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TO READER
This manual has been printed for a skilful engineer NEW HOLLAND KOBELCO CONSTRUCTION
to supply necessary technical information to carry MACHINERY S.p.A.
out service operations on this machine. Strada di Settimo, 323 - 10099
S. Mauro Torinese (TO) - Italia
Read carefully this manual to collect correct infor-
mation relevant to repair procedures.
REFERENCE
Beyond this Service Manual, also refer to
documents hereunder listed:
Operator’s Manual
Parts Catalogue
COMPLETE HANDBOOK FOR INSTRUCTIONS The Service Manuals for “Loader backhoe” and
AND REPAIRS “Engine” contain the necessary technical informa-
The complete Service Manual consists of two tion to carry out service and repair on machine and
volumes: on engine, necessary tools to carry out those op-
erations and information on service standard, on
LB90.B - LB95.B - LB110.B - LB115.B procedures for connection, disconnection, disas-
Service Manual “LOADER BACKHOE” sembly and assembly of parts.
LB90.B - LB95.B - LB110.B - LB115.B
Service Manual “Engine” The complete Service Manual which covers the
loader backhoe models LB90.B - LB95.B -
LB110.B - LB115.B consists of the following vol-
umes, which can be identified through their print
number as stated below:
AVOID ACCIDENTS
The majority of accidents and injuries which occur in industry, on the farm, at home or on the
road, are caused by the failure of some individual to follow simple and fundamental safety rules
or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the
real cause and taking the necessary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be
conditions that cannot be completely safeguarded against, without interfering with reasonable
accessibility and efficient operation.
A careful operator and / or technician is the best insurance against accidents. The complete ob-
servance of one simple rule would prevent many thousands of serious injuries each year.
This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.
WARNING
Before carrying out any maintenance operation, adjustment and or repair on machines equipped
with attachments, controlled hydraulically or mechanically, make sure that the attachment is low-
ered and safely set on the ground. If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suitably supported by means other than
the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
3
INDEX
SECTION 00 - SAFETY PRECAUTIONS
SECTION 01 - MAINTENANCE
SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 TIGHTENING TORQUES ...................................................................................................................... 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS ....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS.............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32
2
7.2 FAULT FINDING (WITH “HUSCO” CONTROL VALVES) - LB110.B CENTRE PIVOT..................... 175
7.3 PRESSURE TESTING (WITH “HUSCO” CONTROL VALVES) - LB110.B CENTRE PIVOT............ 180
7.4 FAULT FINDING (WITH “REXROTH” CONTROL VALVES)............................................................. 188
7.5 PRESSURE TESTING (WITH “REXROTH” CONTROL VALVES).................................................... 192
SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 6
2.1 COMPONENTS WITHIN THE CHASSIS............................................................................................... 6
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 7
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 9
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS......................................................................... 10
2.5 TIGHTENING TORQUES .................................................................................................................... 12
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 4
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 7
3. LOADER ATTACHMENT SAFETY STRUT................................................................................................ 10
4. LOADER BUCKET REMOVAL ................................................................................................................... 12
5. LOADER REMOVAL (2WS) ....................................................................................................................... 15
6. LOADER REMOVAL (4WS) ....................................................................................................................... 17
SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROL VERSION .............................................................. 6
3. BACKHOE ATTACHMENT PILOT CONTROL VERSION.......................................................................... 12
4. REMOVAL AND INSTALLATION ............................................................................................................... 14
5. TELESCOPIC DIPPER REVISION............................................................................................................. 24
6
SECTIONS INDEX
Where disassembly of a specific component is required refer to the relevant repair manual section.
TO PREVENT ACCIDENTS
Most accidents and personal injuries that occur in 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 RULES
Carefully follow specified repair and maintenance For electrical heaters, battery-chargers and similar
procedures. equipment use exclusive auxiliary power supplies
Do not wear rings, wristwatches, jewels, unbut- with a efficient ground to avoid electrical shock
toned or flapping clothing such as ties, torn hazard.
clothes, scarves, open jackets or shirts with open Always use lifting equipment and similar of appro-
zips which could get hold into moving parts. priate capacity to lift or move heavy components.
We advise to use approved safety clothing such as Pay special attention to bystanders.
anti-slipping footwear, gloves, safety goggles, hel- Never pour gasoline or diesel oil into open, wide
mets, etc. and low containers.
Never carry out any repair on the machine if some- Never use gasoline, diesel oil or other flammable
one is sitting on the operator’s seat, except if they liquids as cleaning agents. Use non-flammable
are certified operators to assist in the operation to non-toxic proprietary solvents.
be carried out. Wear protection goggles with side guards when
Never operate the machine or use attachments cleaning parts using compressed air.
from a place other than sitting at the operator’s Do not exceed a pressure of 2.1 bar, in accordance
seat. with local regulations.
Never carry out any operation on the machine Do not run the engine in a closed building without
when the engine is running, except when specifi- proper ventilation.
cally indicated. Do not smoke, use open flames, cause sparks in
Stop the engine and ensure that all pressure is re- the nearby area when filling fuel or handling highly
lieved from hydraulic circuits before removing flammable liquids.
caps, covers, valves, etc. Do not use flames as light sources when working
All repair and maintenance operations should be on a machine or checking for leaks.
carried out with the greatest care and attention. Move with caution when working under a Machine,
Service stairs and platforms used in a workshop or and also on or near a Machine. Wear proper safety
in the field should be built in compliance with the accessories:
safety rules in force. helmets, goggles and special footwear.
Disconnect the batteries and label all controls to During checks which should be carried out with the
warn that the Machine is being serviced. Block the engine running, ask an assistant to sit at the oper-
machine and all equipment which should be ator’s seat and keep the service technician under
raised. visual control at any moment.
Never check or fill fuel tanks and accumulator bat- In case of operations outside the workshop, drive
teries, nor use starting liquid if you are smoking or the machine to a flat area and block it. If working
near open flames as such fluids are flammable. on an incline cannot be avoided, first block the Ma-
Brakes are inoperative when they are manually re- chine carefully. Move it to a flat area as soon as
leased for maintenance purposes. In such cases, possible with a certain extent of safety.
the machine should be kept constantly under con- Ruined or plied cables and chains are unreliable.
trol using blocks or similar devices. Do not use them for lifting or trailing. Always han-
The fuel filling gun should remain always in contact dle them wearing gloves of proper thickness.
with the filler neck. Chains should always be safely fastened. Ensure
Maintain this contact until the fuel stops flowing that fastening device is strong enough to hold the
into the tank to avoid possible sparks due to static load foreseen. No persons should stop near the
electricity buildup. fastening point, trailing chains or cables.
Use exclusively specified towing points for towing The working area should be always kept CLEAN
the machine. Connect parts carefully. and DRY. Immediately clean any spillage of water
Ensure that foreseen pins and/or locks are steadily or oil.
fixed before applying traction. Do not pile up grease or oil soaked rags, as they
Do not stop near towing bars, cables or chains constitute a great fire hazard. Always place them
working under load. into a metal container. Before starting the Machine
To transfer a failed machine, use a trailer or a low or its attachments, check, adjust and block the op-
loading platform trolley if available. erator’s seat. Also ensure that there are no per-
To load and unload the machine from the transpor- sons within the Machine or attachment operating
tation mean, select a flat area providing a firm sup- range.
port to the trailer or truck wheels. Firmly tie the Do not keep in your pockets any object which
machine to the truck or trailer platform and block might fall unobserved into the Machine’s inner
wheels as required by the forwarder. compartments.
SECTION 00 - SAFETY PRECAUTIONS 5
Whenever there is the possibility of being reached dental explosion hazard due to build-up of gasses
by ejected metal parts or similar, use protection relieved during charging.
eye mask or goggles with side guards, helmets, Always disconnect the batteries before performing
special footwear and heavy gloves. Wear suitable any type of service on the electrical system.
protection such as tinted eye protection, helmets,
special clothing, gloves and footwear whenever it HYDRAULIC SYSTEMS
is necessary to carry out welding procedures. All Some fluid slowly coming out from a very small
persons standing in the vicinity of the welding proc- port can be almost invisible and be strong enough
ess should wear tinted eye protection. NEVER to penetrate the skin. For this reason, NEVER USE
LOOK AT THE WELDING ARC IF YOUR EYES YOUR HANDS TO CHECK FOR LEAKS, but use
ARE NOT SUITABLY PROTECTED. a piece of cardboard or a piece of wood for this
Metal cables with the use get frayed. Always wear purpose. If any fluid is injected into the skin, seek
adequate protections (heavy gloves, eye protec- medical aid immediately. Lack of immediate medi-
tion, etc.). cal attention, serious infections or dermatitis may
Handle all parts with the greatest caution. Keep result.
your hands and fingers far from gaps, moving Always take system pressure readings using the
gears and similar. Always use approved protective appropriate gauges.
equipment, such as eye protection, heavy gloves
and protective footwear. WHEELS AND TYRES
Check that the tyres are correctly inflated at the
START UP
pressure specified by the manufacturer. Periodi-
Never run the engine in confined spaces which are cally check possible damages to the rims and
not equipped with adequate ventilation for exhaust tyres.
gas extraction. Keep off and stay at the tyre side when correcting
Never bring your head, body, arms, legs, feet, the inflation pressure.
hands, fingers near fans or rotating belts. Check the pressure only when the machine is un-
loaded and tyres are cold to avoid wrong readings
ENGINE due to over-pressure. Do not reuse parts of recov-
Always loosen the radiator cap very slowly before ered wheels as improper welding, brazing or heat-
removing it to allow pressure in the system to dis- ing may weaken the wheel and make it fail.
sipate. Coolant should be topped up only when the Never cut, nor weld a rim with the inflated tyre as-
engine is stopped or idle if hot. sembled.
Do not fill up fuel tank when the engine is running, To remove the wheels, block both front and rear
mainly if it is hot, to avoid ignition of fires in case of Machine wheels. Raise the Machine and install
fuel spilling. safe and stable supports under the Machine in ac-
Never check or adjust the fan belt tension when the cordance with regulations in force.
engine is running. Never adjust the fuel injection Deflate the tyre before removing any object caught
pump when the machine is moving. into the tyre tread.
Never lubricate the machine when the engine is Never inflate tyres using flammable gases as they
running. may originate explosions and cause injuries to by-
standers.
ELECTRICAL SYSTEMS
If it is necessary to use auxiliary batteries, cables REMOVAL AND INSTALLATION
must be connected at both sides as follows: (+) to Lift and handle all heavy components using lifting
(+) and (-) to (-). Avoid short-circuiting the termi- equipment of adequate capacity. Ensure that parts
nals. GAS RELEASED FROM BATTERIES IS are supported by appropriate slings and hooks.
HIGHLY FLAMMABLE. During charging, leave the Use lifting eyes provided to this purpose. Take
battery compartment uncovered to improve venti- care of the persons near the loads to be lifted.
lation. Avoid checking the battery charge by Handle all parts with great care. Do not place your
means of “jumpers” made by placing metallic ob- hands or fingers between two parts. Wear ap-
jects across the terminals. Avoid sparks or flames proved protective clothing such as safety goggles,
near the battery area. Do not smoke to prevent ex- gloves and footwear.
plosion hazards. Do not twist chains or metal cables. Always wear
Prior to any service, check for fuel or coolant leaks. protection gloves to handle cables or chains.
Remove these leaks before going on with the work.
Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent acci-
6 SECTION 00 - SAFETY PRECAUTIONS
Helpful hints
Avoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
In general, avoid skin contact with all fuels, oils, ac-
ids, solvents, etc.
Most of them contain substances which can be
harmful to your health.
Modern oils contain additives. Do not burn contam-
inated fuels and/or waste oils in ordinary heating
systems.
Avoid spillage when draining off used engine cool-
ant mixtures, engine, transmission and hydraulic
oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubri-
cants. Store them safely until they can be disposed
of in a proper way to comply with local legislation
and available resources.
Modern coolant mixtures, i.e. antifreeze and other
additives, should be replaced every two years.
They should not be allowed to get into the soil but
should be collected and disposed of safely.
Do not open the Air-Conditioning system yourself.
It may contain gases which should not be released
into the atmosphere. Your air conditioning special-
ist has special equipment for discharging and
charging the system.
Repair any leaks or defects in the engine cooling or
hydraulic system immediately.
Do not increase the pressure in a pressurized cir-
cuit as this may lead to a catastrophic failure of the
system components.
Protect hoses during welding as penetrating weld
chips may burn a hole or weaken them, causing
the loss of oils, coolant, etc.
LB90.B
LB95.B
LB110.B
LB115.B
SECTION 01 - MAINTENANCE
2 SECTION 01 - MAINTENANCE
SECTION 01 - MAINTENANCE 3
All maintenance and repair operations described in Ballooning of the hose indicates an internal leakage
this manual should be carried out exclusively by au- due to structural failure. This condition rapidly dete-
thorized workshops. All instructions detailed should riorates and total hose failure soon occurs.
be carefully observed and special equipment indi- Kinked, crushed, stretched or deformed hoses gen-
cated should be used if necessary. erally suffer internal structural damage which can
Everyone who carries out service operations de- result in oil restriction, a reduction in the speed of
scribed without carefully observing these prescrip- operation and ultimate hose failure.
tions will be directly responsible of deriving Free-moving, unsupported hoses must never be al-
damages. lowed to touch each other or related working surfac-
es. This causes chafing which reduces hose life.
GENERAL
Clean the exterior of all components before carrying O-RING FLAT FACE SEAL FITTINGS
out any form of repair. Dirt and dust can reduce the When repairing O-ring face seal connectors, the fol-
efficient working life of a component and lead to lowing procedures should be observed.
costly replacement.
Time spent on the preparation and cleanliness of WARNING
working surfaces will pay dividends in making the Never disconnect or tighten a hose or tube that is
job easier and safer and will result in overhauled under pressure, if in doubt, actuate the operating le-
components being more reliable and efficient in op- vers several times with the engine switched off prior
eration. Use cleaning fluids which are known to be to disconnecting a hose or tube.
safe. Certain types of fluid can cause damage to O-
rings and cause skin irritation. Solvents should be Release the fittings and separate the hose or tube
checked that they are suitable for the cleaning of assembly, then remove and discard the O-ring seal
components and also that they do not risk the per- from the fitting.
sonal safety of the user. Dip a new O-ring seal into clean hydraulic oil prior to
Replace O-rings, seals or gaskets whenever they installation. Install a new O-ring into the fitting and,
are disturbed. Never mix new and old seals or O- if necessary, retain in position using petroleum jelly.
rings, regardless of condition. Always lubricate new Assemble the new hose or tube assembly and tight-
seals and O-rings with hydraulic oil before installa- en the fitting finger tight, while holding the tube or
tion. hose assembly to prevent it from turning.
When replacing component parts, use the correct Use two suitable wrenches and tighten the fitting to
tool for the job. the specified torque according to the size of the fit-
ting.
HOSES AND TUBES
Always replace hoses and tubes if the cone end or NOTE: to ensure a leak-free joint is obtained, it is
the end connections on the hose are damaged. important that the fittings are not over or under
When installing a new hose, loosely connect each torqued.
end and make sure the hose takes up the designed
position before tightening the connection. Clamps
should be tightened sufficiently to hold the hose SHIMMING
without crushing and to prevent chafing. At each adjustment, select adjusting shims, meas-
After hose replacement to a moving component, ure them individually using a micrometre and then
check that the hose does not foul by moving the sum up recorded values.
component through the complete range of travel. Do not rely on measuring the whole shimming set,
Be sure any hose which has been installed is not which may be incorrect, or on rated value indicated
kinked or twisted. for each shim.
Hose connections which are damaged, dented,
crushed or leaking, restrict oil flow and the produc- ROTATING SHAFT SEALS
tivity of the components being served. Connectors To correctly install rotating shaft seals, observe the
which show signs of movement from the original following instructions:
swagged position have failed and will ultimately sep- let the seal soak into the same oil as it will seal for
arate completely. at least half an hour before mounting;
A hose with a chafed outer cover will allow water en- thoroughly clean the shaft and ensure that the
try. Concealed corrosion of the wire reinforcement shaft working surface is not damaged;
will subsequently occur along the hose length with
resultant hose failure.
4 SECTION 01 - MAINTENANCE
place the sealing lip towards the fluid. In case of a NOTES FOR SPARE PARTS
hydrodynamic lip, consider the shaft rotation direc- Only genuine parts guarantee same quality, life,
tion and orient grooves in order that they deviate safety as original components as they are the same
the fluid towards the inner side of the seal; as mounted in production. Only the genuine spare
coat the sealing lip with a thin layer of lubricant (oil parts can offer this guarantee.
rather than grease) and fill with grease the gap be- All spare parts orders should be complete with the
tween the sealing lip and the dust lip of double lip following data:
seals; machine model (commercial name) and chassis
insert the seal into its seat and press it down using number;
a flat punch. Do not tap the seal with a hammer or engine type and number;
a drift; part number of the ordered part, which can be
take care to insert the seal perpendicularly to its found on the “Spare Parts Catalogue”, which is the
seat while you are pressing it. Once the seal is set- base for order processing.
tled, ensure that it contacts the thrust element if re-
quired; NOTES FOR EQUIPMENT
to prevent damaging the sealing lip against the
shaft, place a suitable protection during installa- Equipment which proposes and shows in this man-
tion. ual are as follows:
studied and designed expressly for use on compa-
O-RINGS ny machines;
necessary to make a reliable repair;
Lubricate the O-rings before inserting them into their accurately built and strictly tested to offer efficient
seats. This will prevent the O-rings from rolling over and long-lasting working means.
and twisting during mounting which will jeopardize We also remind the repair personnel that having
sealing. these equipment means:
work in optimal technical conditions;
BEARINGS
obtain best results;
It is advisable to heat the bearings to 80 to 90 °C be- save time and effort;
fore mounting them on their shafts and cool them work more safely.
down before inserting them into their seats with ex-
ternal tapping. NOTICES
Wear limits indicated for some details should be in-
SPRING PINS
tended as advised, but not binding values. The
When mounting split socket spring pins, ensure that words “front”, “rear”, “right hand”, and “left hand” re-
the pin notch is oriented in the direction of the effort ferred to the different parts should be intended as
to stress the pin. seen from the operator’s seat oriented to the normal
Spiral spring pins should not be oriented during in- sense of movement of the machine.
stallation.
HOW TO MOVE THE MACHINE WITH THE
HARDWARE TORQUE VALUES BATTERY REMOVED
Check the tightness of hardware periodically. Cables from the external power supply should be
Use the following charts to determine the correct connected exclusively to the respective terminals of
torque when checking, adjusting or replacing hard- the Machine positive and negative cables using pli-
ware on the Backhoe loader. ers in good condition which allow proper and steady
contact.
IMPORTANT: Torque values listed are for general Disconnect all services (lights, wind-shield wipers,
use only. Make sure fastener threads are clean and etc.) before starting the Machine.
not damaged. If it is necessary to check the machine electrical sys-
tem, check it only with the power supply connected.
At check end, disconnect all services and switch the
NOTE: a torque wrench is necessary to properly power supply off before disconnecting the cables.
torque hardware.
LB90.B
LB95.B
LB110.B
LB115.B
SECTION 02 - TECHNICAL
SPECIFICATIONS
1. MODELS ....................................................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
4. LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ................................................................ 9
5. BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ........................................................... 13
6. LIFTING CAPACITIES ................................................................................................................................ 18
7. LOADER BUCKET WITH FORKS DIMENSIONS AND PERFORMANCE................................................. 23
8. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 24
2 SECTION 02 - TECHNICAL SPECIFICATIONS
1.
SECTION 02 - TECHNICAL SPECIFICATIONS 3
1. MODELS
3. TECHNICAL SPECIFICATIONS
ENGINE - IVECO 95 HP - 71 KW MODEL F4GE0454C*D660 (LB90.B - LB95.B)
Power ...................................................................................................................... 95 hp/ 71 kW, turbocharged
Type .......................................................................................................................................................... Diesel
No. of cylinders ................................................................................................................................................. 4
Bore ....................................................................................................................................................... 104 mm
Stroke..................................................................................................................................................... 132 mm
Displacement ....................................................................................................................................... 4500 cm3
Compression Ratio ................................................................................................................................... 17.5:1
Firing Order .............................................................................................................................................. 1.3.4.2
Idle Speed.................................................................................................................................. 850-950 rev/mn
Maximum “No-Load” Speed................................................................................................... 2380-2480 rev/mn
Maximum “Full Load” Speed .................................................................................................. 2225-2275 rev/mn
Maximum Torque (CEE) .........................................................................................................................398 Nm
COOLING SYSTEM
Type .................................................................................................................................. Pressurized Full Flow
Fan Belt Type..................................................................................................................... 8 Groove Serpentine
Fan Belt Tension..................................................................................................................Automatic tensioner
Air Conditioning Compressor Belt.......................................................................................................... Single V
Air Conditioning Belt Tension...................................................................................................................Manual
Thermostat:
Starts to Open at ........................................................................................................................................ 81 °C
Fully Open at.............................................................................................................................................. 96 °C
Radiator Cap.......................................................................................................................................... 0.90 bar
FUEL SYSTEM
Injection Pump Manufacture and Type ............................................................... Bosch Rotary VE 4/12 F1100L
Cold Start Device ............................................................................................................... Optional Grid Heater
Excess Fuel Device ............................................................................................................................ Automatic
Fuel Shut Off......................................................................................................................................... Solenoid
Lift Pump ........................................................................................................................................... Mechanical
Fuel lift pump supply pressure to injection pump.................................................................................... 245 bar
Timing .......................................................................................................................................1 mm lift @ TDC
6 SECTION 02 - TECHNICAL SPECIFICATIONS
TRANSMISSION (LB115.B)
Transmission DANA T16000 POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears
Torque Convertor Ratio............................................................................................................................. 2.54:1
ELECTRICAL SYSTEM
Alternator Type............................................................................................................ BOSCH NCBI 28 90 amp
Battery Type......................................................................................... 95 amp hr (12V/900 CCA) SAE - Single
............................................................................................................ 60 amp hr (12V/600 CCA) SAE - Double
Battery Disconnect via the Isolator Switch ................................................................ on Negative/chassis cable
Regulator.......................................................................................................................................Transistorized
Ground (Earth) ...................................................................................................................................... Negative
Starting Motor......................................................................Positive Engagement, Solenoid Operated (2.7 kW)
BRAKES
Type ............................................................................................ Wet Multi-Discs x8 per Axle (x4 per half Axle)
Disc Diameter...................................................................................................................................... 203.2 mm
Parking Type .................................................................................................................. Single disc on driveline
STEERING
Power Steering Type......................................................................................................................... Hydrostatic
Power Steering Displacement 2WS ....................................................................................................125 cc/rev
Power Steering Displacement 4WS ....................................................................................................160 cc/rev
Turns Lock to Lock 2WD + 4WD.........................................................................................Left 3.25; Right 3.25
System Pressure............................................................................................................................... 177 ± 3 bar
FRONT AXLE
Type (2WD)...................................................................................................... CARRARO mod. 26.00 steering
Type (4WD)........................................................................... CARRARO mod. 26.16 steering, single reduction
Type (4WS) ........................................................................... CARRARO mod. 26.28 steering, single reduction
REAR AXLE
Type (2WS) .............................................................................................. Double Reduction, Inboard Planetary
Type (4WS) .......................................................................... CARRARO mod. 26.32 steering, double reduction
Differential Lock (Powershuttle Transmission) .................................................................................. Mechanical
Differential Lock (Powershift Transmission)....................................................................... Electrically Operated
HYDRAULIC SYSTEM
Hydraulic pump:
- Manufacturer .................................................................................................................................... CASAPPA
- Type ...........................................................Twin Gear Pump; Hydraulic System and Priority Steering System
- 95HP Model ....................................................................................................................... KP30.34-0556-LMF
- 110HP Model .....................................................................................................................KP30.38-0556-LMF
Pump Displacement:
- 95 HP ..................................................................................................... 35.427 + 35.427 cm3/rev (34 + 34 cc)
- 110 HP ................................................................................................... 40.258 + 35.427 cm3/rev (38 + 34 cc)
Hydraulic System Pressure:
Main Relief Valve Pressure............................................................................................................206 - 210 bar
Stabilizer Relief Valve Pressure .....................................................................................................196 - 202 bar
SECTION 02 - TECHNICAL SPECIFICATIONS 7
FRONT COUNTERWEIGHT
Weight ....................................................................................................................................................225.4 kg
Weight (extra counterweight) ...................................................................................................26.2 kg + 31.5 kg
Weight (LB115.B)......................................................................................................................................170 kg
RADIATOR COOLANTS
Anti-freeze should be changed every 2000 hours or 24 months.
In order to reduce deposits and corrosion, water in the cooling system should not exceed the following limits:
Total hardness ................................................................................................................... 300 parts per million
Chloride............................................................................................................................... 100 parts per million
Sulphates ............................................................................................................................ 100 parts per million
NOISE LEVEL
Certified by the manufacturer.
In accordance with European directive 2000/14/EC - Stage II.
Internal noise level (LpA) .................................................................................................................. 77 decibels
External noise level (LwA) (LB90.B - LB95.B) ................................................................................ 102 decibels
External noise level (LwA) (LB110.B - LB115.B) ............................................................................ 103 decibels
VIBRATION LEVEL INSIDE THE CAB
Upper members ........................................................................................................... level lower than 2.5 m/s²
Abdomen...................................................................................................................... level lower than 0.5 m/s²
LOADER BUCKETS
BACKHOE BUCKETS
TYRES - 2WS
TYRES - 4WS
6. LIFTING CAPACITIES
The following tables reflect the lifting capacities of the backhoe dipper (A) and boom (B) on a typical 4WD ma-
chine.
LB115.B
(A) Reach Full Height................................2350 mm
(B) Reach Ground Level ...........................2700 mm
(C) Lift Height ............................................3458 mm
(D) Lift Height ............................................3040 mm
Fork Spacing - Minimum centres ................275 mm
Fork Spacing - Maximum centres .............1773 mm
Fork Length ...............................................1026 mm
Fork Width.....................................................80 mm
24 SECTION 02 - TECHNICAL SPECIFICATIONS
1.3 OVERHAUL
1.4 INSPECTION
(See section “TRANSMISSION” chapter “TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST
POINTS” at page 18)
SECTION 17 - TORQUE CONVERTERS 7
Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the torque converter and is the primary component which starts the oil flow-
ing to the other components which results in torque multiplication. This element can be compared to a centrif-
ugal pump in that it picks up fluid at its centre discharges at its outer diameter. The torque converter turbine is
mounted opposite the impeller and is connected to the turbine shaft or clutch shaft. This element receives fluid
at its outer diameter and discharges at its centre. The stator of the torque converter is located between and at
the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is
exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation
into the impeller element. This recirculation will make the converter to multiply torque. The torque multiplication
in function of following elementes, impeller, turbine and stator, and the converter output speed (turbine speed).
The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is
at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multipli-
cation is increasing. In the impeller cover a splined shaft is fitted which runs inside and through the turbine shaft
to drive a hydraulic pump which is fitted at the back of the transmission. Since the shaft is connected to the
centre of the impeller cover, the pump speed will be the same as engine speed. The rear side of the impeller
cover has a tanged drive which drives the transmission charging pump located in the converter housing. The
transmission charging pump speed is also the same as the engine speed.
(See section “TRANSMISSION” chapter “PRESSURE SPECIFICATIONS AND CHECK POINTS” at page 106)
8 SECTION 17 - TORQUE CONVERTERS
Hydraulic tests
Tachometer setting .......................................................................................................................2200 revs/min
Test temperature, oil ............................................................................................................................. 82-93 °C
Torque converter relief valve..................................................................................................................... 10 bar
Oil temperature converter out:
Normal operating range .............................................................................................................. 80-90 °C
Maximum temperature ................................................................................................................... 120 °C
2.3 OVERHAUL
2.4 INSPECTION
DISASSEMBLY
Remove drive plate screws.
ASSEMBLY
Install converter assembly on input shaft.
(See section “TRANSMISSION” chapter “PRESSURE SPECIFICATIONS AND CHECK POINTS” at page 106)
LB90.B
LB95.B
LB1ï0.B
LB115.B
SECTION 21 - TRANSMISSION
GEAR RATIO
Forward Reverse
1 2 3 4 1 2 3 4
4.824 2.998 1.408 0.792 4.020 2.496 1.173 0.660
DETENT SPRING
Free length (Approximately)................................................................................................................ 42.06 mm
4 SECTION 21 - TRANSMISSION
END FLOAT
Input forward Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Input reverse Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Output shaft................................................................................................................ 1st Gear - 0.33-0.508 mm
.................................................................................................................................. 2nd Gear - 0.35-0.558 mm
...................................................................................................................................3rd Gear - 0.38-0.838 mm
...................................................................................................................................4th Gear - 0.20-0.558 mm
Four Wheel Drive Shaft............................................................................................................... 0.050-0.28 mm
Bearing End Floats.................................................................................................................... 0.025-0.076 mm
Bearing End Float Shims available ................................................... 0.050/0.076/0.127/0.177/0.381/0.508 mm
HYDRAULIC TESTS
Tachometer setting .......................................................................................................................2000 revs/min
Test temperature, oil ............................................................................................................................. 80-85 °C
Cold Start Valve (For reference only)........................................................................................................ 26 bar
System Pressure Test.................................................................................................................... 13.7-15.2 bar
Torque Converter ...................................................................................................................................7-11 bar
Reverse Clutch...............................................................................................................................13.7-15.2 bar
Forward Clutch...............................................................................................................................13.7-15.2 bar
Four Wheel Drive Supply ...............................................................................................................13.7-15.2 bar
Strainer bolts.................................................................................................................................... 18 to 31 Nm
Pump retaining bolts ........................................................................................................................ 18 to 31 Nm
Output Yoke bolts ............................................................................................................................ 68 to 88 Nm
Pressure test plugs .......................................................................................................................... 41 to 54 Nm
Main transmission case bolts........................................................................................................... 45 to 64 Nm
Shift detent plug ...............................................................................................................................41 to 54 Nm
Shift fork screws...............................................................................................................................18 to 25 Nm
Shift lever assembly screws.............................................................................................................16 to 24 Nm
Drain plugs....................................................................................................................................... 34 to 54 Nm
Relief valve ......................................................................................................................................23 to 30 Nm
Pressure regulator valve .................................................................................................................. 46 to 60 Nm
Cold start valve ................................................................................................................................46 to 60 Nm
4WD solenoid valve spool................................................................................................................20 to 27 Nm
4WD Solenoid coil retaining nut ............................................................................................................... 5.4 Nm
Control valve retaining screws ....................................................................................................... 6.8 to 8.5 Nm
4WD hydraulic pipe connections.................................................................................................. 6.8 to 10.2 Nm
Filter housing bolts...........................................................................................................................45 to 64 Nm
Oil filter ...............................................................................................................................................7 to 10 Nm
Temperature sender ........................................................................................................................ 20 to 27 Nm
RECOMMENDED SEALANTS
Transmission case joint ................................................................................................................... Loctite 5203
4WD Output gear ...............................................................................................................................Loctite 649
4WD gear (Permanent 4WD assy) .................................................................................................... Loctite 649
4WD clutch supply pipe ..................................................................................................................... Loctite 542
Gear lever housing...................................................................................................................Loctite 5900 RTV
Shimming access plug ....................................................................................................................... Loctite 649
6 SECTION 21 - TRANSMISSION
1. GEAR LEVER: Four gears are selectable for the 5. TRANSMISSION SHUTTLE DIRECTION LE-
required ground speeds in both forward or re- VER: Movement of this lever from the neutral
verse travel. position will engage forward or rearward travel.
2. TRANSMISSION DISCONNECT BUTTON: Prior
to changing gear depress and hold down this NOTE: in reverse gear an audible alarm device
switch which disengages transmission drive, se- sounds.
lect the required gear with the gear lever and re-
lease the switch to re-engage drive. 6. WARNING HORN BOTTON
3. LOADER ATTACHMENT CONTROL LEVER 7. TRANSMISSION DISCONNECT BUTTON (on
4. MECHANICAL DIFFERENTIAL LOCK PEDAL: the loader attachment control lever)
Depressing this pedal will lock both rear wheels 8. ROLLER FOR THE PROPORTIONAL CON-
together giving equal drive and will disengage TROL OF LOADER BUCKET 4X1
when wheel torque equalizes or foot brakes are
applied.
SECTION 21 - TRANSMISSION 7
Transmission
The transmission is fully synchronized 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 shuttle lever (4) enables shifts be-
tween forward and reverse travel without
disengaging gear ratios.
A device for “transmission decoupling” activates by
pushing button (2), placed on the gear shift lever (1)
or by pushing button (5), placed on the loader control
lever (3).
WARNING
Always apply the parking brake whenever the ma-
chine is parked as the machine is free to roll even
though the transmission gearshift lever and power
reversing lever may be “In Gear” and the engine is
turned “OFF”.
Transmission Disconnect
The 4 x 4 transmission provides for easy upward and
downward gear ratio changes on the move. Howev-
er, as a clutch is not used between the engine and
transmission, the power flow from the engine to the
transmission must be interrupted to shift from one
gear ratio to another. This is accomplished by using
a transmission disconnect (dump) button.
The finger operated button (2) on the main gearshift
lever knob (1) is easy to operate.
WARNING
To avoid personal injury do not use the disconnect
switch control to coast down hill. Excessive speed
may cause loss of control, personal injury to a by-
stander or failure of the transmission.
SECTION 21 - TRANSMISSION 9
WARNING
Never use the differential lock at speeds above 8 km/h
or when turning the machine.
When engaged the lock will prevent the machine turn-
ing and personal injury could result.
SECTION 21 - TRANSMISSION 11
1.4 LUBRICATION
To ensure proper lubrication and operating temperatures it is most important that appropriate lubricants are
used and that the correct oil level is maintained.
Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the
churning action of the gears. Early breakdown of the oil will result in heavy sludge deposits that block oil ports
and build up on splines and bearings. Overfilling may also cause oil leaks.
Oil changes
An initial oil change and flush is recommended after the transmission is placed in actual service.
This change should be made at any time following 50 hours in service, but should not exceed 100 hours.
When changing the oil it is essential to renew the oil filter and clean out the suction strainer.
The object in draining the oil is to eliminate possible bearing surface abrasion and attendant wear. Minute par-
ticles of metal, the result of normal wear in service are deposited in and circulated with the oil. Oil changes are
best carried out when the transmission is thoroughly warm.
WARNING
To prevent oil starvation and possible seizure of the transmission whilst towing the vehicle, it is imperative that
the propeller shafts are disconnected.
Failure to observe this precaution may result in extensive damage to the transmission.
Suggested oil:
10W or 10W30 Grade mineral oils or automatic transmission fluids which meet at least one of the following
specifications are allowable for use in ambient temperatures of between -20 and 40 Deg.C:
Ambra Multi G NH 410 B.
12 SECTION 21 - TRANSMISSION
Úîççêé
Pressure oil
Disengaged
Lubrication
SECTION 21 - TRANSMISSION 13
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SECTION 21 - TRANSMISSION 17
OIL FLOW SOLENOID CONTROL VALVE OPERATION (FORWARD DRIVE ONLY SHOWN)
The solenoid valve when in neutral position dead
heads the oil flow at the spool (1) from the supply ï
port and no oil is allowed to pass through the valve.
Therefore the oil in the galleries beyond the spool at
the fill time metering valve (2) remains static.
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NOTE: the control valve also includes a pressure Regulated Pressure Oil
regulating (feathering) valve and a fill time metering Return Oil
valve for the reverse clutch pack. Pressure Oil
18 SECTION 21 - TRANSMISSION
1. Cold Start oil pressure relief valve 10. Torque converter pressure regulating valve
26 bar reference only 7-11 bar
2. Forward Solenoid valve 11. Oil in from cooler, test port
13.7-15.2 bar 3.5 bar
3. Test port for reverse clutch pack 12. Backhoe Boom Lock supply
13.7-15.2 bar 13.7-15.2 bar
4. Test port for forward clutch pack 13. System pressure test point
13.7-15.2 bar 13.7-15.2 bar
5. System pressure sequencing valve 14. Converter pressure oil test port
13.7-15.2 bar 7-11 bar
6. Oil flow OUT to cooler 15. Front Wheel Drive Solenoid
7. Oil OUT to cooler, test port 13.7-15.2 bar
6.5 bar 16. Oil Filter
8. Front Wheel Drive test point 17. Reverse Solenoid valve
13.7-15.2 bar 13.7-15.2 bar
9. Oil flow IN from cooler
SECTION 21 - TRANSMISSION 19
Power flow for all four reverse gear ratios is the same
as for all four forward gear ratios except that the rear
clutch (4) is engaged to transmit power to the reverse
idler gear. The reverse idler gear in turn transmits
power to the gear on the countershaft and in turn
transmits power to the output shaft.
Úîççèð
Input Output
Intermediate
SECTION 21 - TRANSMISSION 21
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24 SECTION 21 - TRANSMISSION
Úîéëïï
SECTION 21 - TRANSMISSION 25
Úîéëïî
SECTION 21 - TRANSMISSION 27
28 SECTION 21 - TRANSMISSION
1. Solenoid Retainer
2. Dirt Seal 12. Circlip
3. Solenoid 13. Clutch fill metering valve
4. Washer 14. Spring
5. Solenoid Body 15. Spool
6. Guide 16. Piston Clutch fill
7. Spring 17. Spring
8. Solenoid Pin 18. Retainer
9. Seal 19. Spring
10. Support Body Solenoid 20. Seal
11. End Cap 21. End Plug
SECTION 21 - TRANSMISSION 31
TRASMISSION DISASSEMBLY
Invert the transmission on a suitable bench.
For convenience the bench top should have a hole
in it to accommodate the input shaft and pump. Re-
move 3 screws and withdraw the gear shift lever as-
sembly.
Invert the shaft and refit the 3rd gear, synchro hub
and circlip.
SECTION 21 - TRANSMISSION 55
Invert the shaft and refit the two needle bearings and
spacer as shown.
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 is re-
corded.
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. 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 dum-
my 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.
Check that the interlock ball is correctly positioned in
between the two rails.
Refit the 4th gear lock out screw, (when this feature
is not required a shorter blanking screw is fitted). On
some applications an additional sealing plug may be
fitted.
TEST PORT
The transmission oil, should be at an approximate
temperature of 80 °C during pressure tests.
All pressure test ports have a 9/16” UNF thread.
Forward, reverse and 4WD clutch pack pressures
should not be more than 1 bar lower than the oil
pump pressure.
PARKING BRAKE
The caliper assembly is mounted directly onto the
rear face of the transmission housing.
1. Mounting face
2. Locknut
3. Mounting bolt
4. Outer locknut
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A. Adjust the two mounting bolts and locknuts to
leave a 0.25/1.50 mm gap between the locknut
and sleeve.
Then torque locknuts against mounting surface
to 155 Nm.
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.
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IMPORTANT:
BRAKE PAD: the minimum acceptable thickness of
the brake pads is 2.286 mm.
BRAKE DISK: the nominal thickness of the disk is
9.5 mm.
The maximum total wear limit for the disk is 1.524
mm.
Based on the nominal thickness of 9.5 mm this
would give a minimum thickness of 7.976 mm.
SECTION 21 - TRANSMISSION 89
FAULT CAUSE
Transmission fails to drive in Low or no pump pressure.
either direction Low or no oil in transmission.
Mechanical failure in transmission.
Worn or broken input shaft sealing rings.
Pressure regulator valve faulty.
Direction control valve not operating.
Blockage in oil ports restricting flow.
Transmission drives in one Low oil pressure on one clutch pack due to leaks.
direction only Clutch piston seals worn or damaged.
Clutch pack excessively worn.
Direction valve or coil faulty.
Mechanical failure in transmission.
Blockage in oil ports restricting flow.
Worn or damaged input shaft sealing ring.
Delay in taking up drive Low converter pressure.
Low oil level.
Low clutch pressure.
Faulty modulation in direction control valve.
Blockage in direction valve.
Blockage in oil ports restricting flow.
No drive from 4WD 4WD solenoid valve or coil not operating.
Mechanical failure in transmission.
Low 4WD clutch pack pressure.
4WD clutch pack worn.
Transmission overheating Oil level too high or low.
Restriction in cooler flow.
Low oil pressure.
Clutch packs slipping due to low pressure or wear.
Mechanical failure in transmission.
Excessive stall operation.
Operating in too high of gear Shift to lower gear.
range for conditions
Difficult gear selection Forward or reverse clutch pack pressurized when not selected.
Direction valve faulty.
Input shaft sealing rings leaking.
Mechanical failure in transmission.
Forward or reverse clutch pack not releasing due to mechanical failure.
Vehicle moves with direction See “Difficult gear selection”.
valve in neutral position
High stall speed Low oil level. Air in oil.
Clutch plates slipping due to low pressure or wear.
Torque converter faulty.
Converter relief valve faulty.
Incorrect torque converter fitted.
Low stall speed Poor engine performance.
Torque converter defective.
Incorrect torque converter fitted.
SECTION 21 - TRANSMISSION 91
FAULT CAUSE
Noise Vehicle driveline problem:
Axles, propshafts, engine, engine mounts.
Misalignment of transmission/engine.
Bearings worn or damaged.
Gear teeth damaged or broken.
Excessive end float of shafts or gears.
Clutch plate failure forward, reverse or 4WD.
Incorrect grade of oil in transmission.
Low oil level.
Gear or thrust washer beginning to seize.
Difficult gear selection Shift rods worn or bent.
Shift forks worn, loose or twisted.
Synchronizer assemblies worn or damaged.
Clutch pack not releasing due to mechanical fault.
Clutch pack not releasing due to hydraulic fault.
Gear shift stub lever worn or damaged.
Incorrect grade of oil in transmission.
Low oil level.
Jumping out of gear Detent springs worn or broken.
Synchronizer or gear dog teeth worn or damaged.
Synchronizer assemblies worn or damaged.
Shift forks worn, loose or twisted.
Restriction or wear in gear linkage or stub lever assy.
not allowing gears to be fully selected.
Excess end float on output shaft assembly or gears.
SECTION 21 - TRANSMISSION 93
Úîééïè
HYDRAULIC SPECIFICATIONS
Suitable for operation from ambient to 120 °C continuous operating temperature.
Must withstand a 20 bar continuous pressure and a 40 bar variable pressure.
Conform SAE J1019 and SAE J517, 100RI.
BOLT TORQUES
Output flanges............................................................................................................................... 339 - 407 Nm
Filter torque ....................................................................................................................................... 30 - 38 Nm
Control valve, connector nut to cover.................................................................................................... 6 - 8 Nm
ELECTRICAL SPECIFICATIONS
Solenoid (forward reverse, high/low, 2nd/1st, modulation, disconnect) coil resistance........... 28 ± 2 at 20 °C
Electronic controlled modulation valve, coil resistance ...................................3.55 Ohm ± 0.25 Ohm at 20 °C
Speed sensor:
- type ................................................................................. magneto resistive sensor with 7/14 mA current loop
- frequency ......................................................................................................................................0 - 25000 Hz
- sensing distance .............................................................................................................................. 0 - 2.5 mm
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 the T and N LED’s are displayed simultaneously
to indicate that a reset has taken place.
If no critical faults are active the microprocessor se-
lects N2 and goes to the Neutral lock state. See
“Driving with Powershift” chapter.
Limp home:
If a fault is detected at power up the limp home facil-
ity is automatically selected.
Selecting Neutral
At power up, “Neutral and 2nd Gear” are automati-
cally selected regardless of the Powershift lever po-
sition (1). The LED-2 and the N-LED are illuminated
RED, (neutral 2nd), the microprocessor is in a neu-
tral lock state.
If after driving, neutral is selected and the shift lever
stays in neutral for more than 3 seconds the micro-
processor automatically defaults to the neutral lock
state for safety. In neutral an automatic shift routine
takes effect to prevent damage to the transmission
due to overspeeding.
Leaving Neutral
A feature of the Powershift lever is the neutral lock
state, which does not allow forward or reverse direc-
tion drive to be selected. This feature prevents the
machine accidentally moving should the lever be
knocked into forward or reverse. To leave the neutral
lock state, you select drive direction followed by an
upshift by rotating the shift lever.
Selecting Forward
To select forward travel push the lever away from
you and the LED will illuminate green.
Selecting Reverse
To select reverse travel pull the lever towards you
and the reverse LED will illuminate orange.
Upshifting
Upshifting to a desired gear from neutral is achieved
by twisting the handgrip counter clockwise (+) in sin-
gle movements. If held in this position the processor
will advance the shift selection from 2 through to 4 in
1.8 sec intervals.
Downshifting
WARNING
If descending down a steep incline select 2nd and
proceed, upshifting only when safe to do so. You can
not downshift to reduce speed if the machine speed
is above 15 km/h.
Direction Changes
Changing driving direction is achieved simply by
shuttling the Powershift lever between forward and
reverse and vice versa which is allowed at any time.
The system response however depends on machine
speed and currently engaged gear. When driving in
1st or 2nd gear direction changes are unrestricted
and are granted immediately.
F1 - R1 F2 - R2
R1 - F1 R2 - F2
Transmission Powershift
In the previous paragraphs shift changes have been
shown as precise movements and twist actions of
the Powershift lever. However the transmission can
change gear automatically in forward or reverse as
described in the following paragraph:
Select forward and 4th gear on the Powershift lever
and with the handbrake released apply pressure to
the foot accelerator. As the engine revs and machine
speed increase the transmission will start from 2nd
gear and change up through 3rd and 4th gears up to
maximum road speed.
When you require to slow down or stop release the
foot accelerator and apply the foot brake, the trans-
mission will automatically downshift through 4th, 3rd
and 2nd gear as the machine speed decreases.
Once stopped apply the handbrake and neutral will
be selected by the microprocessor.
To select drive again, simply twist the handgrip to se-
lect 4th and with the handbrake released apply pres-
sure to the foot accelerator.
Kick Down
The kick down facility (2nd to 1st gear only) on this
transmission increases torque instantly to the driving
wheels and hence pushing power. For example
when the loader is pushing into a pile and more
torque is required at the wheels.
This is achieved by the instant gear change from 2nd
to 1st by the use of the button (1) without the need to
use the twist grip on the Powershift lever.
Transmission Disconnect
The disconnect feature is useful when loading, for
example; when pushing the loader into a pile and you
have sufficient dirt in the bucket press the disconnect
switch which disengages the transmission and al-
lows the full power of the engine to be directed to the
hydraulic oil pump.
Disconnect is available in 1st and 2nd gear.
Speed Ranges
The microprocessor controlling the Powershift trans-
mission is pre-programmed to control the speed at
which the gear changes take place.
This effectively protects the transmission from ex-
cess forces, should gear changes be selected at
higher speeds than is desirable.
Shown in the chart opposite with an 18.4 X 26 R4
tyre fitted is the approximate (within 10%) maximum
speed available and at which speed an automatic
shift takes place in each gear.
(...) = Automatic upshift speed
[...] = Automatic downshift speed
As can be seen when downshifting from 4th gear at
maximum speed 39.5 km/h the microprocessor will
not allow the downshift to take place until the speed
has lowered to approximately 19.9 km/h.
Refer to the chart for complete upshift and downshift
speed change details.
2.3 LUBRICATION
Daily
Check oil level daily with engine running at idle (600
rpm) and oil at 82 - 93 °C.
Maintain oil level at full mark.
Normal operating temperature 70 - 120 °C Filter by-pass valve set at 4.1 - 5 bar (*).
measured at temperature check port to cooler.
Lube pressure (*) 0.3 - 0.5 bar at 47 l/min pump flow
Maximum allowed transmission temperature 120 (±1800 rpm).
°C.
Internal leakage (*) 1.5 - 3.0 l/min for each clutch.
Transmission regulator pressure (*) - (neutral 2nd Maximum total leakage 6.8 l/min (1.8 GPM) (clutch
speed). leakage + range + converter leak + valve leak) with-
at 600 rpm: 16.5 bar. out disconnect clutch.
at 2200 rpm: 19.6 - 23.1 bar.
Safety valve: cracking pressure (*) 9,5 - 10,5 bar
Pump flow (*)
at 2200 rpm in neutral 2nd speed: 64.9 l/min To cooler (converter out) pressure (*) 2 bar mini-
minimum. mum at 2000 rpm and maximum 5 bar at no load
at 2200 rpm in reverse 1st, 2nd, forward 1st, 2nd governed speed.
maximum 3 l/min less than in neutral 2nd.
at 2200 rpm in forward 3rd and 4th: maximum Converter by-pass valve set at 5 - 7 bar (*).
5l/min less than in neutral 2nd.
(*) All pressures and flows to be measured with oil
Clutch pressures (*) at 2200 rpm: temperature of 82 - 93 °C.
18.1 - 21.5 bar clutch activated.
0 - 0.2 bar clutch released.
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Temperature check port
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.
The pressure regulating valve maintains pressure for the control valve and clutches at 20 bar.
Excess oil volume is bled off into the converter circuit. A safety valve is fitted between the pressure regulator
and converter.
The valve will open if pressure in this line becomes higher than 10 bar.
After entering the converter the oil is directed through the converter blade cavity and exits in the passage be-
tween the turbine shaft and pump drive shaft and flows to the cooler.
After leaving the cooler the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates and cools the transmission bearings and clutches.
The oil then gravity drains back to the transmission sump.
Across the converter and oil cooler is a converter by-pass valve which will open if the pressure difference is
higher than 4 bar (during start up from cold or at high rpm).
SECTION 21 - TRANSMISSION 111
Úîééîí
pressure through tubes and passages to the select- The input or directional clutches
ed clutch shafts.
Oil seals are located on the clutch shafts.
These rings direct the oil through a drilled passage
in the shaft to the desired clutch.
Pressure of the oil forces the piston and discs
against the back up plate.
The discs with splines on the outer diameter clamp-
ing against discs with teeth on the inner diameter en-
ables the drum and hub to be locked together and
allows them to drive as one unit.
When the clutch is released, a return spring will push
the piston back and oil will drain back via the control
valve into the transmission sump.
The T16000 transmission has one reverse clutch
and two forward clutches (forward low and forward
high).
This in combination with the two range clutches re-
sult in the transmission having 4 forward speeds and
2 reverse speeds.
The engagement of the directional clutches is modu-
lated; which means that clutch pressure is built up
gradually.
This will enable the unit to make forward, reverse
shifts while the vehicle is still moving and will allow
smooth engagement of drive.
The modulation is controlled electronically in the
control valve.
114 SECTION 21 - TRANSMISSION
Úîééîê
Úîééîé
that a curve from 0 to 20 bar is available for the di- The transmission controls
rectional clutches.
Between the electronic modulation valve and the
booster is an accumulator to damper any hydraulic
vibration.
When forward is selected the electronic modulation
valve and the forward solenoid are activated.
The pilot pressure of the forward solenoid will move
the shift spool so that a forward clutch can be fed
with modulated pressure.
If the high/low solenoid is not activated the forward
high clutch is engaged, if it is activated the forward
low clutch is engaged.
When reverse is selected the electronic modulation
valve and the reverse solenoid are activated, the pi-
lot pressure of the reverse solenoid will move the
shift spool so that the reverse clutch can be fed with
modulated pressure.
The shift spools from forward and reverse are locat-
ed against each other with a return spring in be-
tween; this is to make sure that only one direction
can be selected.
Range is selected as follows:
if the range solenoid (2nd/1st) is not activated, regu-
lated pressure is fed through the modulation shift
spool and through the 2nd/1st shift spool to the 2nd
clutch.
If the range solenoid (2nd/1st) is activated, the pilot
pressure will move the shift spool so that 1st clutch
is fed.
The range clutches also have modulation which op-
erates as follows:
When the range is changed, oil will flow through the
modulation shift spool to the chosen range clutch
momentary until the friction discs are closed against
the dished plate. At that moment the range modula-
tion solenoid is activated.
116 SECTION 21 - TRANSMISSION
Úîééîç Úîééíð
Úîééíï Úîéïíî
Úîééíí Úîééíì
Úîççèê
Úîççèé
Úîççèè
Úîççèç
Úîçççð
Úîçççï
CONTROL VALVE OPERATION FORWARD, SECOND GEAR WITH FOUR WHEEL DRIVE ENGAGED
Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar. This oil flows to the 6 solenoids.
Oil also supplies the modulation valve.
When the powershift lever is moved forward and twisted anti clock wise a electrical signal is sent to:
Oil flows from the system pressure regulating valve at 20 bar through the four wheel drive spool to engage
the 4WD clutch.
System pressure also flows through the range modulation valve, then through the 1st 2nd spool to engage
the 2nd gear clutch.
The high low solenoid which energizes allowing pilot oil to flow to the shift spool. This will allow oil to flow to
the low clutch.
The neutral forward solenoid which energizes allows pilot pressure to flow to the shift spool this will allow oil
to flow on to the forward low shift spool.
The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases act-
ing on the boost valve and it multiplies pilot pressure.
The oil from the boost valve is modulated allowing a steady increase of pressure to act on the forward low
clutch pack which gradually takes up drive until clutch pressure reaches 20 bar.
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
7. System pressure test port 20 bar
8. System pressure regulating valve 20 bar
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar
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. Four wheel drive solenoid
19. Four wheel drive shift spool
20. Four wheel drive 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
31. Accumulator
32. Pressure booster 0-20 bar
126 SECTION 21 - TRANSMISSION
Control valve operation forward, second gear with four wheel drive engaged
Úîçççî
CONTROL VALVE OPERATION FORWARD, THIRD GEAR WITH FOUR WHEEL DRIVE DISENGAGED
Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar. This oil flows to the 6 solenoids. Oil also supplies the modulation valve.
When the powershift lever is moved forward and twisted anti clock wise and the 4WD is switched off a electrical
signal is sent to:
The 4WD solenoid, sending pilot pressure to the shift spool.
This will move the spool preventing oil flowing to the clutch disengaging 4WD.
The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
The neutral forward solenoid which energizes allows pilot pressure to flow to the shift spool this will allow oil
to flow on to the forward high shift spool.
The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases act-
ing on the boost valve and it multiplies pilot pressure by 4.
The oil from the boost valve is modulated allowing a steady increase of pressure to act on the forward high
clutch pack which gradually takes up drive until clutch pressure reaches 20 bar.
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
7. System pressure test port
8. System pressure regulating valve 20 bar
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar
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. Four wheel drive solenoid
19. Four wheel drive shift spool
20. Four wheel drive 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
31. Accumulator
32. Pressure booster 0-20 bar
128 SECTION 21 - TRANSMISSION
Control valve operation forward, third gear with four wheel drive disengaged
Úîçççí
CONTROL VALVE OPERATION REVERSE, FIRST GEAR WITH FOUR WHEEL DRIVE ENGAGED
Pressure oil from the system regulating valve flows to the pressure reducing valve. The pressure lowers to 5.5
bar. This oil flows to the 6 solenoids.
Oil also supplies the modulation valve. When the powershift lever is moved rearward, kick-down button is de-
pressed and the 4WD is switched off a electrical signal is sent to:
The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
The neutral reverse solenoid which energizes allows pilot pressure to flow to the shift spool. This will allow oil
to flow on to the reverse shift spool.
The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases act-
ing on the boost valve and it multiplies pilot pressure.
The oil from the boost valve is modulated allowing a steady increase of pressure to act on the reverse clutch
pack which gradually takes up drive until clutch pressure reaches 20 bar.
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
7. System pressure test port 20 bar
8. System pressure regulating valve 20 bar
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar
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. Four wheel drive solenoid
18. Range modulation restriction
19. Four wheel drive shift spool
20. Four wheel drive 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
31. Accumulator
32. Pressure booster 0-20 bar
130 SECTION 21 - TRANSMISSION
Control valve operation reverse, first gear with four wheel drive engaged
Úîçççì
Suction Oil
High Pressure Oil
Torque Converter and Lubrication Oil
Return to Tank
Pilot Pressure
Modulated Pilot Oil
SECTION 21 - TRANSMISSION 131
Úîééíë
Forward low
Forward high
Reverse and 1st
2nd
Disconnect
Input shaft
SECTION 21 - TRANSMISSION 133
REMOVAL
WARNING
Before performing any service or maintenance on the machine ensure the wheels are chocked / blocked to
prevent the machine from moving.
1. Lower the loader to the ground or raise and secure (dependent upon lifting apparatus) and release any
pressure in the system as required. Apply the handbrake and chock the wheels.
2. Switch off engine.
3. Isolate battery.
4. Remove all engine panels.
5. Remove front cast cowling.
6. Drain engine coolant and remove hoses.
IMPORTANT: air conditioning where fitted - Do not disconnect the air conditioning hoses from the compressor
or condenser unless a refrigerant reclaim system is to be used. Engine / Transmission removal from the ma-
chine does not require the system to be discharged.
Remove the condenser from the front radiator and place the condenser to one side of the chassis.
Disconnect the air conditioning compressor attaching hardware and place the compressor to one side of the
chassis.
Disconnect the expansion bottle connections from the radiator.
7. Remove all attaching bolts from radiator.
8. Disconnect transmission cooler pipes.
9. Remove radiator, taking care not to damage the fan or hydraulic oil cooler.
10. Remove air cleaner assembly.
11. Disconnect all electrical connections.
12. Disconnect hydraulic pipe clamps.
13. Disconnect the fuel tank feed and return pipes.
14. Disconnect the foot throttle cable at the fuel injection pump.
15. Remove the cab mat.
16. Remove the cab floor access panel.
134 SECTION 21 - TRANSMISSION
Úîééíê
Úîééíé
Úîééíç
î
Úîééìð
INSTALLATION
Place a stud in one tang of the flexi plate and as the
transmission is assembled up to the engine guide
the stud through a bolt hole of the flywheel, remove
the stud and refit a bolt.
Refit the attaching bolts which couple the transmis-
sion to engine.
Turn the engine crankshaft using a torque bar to ex-
pose in turn each attaching bolt hole of the flywheel
through the flexi plate and refit all of the bolts.
Hoist the engine / transmission assembly back into
the vehicle and centralize in the machine using a
measure between the chassis and centre line of the
crankshaft pulley. This ensures the engine is cen-
trally positioned before torque up of the engine /
transmission to chassis bolts.
Reconnect all ancillary equipment as previously de-
scribed.
Ensure all attaching hardware is tightened to the
correct torque value as detailed in the specifications.
Ensure after installation that all fluid levels are cor-
rect prior to start up.
Start and run the engine until correct operating tem-
perature is achieved to purge air from cooling sys-
tem.
Stop engine, check for leaks, rectify as required and
recheck fluid levels.
136 SECTION 21 - TRANSMISSION
fied torque.
INPUT SHAFT, TORQUE CONVERTER, PUMP DRIVE, INTERNAL CHARGING PUMP AND DRIVE PLATE
ïè
ïé
ë
ì
î í
ï
ïê
ïë
ïì
ïí
ïî
ïï
ïð
ç
è
é
ê íî
íï
íð
îç
îè
îé
îê
îë
ëð
îì
ìç
îí ìè
îî ìé
ìê
îï
îð
ïç ìë
ìì
ìí
ìî
ìï
ìð
íç
íè
íé
íê
íì íë
íí
Úîééìê
ç
è
é
ê
ë
ì
î í
ïè
ï ïê ïé
ïë
ïì íî
ïí
ïî
ïï
íï
ïð
íð
îç
îé îè
îê
ìé
îë
ìê
îì ìë
îí ìì
îî ìí
îï
ìî
îð
ïç
ìï
ìð
íç
íè
íé
íê
íì íë
íí
Úîééìé
146 SECTION 21 - TRANSMISSION
2ND SHAFT
é
ê
ë
ì
í
î
ïë
ïì
ï ïí
ïî
ïï
ïð
ç
è
îí
îî
îï
îð
íï
ïç
íð
ïè îç
ïé
îè
ïê
îé
îê
îë
îì
Úîééìè
SECTION 21 - TRANSMISSION 149
ïí
ïî
ïï
ïð
è
é
ë
ì
îî
í
î îï
ï îð
ïç
ïè
ïé
ïê
ïë
íî
íï
íð
îç
îè
ïì
îé
îê
îë
îì
îí
Úîééìç
PARKING BRAKE
ïç
îð
í
ïç
î ïè
ï
ïé
îï
ïë
ïê
ïì
ïî ïí
ïï
ïð
ç
è
é
ê
ë
ì
Úîééëð
ê í
ë Úîééëï
ASSEMBLY INSTRUCTIONS
Úîééëî
Úîééëí
SECTION 21 - TRANSMISSION 157
DISASSEMBLY TRANSMISSION
Remove oil filter.
Remove spacer.
Install spacer.
Remove spacer.
Install spacer.
WARNING
Be sure that bearing shield is on the outside.
210 SECTION 21 - TRANSMISSION
WARNING
Be sure that bearing shield is on the outside.
TRANSMISSION ASSEMBLY
Remove lower output bore plug. Position transmis-
sion case on converter housing (using lifting brack-
et).
Tighten screws.
ïç
îð
í
ïç
î ïè
ï
ïé
îï
ïë
ïê
ïì
ïî ïí
ïï
ïð
ç
è
é
ê
ë
ì
Úîééëð
Loosen two adjustment locking nuts (4 and 5) enough to slide each torque plate (16 and 18) away from disc
far enough to provide clearance to remove old pads assembly and install new ones. (It may be necessary to
remove one or both nuts).
Collapse pad retraction spring (21) and remove from brake head assembly.
Slide torque plates (16 and 18) away from disc, move pads assembly (17) out of pockets, and remove from
the brake head assembly from the side.
Install new pads assembly (17) in each torque plate (16 and 18).
Install pad retention spring (21) into brake head assembly. Be sure spring’s “feet” are positioned properly in
holes in both pads assembly (17).
Tighten inner adjusting nut (5) until firm contact is made with the disc by the pads. Torque to 11 Nm make
certain lever is in proper operating position for application.
Back off inner adjusting nut (5) and check that disc is free to move (total clearance 0.8 - 1.1 mm).
Tighten outer locking nut (4) against inner adjusting nut to lock adjustment bolt in place. Torque to 61 - 75 Nm.
264 SECTION 21 - TRANSMISSION
STALL TEST
Use a stall test to identify transmission, converter, or
engine problems.
HYDRAULIC CHECK
Also, before checking the transmission clutches,
torque converter, charging pump, and hydraulic cir-
cuit for pressure and rate of oil flow, it is important to
make the following transmission fluid check:
Check oil level in the transmission. The transmis-
sion fluid must be at the correct (full level). All clutch-
es and the converter and its fluid circuit lines must
be fully charged (filled) at all times. See note below.
LED display.
INDICATION OF FAULTS
In case a fault is present during normal operation
and is detected by the microprocessor, both the T-
LED and N-LED may be blinking in some way as
Ú Ò Î Ì Ò
shown in the table below.
Úïîðìë
FAULT GROUP
The faults are displayed using 2 LEDs on the 8 LED
display. Faults are displayed as 3 subgroups - Ú Ò Î Ì Ò
Group A:
ß Þ
Within each group several faults are possible. The Úîèíëç
Úîèíêð
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
voltage.
YES
Check speed sensor has it failed
NO
Úîèíéï
YES
Replace sensor
If static is not 0.6 - 0.8 V
or 1.3 - 1.5 V
Úîèíéð
SECTION 21 - TRANSMISSION 273
Over voltage Ú Ò Î Ì Ò
Even power supply levels up to 30V will not damage Þ´·²µ- Í´±©»®
Þ´·²µ
circuit components.
Above a power supply of 17 Vdc: Þ´·²µ-
Þ´·²µ-
Group Fault 1 - Fault code 7.
ï î í ì ë ê é è
NOTE: the speed sensor circuit will not operate
when an over voltage is present. ï î í ì
Úîèíêî
õ îì ÊÜÝ Úîèíêí
ó è ÊÜÝ Úîèíêì
274 SECTION 21 - TRANSMISSION
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
Úîèíêë
Gear Shifts
low/high solenoid:
inactive = forward high is selected
active = forward low is selected
During the output test LEDs 1234567 one by one are used and by
colour identifies the possible component at fault. Green= No fault
Red = short circuit NO
found
Yellow = open circuit or short to battery plus
YES YES
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 High/Low Solenoid 4 - Forward Hi/Lo 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 Example: LED 2 (orange)
solenoid output shorted to reverse solenoid output open
ground or a component. circuit or shorted to battery plus
Check component and continuity Check component and continuity
of the cables and connectors of the cables and connectors
output test
Output test
SECTION 21 - TRANSMISSION 277
COLOUR STATUS
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)
Úìîèè
278 SECTION 21 - TRANSMISSION
Key start ON
YES
T-LED Blinks
NO Safety critical output
N-LED Blinks Faster
YES
Replace the
Powershift lever unit
Úîèíéî
SECTION 21 - TRANSMISSION 279
Key start ON
YES
T-LED Blinks
NO Non critical output
N-LED Blinks in phase
fault
YES
Replace the
Powershift lever unit
ë
Úîèíéí
SECTION 21 - TRANSMISSION 281
Úìîçê
282 SECTION 21 - TRANSMISSION
Key start ON
YES
T-LED Blinks
NO No fault
N-LED Blinks in phase
YES
Replace the
Powershift lever unit
Úîèíéì
SECTION 21 - TRANSMISSION 283
Internal faults Ú Ò Î Ì Ò
Þ´·²µ- Í´±©»®
Þ´·²µ
At power up a series of integrity checks is done.
If a fault is detected: Þ´·²µ-
Þ´·²µ-
and the fault prevent operation as a transmission
ï î í ì ë ê é è
controller: the microprocessor locks itself in a reset
state.
and controlling the transmission is still possible: the ï î í ì
microprocessor reverts to limp home mode.
Úîèíêç
Limp Home mode
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks slower
YES
Select neutral and push
NO kick down button (F11) Other output fault 2 red - 6 red
3 red - 5 red NO Refer F1, F2, F3 or F4
YES
Replace the
Powershift lever unit
284 SECTION 21 - TRANSMISSION
F12
Key start ON
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 start ON
YES
Perform output test and
check range modulation
Repair or LED 7 (wire E08)
replace YES Green = Okay
Orange = Open circuit
Red = Short circuit
286 SECTION 21 - TRANSMISSION
Úïïèíí
Úïïèíì
Úïïèíë
Úïïèíê
LB90.B
LB95.B
LB1ï0.B
LB115.B
TYPE
Front steering axle, model 26.00
Úîéíìç
GREASING
ß ß
ß ß
Úîéíëð
DESCRIPTION POSITION
Greasing points A
SECTION 25 - FRONT AXLES 5
ï
é
ê î ç
ì
ë
è
ïë í
ïí
ï
ïï
ïð
ïì
ïî
è
Úîéíëï
Disassembly
ïð
Úîéíëî
6 SECTION 25 - FRONT AXLES
ïï
ïð
Úîéíëí
ïî
ïð
è
ç
Úîéíëì
ïð
Úîéíëë
Úîéíëê
SECTION 25 - FRONT AXLES 7
Take the front support (2) out from the axle housing
(6).
î
ê
Úîéíëé
î
è
í
ç
Úîéíëè
Remove the bush (4) and the thrust washer (5) from
the axle housing (6) only if necessary. ê ë
Úîéíëç
Assembly
Úîéíëê
8 SECTION 25 - FRONT AXLES
ïð
Úîéíëë
WARNING
Align the bush hole with the bolt (8) hole.
Úîéíêð
ïï
ïð
Úîéíëí
WARNING
Do not damage the O-ring when inserting the rear ïð
support on the axle housing.
ç Úîéíêï
SECTION 25 - FRONT AXLES 9
Úîéíëç
Úîéíêî
Assemble the bush (3) into the front support (2) with
a suitable driver and a hammer.
WARNING
Align the bush hole with the bolt (8) hole.
î
è
Assemble the bolt (8). í
Úîéíêí
è
ç
Úîéíêì
10 SECTION 25 - FRONT AXLES
STEERING CYLINDER
ïç
ïî
ïï
îï ïð
ïé
îð
ïë
ïè
ïê é
ïì è ç
ê
ïí
ë
ì
í
î ï
Úîéîîé
Disassembly
WARNING
Don’t beat on the threaded pin end of the tie rod (3). í
Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the ïï
conditions.
Unscrew the fastening screws (6) and take the
ê
steering cylinder (7) out of its housing, if necessary ïî
ì
use a rubber hammer.
Remove only parts that need to be overhauled and/ ïð
or replaced. é
í ë
Úîéîîç
Assembly
ïê
ïì îð
ïí
ïè
ïé
ïë
Úîéîíï
ïé
ïë
ïç
Úîéîíî
12 SECTION 25 - FRONT AXLES
Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod ïï
(17), then tighten to the requested torque.
ê
ïî
ì
ïð
é
ïé
í ë
Úîéîíí
Úîéëðì
è
Úîéîíë
Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). í
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
ï
Úîéîíê
SECTION 25 - FRONT AXLES 13
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been ïï ïî
carried out.
Úîéîíè
14 SECTION 25 - FRONT AXLES
WHEEL HUB
ïç
ïî
ïè
ïï
ïè
îð
îï
ïð
ç ïé
è
é ïê
ê
ë
ì îî
í ïë
ïí ïì
î ïî
Úîéíêë
Disassembly
Úîéíêê
SECTION 25 - FRONT AXLES 15
Úîéíêè
Úîéîëë
WARNING ïï ïí
Before removing the king pins (11) and (13), secure
the swivel housing (10) with a belt or a rope to a
hoist or any other supporting device; observe all cur-
ïð
rent safety regulations to guarantee operator’s safe-
ty.
ïð
Úîéíéï
ïè
ïé
ïê
Úîéíéî
Assembly
Úîéíéí
ïè
ïé
ïê
Úîéíéî
SECTION 25 - FRONT AXLES 17
îî îï
ïí ïï
Úîéíéì
Úîéíéï
Assemble the king pins, the lower (13) and the up-
per (11), and tighten the retaining screws (12) to the
requested torque.
ïî
ïï ïí
Úîéíéë
Úîéíéê
18 SECTION 25 - FRONT AXLES
Úîéíéé
Úîéíêê
SECTION 25 - FRONT AXLES 19
ïï
ï î í ïï
í î ï
ë ë
ì ì
Úîéííç
Toe-in
WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
ëðð ³³ ëðð ³³
Úîéíìð
20 SECTION 25 - FRONT AXLES
Úîéíìï
Ó óðë
Úîéíìî
Úîéíìí
SECTION 25 - FRONT AXLES 21
Úîéíìì
Úîéíìë
Úîéíìê
ë ì
Úîéíìé
22 SECTION 25 - FRONT AXLES
Úîéíìè
SECTION 25 - FRONT AXLES 23
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
Úîéîðí
Úîéîðì
í ë ï ì ë í
ë î ë
ë ì ë
Úîéîðë
DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
28 SECTION 25 - FRONT AXLES
Before draining the oil from axle housing, use the oil
breather (2) to release possible internal pressure. î
WARNING
Risk of violent oil ejection.
Úîéîðê
To drain the oil remove the level plug (1) and the
drain plug (4).
WARNING
Risk of violent oil ejection.
ï ì
Úîéîðé
ï
Úîéîðè
Úîéîðç
SECTION 25 - FRONT AXLES 29
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. í
Tighten the plug (3) to the requested torque.
Úîéîïð
30 SECTION 25 - FRONT AXLES
TIGHTENING TORQUES
ïêë Ò³
çë Ò³ ïîð Ò³ è Ò³ ïëð Ò³ çë Ò³ ïí Ò³
ïîð Ò³
îêê Ò³ ëé Ò³
ïêë Ò³
ïð Ò³ è Ò³ èì Ò³ êð Ò³ è Ò³ èì Ò³
Úîéîïï
SECTION 25 - FRONT AXLES 31
îï
ïè
îð
ïë ïé
ïê ïç
ïì
ïî
ç
ê è
í ë ïí
ïï
ïð
é
ì
î
ï
Úîéîïî
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1) from the pinion shaft end (14).
ïì
ï î
Úîéîïí
32 SECTION 25 - FRONT AXLES
ì
Úîéîïì
Remove the O-ring (6) from the bush (8) in rear sup-
port (5).
ë
é
Úîéîïë
ë è
ì
Úîéîïê
Úîéîïé
SECTION 25 - FRONT AXLES 33
ïï
Úîéîïè
Remove the seal rings (12) and (13) from the cover
(11). ïí
NOTE: destructive operation for the seal rings. ïî
ïï
Úîéîïç
Úîéîîð
ïç
Úîéîîï
34 SECTION 25 - FRONT AXLES
ïç
Úîéîîî
ïé
Úîéîîí
Assembly
Úîéîîð
ïï
Úîéîïç
SECTION 25 - FRONT AXLES 35
ïï
Úîéîïè
Úîéîïé
WARNING
Align the bush hole with the bolt (4) hole.
Úîéîïê
ë
é
Úîéîïë
36 SECTION 25 - FRONT AXLES
WARNING
Do not damage the O-ring when inserting the rear
support on the central body. ë
ì
Úîéîïì
ïì
ï î
Úîéîïí
Úîéîîí
îð
Úîéîîì
SECTION 25 - FRONT AXLES 37
ïç
Úîéîîë
ïç
Úîéîîê
38 SECTION 25 - FRONT AXLES
STEERING CYLINDER
ïç
ïî
ïï
îï ïð
ïé
îð
ïë
ïè
ïê é
ïì è ç
ê
ïí
ë
ì
í
î ï
Úîéîîé
Disassembly
WARNING
Don’t beat on the threaded pin end of the tie rod (3). í
Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the ïï
conditions.
Unscrew the fastening screws (6) and take the
ê
steering cylinder (7) out of its housing, if necessary ïî
ì
use a rubber hammer.
Remove only parts that need to be overhauled and/ ïð
or replaced. é
í ë
Úîéîîç
Assembly
ïê
ïì îð
ïí
ïè
ïé
ïë
Úîéîíï
ïé
ïë
ïç
Úîéîíî
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 ïï
(17), then tighten to the requested torque.
ê
ïî
ì
ïð
é
ïé
í ë
Úîéîíí
Úîéîíì
è
Úîéîíë
Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). í
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
ï
Úîéîíê
SECTION 25 - FRONT AXLES 41
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been ïï ïî
carried out.
Úîéîíè
42 SECTION 25 - FRONT AXLES
ïð
ç
è
é
ê
ë
ì
î
ï
í
Úîéîíç
Disassembly
Úîéîìð
SECTION 25 - FRONT AXLES 43
ï
Úîéîìï
Úîéîìî
Assembly
Úîéîìê
ï
Úîéîìï
Úîéîìé
SECTION 25 - FRONT AXLES 45
WHEEL HUB
îè
ïç
îé
ïè
îì
ïì
îî
ïí
ïî îê
îë
îí
ïï
ïð
ç
è ïë
é îï
ì ïê îð
í ïé
î ë ê
Úîéîìè
Disassembly
WARNING
Do not damage the double U-Joint.
ïì
Úîéîìç
46 SECTION 25 - FRONT AXLES
Úîéîëð
Úîéîëï
Úîéîëí
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). è
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- ê
cial tool 380002223.
é
Úîéîëî
SECTION 25 - FRONT AXLES 47
Úîéîëì
Úîéîëë
ïì
Úîéîëé
48 SECTION 25 - FRONT AXLES
Úîéîëè
ïì îí
Úîéîëç
Assembly
îð îï
Úîéîêð
Insert the bush (22) into the swivel housing (14) with
the special tool 380002660 and a hammer or a
îí ïì
press.
Assemble the seal ring (23) on the swivel housing
îî
(14) with the special tool 380002661 and a hammer.
Grease carefully the seal ring (23).
Úîéîêï
SECTION 25 - FRONT AXLES 49
Úîéîëè
Úîéîêî
Úîéîëé
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
ïé ïç
ïê ïè
Úîéîêí
50 SECTION 25 - FRONT AXLES
ïï ïï
NOTE: do not lubricate the seal ring (13).
Úîéîêì
Úîéîêë
Úîéîêê
Úîéîêé
SECTION 25 - FRONT AXLES 51
Úîéîêè
Úîéîêç
A= 11.975 ÷ 12.025 Ý ß Ý
B= 52.229 ÷ 52.279
C= 20.000 ÷ 20.100
Þ
Úîéîéð
Úîéîéï
52 SECTION 25 - FRONT AXLES
Slide the thrust washers (2) and (3) onto the double
U-Joint shaft end. í î
Insert the lock ring (1) at the end of the splined hub
and push it into its seat.
Úîéîëð
SECTION 25 - FRONT AXLES 53
DOUBLE U-JOINTS
ï î
ì
ë
ê
Úîéîéî
Disassembly
ï
ê
Úîéîéí
54 SECTION 25 - FRONT AXLES
Remove the seal rings (5) from the axle beam (1).
WARNING
Be careful not to damage the bush seat.
ë
Úîéîéì
Remove the upper king pin bush (2) and the ball
bearing cup (3) from the king pin seats using a suit-
able extractor only if the wear conditions require
this.
Úîéîéë
Assembly
Cool the upper king pin bush (2) and the ball bearing
cup (3) at a temperature lower than -100 °C with liq-
uid nitrogen.
î
WARNING
Wear safety gloves.
Assemble the bush (4) on the axle beam (1) with the
special tool 380002665 and a hammer.
Assemble the seal ring (5) on the axle beam with the
ï
special tool 380002666 and a hammer.
ì
NOTE: grease carefully the seal rings. ë
Úîéîéé
SECTION 25 - FRONT AXLES 55
WARNING ë
Positioning the seal ring (5) as in figure.
Úîéîéè
WARNING
Be careful not to damage the seal ring.
ï
ê
Úîéîéí
56 SECTION 25 - FRONT AXLES
DIFFERENTIAL SUPPORT
ç è ïí
ïî
ïï
ïð
é
ê
ïì
è
ë
ì
î í
ï
Úîéîèî
Disassembly
è è
Úîéîèì
Úîéîèë
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
Úîéîèê
ïð
Úîéîèé
58 SECTION 25 - FRONT AXLES
Úîéîèè
Assembly
WARNING
Do not invert the bearing cones if the bearings are
not replaced. ì
ê
ë
Úîéîèç
WARNING
Check the right side of the bevel crown assembly.
Úîéîçð
ïð
Úîéîçï
SECTION 25 - FRONT AXLES 59
Úîéîçî
Úîéîçí
Úîéîçë
60 SECTION 25 - FRONT AXLES
Úîéîçí
WARNING Úîéîçê
Úîéîçè
ïî
ïí
Úîéîçç
Úîéíðð
Úîéíðï
62 SECTION 25 - FRONT AXLES
Úîéíðî
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
ï
Úîéíðì
SECTION 25 - FRONT AXLES 63
DIFFERENTIAL GROUP
Disassembly
ïî
Úîéíðê
64 SECTION 25 - FRONT AXLES
Úîéíðé
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîéíðè
ïï
Úîéíðç
Úîéíïð
SECTION 25 - FRONT AXLES 65
Assembly
Úîéíïð
Úîéíïì
66 SECTION 25 - FRONT AXLES
ï
Úîéíïê
Úîéíïë
ïî
Úîéíïé
Úîéíïè
SECTION 25 - FRONT AXLES 67
PINION GROUP
Disassembly
ïð
Úîéíîð
68 SECTION 25 - FRONT AXLES
ç
ïð
Úîéíîï
WARNING
Take care not to lower the bevel pinion (1). ë
ï
Collect the washers (4) and (6), the collapsible
spacer (5) and the bearing cone (8).
ê
ì
Úîéíîî
è
Úîéíîê
Úîéíîì
SECTION 25 - FRONT AXLES 69
WARNING
The ring nut (10) and the collapsible spacer (5) must ë
be replaced when reassembling the unit.
ïð
Úîéíîë
Assembly
è
Úîéíîê
Úîéíîé
ïð
Úîéíîè
70 SECTION 25 - FRONT AXLES
Úîéíîç
Úîéííð
S = X-V mm
Ê
Úîéííï
Úîéííî
SECTION 25 - FRONT AXLES 71
ïð
Úîéíîè
Úîéííì
Úîéííë
Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
ç
ïð
Úîéíîï
72 SECTION 25 - FRONT AXLES
WARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
ïð
P = 9.2÷13.7 daN
WARNING
All preloadings must be measured without the seal
Úîéííé
ring.
Úîéííè
SECTION 25 - FRONT AXLES 73
ïï
ï î í ïï
í î ï
ë ë
ì ì
Úîéííç
Toe-in
WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
ëðð ³³ ëðð ³³
Úîéíìð
74 SECTION 25 - FRONT AXLES
Úîéíìï
Ó óðë
Úîéíìî
Úîéíìí
SECTION 25 - FRONT AXLES 75
Úîéíìì
Úîéíìë
Úîéíìê
ë ì
Úîéíìé
76 SECTION 25 - FRONT AXLES
Úîéíìè
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
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 bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm thickness lower
than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
80 SECTION 25 - FRONT AXLES
TYPE
Front steering axle, model 26.28
Úîéíéè
ï ì
í ë ë í
ë î ë
ë ë
Úîéíéç
DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
82 SECTION 25 - FRONT AXLES
WARNING
Risk of violent oil ejection.
Úîéîðê
To drain the oil remove the level plug (1) and the
drain plug (4).
WARNING
Risk of violent oil ejection.
ï ì
Úîéîðé
ï
Úîéîðè
Úîéîðç
SECTION 25 - FRONT AXLES 83
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. í
Tighten the plug (3) to the requested torque.
Úîéîïð
84 SECTION 25 - FRONT AXLES
îï
ïè
îî
ïé
ïë ïê
ïç
îí
é
ê
è
ë
ïï
ï ïì
í ïð
ì
ç
ïî
ïí
î Úîéíèð
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1).
ï
í
î
Úîéíèï
SECTION 25 - FRONT AXLES 85
ïí
Úîéíèî
ïî
ïï
Úîéíèí
ì
Úîéíèì
ë
Úîéíèë
86 SECTION 25 - FRONT AXLES
è
ë
ì
ç
Úîéíèê
Úîéîïé
ïð
Úîéíèé
ïç
Úîéíèè
SECTION 25 - FRONT AXLES 87
îð
ïç
ïè
îí
îî
Úîéíèç
Úîéíçð
Assembly
ïð
Úîéíèé
Úîéîïé
88 SECTION 25 - FRONT AXLES
WARNING
Align the bush hole with the bolt (4) hole.
Úîéîïê
ë
é
Úîéîïë
WARNING
Do not damage the O-ring when inserting the rear ë
support on the central body.
ç
Úîéíçï
Úîéíçð
SECTION 25 - FRONT AXLES 89
îð
Úîéîîì
WARNING
îð
Align the bush hole with the bolt (19) hole. ïç
ïè
Mount the bolt (19). îî
Assemble O-ring (22).
Úîéíçí
îí
Úîéíçì
ïî
ïï
Úîéíèí
90 SECTION 25 - FRONT AXLES
ïí
Úîéíèî
ï
í
î
Úîéíèï
SECTION 25 - FRONT AXLES 91
STEERING CYLINDER
îì
îí
îî
ïð
îï
ç
ïí îð
è
ïç
ïì ïè
é
ê
ë
ì
í
ïé ïî
ïê ïï
ïë
ï
Úîéíçê
Disassembly
WARNING
Don’t beat on the threaded pin end of the tie rod (3). í
Remove the tie rods (3) and (10) by loosing the nuts
(4) and (9) with a suitable wrench, then check the ïí
ïí
conditions.
Unscrew the fastening screws (13) and take the ïð
ïì
steering cylinder (7). ç
Remove only parts that need to be overhauled and/ è
ïë
or replaced. é
ê
ë
ì
í
Úîéíçé
ïç
ïè Úîéíçè
Assembly
îì
ïé îî
ïê îï
îð
ïç
ïè
Úîéíçî
îî
îð
ïè
Úîéíçç
SECTION 25 - FRONT AXLES 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. ïð
ç
è
é
ê
ë
ì
í
Úîéìðð
ïï
Úîéìðî
Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). í
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
ï
Úîéîíê
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- ì ç í ïð
ried out.
Úîçëîê
SECTION 25 - FRONT AXLES 95
ïï
ç
ïð
è
é
ê
ë
ï
í
î
Úîéìðì
Disassembly
Úîéîìð
96 SECTION 25 - FRONT AXLES
ï
Úîéîìï
Úîéìðë
Assembly
Úîéìðë
Úîéìðé
Úîéìðè
98 SECTION 25 - FRONT AXLES
WHEEL HUB
ïç
îê
ïè
îì
îé
ïì
îî
ïí
ïî
îë
ïï îí
ïð
ç
è ïë
é îï
ì ïê îð
í ïé
î ë ê
Úîéìðç
Disassembly
WARNING
Do not damage the double U-Joint.
ïì
Úîéìïð
SECTION 25 - FRONT AXLES 99
Úîéîëð
Úîéîëï
Úîéîëí
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). è
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- ê
cial tool 380002667.
é
Úîéîëî
100 SECTION 25 - FRONT AXLES
Úîéîëì
Úîéìïî
ïì
Úîéîëé
SECTION 25 - FRONT AXLES 101
îê
îë
Úîéìïí
Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.
ïì îí
Úîéîëç
Assembly
îð îï
Úîéîêð
Úîéîêï
102 SECTION 25 - FRONT AXLES
Úîéìïì
Úîéîëé
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
ïé ïç
ïê ïè
Úîéîêí
Úîéëîë
SECTION 25 - FRONT AXLES 103
Úîéîêë
Úîéîêê
Úîéîêé
Úîéîêè
104 SECTION 25 - FRONT AXLES
Úîéîêç
ïì
Úîéìïð
í î ï
Úîéìïê
SECTION 25 - FRONT AXLES 105
DOUBLE U-JOINTS
ï
î
í
ì
Úîéìïé
Disassembly
ï
ì
Úîéìïè
106 SECTION 25 - FRONT AXLES
Remove the seal rings (3) from the axle beam (1).
ï
NOTE: destructive operation for the seal rings (3). î
í
Remove the bush (2) from the axle beam (1) only if
the wear conditions require this.
WARNING
Be careful not to damage the bush seat.
í
Úîéìïç
Assembly
Assemble the bush (2) on the axle beam (1) with the
special tool 380002226 and a hammer.
Assemble the seal ring (3) on the axle beam with the
ï
special tool 380002670 and a hammer.
î
NOTE: grease carefully the seal rings. í
Úîéìîð
Úîéìîï
WARNING
Be careful not to damage the seal ring.
ï
ê
Úîéîéí
SECTION 25 - FRONT AXLES 107
ç è ïí
ïî
ïï
ïð
é
ê
ïì
è
ë
ì
î í
ï
Úîéìïï
Disassembly
WARNING
Support the differential support with a rope or other
appropriate means.
î
ïì
ï
Úîéëðï
108 SECTION 25 - FRONT AXLES
è
è
Úîéíçë
Úîéìîî
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
Úîéìîí
ïð
Úîéìîì
SECTION 25 - FRONT AXLES 109
Úîéìîë
Assembly
WARNING
Do not invert the bearing cones if the bearings are
not replaced. ì
ê
ë
Úîéîèç
WARNING
Check the right side of the bevel crown assembly.
Úîéìîé
ïð
Úîéìîè
110 SECTION 25 - FRONT AXLES
Úîéìîç
Úîéîçí
Úîéîçë
SECTION 25 - FRONT AXLES 111
Úîéìíï
WARNING Úîéìíî
Úîéîçè
ïî
ïï
Úîéìíì
ïì
Úîéìíë
î
ïì
ï
Úîéëðï
SECTION 25 - FRONT AXLES 113
Úîéíðî
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
ï
Úîéíðì
114 SECTION 25 - FRONT AXLES
è
ï
ïï
ïð
ç
ïí
ïî
é
ê
è
é
ê
ë
ì
í
î
Úîéìíé
Disassembly
ïð
Úîéìíè
SECTION 25 - FRONT AXLES 115
Úîéíðé
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîéíðè
ïï
Úîéíðç
Úîéìíç
116 SECTION 25 - FRONT AXLES
Úîéììð
ê ê
é é
Úîéììï
ïí
Úîéììî
Assembly
WARNING
Remove rests of dope.
Úîéììí
SECTION 25 - FRONT AXLES 117
ïî
Úîéììì
ïí
Úîéììî
ê ê
é é
Úîéììï
Úîéììð
118 SECTION 25 - FRONT AXLES
Úîéìíç
Úîéíïì
ï
Úîéíïê
Úîéíïë
SECTION 25 - FRONT AXLES 119
ïð
Úîçðïð
Úîéíïè
120 SECTION 25 - FRONT AXLES
ïì
ïð
ïí
è
ïî
ç
ë
ï
ì
ê
ïï
ïð
è
ç
é
ê
ë
ì
í
î
Úîéììè
Disassembly
ïí
Úîéììç
SECTION 25 - FRONT AXLES 121
Úîéíðé
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîéììê
ïì
Úîéìëð
Úîéìëï
122 SECTION 25 - FRONT AXLES
Úîéìëî
Úîéìëí
ç ç
è è
ïð
Úîéìëì
Úîéìëë
SECTION 25 - FRONT AXLES 123
ì ë
Úîéìëê
Assembly
WARNING
Remove rests of dope.
Úîéìëé
ïï
Úîéìëè
ì ë
Úîéìëê
124 SECTION 25 - FRONT AXLES
Úîéìëë
ç ç
è è
ïð
Úîéìëì
Úîéìëç
Úîéìëî
SECTION 25 - FRONT AXLES 125
Úîéìëï
ïì
Úîçíîð
ï
Úîéíïê
Úîéíïë
126 SECTION 25 - FRONT AXLES
ïí
Úîéìêð
Úîéíïè
SECTION 25 - FRONT AXLES 127
PINION GROUP
ï
î
í
ì
ë
ê
é
è
ç
ïð
Úîéìêï
Disassembly
Úîéìêî
128 SECTION 25 - FRONT AXLES
ç
ïð
Úîéìêí
WARNING
Take care not to lower the bevel pinion (1).
ë
Collect the washers (4) and (6), the collapsible ï
spacer (5) and the bearing cone (8).
ê
ì
Úîèïðê
è
Úîèïðé
Úîéíîì
SECTION 25 - FRONT AXLES 129
WARNING
The ring nut (10) and the collapsible spacer (5) must ë
be replaced when reassembling the unit.
ïð
Úîéíîë
Assembly
è
Úîèïðé
Úîèïðè
í
è
ïð
Úîèïðç
130 SECTION 25 - FRONT AXLES
Úîèïïð
Úîèïïï
S = X-V mm
Ê
Úîéííï
Úîéííî
SECTION 25 - FRONT AXLES 131
í
è
ïð
Úîèïðç
Úîéííì
ê
ì
Úîèïïî
Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
ç
ïð
Úîéìêí
132 SECTION 25 - FRONT AXLES
WARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
ïð
P = 9.2÷13.7 daN
WARNING
All preloadings must be measured without the seal
Úîéìíî
ring.
Úîéííè
SECTION 25 - FRONT AXLES 133
ï î í í î ï
ë ë
ì ì
Úîèïïí
Toe-in
WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
ëðð ³³ ëðð ³³
Úîéíìð
134 SECTION 25 - FRONT AXLES
Úîéíìï
Ó óðë
Úîéíìî
Úîéíìí
SECTION 25 - FRONT AXLES 135
Úîéíìì
Úîéíìë
Úîéíìê
ë ì
Úîéíìé
136 SECTION 25 - FRONT AXLES
Úîéíìè
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
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all com-
ponents. Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
10. Incorrect adjustment of bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm thickness lower
than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
140 SECTION 25 - FRONT AXLES
4. SPECIAL TOOLS
ELECTRO-HYDRAULIC DIFFERENTIAL
LOCKING OPERATION (only Powershift)
WARNING
The differential lock fitted to this machine is operated
by oil pressure and controlled by an electrically op-
erated solenoid. The solenoid is energized when the
switch (1) mounted in the front console is de-
pressed.
WARNING
Never use the differential lock at speeds above 8
km/h (5 mph) or when turning the machine. When
engaged the lock will prevent the machine turning
and personal injury could result.
Úîçëìç
6 SECTION 27 - REAR AXLE
Úîçëëð
LUBRICATION
Oil capacity: 21.2 litres
Oil specification: Ambra Mastertran NH 410 C + AoA Axle oil additive (0.8 litres)
SECTION 27 - REAR AXLE 7
TIGHTENING TORQUES
î ïï í ì
è ç ïð
Úîçëëï
DIFFERENTIAL REMOVAL
î
Úîçëëî
DIFFERENTIAL DISASSEMBLY
PINION REMOVAL
Remove the lock pin (2) to unlock the ring nut (1).
SECTION 27 - REAR AXLE 13
Remove the ring nut (1), the washer (3) and the gas-
ket (4).
Remove the coupling (5).
Remove the snap ring (14) from the axle inner cen-
tral body.
Using an rubber hammer, take out the pinion (12). ïî
ïì
Úîçëëí
Powershuttle
ïì
ïé
ïï
ïð
ç ïê
è î
é í
ê ì
ë ë
ì ê
í ïë ÎØ
î ïí
ï ïî
ÔØ
Powershift
ïè
ïç ï
îð î
ïë í
ê ì
ë ê
ì ë
í é ÎØ
î ïî
ïê ïí
ÔØ
Úîçëëë
ïé
ïî ïí
è
Úîçëëê
Úîçëëé
í
Úîçëëè
22 SECTION 27 - REAR AXLE
VALUE “T”
SHIMS
mm
0.034 ÷ 0.039 81803515
0.040 ÷ 0.045 81803516
Ì
0.046 ÷ 0.051 81803517 Úîçëëç
MEASURING OF RANGE BETWEEN THE FACE THRUST BLOCK AND THE BACK FACE OF
DIFFERENTIAL
VALUE “S”
SHIMS
mm
0.80 ÷ 0.89 87346232 + 87346228
0.90 ÷ 0.99 87346232 + 87346231
1.00 ÷ 1.10 87346232 + 87346427 Úîçëêð
Úîçêíé
Úîçêíè
26 SECTION 27 - REAR AXLE
Úîçêíç
Úîçêìð
Úîèððí
í ë é ï ê ê ï é î
ì
Úîèððì
DESCRIPTION POSITION
Differential oil filling and level plug 1
Oil breather 2
Fill / drain and level plug of epicyclic reduction gear oil 3
Differential oil drain plug 4
Greasing points 5
Brake bleed plug 6
Service brake oil port 7
30 SECTION 27 - REAR AXLE
Úîèððë
ì ï
Úîèððê
Úîèððé
Úîèððè
SECTION 27 - REAR AXLE 31
ê
Úîèððç
32 SECTION 27 - REAR AXLE
FRONT FLANGE
é
ê
ë
ì
ï î í
Úîèðïð
Disassembly
Úîèðïï
SECTION 27 - REAR AXLE 33
Úîèðïî
Remove the seal (3), the O-ring (4), the gasket (5),
the O-ring (6) and the washer.
ë
ì
í
é
ê
Úîçððç
Assembly
é
ê
Úîçíîî
Úîçíîí
34 SECTION 27 - REAR AXLE
ì
í
Úîçíîì
Úîèðïî
Úîèðïï
SECTION 27 - REAR AXLE 35
STEERING CYLINDER
ì
ë
é
í ïð
ïï
ïî
î
ê
è ïí
ç
ïì
ïë
ïê
ïé
ïè
ïç
îð
îï
îî
îí
îì
Úîèðïí
Disassembly
WARNING
Don’t beat on the threaded pin end of the tie rod (3). í
Remove the tie rods (3) and (13) by loosing the nuts
(4) and (12) with a suitable wrench, then check the ì
conditions. ë
é
Unscrew the fastening screws (6) and (9) and take ïð
the steering cylinder (7) out of its housing, if neces- ïï
ïî
sary use a rubber hammer.
Remove only parts that need to be overhauled and/
or replaced.
í ê è ç ïí
Assembly
ïé
ïç
îî
îí
îì
Úîèðïê
Assemble the tie rods (3) and (13), the ball joints (5)
and (11), the nuts (4) and (12) to the ends of the rod, ì
then tighten with a dynamometric wrench to the re- ë
quested torque. é
ïð
ïï
ïî
ïí
SECTION 27 - REAR AXLE 37
ïì
Úîèðîð
Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). í
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
ï
Úîéîíê
38 SECTION 27 - REAR AXLE
ïï
ç
ïð
è
é
ê
ë
ï
í
î
Úîéìðì
Disassembly
Úîéîìð
SECTION 27 - REAR AXLE 39
Úîèðìì
Úîéìðë
Úîèðîï
Úîèðîî
40 SECTION 27 - REAR AXLE
Úîèðîí
Assembly
Úîèðîì
Úîèðîë
Úîèðîê
SECTION 27 - REAR AXLE 41
Úîéìðë
Úîèðìì
Úîéìðè
42 SECTION 27 - REAR AXLE
WHEEL HUB
Disassembly
WARNING
Do not damage the double U-Joint.
ïì
Úîéìïð
SECTION 27 - REAR AXLE 43
Úîéîëð
Úîéîëï
Úîéîëí
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). è
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- ê
cial tool 380002667.
é
Úîéîëî
44 SECTION 27 - REAR AXLE
Úîéîëì
Úîéìïî
ïì
Úîéîëé
SECTION 27 - REAR AXLE 45
îè
îí
Úîèðìê
Turn the swivel housing and take the bush (26) out,
using a suitable drift and a hammer.
ïì îí
Úîéîëç
Assembly
îð îï
Úîéîêð
Force the bush (26) into the swivel housing (14) with
the special tool 380002668 and a hammer.
Assemble the seal ring (22) on the swivel housing
(14) with the special tool 380002669 and a hammer. ïì
Grease carefully the seal ring (22). îê
îî
Úîèðìé
46 SECTION 27 - REAR AXLE
îí
Úîèðìê
Úîèðîé
Úîéîëé
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
ïé ïç
ïê ïè
Úîéîêí
SECTION 27 - REAR AXLE 47
ïï ïï
Úîèðîè
Úîéîêë
Úîéîêê
Úîéîêé
48 SECTION 27 - REAR AXLE
Úîéîêè
Úîéîêç
Úîéîëð
SECTION 27 - REAR AXLE 49
DOUBLE U-JOINTS
ì
í
î
ï
Úîéîéç
Disassembly
ì
ï
Úîéîèð
50 SECTION 27 - REAR AXLE
Remove the seal rings (2) from the axle beam (4).
WARNING
Be careful not to damage the bush seat.
î
Úîéîèï
Assembly
Úîèðîç
Úîèðìè
WARNING
Be careful not to damage the seal ring.
ì
ï
Úîèðìç
SECTION 27 - REAR AXLE 51
Disassembly
Úîèðíï
52 SECTION 27 - REAR AXLE
î ï
Úîèðíí
WARNING ì
Once the axle beam trumpet has been removed, the
brake disks are free. ï
Úîèðíì
Úîèðíë
Remove the O-ring (4) and (19) from its housing and
from oil pipe hole and check its conditions. ì
ïç
Úîèðíé
Úîéíïí
Take from the piston (14), the springs (13) and the
bushes (12) and (27) and spacer (26). îé
îê
ïì
ïí
ïî
Úîèðíè
Úîèðíç
54 SECTION 27 - REAR AXLE
Úîèðìð
Assembly
Úîèðìð
Install the piston (14) into the brake flange (7) and
then a support flat disk on the piston and with a lever
ïì
anchored to an eyescrew, exert a pressure just
enough to insert the piston (14) into the brake flange
(7).
é
Úîèðìî
Úîèïïê
SECTION 27 - REAR AXLE 55
ïç
Úîèðíé
ë ê
Úîèðìí
Úîèðíë
Úîèðíì
56 SECTION 27 - REAR AXLE
WARNING
Support the groups properly as already pointed out
for disassembly phase.
î ï
Úîèðíí
SECTION 27 - REAR AXLE 57
ì
ë
ïë
ïð
ïì
ê
ïè
ç
í ïé
î ïê
ï
ïí
ë
ì ïì
ïë
ïî
ïï
è
é
ê Úîèðëð
Disassembly
ê
Úîèðëï
58 SECTION 27 - REAR AXLE
Úîèðëî
Úîèðëí
ïè
Úîèðëì
Úîèðëë
SECTION 27 - REAR AXLE 59
WARNING ï
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
Úîèðëê
ïð
Úîèðëé
Úîèðëè
ïê
Úîèðëç
60 SECTION 27 - REAR AXLE
ïë ïë
ïì ïì
ïí
Úîèðêð
ïï
Úîèðêï
Assembly
WARNING
Remove rests of dope.
Úîèðéç
ïî
ïê
ïì
Úîèðêí
SECTION 27 - REAR AXLE 61
ïé
Úîèðêì
ïë ïë
ïì ïì
ïí
Úîèðêð
ïî
Úîèðêê
Úîèðëè
62 SECTION 27 - REAR AXLE
Úîèðêé
ï
Úîéíïê
Úîéíïë
ïè
Úîèðêè
SECTION 27 - REAR AXLE 63
Úîèðêç
Úîèðéð
Úîèðéï
ì
ë
ê
ïê ïë
ïé ïð
ïé
ïè
ïê
ç
ïë ïï
í ïî
î
ïí
ï
ë ïç
ì ïê
ïë
ïê
ïë
ïì
ïí
ïî
ê é è ïï
Úîèðéí
Disassembly
ê
Úîèðëï
SECTION 27 - REAR AXLE 65
Úîèðëî
Úîèðëí
ïè
Úîèðëì
Úîèðëë
66 SECTION 27 - REAR AXLE
WARNING ï
This operation makes both differential half housings
free, so take care not to lower the inner compo-
nents.
Úîèðëê
ïð
Úîèðëé
Úîèðëè
Úîèðéì
SECTION 27 - REAR AXLE 67
ïí
Úîèðéë
ïë ïë
ïê ïê
ïé
Úîèðéê
ïì
ïí
Úîèðéé
ïï ïî
Úîèðéè
68 SECTION 27 - REAR AXLE
Assembly
WARNING
Remove rests of dope.
Úîèðéç
ïì
ïç
ïê
Úîèðèð
ïï ïî
Úîèðéè
ïì
ïí
Úîèðéé
SECTION 27 - REAR AXLE 69
ïë ïë
ïê ïê
ïé
Úîèðèî
ïí
Úîèðèï
Úîèðéì
Úîèðëè
70 SECTION 27 - REAR AXLE
Úîèðêé
ï
Úîéíïê
Úîéíïë
ïè
Úîèðêè
SECTION 27 - REAR AXLE 71
Úîèðêç
Úîèðéð
Úîèðéï
ï
î
í
ì
ë
ê
é
è
ç
Úîèðèí
Disassembly
Úîçêìë
SECTION 27 - REAR AXLE 73
Úîèðèë
Remove the washer (6), the ring (5) and the shims
(4) from the bevel pinion (1).
ï
ì
ë
ê
Úîèðèê
í î
Úîèðèé
Úîèðèè
74 SECTION 27 - REAR AXLE
Úîèðèç
Assembly
Úîèðçð
Úîèðçï
Úîèðçî
SECTION 27 - REAR AXLE 75
Úîèðçí
Úîèðçì
Úîéííï
Úîèðçë
76 SECTION 27 - REAR AXLE
Insert the shim (2) on the bevel pinion (1) with cham-
fer against the gear.
Press the bearing (3) into the pinion, making sure í
that it is well set.
ï
Úîèðçê
Insert the shims (4) and (6) and the ring (5) into the
bevel pinion (1).
ï
ì
ë
ê
Úîèðèê
Insert the bevel pinion (1) unit into the central body
housing and the bearing (7) cone into the pinion
end. ï
Úîèðçé
Úîèðèì
SECTION 27 - REAR AXLE 77
Úîèðçè
78 SECTION 27 - REAR AXLE
ï î í í î ï
ë ë
ì ì
Úîèðçç
Toe-in
WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
ëðð ³³ ëðð ³³
Úîéíìð
Úîéíìï
SECTION 27 - REAR AXLE 79
Ó óðë
Úîéíìî
Úîéíìí
Úîéíìì
80 SECTION 27 - REAR AXLE
Steering angle
Úîéíìë
Úîéíìê
ë ì
Úîéíìé
Úîéíìè
SECTION 27 - REAR AXLE 81
PROBLEMS CAUSE
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
10. Incorrect adjustment of bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm thickness lower
than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
84 SECTION 27 - REAR AXLE
3. SPECIAL TOOLS
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. HAND BRAKE............................................................................................................................................... 6
2.1 HAND BRAKE ADJUSTMENT .............................................................................................................. 7
3. BRAKE CYLINDERS .................................................................................................................................... 8
4. OIL TANK.................................................................................................................................................... 13
5. BLEEDING PROCEDURE.......................................................................................................................... 13
2 SECTION 33 - BRAKES SYSTEM
SECTION 33 - BRAKES SYSTEM 3
1. TECHNICAL SPECIFICATIONS
2WS
4WS
2. HAND BRAKE
The hand brake is fitted to all models and incorpo-
rates two free floating friction pads.
When operated the cam (1) forces the friction pads
against the disc (2), effecting a braking action on the
output shaft from the transmission, locking the drive
shaft to the rear and front axles.
ïç
îð
í
ïç
î ïè
ï
ïé
îï
ïë
ïê
ïì
ïî ïí
ïï
ïð
ç
è
é
ê
ë
ì
Úîééëð
Adjust the cable clevis and lock the nut (1) to get 4 to
5 clicks on the hand brake lever.
8 SECTION 33 - BRAKES SYSTEM
3. BRAKE CYLINDERS
Brake cylinders are accessible from the engine com-
partment.
The brake cylinders are linked by a balancing pipe
(12) situated below the cylinders to maintain equal oil
pressure between the two cylinders.
1. Fitting 7. Seal
2. Pressure switch 8. Clevis
3. Fitting 9. Seals
4. Body 10. Secondary spool
5. Primary spool 11. Spring
6. Bottom 12. Balancing pipe
SECTION 33 - BRAKES SYSTEM 9
ï î í ì ë ê
ïð
ç è é
Úîçíéï
Trapped oil
Tank oil (no pressure)
ï î í ì ë ê
ïð
ç è é
Úîçíéî
ï î í ì ë ê
ïð
ç è é
Úîçíéí
5. BLEEDING PROCEDURE
1. Oil brake tank is full (1)
NOTE:
LB90.B
LB95.B
LB110.B
LB115.B
1. HYDRAULIC DIAGRAMS
1.1 HYDRAULIC DIAGRAM - 2WS CENTRE PIVOT MECHANICAL MODELS
ê
ì
ïç
ï
í
ë ïè
ïé
îî
îð
îï
ïê
ïï
ïë
ïî
ïì
é
ïí
ïð
è ç
Úîéëðé
4 SECTION 35 - HYDRAULIC SYSTEM
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinder
4. Loader bucket cylinder
5. Loader cylinder
6. Ride control valve
7. Pump
8. Oil cooler
9. Oil filter
10. Return
11. Hand hammer
12. Backhoe hammer
13. Backhoe digging cylinder
14. Bucket cylinder
15. Swing cylinder
16. Backhoe lifting cylinder
17. Telescopic cylinder
18. Stabilizers right cylinder
19. Stabilizers left cylinder
20. Loader control valve
21. Stabilizers control valve
22. Backhoe control valve
SECTION 35 - HYDRAULIC SYSTEM 5
ë ì í ê
Ü×ßÙÒ ÑÍÌ×Ý ß Þ
ÞËÔÕØÛßÜ
ï Ýî Ýï
Ê Ê Ê Ê
Êî з´ з´ Êî Êî з´ з´ Êî
ÓÈ
Ðî
Êî Êï
Èî Ì
Óï Óî ÔÍ Þï ß ï Þî ßî Þí ßí
Ðï
îî
¾ ¾ ¾
Ô Î
Ì
é Êî Ýî
ÞÔ
¿ ¿
з´
¿
Ìí
îï
Ì Ì
Þ ß ß
ÔÑßÜÛÎ
ÝÑÒ ÌÎÑÔ
Êß ÔÊÛ
îð
ïç
Ð ÔÍ Ì
Ì
î
ïí Ì
Ð
Êî Ýî
Þ Û ÞÔ
ïè
ïî з´
Êî Ýî
Êï Ýï
ïé
Êï Ýï
ÛÚ ÝÚ ÔÍ
Êî Ýî
ïê
è
ïë
ïï
ïð
ïì
ç
Úíðîçè
6 SECTION 35 - HYDRAULIC SYSTEM
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinder
4. Loader bucket cylinder
5. Loader cylinder
6. Ride control valve
7. Loader control valve
8. Pump
9. Oil cooler
10. Oil filter
11. Return
12. Hand hammer
13. Backhoe hammer
14. Backhoe control valve
15. Sideshift cylinders
16. Stabilizers right cylinder
17. Stabilizers left cylinder
18. Backhoe digging cylinder
19. Bucket cylinder
20. Swing cylinder
21. Backhoe lifting cylinder
22. Telescopic cylinder
SECTION 35 - HYDRAULIC SYSTEM 7
ï î
Ð Ð
Ì Ì
ê
ï í î ì ï í î ì
í ì ë
Ìï Ìî
ß Þ Ì Þ Ì Þ Ì ß Þ Ì ß Þ Ì Ì ß
Ì Ì Ì
Ìí
Ì Ý
ÔÍ
Ü Þ
Ð
ß
ßè Þè ßé Þé ß ê Þê ßë Þë ßì Þì ßí Þí ßî Þî ßï Þï Ó Ðî
é
Û Êï Êî
ïî ïì
ïï
Êï Êî
Ýï Ýî
ïð
ïí
Ýï Ýî
Úîéëðî
8 SECTION 35 - HYDRAULIC SYSTEM
Þ
îë
îî îí îì ß Þ
îð
ïç Ýî Ýï
ÓÈ
Ðî
Êî Êï
Èî Ì
Óï Óî ÔÍ Þï ßï Þî ßî Þí ßí
Ðï
¾ ¾ ¾
Ô Î
îê
¿ ¿
¿
Ìí
Ì Ì
Þ ß ß
Ð ÔÍ Ì
Ì
îï îé
îè
Ð Ý
Þ Û
ÛÚ ÝÚ ÔÍ
ïë
Û
ïè
ïê ïé
Úîéëðí
SECTION 35 - HYDRAULIC SYSTEM 9
ï î
Ð Ð
Ì Ì
ï í î ì ï í î ì
í ì ë ê
Ìï Ìî
ß Þ Ì Þ Ì Þ Ì ß Þ Ì ß Þ Ì Ì ß
Ì Ì Ì
Ìí
Ì Ý
ÔÍ
Ü Þ
Ð
ß
Ý ßè Þè ßé Þé ß ê Þê ßë Þë ßì Þì ßí Þí ßî Þî ßï Þï Ó Ðî
é
Û
Êï Êî
ïï ïî ïì
ïë Ýï Ýî
Êï Êî
ïð
Ýï Ýî ïí
Úíðîçç
SECTION 35 - HYDRAULIC SYSTEM 11
Þ
îì îë
îî îí ¨ï ß Þ
îð
Ýî з´ з´ Ýî Ýî з´ з´ Ýî
Ý Ý Ý Ý
ïç Ýî Ýï
Ê Ê Ê Ê
Êî з´ з´ Êî Êî з´ з´ Êî
ÓÈ
Ðî
Êî Êï
Èî Ì
Óï Óî ÔÍ Þï ßï Þî ßî Þí ßí
Ðï
¾ ¾ ¾
Ô Î
¿ ¿
¿
Ìí
Ì Ì
Þ ß ß
îê
Ð ÔÍ Ì
Ì
îï îé îè
Ð
Ý
Þ Û
ÛÚ ÝÚ ÔÍ
ïë
Û
ïè
ïé
ïê
Úíðíðð
12 SECTION 35 - HYDRAULIC SYSTEM
ï
è
ë ê é
îî
з´
îï
ç îð
ïç
ì ïð
ïï
ïè
з´
ïé
ïî ïê
îí
ïë
ïí ïì
Úíðíðï
14 SECTION 35 - HYDRAULIC SYSTEM
1. Rear axle
2. Front axle
3. Diagnostic
4. Steering control valve
5. Loader cylinder
6. Loader bucket cylinder
7. Bucket 4x1 cylinder
8. Ride control valve
9. Loader control valve
10. Hand hammer
11. Backhoe hammer
12. Pump
13. Oil cooler
14. Oil filter
15. Return
16. Stabilizers right cylinder
17. Stabilizers left cylinder
18. Backhoe digging cylinder
19. Backhoe bucket cylinder
20. Swing cylinder
21. Backhoe lifting cylinder
22. Telescopic cylinder
23. Backhoe control valve
SECTION 35 - HYDRAULIC SYSTEM 15
ï
ß Þ é è
¿ ¾ ë ê ì ¨ïóê¨ï ß Þ
¿ ¾ í
Ð Ì Ýî з´ з´ Ýî Ýî з´ з´ Ýî
Ý Ý Ý Ý
î Ê Ê Ê Ê
Ýî Ýï
Èî Ì
Óï Óî ÔÍ Þï ß ï Þî ßî Þí ßí
îî
Ðï
¾ ¾ ¾
Ô Î
Ì
ç Êî Ýî
ÞÔ
¿ ¿ îï
з´
¿
Ìí
Ì Ì
Þ ß ß
îð
ïç
Ð ÔÍ Ì
Ì
ì ïð ïï
Ì
Ð
Êî Ýî
Þ Û
ïè
ÞÔ
з´
Êî Ýî
Êï Ýï
ïé
Êï Ýï
ÛÚ ÝÚ ÔÍ
Êî Ýî
ïê
ïî
îì
ïë
ïì
îí
ïí
Úíðíðî
16 SECTION 35 - HYDRAULIC SYSTEM
1. Rear axle
2. Front axle
3. Diagnostic
4. Steering control valve
5. Loader cylinder
6. Loader bucket cylinder
7. Bucket 4x1 cylinder
8. Ride control valve
9. Loader control valve
10. Hand hammer
11. Backhoe hammer
12. Pump
13. Oil cooler
14. Oil filter
15. Return
16. Stabilizers right cylinder
17. Stabilizers left cylinder
18. Backhoe digging cylinder
19. Backhoe bucket cylinder
20. Swing cylinder
21. Backhoe lifting cylinder
22. Telescopic cylinder
23. Backhoe control valve
24. Sideshift cylinders
SECTION 35 - HYDRAULIC SYSTEM 17
ï î
ê
í ì ë
ïì
ïï ïî
ïð
ç ïí
Úîéìîê
18 SECTION 35 - HYDRAULIC SYSTEM
ïë
îî
ïç îð îï
ïé
ïê
îí
ïè îì îë
îê
îç
îé îè
Úîèïïì
SECTION 35 - HYDRAULIC SYSTEM 19
ï î
Ð Ð
Ì Ì
ï í î ì ï í î ì
í ì ë ê
é
Ìï Ìî
ß Þ Ì Þ Ì Þ Ì ß Þ Ì ß Þ Ì ß
Ì Ì Ì Ì
Ìí
Ì Ý
ÔÍ
Ü Þ
Ð
ß
Ý ßè Þè ßé Þé ß ê Þê ßë Þë ßì Þì ßí Þí ßî Þî ßï Þï Ó Ðî
Þ ×ó Ü×Î ß ËÈ
Û
Êï Êî
ïï ïî ïì
Ýî
ïë Ýï
Êï Êî
ïð
Ýï Ýî ïí
Úíðíðí
SECTION 35 - HYDRAULIC SYSTEM 21
Þ
ïê
ß Þ îï îî
¿ ¾ ïç îð ì¨ ¨ï ß Þ
¿ ¾ íð
Ð Ì Ýî з´ з´ Ýî Ýî з´ з´ Ýî
Ý Ý Ý Ý
ïé Ýî Ýï
Ê Ê Ê Ê
Êî з´ з´ Êî Êî з´ з´ Êî
ÓÈ
Ðî
Êî Êï
Èî Ì
Óï Óî ÔÍ Þï ßï Þî ßî Þí ßí
Ðï
¾ ¾ ¾
Ô Î
¿ ¿
¿
Ìí
Ì Ì
Þ ß ß
îí
Ð ÔÍ Ì
Ì
ïè îì îë
Ð
Ý
Þ Û
ÛÚ ÝÚ ÔÍ
îê
Û
ïç
îè
îé
Úíðíðì
22 SECTION 35 - HYDRAULIC SYSTEM
2. HYDRAULIC PUMP
2.1 DESCRIPTION AND OPERATION
TIGHTENING TORQUES
HYDRAULIC DIAGRAM
26 SECTION 35 - HYDRAULIC SYSTEM
î é
ê
Úîçìëé
The pressure on (CF) increases until the pressure value (standby pressure) is sufficient to move the spool valve
in a way to divert the flow toward (EF).
î é
ê
Úîçìëè
2.4 REMOVAL
2.5 COMPONENTS
3. CONTROL VALVES
3.1 CONTROL VALVES “HUSCO” (LB110.B CENTRE PIVOT MECHANICAL MODELS)
Úîçîîð
Úîçîîï
Úîçîîî
SECTION 35 - HYDRAULIC SYSTEM 35
Ü î í ì
Û ç è é ê Ú
ê
è
é
ç
ë
í
Û Ú
Úîçîîë
Neutral
Oil supply from the front pump flows directly into the
loader valve through port D.
If the loader arm and bucket control valves are in
neutral, oil flow continues through the staggered
open centre gallery before exiting at port F to flow to
the backhoe control valve at the rear of the machine.
Spool operation
When the bucket or loader control valves are
operated, flow through the staggered open centre
gallery is blocked by the operated spool and pump
(system) pressure rises in the parallel gallery.
The rise in pressure in the parallel gallery lifts the
circuit check valve of its seat and oil flows through
the check valve and over the spool to operate the
cylinder.
Exhaust oil from the operated cylinder returns
through the control valve exhaust gallery and back to
tank through port G.
Disassembly
Prior to disassembly the valve should be thoroughly
cleansed using an approved degreasant.
When reassembling the end cover progressively
tighten the clamping screws to following torques.
1. Main pump flow check valve 5. Bucket and loader valve section check valves
2. Spring seat 6. Spring seat
3. Spring 7. Spring
4. Valve body 8. Valve body
Inspection
The bucket and loader valve spools are selectively
fitted inside of relevant seats and if damaged the
mono block assembly must be replaced.
Inspect spools and bores for scores.
Reassembly
Reassembly follows the disassembly procedure in
reverse.
During reassembly the seals on either end of the
spools must be installed using seal insertion tool
380000728.
If the tool is not used the lip seals will be damaged
and subsequently leak.
The use of this tool is described hereunder.
A. Stabilizer left and right 6. Return to tank from stabilizer and telescopic
B. Telescopic dipper dipper circuits
1. Outlet end cover 7. Inlet port flow from rear hydraulic pump
2. Telescopic dipper section 8. Inlet end cover
3. Left hand stabilizer section 9. Telescopic dipper (piston end) relief valve - 124
4. Right hand stabilizer section bar
5. Rear pump relief valve - 196 bar
SECTION 35 - HYDRAULIC SYSTEM 47
ß î í ì Ý
î í ì
ß Ý
Úîçîìì
Stabilizer section
The stabilizer control valves are unique to all other
valve sections.
The stabilizers are operated by two levers (1) at the
rear of the cab.
Each stabilizer circuit incorporates a pilot operated
lock valve (2) which automatically prevents the leak
down or collapse of a stabilizer should a hose burst,
hydraulic system fail or the stabilizer levers are
moved if the stabilizers are extended and the engine
is turned off.
ï î í ì ë
ç è é ê
Úîçîìè
ï î í ì ë
ç è é ê
Úîçîìç
ï î í ì ë
ç è é ê
Úîçîëð
ï î í ì ë
ç è é ê
Úîçîëï
Removal
Lower loader to ground and position the dipstick in
the vertical plane with bucket positioned firmly on the
ground.
Stop the engine and relieve any residual pressure in
the backhoe and loader circuits by moving the loader
and backhoe control levers through all operating
positions.
Disconnect the battery.
Clean area around control valve.
Disconnect each hose connection to the valve and
plug hose ends. The use of a drip tray will be
required to catch oil draining from inside the hoses.
Remove valve from tractor.
Disassembly
1. Nut 8. O-ring
2. Stud 9. Left stabilizer section
3. Stud 10. Right stabilizer section
4. Outlet end cover 11. Rear pump relief valve
5. O-ring 12. O-ring
6. Telescopic dipper section 13. Inlet end cover
7. Telescopic dipper relief valve 14. Nut
54 SECTION 35 - HYDRAULIC SYSTEM
Inspection
Wash components in an approved degreasant.
Inspect spool and bore for scoring and damage.
If spool is badly scored or worn the valve assembly
must be replaced.
Reassembly
Reassembly follows the disassembly procedure in
reverse.
Lubricate spool before reassembly.
To avoid damage to O-ring seals on either end of
spools insert spool into valve housing before
installing O-ring (1) and wiper (2).
58 SECTION 35 - HYDRAULIC SYSTEM
î í ì ë
î í ì ë
è
é
Úîçîêî
Neutral
When all control valve sections are in neutral pump
oil flows through the staggered open centre gallery
and returns to tank through port (J).
Spool operation
When a control valve spool is operated flow through
the staggered open centre gallery is blocked.
Pump pressure will now rise with a corresponding
rise of pressure in the parallel gallery which is
blocked at the outlet end cover. When a spool is
operated the oil behind the circuit check valve is no
longer trapped. The rise in system pressure in the
parallel gallery lifts the check valve of its seat and oil
flows through the valve to operate the cylinder.
Exhaust oil
Exhaust oil from the cylinder returns via the spool
through the control valve exhaust gallery and back to
tank via the back pressure valve.
ï î í ì ë ê
ïð ç è é
Úîçîêì
ï î í ì ë ê
ïð ç è é
Úîçîêë
Removal
Lower loader to ground and position the dipstick in
the vertical plane with bucket positioned firmly on the
ground.
Stop the engine and relieve any residual pressure in
the backhoe and loader circuits by moving the loader
and backhoe control levers through all operating
positions.
Disconnect the battery.
Clean area around control valve.
Disconnect each hose connection to the valve and
plug hose ends. The use of a drip tray will be
required to catch oil draining from inside the hoses.
Disconnect control lever linkages (1).
Disassembly
Inspection
Wash components in an approved degreasant.
Inspect spool and bore for scoring and damage.
If spool is badly scored or worn the valve assembly
must be replaced.
Reassembly
Reassembly of the spool seals into each end of the
valve housing requires special care and the use of
Seal Insertion tool 380000728 must be used to
prevent damage.
The hydraulic circuit is a load sensing flow sharing Loader control valve
system working in conjunction with a fixed The loader control valve is mounted on the right
displacement gear type hydraulic pump. hand side of the machine adjacent to the pump.
This system has the advantage that at any time the The valve assembly consists of a maximum of three
distribution of flow to the services being operated is spool operated sections and provides oil flow to the
in proportion to the openings of the control valve loader boom, bucket and auxiliary services where
spools. fitted.
The flow distribution to the backhoe and loader
control valves is independent of the load and it is Backhoe control valve
therefore possible to operate two or more spools The backhoe control valve is located at the rear of
satisfactorily at the same time. the chassis.
The principal components of the load sensing flow The control valve consists of a maximum of seven
sharing system are the pressure compensator sections of spool control valves and provides the oil
valves in each control valve section, together with flow for operating the lifting, the digging, the bucket,
the load sense line which connects all the spool the stabilizers, the swing and telescopic arm
sections in both the loader and backhoe control (optional).
valve assemblies.
Because the hydraulic pump is a fixed displacement
gear type pump it should be noted that the load
sense line only connects the loader and backhoe
control valve assemblies and does not have any
connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and flow
from the front pump is directed to the centre
galleries of the loader and backhoe control valves
assemblies.
Flow from the rear section of the pump passes
through the load sensing flow divider valve mounted
on the pump and gives priority flow to the steering
circuit with remaining flow directed to supplement
the flow from the front pump for the loader and
backhoe circuits.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply circuit is controlled by the
pump flow balancer valve in accordance with the
pressure in the load sense line.
Consequently the higher the load sense pressure
the less flow is returned to tank with corresponding
increase in flow/pressure to the hydraulic circuits.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure
in the load sense line when it reaches 210 bar.
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.
72 SECTION 35 - HYDRAULIC SYSTEM
ï
î
ë
é
ê
Úîçîèé
ï î í
ì ì ì
Úîçîèè
ï
î
ë
é
ê
Úîçîèç
ï î í
ì ì ì
Úîçîçð
ï
î
ë
é
ê
Úîçîçï
ï î í
ì ì ì
Úîçîçî
Removal
Lower the loader to the ground, with the bucket
firmly placed on the ground.
Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Unscrew and remove clamping screws to chassis.
Remove the control valve assembly from the
machine.
Installation is the reverse of the removal procedure.
Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 ± 2 Nm. Slide out the three tie rods (2).
Removal
Position the tractor on a hard level surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Disconnect the battery.
Clean the area around the control valve.
Tag and identify the position of all hoses.
Disconnect and plug all the hoses.
Disconnect the levers of the manual control.
Unscrew and remove clamping screws to chassis.
Remove the control valve assembly from the
tractor.
Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm.
Slide out the three tie rods (2).
Disassembly
Remove the screws (A), the boot along with its
plate (B) and the plate (C).
Remove the mounting screws (D) and the cover
(E).
Remove the spool (F) from the valve section.
Remove the lip seal (L).
Reassembly
Reassemble parts in reverse order after greasing
the spring.
Position the metal part of the lip seal (L) on the
outside of the spool.
The lip seal must be fitted on the end of the spool
so that it is not damaged by the spool grooves (N)
and its tightness is not damaged.
Slide the lip seal perpendicularly onto the spool.
Tighten the screws (A and D), the adapter (H) and
the tongue (M) from 9 to 11 Nm.
86 SECTION 35 - HYDRAULIC SYSTEM
WARNING
The lip seal must be fitted on the end of the spool so
that it is not damaged by the spool grooves (N) and
its tightness is not damaged.
Disassembly
Remove the tongue and the cover sides.
Use a spool clamp (G) and a vice to secure the
spool.
Using a metal rod (minimum length = 80 mm,
diameter 6) push the central ball (H) while
extracting the detent bush (I).
Mark the orientation of the detent bush for the
reassembly.
Remove the balls (J) and the spring (K) from the
adapter (M).
Reassembly
Introduce the spring (K) into the adapter (M).
Place the 3 balls (J) into the radial holes of the
adapter (M) and use grease to prevent them from
falling.
Position the central ball (H) against the spring (K).
Slip the detent bush (I) onto a metal rod.
Using the metal rod, press the central ball (H) into
the adapter (M), then slide the detent bush (I) onto
the adapter, making sure that the 3 balls are still in
place.
Removal
Lower the loader to the ground, with the bucket firmly
placed on the ground.
Stop the engine and eliminate any residual pressure
in the backhoe and loader circuits by moving the
loader and backhoe control levers through all
operating positions.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Unscrew and remove clamping screws to chassis.
Remove the valve assembly from the machine.
Installation is the reverse of the removal procedure.
Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 ± 2 Nm. Slide out the three tie rods (2).
Removal
Position the tractor on a hard level surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Stop the engine and eliminate any residual pressure
in the backhoe and loader circuits by moving the
loader and backhoe control levers through all
operating positions.
Disconnect the battery.
Clean the area around the control valve.
Tag and identify the position of all hoses and
hydraulic tubes.
Disconnect and plug all the hoses and all the
hydraulic tubes.
Unscrew and remove clamping screws to chassis.
Remove the control valve assembly from the tractor.
Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm.
Slide out the three tie rods (2).
Disassembly
Remove the screws (A), and the plate (B).
Extract the spring guides (C) and the springs (D).
Discard the seals (E).
Remove the spool (F) from the valve section.
Reassembly
Grease and install the spool (F) in the valve
section.
Install the springs (D) in the caps (B).
Install the spring guides (C) in the springs (D).
Install new seals (E).
Install the cap assemblies on the valve section,
install and tighten the screws (A) to a torque of 9 to
11 Nm.
SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE (WITH HYDRAULIC CONTROL)
Removal
Position the tractor on a hard level surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Disconnect the battery.
Clean the area around the solenoid valve.
Tag and identify the position of all hoses and
hydraulic tubes.
Disconnect and plug all the hoses and all the
hydraulic tubes.
Unscrew and remove clamping screws to chassis
supporting the operating levers.
Remove the solenoid from the tractor.
Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).
98 SECTION 35 - HYDRAULIC SYSTEM
In case of necessity it is possible to disassemble the Check and possibly replace the O-rings (10).
various solenoid valves from the manifold blocks. Remove check valve (11) and orifice (12).
Untighten and remove screws (6). Untighten and remove solenoid valves (13).
Disassemble solenoid valves (7). Check and possibly replace the O-rings (14).
Check and possibly replace the O-rings (8). Untighten and remove solenoid valves (15).
Untighten and remove valve (9). Check and possibly replace the O-rings (16).
SECTION 35 - HYDRAULIC SYSTEM 99
ACCUMULATOR “PARKER”
Technical specifications
Capacity (gas) ...........................................................................................................................................2 litres
Capacity (oil) ........................................................................................................................................1.84 litres
Precharge ........................................................................................................................................... 30 ± 1 bar
Maintenance
Check the gas pre-charge pressure regularly during the first few weeks of operation, and then at suitable
intervals afterwards based on this initial experience.
Carry out a visual examination of the accumulator periodically in order to detect any early signs of
deterioration such as corrosion, deformation etc.
Comply with the regulatory provisions concerning the monitoring of operational equipment.
Before removal, it is vital to ensure that there is no residual hydraulic pressure in the accumulator. Discharge
the gas side of the accumulator using a Parker UCA charging and gauging assembly before carrying out any
maintenance operations
Safety
Charging must be carried out by qualified personnel.
Before taking any readings or pressurizing with nitrogen, the accumulator must be isolated from the hydraulic
system and the fluid side discharged in order to depressurize it.
Use only nitrogen (N2) to pressurize the accumulator.
Warning - Stabilization
The process of charging or discharging an accumulator with nitrogen causes a temperature change which is
transmitted to the surrounding air as the temperature of the accumulator stabilizes. To allow for the effects of
temperature transfer, the accumulator should be allowed to stand for a minimum of 15 minutes before a final
reading of the precharge pressure is taken.
100 SECTION 35 - HYDRAULIC SYSTEM
A. Inflation valve
B. Bleed valve
1. UCA
2. Adapter (long)
3. Adapter (short)
4. Adapter (insert)
5. Pressure gauge
6. Protective cap - gauge port
7. Collar - gas port
8. Knurled protective cap - filling port
9. Hose (G1/4 fitting, 60° cone) with O-ring
10. Valve
RELIEF VALVES
The relief valves may be operated with anti-
cavitation feature (1) or direct acting (2) and protect
individual circuits from excessive pressure.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston é ê ë ì Úîçëìï
Anti-cavitation operation
Circuit relief valves with an anti-cavitation feature
are fitted in circuits where rapid extension of the
cylinder could create a void condition and permit the
transfer of oil from the high pressure side of a
cylinder to the lower pressure (void) end of the
cylinder.
When for example the boom is rapidly lowered and
the cylinder rod end circuit relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is
automatically replenished by the anti-cavitation
device in the opposite circuit relief valve as follows:
The void creates a pressure lower in the cylinder
supply gallery and back pressure in the control valve
exhaust gallery acts on the outer face of the sleeve
poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.
î
ï
ë ì Úîçëìî
é ê ë ì Úîçëìí
ê ë î Úîçëìì
ê ë î Úîçëìë
Exhaust oil
High pressure circuit oil
SECTION 35 - HYDRAULIC SYSTEM 107
Overhaul
1. Body 9. O-ring
2. Poppet 10. Locknut
3. Spring 11. O-ring
4. Spring 12. Adjuster
5. O-ring 13. Spring
6. O-ring 14. Pilot valve
7. Fitting 15. Piston
8. Cap 16. Poppet valve
108 SECTION 35 - HYDRAULIC SYSTEM
1. Body 6. Cap
2. Poppet 7. O-ring
3. Spring 8. Locknut
4. Spring 9. O-ring
5. Shim 10. Adjuster screw
Hydraulic feed to the swing cylinders is controlled by If the swing control valve is suddenly returned to
the swing section of the backhoe control valve which neutral mid-way through a full power swing the
contains pilot operated relief valves with anti supply and exhaust ports in the main control valve
cavitation feature to protect the circuit and cylinders are totally blocked.
should an overload condition occur. The momentum of the swinging backhoe assembly
The diagram illustrates operation of the swing circuit if not controlled will make the machine extremely
when retracting the right hand cylinder (4) and unstable.
extending the left hand cylinder (5) in order to swing To prevent this from occurring the circuit relief
the backhoe to the right. valves operate and dumps oil to exhaust until the
When swinging the backhoe to the left the oil flows excess pressure is relieved. When the relief valve
are reversed and exactly the same principle of operates the cylinder rod will move and a void will be
operation applies. created in the low pressure side of the cylinder. The
Oil flow for a right hand swing is as follows: anti-cavitation feature in the relief valves prevent the
When the swing control is operated the control valve void from occurring by transferring exhaust oil from
directs oil flow to the rod end of the right hand the excess pressure side of the circuit to the low
cylinder. pressure side.
The flow of oil at pump pressure lifts the one way
restrictor (2) of its seat allowing the flow to continue
unrestricted to the inlet port of the piston end of the
left hand cylinder.
System pressure increases causing the right hand
cylinder to retract and the left hand cylinder to
extend.
As the cylinders move, displaced oil on the piston
side of the left hand cylinder flows towards the one
way restrictor (7) in the inlet port on the rod end of
the right hand cylinder.
The oil flow moves the restrictor to the restrict
position which limits the flow of oil and creates a
back pressure (1st stage restricted return oil) in the
right hand cylinder.
The restricted flow of oil passes through restrictor
(7) into the rod end of the left hand cylinder before
returning to the control valve and back to tank.
The spool in the swing control valve assembly (1) is
designed such that during operation oil can flow
freely through the port directing oil flow to the swing
cylinders but restricts the flow returning oil back to
tank.
This restriction is achieved using metering lands
machined into the lands of the spool and creates a
secondary back pressure (2nd stage restricted
return oil) in the rod end of the cylinder.
By allowing oil to flow unrestricted to the power side
of the cylinder and be restricted on the exhaust side
a smooth controlled swing of the backhoe at
optimum speed is achieved.
When the swing system reaches the last 20-25° of
travel the sliding restrictor in the end of the piston
rod touches the outlet port in the cylinder barrel.
This further restricts the flow of oil exhausted from
the cylinder and as the piston moves towards the
end of its stroke the sliding restrictor is gently
pushed down the centre of the cylinder rod allowing
a progressive and controlled halt to the swing cycle.
SECTION 35 - HYDRAULIC SYSTEM 113
é î
ê í
ë ì
Úîçìèð
OPERATION
5. HYDRAULIC CYLINDERS
1. Loader cylinder
2. Loader bucket cylinder
3. Bucket cylinder 4x1
4. Backhoe boom cylinder
5. Backhoe dipper cylinder
6. Backhoe bucket cylinder
7. Cylinder telescopic
8. Cylinder swing backhoe
9. Stabilizer cylinder (centre pivot models)
10. Stabilizer cylinder (sideshift models)
11. Backhoe sideshift locking cylinder (sideshift models)
118 SECTION 35 - HYDRAULIC SYSTEM
4WS
1. Stroke
2. Completely retracted
2WS
1. Stroke
2. Completely retracted
SECTION 35 - HYDRAULIC SYSTEM 119
Úîèéëé
WARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal
injury may occur.
Úîèéëç
WARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal
injury may occur.
Úíðíïè
í ì
Úíðíîð
WARNING
Cylinder weight: 36 kg.
Only if required:
Remove from the cylinder head (7), the wiper ring
(3), the seal (4), the seal (5), the bearing sleeve (6)
and the back-up ring (9) with O-ring (10).
Remove from the piston (11) the seal (12) and the
ring guide (13).
124 SECTION 35 - HYDRAULIC SYSTEM
4WS
1. Stroke
2. Completely retracted
2WS
1. Stroke
2. Completely retracted
SECTION 35 - HYDRAULIC SYSTEM 125
Remove the ring (2) with the dowel (3). Remove the
pin (4) using an hammer to release the rod (5).
126 SECTION 35 - HYDRAULIC SYSTEM
1. Bushing 9. O-ring
2. Rod 10. Piston
3. Wiper ring 11. Piston seal
4. Seal 12. Piston ring guide
5. Seal 13. Screw
6. Cylinder head 14. Tube
7. Snap ring 15. Bushing
8. Back-up ring
WARNING
Cylinder weight: 32.5 kg
CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket firmly on the ground.
Relieve the residual pressure in the system by
moving the loader control lever through all operating
positions.
SECTION 35 - HYDRAULIC SYSTEM 131
Remove the pin (2). Slide out the pin (1) with an
hammer.
Unscrew and remove the nut (6) and the dowel (5).
Slide out the lower pin (7) with an hammer.
DISASSEMBLY CYLINDER
(1) Stroke
(2) Completely retracted
with long dipper
with short dipper
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
WARNING
Cylinder weight (with short dipper): 77.5 kg
Cylinder weight (with short dipper): 80.5 kg
Pull out the cylinder head (7) from the cylinder tube
(16) by tapping with a plastic hammer. Remove
cylinder rod (3) and the cylinder head (7).
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Untighten and remove the nut (1) and the dowel (2).
Hammer to slide out the rod pin (3).
If necessary use hydraulic power to very slowly
retract the cylinder so that the rod comes clear of the
attaching point.
WARNING
Cylinder weight: 64 kg
Pull out the cylinder head (7) from the cylinder tube
(15) by tapping with a plastic hammer. Remove
cylinder rod stem (3) and the cylinder head (7).
Only if required:
remove from the cylinder head (7), the wiper ring
(4), O-ring (5), the guide bush (6), and the back-up
ring (8) with O-ring (9);
remove from the piston (12) the piston ring guides
(10) the and piston gasket (11).
SECTION 35 - HYDRAULIC SYSTEM 141
(1) Stroke
(2) Completely retracted
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Remove the stop ring (1) with the shim (2). Slide out
the pin (3) by means of hammer and pay attention to
levers.
If necessary use hydraulic power to very slowly
retract the cylinder.
WARNING
Cylinder weight: 64 kg
Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a plastic hammer. Remove the
cylinder rod (3) and the cylinder head (7).
Only if required:
remove from the cylinder head (7), the wiper seal
(4), O-ring (5), the bearing sleeve (6), and the back-
up ring (8) with the O-ring (9);
remove from the piston (12) piston the ring guide
(11) and the piston gasket (10).
SECTION 35 - HYDRAULIC SYSTEM 145
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
WARNING
Cylinder weight (with short telescopic): 41.5 kg
Cylinder weight (with long telescopic): 45 kg
Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a plastic hammer. Remove
cylinder rod (1) and the cylinder head (7).
Only if required:
remove from the cylinder head (7), the wiper ring
(2), the seal (3), the seal (4), the guide bush (5), the
O-ring (9) with the back-up ring (8);
remove from the piston (12) the piston ring guide
(11) and the piston gasket (10).
SECTION 35 - HYDRAULIC SYSTEM 149
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Make sure that the backhoe loader is locked in the
transfer position or parked in a safety work position.
Lower the stabilizers to the ground.
WARNING
Cylinder weight: 43.5 kg
Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a plastic hammer. Remove the
cylinder rod (1) and the cylinder head (7).
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
bucket on the ground.
1. Rod 8. O-ring
2. Wiper ring 9. Piston
3. Seal 10. Piston ring guide
4. Seal 11. Piston gasket
5. Cylinder head 12. Screw
6. Snap ring 13. Cylinder tube
7. Back-up ring
WARNING
Cylinder weight: 33.7 kg
Pull out the cylinder head (5) from the cylinder tube
(13) by tapping with a plastic hammer. Remove the
cylinder rod (1) and the cylinder head (5).
Only if required:
remove from the cylinder head (5), the wiper ring
(2), the seal (3), the seal (4), and the back-up ring
(7) with O-ring (8);
remove from the piston (9) the piston ring guide
(10) and the piston gasket (11).
SECTION 35 - HYDRAULIC SYSTEM 157
(1) Stroke
(2) Completely retracted
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
WARNING
Cylinder weight: 31 kg
CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket on the ground.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Úíðíîï
Úíðíîî
162 SECTION 35 - HYDRAULIC SYSTEM
Úíðíîí
WARNING
Before moving machine forward check that backhoe
is still fully supported by the hoist and remains
stable.
Úíðíîì
í ì
Úíðíîë
SECTION 35 - HYDRAULIC SYSTEM 163
6. CONTROL LEVERS
6.1 TECHNICAL SPECIFICATIONS
Disassembly
Release pressure in the hydraulic circuits using the
following procedure: turn key switch “ON”, but do not
start the engine. Turn pilot control cancellation
switch to the “ON” position. Move both joysticks in all
directions. Turn key switch “OFF”. Disconnect the
negative battery cable(s).
Mark the position of the lever parts (see the
exploded view on previous pages).
Remove knob (P) and support (S).
Remove bracket (O) with relevant screws (with left
control lever).
Lift rubber boot (RL) for left control lever and (RR)
for right control lever.
170 SECTION 35 - HYDRAULIC SYSTEM
Reassembly
To reassemble the control levers, proceed in the
reverse order to that of removal.
Follow the marks made during disassembly, and
tighten the nut (4) to a torque of 36 to 44 Nm.
SECTION 35 - HYDRAULIC SYSTEM 171
P. Supply
T. Tank return
Disassembly
1. Mark the direction of installation of all 15. Separate the upper (4) and lower (19) bodies
disassembled parts. and replace the seals (20) and (21).
2. Remove the U/J cam (1) using a key.
3. Remove the plate (2). Reassembly
4. Remove the shim (3) from the upper body (4). 1. To reassemble, proceed in the reverse order to
5. Extract the rod guide (5) and replace the seals that of removal.
(6) and (7). 2. In the case of reassembly without changing the
6. Drift the rod (8) out. U/J cam (1), put the same value of shims (3) as
7. Remove the bearing (9), the spring (10) and the those in place.
shims (11). 3. After changing the U/J cam (1) adjust the
8. Extract the spool assembly. pressure of the cam on the rods.
9. Hold the cup (12) and remove the lock ring (13). 4. Install a 2 mm shim (3), check that the recessing
10. Remove the spring (14) and the spool (15). of the push-rods is less than 0.2 mm, modify the
11. Remove and note the thickness of the shims shimming to more or less if required.
(16). 5. Install new seals (6), (7), (18), (20) and (21).
12. Proceed in the same manner for the other rods. 6. Lubricate the moving parts.
13. Secure the upper body (4) in a vice. 7. Apply brake thread fluid on the threads of the U/
14. Loosen and remove the screw (17) using a key J cam (1) and the screw (17).
and replace the seal (18). 8. Tighten the U/J cam (1) to 50 Nm and the screw
(17) to 50 Nm.
174 SECTION 35 - HYDRAULIC SYSTEM
7.2 FAULT FINDING (WITH “HUSCO” CONTROL VALVES) - LB110.B CENTRE PIVOT
GENERAL
Restricted pump suction line Inspect suction line and tank, repair
as necessary.
Slow operation or loss of power Pump worn Perform pump performance test and
in all circuits replace/reseal as necessary.
Restricted pump suction line Inspect suction line and tank, repair
as necessary.
Backhoe and loader circuits fail to Main system relief valve leaking Perform main system relief valve
operate or operate slowly while or incorrectly adjusted pressure test.
telescopic dipper and stabilizers
operate correctly Front pump worn Perform pump performance and
pressure test and overhaul as
necessary.
BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. The backhoe chart
should only be referred to if the supply circuit is performing normally, thereby confirming that the pump and
hydraulic supply circuits are functioning to specification. See also “Fault finding hydraulic pump”.
SWING
LOADER
HYDRAULIC PUMP
Hydraulic oil exhausts from Tank overfilled Check hydraulic oil level.
breather at the tank
Aeration: air entering the system Hydraulic pump performance test.
at: suction tube, pump shaft,
fittings, or cylinder glands
Setting of relief valve too high or Drain tank and refill with clean oil.
too low Test relief valves.
Oil in system too light Drain tank and refill with correct
viscosity oil.
7.3 PRESSURE TESTING (WITH “HUSCO” CONTROL VALVES) - LB110.B CENTRE PIVOT
Steering standby
Install 0 - 200 bar pressure gauge in middle test port
on left hand side of machine.
Set engine speed to 1000 rev/min.
WARNING
When removing circuit relief valves from the machine
observe the following procedure:
FLOW TESTING
Analysis
If flow (B) recorded in step 4 is less than 69 litres/min
the front pump is worn and requires overhaul.
Subtract the flow (B) recorded in step 4 from the flow
(A) recorded in step 3.
This is the flow from the rear pump under “no load”
conditions and should be greater than 53 litres/min.
If the flow is less than 53 litres/min the rear pump is
worn and requires overhaul.
Example:
Combined pump flow (no Load) = A
Front pump flow (under load) = A-B
Rear pump flow = B
GENERAL
Restricted pump suction line Inspect suction line and tank, repair
as necessary.
Slow operation or loss of power in Pump worn Perform pump performance test and
all circuits replace/reseal as necessary.
Restricted pump suction line Inspect suction line and tank, repair
as necessary.
LOADER
BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. The backhoe chart
should only be referred to if the supply circuit is performing normally, thereby confirming that the pump and
hydraulic supply circuits are functioning to specification. See also “Fault finding hydraulic pump”.
SWING
HYDRAULIC PUMP
Setting of relief valve too high or Drain tank and refill with clean oil.
too low Test relief valves.
Oil in system too light Drain tank and refill with correct
viscosity oil.
Steering standby
Install 0 - 40 bar pressure gauge into the middle test
port (1) on left hand side of machine.
Set engine speed to 1000 rev/min.
Ensure no turning force is being applied to the
steering wheel and observe pressure on gauge.
The pressure gauge should read approximately 17
bar and is the steering standby pressure.
If pressure incorrect remove and examine flow
divider spool on end of pump.
Loader bucket relief valve (piston end) Dipper bucket and boom relief valves
Set engine speed to 2200 rev/min. These relief valves are set to a higher pressure than
Hold the loader bucket control lever to the right the main system relief valve setting of 210 bar. To
causing the bucket to dump. test these circuit relief valves operate each service
Observe the upper gauge which should read 160 until the corresponding relief valve operates.
bar minimum and is the operating pressure of the If pressure reading in each incidence is 210 bar.
loader bucket, piston end, relief valve. Values up to The system relief valve is operating and it is an
190 bar are acceptable. indication that relief valves are set correctly.
Adjust valve if not to specification. Dipper bucket circuit relief valve (rod end)
To test rod end circuit relief valve hold lever to the specification is 220 bar. Dipper boom circuit relief
left and curl in the bucket. If pressure reading is 210 valve setting (piston end) is 240 bar.
bar the system relief valve is operating and it is an To accurately test the dipper bucket (rod end) and
indication that relief valve which is set at 230 bar is boom (piston end) relief valves the main system
set correctly. pressure can be temporarily increased to 240 bar.
Do Not increase pressure setting to higher than 240
Telescopic dipper relief valve (piston end) bar and reset system relief valve to 210 bar on
Set engine speed to 2200 rev/min. completion of test.
Fully extend the telescopic dipper and continue to dipper boom circuit relief valve setting (rod end) is
depress the control pedal. 315 bar and can not be checked using this system.
Observe the reading on the gauge. Replace this valve if considered faulty.
Pressure recorded is the telescopic dipper relief
valve setting and should read 165-167 bar
minimum. Values up to 200 bar are acceptable.
Adjust valve if not to specification.
FLOW TESTING
Analysis
If flow recorded in step 3 is less than 69 litres/min the
pump is worn and requires overhaul.
ÍÛÝÌ×ÑÒ íç ó ÝØßÍÍ×Í
ÛÒÙ×ÒÛ
Supported by 2 rubber silent blocks and held in po- λ³±ª»æ
sition by 2 support brackets. The brackets, which Air Cleaner bowl
are welded to the frame one either side of the en- Engine guard and panels
gine are positioned just ahead of the loader posts. Radiator’s and related hoses (Or pivot forward
where possible)
ÉßÎÒ×ÒÙ Front support cowling (if required)
The engine and transmission bolted together act as
a one piece unit. If separated in the machine they Ü·-½±²²»½¬æ
are not self supporting and will collapse causing in- Fuel pump throttle cable and electric shut off
jury or damage to the machine. Engine harness
Fuel tank connection and leak off return pipes
Hydraulic pump and related pipework (plug all ports
ÌÑÎÏËÛ ÝÑÒÊÛÎÌÑÎ as required)
Transmission Lever
Fitted between the engine and the transmission can
Transmission harness connectors
only be removed when the engine/transmission as-
Engine supports (with engine supported by hoist)
sembly are separated.
Transmission supports
ÌÎßÒÍÓ×ÍÍ×ÑÒ
Attached to the rear of the engine and supported in
rubber silent blocks in fixed brackets and held within
the frame just at the rear of the loader post.
To make repairs that require disassembly of the
transmission or engine it will be necessary to re-
move the engine/transmission as a complete unit
from the chassis.
To remove the engine/transmission from the ma-
chine it will be necessary to remove or disconnect
the following:
SECTION 39 - CHASSIS 7
ÝÑËÒÌÛÎÉÛ×ÙØÌ
ÌßÒÕÍ
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.
ÝßÞ
In the following table are the torques for the various assemblies that should be removed to affect repair.
×ÓÐÑÎÌßÒÌæ always ensure prior to carrying out repairs on the machine that the vehicle parking brake is on
and the wheels are chocked.
ÛÒÙ×ÒÛñÌÎßÒÍÓ×ÍÍ×ÑÒ
ù
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Engine/Transmission retaining bolts and nuts 95 Nm
Engine coolant tank retaining bolts 25 Nm
Engine/Transmission bolts 95 Nm
Air cleaner retaining bolts to frame 25 Nm
Coolant radiator bolts to frame 95 Nm
Radiator retaining bolts to frame 95 Nm
Front panel cowling to frame 214 Nm
Front bonnet to frame 170 Nm
Upper and front panel to frame 80 Nm
Front cardan joint to axle 38 Nm
Front cardan joint to transmission 38 Nm
Rear cardan joint to axle 38 Nm
Rear cardan joint to transmission (PS) 38 Nm
Rear cardan joint to transmission (PT) 70 Nm
ÚÎÑÒÌñÎÛßÎ ßÈÔÛ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Front axle retaining bolts to frame (2WS) 500 Nm
Front axle retaining bolts to frame (4WS) 500 Nm
Rear axle to frame retaining bolts (2WS) 800 Nm
Rear axle to frame retaining bolts (4WS) 900 Nm
ØÇÜÎßËÔ×Ý ÍÇÍÌÛÓÍ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Power steering hoses to support frame 55 Nm
Backhoe control valve to frame bolts 90 Nm
Loader control pipes clamp to frame 25 Nm
ÌßÒÕ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Oil tank holding bolts 85 Nm
Fuel tank holding bolts 85 Nm
SECTION 39 - CHASSIS 13
ÚÎÑÒÌ ÝÑËÒÌÛÎÉÛ×ÙØÌÍ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Weight 700 Nm
ÔÑßÜÛÎ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Loader control pipe bracket to frame 25 Nm
ÞßÝÕØÑÛ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Backhoe to frame hose retaining clamps 52 Nm
Boom to swing bracket 190 Nm
Stabilizers upper pins retaining bolt 80 Nm
ÝßÞ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Cab support 450 Nm
Front cab retaining bolts 210 Nm
Rear cab retaining bolts 180 Nm
ÉØÛÛÔÍ
ÝÑÓÐÑÒÛÒÌÍ ÌÑÎÏËÛÍ
Front/rear wheels to axle (4WS) 700 Nm
Front wheel to axle (2WD) 330 Nm
Front wheel to axle (4WD) 330 Nm
Rear wheel to axle (2WS) 540 Nm
14 SECTION 39 - CHASSIS
ÒÑÌÛæ
ÔÞçðòÞ
ÔÞçëòÞ
ÔÞïïðòÞ
ÔÞïïëòÞ
Úîçíéç
Úîçíèì
Ìí
Ðí
ßí Þí
ßî Þî
Ðî
Ìî
Úîçëîç
X = Energized
O = Not Energized
í¿ í¾ î¿ î¾
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
íò ÐÑÉÛÎ ÍÌÛÛÎ×ÒÙ
The steering unit consists of a metering pump that wheel, through column, that can be of two types:
includes: fixed or adjustable.
a gear wheel assembly with fixed stator (with inner A cardan shaft, mechanically tied to gear wheel as-
teeth) and a rotor (with outer teeth). sembly and to outer sleeve, allows the movement
A 4 ways rotary distributor consisting of an outer transmission.
sleeve and an inner selection rotor. Set of centering springs between outer sleeve and
The selection rotor is connected to the steering inner rotor.
Ì×ÙØÌÛÒ×ÒÙ ÌÑÎÏËÛÍ
ÝÑÓÐÑÒÛÒÌ ÓßÈ×ÓËÓ Ì×ÙØÌÛÒ×ÒÙ ÌÑÎÏËÛ Ò³
3/4 - 16 UNF 60
7/16 - 20 UNF 20
Steering wheel nut 55
Steering motor to steering column bracket 23
Power steering end cover 30
Power steering pipe connection 45
Power steering pipe adaptors 55
Check valve bolt 30
Shock valve (4WS) 30
14 SECTION 41 - STEERING SYSTEM
ØÇÜÎßËÔ×Ý Ü×ßÙÎßÓ
íòî ÝÑÓÐÑÒÛÒÌÍ
Ü×ÍßÍÍÛÓÞÔÇ
To gain access to the power steering the bonnet and
air cleaner should be removed.
Screw out the screws (18), the screw (17) and the
washers (16) from the end cover (15).
SECTION 41 - STEERING SYSTEM 17
Shake out the check valve ball (3) and suction valve
pins (21) and balls (20). Replace pins (21) prior to
the reassembly.
Press out the cross pin (8). Use the special screw
(17) from the end cover. A small mark has been
made with a pumice stone on both spool and sleeve
close to one of the slots for the neutral position
springs (see drawing). If the mark is not visible, re-
member to leave a mark of your own on sleeve and
spool before the neutral position springs are disman-
tled.
Shake out the two springs and two valve balls into
your hand. The valve seats are bonded into the
housing and cannot be removed.
ÝÔÛßÒ×ÒÙ
Clean all parts carefully.
ÔËÞÎ×ÝßÌ×ÑÒ
Before assembly, lubricate all parts with hydraulic
oil.
22 SECTION 41 - STEERING SYSTEM
ßÍÍÛÓÞÔÇ
Guide the spool (1) into the sleeve (2). Make sure
that spool and sleeve are placed correctly in relation
to each other.
SECTION 41 - STEERING SYSTEM 23
ïò Spool
îò Sleeve
êò Needle bearings
êßò Outer bearing race
êÞò Needle bearing
êÝò Inner bearing race
Lubricate the lip seal (24) with hydraulic oil and place
it on the assembly tool.
Press and turn the lip seal into place in the housing.
The spool set will push out the assembly tool guide.
The O-ring and Roto Glyd are now in position.
Guide the cardan shaft (9) down into the bore so that
the slot is parallel with the connection flange.
SECTION 41 - STEERING SYSTEM 29
ßò Rotor/stator surface
Þò Plate surface
Ýò Pin axis
Üò Housing surface
Ûò Inner gear case
Úò Cardan shaft
Fit the special screw (17) with washer (16) and place
it in the hole shown.
SECTION 41 - STEERING SYSTEM 31
Fit the six screws (18) with washers (16) and insert
them. Cross-tighten all the screws and the rolled pin
with a torque of 30 ± 6 Nm in the sequence shown,
initial torque of 10.8 Nm.
Screw plug with seal ring into the two shock valves
and tighten them with a torque of 30 ± 10 Nm.
Fit the dust seal ring in the housing using the special
tool and a plastic hammer.
ÐÎÛÍÍËÎÛ ÌÛÍÌ×ÒÙ
Connect a suitable pressure gauge capable of read-
ing up to 200 bar to the connector inside the left
hand loader support.
Start engine. A standby pressure of 6-7 bar should
be observed.
Turn steering to the left or right to the stop. A max-
imum pressure of 180 bar should be seen.
ÒÑÌÛæ
LB90.B
LB95.B
LB1ï0.B
LB115.B
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING .................................................................................................................................. 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS.................................................................................................................... 16
3.3 DESCRIPTION AND OPERATION...................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 25
3.5 FLUSHING THE SYSTEM................................................................................................................... 43
3.6 EVACUATING THE SYSTEM.............................................................................................................. 45
3.7 CHARGING THE SYSTEM.................................................................................................................. 46
3.8 COMPONENTS OVERHAUL .............................................................................................................. 47
3.9 COMPRESSOR ................................................................................................................................... 51
3.10 SPECIAL TOOLS............................................................................................................................... 65
2 SECTION 50 - CAB HEATING AND AIR CONDITIONING
SECTION 50 - CAB HEATING AND AIR CONDITIONING 3
1. TECHNICAL SPECIFICATIONS
HEATING
ENGINE RADIATOR COOLANT
Antifreeze - Ambra Agriflu 12 litres
Water 12 litres
System type Pressurized FULL FLOW by-pass with
expansion chamber
FAN BELT DEFLECTION
Naturally aspired 13 - 19 mm
Turbocharged 10 - 16 mm
THERMOSTAT
Start to open at 82 °C
Fully open at 95 °C
Radiator cap 0.90 bar
TORQUE VALUES
Coolant/hot water hose connections 5 Nm
Air hose ducting connections 5 Nm
Heater housing to floor mounting bolts 6.2 Nm
CHECK CONDITIONS
Air inlet temperature 37.8 °C
Rated air inlet moisture 40%
Evaporation temperature 0 °C
Overheating 5 °C
Inlet air speed 1.0 - 2.0 - 3.0 m/s
Condensation temperature 58 °C (absolute 16 bar)
Undercooling 2 °C
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.
WARNING
The cab air filters are designed to remove dust from
the air but may not exclude chemical vapour. When
working in an enclosed area ensure there is ade-
quate ventilation as exhaust fumes can suffocate
you.
Heater radiator
The heater radiator (1) is fitted in a housing under
the cab seat for central displacement of warm or cold
air flow.
NOTE: the vents (B) and (C) are mounted only when
air conditioned (optional) is fitted.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 7
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WARNING
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Once this operation is complete, reset pin (A) in the
correct start position.
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Reinstall the heater valve, repeating the previous
operation in the reverse order.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 9
FAULT FINDING
Excessive air leak (s) around doors Repair and Seal air leak(s).
and windows
Blower motor air flow low Blocked filter or recirculation filter Clean or replace filter(s).
Heater hose from engine to cab Ensure water flow to heater radiator
radiator, kinked or blocked is adequate and not restricted.
Cab does not cool Heater control turned on Turn temperature control knob fully
counterclockwise for maximum
cooling.
OVERHAUL
Úîèêéì
Heater radiator
With the system drained remove the heater radiator
hose connections, attaching bolts and remove from
the vehicle.
Inspect the heater radiator (3).
Check water flow through the heater pipe which
should be free running; if not, clear any blockage.
Fins should be free of all debris and not damaged;
clean and or repair.
Clean the heater radiator using compressed air not
exceeding 7 bar 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.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 11
Blower motor
The blower motor (1) can be removed by removal of
the attaching hardware and disconnection of the wir-
ing connector.
Check the blower is working, if not check fuse and
continuity of blower motor. If defective replace the
blower unit as an assembly.
Úîèêéç
12 SECTION 50 - CAB HEATING AND AIR CONDITIONING
3. AIR CONDITIONING
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 13
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14 SECTION 50 - CAB HEATING AND AIR CONDITIONING
EXPANSION
VALVE
LOW
LOWER TEMPERATURE
TEMPERATURE HIGH PRESSURE
LOW PRESSURE LIQUID FILTERED
ATOMIZED LIQUID AND MOISTURE
REMOVED
RECEIVER DRYER
LOWER
TEMPERATURE
EVAPORATOR
HIGH PRESSURE
LIQUID
CONDENSER
WARM LOW
PRESSURE
VAPOUR
HIGH
TEMPERATURE
HIGH PRESSURE
VAPOUR
COMPRESSOR
It can now be seen that the principal components of The figure in the this page shows in schematic form
an air conditioning system are: the flow of refrigerant through the five major compo-
Refrigerant nents of an air conditioning system.
Compressor Refrigerant is drawn into the compressor as a cool,
Condenser low pressure vapour which is compressed and then
Receiver dryer pumped out as a hot, high pressure vapour to the
Expansion valve condenser.
Evaporator As the hot, high pressure vapour passes through the
The figure in the previous page uses the examples condenser core it gives off heat to the cooler outside
above to illustrate the air conditioning cycle. air, being drawn past the fins by the engine cooling
fan.
16 SECTION 50 - CAB HEATING AND AIR CONDITIONING
By giving off heat to the outside air, the vapour is the cab warm air blown across the coils and fins by
condensed to a liquid which moves under high pres- the cab blower motor. The refrigerant now changes
sure to the receiver dryer where it is stored until re- from a cold low pressure atomized liquid to a warm
leased to the evaporator by the temperature low pressure vapour and leaves the evaporator out-
sensing expansion valve. let, moving to the suction (low pressure) side of the
As liquid refrigerant passes through the metered or- compressor to repeat the cycle.
ifice in the expansion valve the refrigerant changes As this heat loss is taking place, moisture (humidity)
from a high pressure liquid to a low pressure atom- in the cab air will condense on the outside of the
ized liquid with a lower temperature. evaporator and drain off as water through the drain
This low pressure, low temperature, atomized liquid hoses attached to the evaporator drain pan, thereby
enters the evaporator coils and absorbs heat from reducing the humidity level of the cab.
WARNING
The air filter is designed to remove dust from the air
but may not exclude chemical vapour. Refer to
chemical manufacturers directions regarding protec-
tion from dangerous chemicals.
REFRIGERANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air condition- WARNING
ing system, requires the use of a suitable “refriger- If refrigerant should contact the skin use the same
ant” a liquid that has a relatively low temperature treatment as for frostbite.
boiling point, plus certain desirable safety and sta- Warm the area with your hand or lukewarm water
bility features. 32 °C, cover the area loosely with a bandage to
The refrigerant used in the air conditioning system is protect affected area against infection and consult
refrigerant HFC 134a. a doctor immediately.
If refrigerant should contact the eyes wash imme-
NOTE: to help protect the environment legislation diately in cold clean water for at least 5 minutes
has been introduced in most territories banning the and consult a doctor immediately.
release into the atmosphere of refrigerants, includ-
ing HFC 134a. All service procedures contained in
this manual can be carried out without the need to
release refrigerant into the atmosphere.
WARNING
HFC 134a refrigerant is not compatible with R-12
refrigerant. Do not attempt to replace HFC 134a re-
frigerant with R-12 refrigerant or test the system us-
ing gauges or equipment previously used with R12
as damage to the system will result.
WARNING
HFC 134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
explosion, and the production of phosgene gas.
Never disconnect or disassemble any part of the air-
conditioning system as escaping refrigerant can
cause frostbite.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 19
COMPRESSOR
The air conditioning compressor is mounted on the
left hand side of the engine and is belt driven from
the crankshaft pulley.
The compressor separates the low and high pres-
sure sides of the system and has two functions:
1. To raise the refrigerant temperature by com-
pression to a higher degree of temperature than
the ambient (outside air) temperature.
2. To circulate the required volume of refrigerant
through the system.
The refrigerant compressor is a seven cylinder wob-
ble plate unit housed in a die cast aluminium hous-
ing.
Drive to the wobble plate is from the pulley, through
the electro-magnetic clutch to the main driveshaft.
Attached to the driveshaft is a cam rotor which oscil-
lates the wobble plate. The wobble plate is prevent-
ed from rotating by a static gear engaging with teeth
formed in the face of the plate. The seven pistons are
connected to the wobble plate by rods located in ball
sockets.
Refrigerant is drawn in on the downward stroke of a
piston through the reed valves located either end of
the cylinder assembly. Refrigerant enters the cylin-
der assembly through a gallery in the outer circum-
ference of the cylinder assembly.
The upwards stroke of the piston compresses the re-
frigerant and expels it through another reed valve
into an inner gallery in the cylinder assembly and out
into the refrigerant circuit.
The compressor is lubricated with a Polyalklene Gly-
col (PAG) oil Type SP20. This oil is miscible with the
refrigerant and is carried around the refrigerant cir-
cuit.
The compressor is activated by an electro-magnetic
clutch which functions to engage or disengage the
compressor as required in the operation of the air
conditioning system.
The clutch is primarily activated by the:
·Temperature control
·Low pressure cut-out switch
20 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Temperature control
The air conditioner temperature control switch is
mounted on the blower motor assembly.
The switch is a device which turns the compressor
clutch on and off to maintain a constant average
evaporator temperature and senses the evaporator
temperature using a thermistor (1).
The temperature control switch compares the volt-
age of the thermistor, which is dependent on the
temperature of the evaporator, with the voltage
across the potentiometer of the “in cab” temperature
control switch.
The switch upon comparing the two voltages deter-
mines whether the compressor clutch should be
switched “on” or “off” in order to maintain the desired
in cab temperature control.
CONDENSER
The condenser (1), located at the front of the ma-
chine in front of the engine radiator consists of a
number of turns of continuous coil mounted in a se-
ries of thin cooling fins to provide a maximum of heat
transfer in a minimum amount of space.
RECEIVER DRYER
The receiver/dryer (2) situated behind the battery
stores the liquid refrigerant to be sure a steady flow
to the thermostatic expansion valve is maintained
under widely different operating conditions.
The drier section contains a desiccant (Molecular
sieve) to absorb any moisture within the system and
a filter prevents the entry of foreign particles.
EXPANSION VALVE
The expansion valve (1) is located underneath the
evaporator in the pressure line leading from the re-
ceiver/ dryer and performs the following unctions:
1. METERING ACTION
A metered orifice changes the liquid refrigerant
from a high pressure low temperature liquid to a
low pressure, lower temperature atomized liq-
uid.
2. MODULATING ACTION
A thermostatically controlled valve within the ex-
pansion valve body controls the volume of liquid
refrigerant passing through the orifice and
makes sure the refrigerant is fully vaporized
within the evaporator. Liquid refrigerant at would
damage the compressor reed valves or freeze
the pistons.
3. CONTROLLING ACTION
The valve responds to changes in the cooling re-
quirements. When increased cooling is required,
the valve opens to increase the refrigerant flow
and when less cooling is required the valve clos-
es and decreases the refrigerant flow.
EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature refrigerant in the evaporator ab-
sorbs heat from the hotter air in the operator’s com-
partment, thereby cooling the air.
Air Recirculation
An intake grille is located on the left side of the seat
base. A portion of the air flow will recirculate through
the evaporator.
Filter General
The blower fan, draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recircula- î
tion grille (1). The air passes over the evaporator
then into the cab through the six louvered vents.
Two vents are located on the front instrument panel
to direct air onto the windshield. Two are located at
the base of the rear posts to direct air onto the rear
window. Two additional vents are located at the front
and rear of the seat base to direct air at the opera- ï
tor’s feet.
Úîçíîé
Blower Fan
The blower motor is controlled by a three-speed
switch (3) which uses a variable resistor to change
the fan speed.
High blower speed provides the greatest volume of
circulated air, however, a slower speed will allow the
air to contact the cooling fins and coils of the evapo-
rator for a longer period resulting in the warm air giv-
ing up more heat to the cooler refrigerant. Therefore,
the coldest air temperature is obtained when the
blower fan is operated at the lowest speed.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 25
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NOTE: for Dealers who posses the latest design In the closed position, refrigerant circulates around
level of refrigerant recovery, recycling and recharg- the valve stems to the gauges. Therefore, when the
ing station, these gauges are an integral part of the manifold gauge set is connected into a system,
machine. pressure is registered on both gauges.
NEVER open the HIGH SIDE shut off valve when
The following instructions for performance testing the system is operating.
the air conditioning system is based on the use of ALWAYS open the LOW SIDE shut off valve when
the gauge set shown. The principal of operation is adding refrigerant.
however similar when testing the system using a re-
covery and recharging station with integral gauges.
When using this type of equipment always consult
the manufacturers operating instructions.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 27
Attaching The Gauge Set To The Tractor 2. Re-check that both the high and low side shut
off valves on the manifold gauge set are fully
WARNING closed.
To avoid personal injury, stop the tractor engine dur- 3. Run the engine at 1000-1200 rev/min.
ing connection of the manifold gauge set. 4. Turn the heater temperature control “off”.
5. Operate the system at maximum cooling, with
1. Check that the gauge set shut off valves are the blower fan at high speed for 10 minutes to
closed (turned fully clockwise). stabilize all components.
2. Connect the high side gauge hose (normally 6. Check the manifold low pressure gauge reading
red) to the high pressure (discharge) side serv- is within the specified range of approximately
ice valve and the low side gauge hose (normally 0.28-2.48 bar.
blue) to the low pressure (suction) side service 7. Check the manifold high pressure gauge read-
valve on the tractor. Ensure the hose connec- ing and compare the reading to the pressure in-
tions are fully tightened. dicated on the pressure temperature chart
below.
IMPORTANT: prior to connection of the manifold 8. Measure and compare the temperature of con-
gauge set, identify the suction (low pressure) and ditioned air entering the cab through the lou-
discharge (high pressure) service gauge ports. The vered air vents with the ambient air at the air
high pressure service valve is always in the line from intake filters on the outside of the cab.
the compressor to the condenser. If the system is operating correctly the condi-
tioned air entering the cab should be 6-9 °C
The high and low pressure service valves on the cooler than the ambient temperature of the out-
tractor are spring loaded valve and will be automat- side air.
ically opened when the test hose is connected. 9. If it is confirmed that the system is not operating
correctly refer to the fault diagnostic charts and
NOTE: the test hose must incorporate a valve de- performance test gauge reading examples on
pressor to actuate this type of valve. the following pages for possible corrective ac-
tion.
The service valves have a protective cap. This cap
must be removed for test gauge connections and re- WARNING
placed when service operations are completed. A significant amount of refrigerant vapour may have
condensed to a liquid at the service fitting at the high
Test Procedure
side of the compressor. Use a cloth or other protec-
After the manifold gauge set has been connected
tive material when disconnecting the manifold hose
and before pressure tests can be made, the system
from this fitting to prevent personal injury to hands
must be stabilized as follows:
and face.
1. Apply the parking brake, check the gear shift le-
vers are in neutral and close the cab windows
and doors.
Evacuate system.
Evacuate system.
High pressure switch cutting Overcharged with refrigerant Check for overcharge as follows:
out
Air in system Stop the engine. Recover and
recycle the charge using correct
recovery equipment.
Recharge the system with the
correct quantity of refrigerant,
replacing any lost lubricant. Recheck
performance of air conditioning
system.
Evaporator air not cold Expansion valve allowing too much Check expansion valve as follows:
refrigerant to flow through the
evaporator Set for maximum cooling.
Low pressure gauge should lower
slowly.
If expansion valve is defective:
Discharge System.
Replace Expansion Valve.
Evacuate System.
Charge System.
Re-test.
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PROBLEM DIAGNOSIS
Insufficient cooling. System refrigerant is extremely low. A serious leak
is indicated.
CAUSE
Refrigerant excessively low. NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
CONDITIONS* For proper high side gauge reading for other ambi-
Low side pressure very low. ent temperatures, refer to the pressure temperature
Gauge should read 1-2 bar. chart.
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Discharge and recover the refrigerant from the
system.
3. Repair leaks.
4. Check compressor oil to ensure no loss.
5. Evacuate the system.
6. Charge the system.
7. Performance test the system.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 33
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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 1-2 NOTE: * test procedure based upon ambient tem-
bar. perature of 35 °C.
For proper high side gauge reading for other ambi-
High side pressure too low. Gauge should read ent temperatures, refer to the pressure temperature
13.3-14.8 bar. chart.
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PROBLEM At this point, operate the system and check its per-
Insufficient or no cooling. Engine overheats in some formance. If still unsatisfactory, proceed as follows:
cases. 4. Discharge and recover the refrigerant from the
system.
CAUSE 5. Remove the condenser and clean and flush it to
Condenser not functioning properly. ensure a free flow of refrigerant. Or, if the con-
denser appears to be unduly dirty or plugged,
CONDITIONS* replace it.
Low side pressure too high. Gauge should read 1-2 6. Replace the receiver/dryer.
bar. 7. Evacuate the system, and recharge it with the
High side pressure too high. Gauge should read correct quantity of refrigerant.
13.3-14.8 bar. 8. Performance test the system.
Liquid line hot.
Evaporator air warm. DIAGNOSIS
High pressure switch cutting out. Lack of cooling caused by pressure that is too high
on the high side, resulting from improper operation
CORRECTIVE PROCEDURES of condenser. (Refrigerant charge may be normal or
1. Check belt. Loose or worn drive belts could excessive).
cause excessive pressures in the compressor
head. NOTE: * test procedure based upon ambient tem-
2. Look for clogged passages between the con- perature of 35 °C.
denser fins and coil, or other obstructions that For proper high side gauge reading for other ambi-
could reduce condenser airflow. ent temperatures, refer to the pressure temperature
3. If engine is overheating replace engine thermo- chart.
stat and radiator pressure cap.
36 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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Evaporator air not cold. NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
For proper high side gauge reading for other ambi-
ent temperatures, refer to the pressure temperature
chart.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 37
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Evaporator air warm. NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
Evaporator and suction hose (to compressor) sur- For proper high side gauge reading for other ambi-
faces show considerable moisture. ent temperatures, refer to the pressure temperature
chart.
CORRECTIVE PROCEDURES
1. Check for sticking expansion valve as follows:
Operate the system at maximum cooling.
Check the low side gauge. The pressure should
lower slowly.
38 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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CORRECTIVE PROCEDURES
1. Stop the engine and shut off A/C system.
2. Replace thermostatic switch with switch of same
type.
SECTION 50 - CAB HEATING AND AIR CONDITIONING 41
Leak Testing
To perform a leak test if refrigerant leakage is sus-
pected, use a leak detector following the manufac-
turer’s instructions.
Leak detectors use light or sound dependent upon
the type used to alert the operator of a leak. If the
leak detector’s sensitivity is adjustable, be sure you
calibrate the detector according to the manufactur-
er’s instructions before use.
When using a leak detector, keep in mind that a very
slight amount of leakage in the compressor pulley
area is normal and does not necessarily indicate a
repair is required. Úîèéðè
Úîèéðç
42 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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Other recovery systems are available where the tractor air conditioning system. The hose from the
manifold gauges are not an integral part of the ma- recovery unit is then connected to the manifold cen-
chine. When this type of equipment is used a sepa- tre port.
rate manifold gauge set must be used.
The following is a summary of the steps for dis- 3. To recover refrigerant, open both high and low
charging the system using a recovery/recycling unit. side valves on the control panel or the valves on
the manifold gauge set if being used.
WARNING 4. Open the valves labelled “gas” and “liquid” on
Never discharge refrigerant gas into the atmos- the recovery unit refrigerant tank.
phere. Always wear safety goggles and gloves 5. Plug in the unit’s power cord.
when working with refrigerant. Only use authorized 6. Operate the recovery system in accordance with
refrigerant tanks. the manufacturers instructions.
The compressor will shut off automatically when the
recovery is complete.
IMPORTANT: always follow the manufactures in-
structions when operating recovery equipment.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 45
3.7 CHARGING THE SYSTEM conditioning so that the compressor can pull the
remainder of the refrigerant into the system.
5. If the refrigerant charge will not completely
IMPORTANT: be sure there are no leaks in the sys- transfer to the air conditioning system, recover
tem and the system has been fully evacuated. Ob- and recharge the system.
serve all safety recommendations when handling 6. Close the high and low side valves on the units
refrigerant HFC 134a, see “Precautions when Han- control panel, or manifold gauge set if being
dling Refrigerant HFC 134a” in this Section. used and test the air conditioning as detailed in
Performance testing the air conditioning system
1. Ensure the charging unit is correctly connected on page 25.
to the tractor air conditioning system in accord-
ance with the manufacturers instructions. NOTE: after charging a system use the following
2. If a charging unit, in conjunction with the mani- start up procedure to ensure the lubricating oil is
fold gauge set is used, open the high and low properly dispersed around the system.
side hand valves on the manifold.
3. Charge the system with 0.75 kg of refrigerant as Ensure air conditioning is switched OFF.
per the manufacturers instructions. Start the engine and bring speed down to idle.
4. If the charging rate becomes very slow close Turn the air conditioning ON and allow system to
the high side valve carefully, start the tractor operate for at least one minute before increasing
and set engine speed to idle. Turn ON the air engine speed.
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GENERAL
WARNING
Before disconnecting components in the air condi-
tioning system the refrigerant gas must be dis-
charged and recovered using a certified recovery
system. Refer to Discharging the system. Do Not
discharge the gas into the atmosphere.
EXPANSION VALVE
The expansion valve is not a serviceable item and
must be replaced if defective.
1. Fully discharge the air conditioning system.
2. Remove the seat to gain access to the valve.
3. To gain access to the expansion valve partially
lift the evaporator core from its position in the
cab floor.
4. Remove the screw securing the inlet and outlet
connections to the valve and pull valve from tub-
ing.
5. Replace the O-ring seals and lubricate with re-
frigerant oil prior to installing the valve using dis- Úîèéïì
EVAPORATOR
1. Discharge and reclaim refrigerant gas using cer-
tified recovery systems.
2. Remove the seat and cover plate to reveal evap-
orator assembly (1).
3. Remove temperature cycling control thermocou-
ple.
4. Disconnect tubing to expansion valve.
5. Remove evaporator.
6. Check the evaporator assembly fins for damage.
Straighten fins if necessary.
7. Clean the evaporator core of all foreign material
to be sure it is free of obstructions.
8. Check the evaporator assembly for indications
of refrigerant leakage. If damage or leaks are ev-
ident, replace the evaporator core.
If a new evaporator is to be installed drain the refrig-
erant oil in the evaporator into a clean calibrated
container. Measure the quantity of oil obtained and
add the same quantity of new refrigerant oil directly
into the replacement evaporator core.
Install evaporator using disassembly procedure in
reverse.
Evacuate, leak test and recharge the system.
RECEIVER DRYER
The receiver/dryer (3) cannot be overhauled and
must be replaced as an assembly. The receiver/dry-
er assembly should be replaced if it is suspected that
moisture is in the system.
The receiver dryer must also be replaced if the sys-
tem has been discharged and the air conditioning
joints disconnected.
1. Discharge and reclaim refrigerant gas using cer-
tified recovery systems.
2. Disconnect the hoses and switch and remove
the dryer from the tractor.
3. Drain the refrigerant oil from the receiver dryer
into a clean calibrated container. Measure the
quantity of oil obtained and add the same quan-
tity of new refrigerant oil directly into the new
item.
4. Cap and plug all fittings to prevent any dirt enter-
ing the system.
5. Install a new receiver dryer.
50 SECTION 50 - CAB HEATING AND AIR CONDITIONING
CONDENSER
1. Remove the front grid. Unscrew and remove the
upper fixing nuts. Shift the filter sideways. Dis-
connect the connections to the condenser.
2. The removal of the attaching bolts allows the
condenser to be raised for cleaning. Remove
condenser from machine.
3. Inspect the condenser assembly fins for damage
and be sure they are not plugged.
4. Check the condenser for signs of leakage. If the
condenser is damaged or leaking, install a new
condenser assembly.
5. If the condenser is to be replaced, drain the re-
frigerant oil from the condenser into a clean cal-
ibrated container. Measure the quantity of oil
obtained and add the same quantity of new re-
frigerant oil directly into the new condenser.
6. Soak new tubing connector O-rings in clean re-
frigerant lubrication oil and install onto tubing.
7. Evacuate, leak test and recharge the system.
8. Install the grid.
3.9 COMPRESSOR
TECHNICAL SPECIFICATIONS
Belt tension
Measure at the widest gap.................... 10 mm deflection with 1 kg force applied midway between the pulleys
Speed rating
MAXIMUM RPM
Constant Downshift
6000 8000
Tightening torques
COMPONENT Nm
Armature retaining nut, M8 17.7±2.9
Cylinder head bolts, M6 13.7±2.9
Cylinder head bolts, M8 34.3±4.9
Clutch dust cover screw, M5 9±2
Oil filler plug 19.6±4.9
52 SECTION 50 - CAB HEATING AND AIR CONDITIONING
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.
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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).
54 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Installation
Installation is the reversal of the removal but the fol-
lowing points should be noted:
Torque the fixing bolts to 40-51 Nm.
the compressor.
Reconnect the hoses to the compressor and tight-
en all bolts and hoses.
Úîèéîë
SECTION 50 - CAB HEATING AND AIR CONDITIONING 55
Úîèéîê
OVERHAUL COMPRESSOR
Before any internal repair is done, drain the oil from
the compressor:
Remove the oil plug and drain as much oil as pos-
sible into a suitable container.
Remove the caps (if present) from suction and dis-
charge ports.
Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retain-
ing nut.
Úîèéîé
Úîèéîè
56 SECTION 50 - CAB HEATING AND AIR CONDITIONING
CLUTCH
ï î í ì ë ê é è ç ïð
Úîèéîç
Disassembly
All clutch servicing should be done with the com-
pressor removed from the vehicle. Support the com-
pressor. If using a vice, do not hold on to the
housing. If dust cover (2) is present, remove the 3 or
6 bolts (1) holding it in place and remove cover. If
auxiliary sheet metal pulley is present, remove the
screws holding it in place. Then remove pulley. ì
Attach tool to the cover on the front of the clutch
plate and placing a socket and ratchet through the
tool remove the cover attaching nut (3).
Úîèéíð
Using the front plate tool and a tommy bar hold the
clutch plate stationary.
Place the bolt into the tool and by tightening the bolt
onto the end of the shaft the front plate will be ex-
tracted from the shaft.
If shims (5) are above shaft key, remove them now.
If shims (5) are below shaft key, the key and bearing
dust cover (if present) must be removed before
shims can be removed.
Remove dust cover (6) (if present). Use caution to
prevent distorting cover when removing it.
Remove shaft key by tapping loose with a flat blade
screwdriver and hammer. Remove shims (5). Use a Úîèéíï
Remove the snap ring (7), remove the shaft key and
lift the pulley assembly from the compressor.
Úîèéíî
Úîèéíí
Úîèéíì
Úîèéíë
58 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Lift the coil (10) from the housing and replace as re-
quired. ïð
Úîèéíê
Assembly
Install the field coil (10), ensuring that the wire is lo-
cated back at cable clip on the outside of the body
and snap ring (9) is placed in the groove. ïð
Úîèéíé
Úîèéíè
Úîèéíî
SECTION 50 - CAB HEATING AND AIR CONDITIONING 59
Úîèéíð
è
Úîèéìï
Úîèéìî
60 SECTION 50 - CAB HEATING AND AIR CONDITIONING
COMPRESSOR
ë ê é è ç ïð
ï í
î ì
Úîèéìí
Removal
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior
to replacing the shaft seal.
Remove the armature plate, as detailed in the
steps of clutch disassembly.
Remove the shaft key (1), shims and ring (2) to ex-
pose the snap ring (3). í
Remove the snap ring (3).
Úîèéìì
Úîèéìë
SECTION 50 - CAB HEATING AND AIR CONDITIONING 61
Installation
Thoroughly clean the seal cavity in the hub. Use “lint
free” cloth only.
Ensure the new shaft seal O-ring is installed onto
the seal assembly. Dip the new seal assembly in
clean refrigerant oil and attach to the seal remover/
installer tool.
Úîèéìê
Úîèéïç
Install the snap ring (3). If the snap ring has a bevel-
led edge this should face outwards.
Úîèéìì
Úîèéïí
62 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Position the shims over the shaft and refit the shaft
key.
Reinstall the plate as described in clutch reassem-
bly.
Úîèçïï
SECTION 50 - CAB HEATING AND AIR CONDITIONING 63
CYLINDER HEAD
Disassembly
Drain the refrigerant oil from the compressor into a
clean calibrated container. Measure and record the ïð ç
quantity of oil obtained. This information is required
during installation of the new or overhauled unit.
Remove the six cylinder head bolts (10) and using a
hide mallet, gently tap the cylinder head (9) free.
The use of a gasket scraper may also be required to
free the cylinder head from the compressor body.
Úîèéìé
Úîèéìè
Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage. é
Úîèéìç
Reassembly
Coat the top of the valve plate with clean refrigerant
oil and reassemble the cylinder head using the re-
verse of the disassembly procedure.
When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins
in the cylinder block.
Install the cylinder head bolts and tighten using the
sequence shown. Torque initially to 20 Nm.
When the overhaul is complete add to the compres-
sor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.
Úîèéëð
64 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Preliminary Inspection
1. Rotate the compressor shaft. Use a suitable
socket on the hub centre bolt or by hand using
the rubber dampers.
If severe roughness is felt while rotating the hub,
the compressor should be disassembled.
2. Using a 12 volt battery check current drawn by
the field coil which should be between 3.6-4.2
Amps.
Very high current readings indicate a short cir-
cuit in the field coil and no current reading indi-
cate an open circuit. Replace coil with either
fault. Resistance of the coil using an ohmmeter Úîèéëï
Úîèéëî
SECTION 50 - CAB HEATING AND AIR CONDITIONING 65
Only certified refrigerant recovery, recycling and recharge equipment suitable for the type of refrigerant gas
HFC 134a should be used on these vehicles when servicing the air conditioning system.
This special equipment is available through recognized suppliers of air conditioning equipment. Refer to the
“Tool supplier” for details on the latest equipment available for servicing the air conditioning system.
NOTE:
ÔÞçðòÞ
ÔÞçëòÞ
ÔÞïïðòÞ
ÔÞïïëòÞ
1. GENERALITIES ............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB ........................................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB ............................................................................... 24
2.3 ELECTRICAL DIAGRAMS - 4WS........................................................................................................ 43
2.4 ELECTRICAL DIAGRAMS - ROPS ..................................................................................................... 62
3. CONTROLS AND INSTRUMENTS ............................................................................................................ 77
3.1 FRONT INSTRUMENT PANEL ........................................................................................................... 77
3.2 SIDE INSTRUMENT PANEL ............................................................................................................... 79
3.3 DIAGNOSTIC SIGNALING .................................................................................................................. 81
3.4 CALIBRATION OF SPEEDOMETER .................................................................................................. 83
3.5 IMMOBILISER CIRCUIT...................................................................................................................... 84
4. STARTING SYSTEM .................................................................................................................................. 85
4.1 DESCRIPTION AND OPERATION...................................................................................................... 85
4.2 FAULT FINDING.................................................................................................................................. 86
4.3 STARTER MOTOR.............................................................................................................................. 89
5. ALTERNATOR............................................................................................................................................ 95
5.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 95
5.2 DESCRIPTION AND OPERATION...................................................................................................... 95
5.3 COMPONENTS ................................................................................................................................... 97
5.4 REMOVAL ........................................................................................................................................... 98
5.5 PRELIMINARY CHECK AND TESTS.................................................................................................. 99
5.6 FAULT FINDING................................................................................................................................ 108
6. BATTERY ................................................................................................................................................. 109
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 109
2 SECTION 55 - ELECTRICAL SYSTEM
ïò ÙÛÒÛÎßÔ×Ì×ÛÍ
ïòï ÌÛÓÐÑÎßÎÇ É×Î×ÒÙ ØßÎÒÛÍÍ ÎÛÐß×Î
îò ÛÔÛÝÌÎ×ÝßÔ Ü×ßÙÎßÓÍ
îòï ÛÔÛÝÌÎ×ÝßÔ Ü×ßÙÎßÓÍ ó ÐÑÉÛÎÍØËÌÌÔÛ ÝßÞ
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
Rear windshield wiper and rear windshield washer (15 Õïî
F1A
A)
Õïð Õïï
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A)
F1C Stop lights switch (10 A) ÞÆï Õï
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat, buzzer (15 A) Õî
Üê
F2B Conditioner fuse (15 A) Üì
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
K1 Forward-reverse speed switch relay
Õïî
K2 Speed alarm, hand brake relay
Õïð Õïï
K3 Starting relay
K4 Grab level solenoid valve relay ÞÆï Õï
K5 Traffic and main beam lights relay
Õî
K6 Inner front work lights relay Üê
Üì
K7 Inner rear work lights relay
K8 Outer front work lights relay
K9 Outer rear work lights relay
K10 Reverse speed relay
K11 Forward speed relay
K12 Flasher Õí
Õì
Õë
Õê
Õé
Õè
Õç
Úîéïêé
SECTION 55 - ELECTRICAL SYSTEM 7
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
XD Fuel shut off diode 2 way connector
XX Diodes 5 way connector
XY Safety seat switch 2 way connector
10 SECTION 55 - ELECTRICAL SYSTEM
ÛÒÙ×ÒÛ Ô×ÒÛ
ÍÌï
ïë
ïð îð
Íïé ÊóÞï ë îë
Æï
ÙóÎï Î ÐÓ ¨ ïðð íð
ßóÙï »´ »½¬®± ²· ½
ððð ðð ðð ¸
ÔóÞï
ÎóÒïòë èòï
ÙñÒï èòì
ÓóÞï îòí
Íëð
ÓóÒï
îòì
Íïè
ÔóÙï
íòï
ßîòë
ßîòë
ßîòë
õïë
í îòë
Îê
õíð
ï
îòí
Õí èé
î ìòí
èë íð
õïë
ïëß
Õïí
ÕÝ
ÙóÊïòë èòì
ÙÎ×Ü ØÛßÌÛÎ
ÌÑ ÝÑÔÜ
ÍÌßÎÌ Õ×Ì
ÞóÒï
Õðï
èê èé èê èé
èë íð èë íð
ïðß
Îïê
Îéð
Ùï
Óï Óïð
ï îÊ ½½
ëð
Ùî Îí
íð
Ó Íìç Ó
Üõ
É
Íîð Íîï Íìè Íîì Íîë
íð Ù
° í ° ° ¬ ° ¬
Ë
¬
Íìé íï
íï
îòï
Úîéïèè
SECTION 55 - ELECTRICAL SYSTEM 11
ÎñÒï
ìòï
ÓóÊï
î ê ï ë ç ï ç × Ú Ò Î ÒÑ
ï ï ð ×
î ð Ú
ð
Î
Íî
ì è í é ïð
Íí
ë ïð
õ õ Ò×
Íìð
ÓñÞï
Ýï ìòì
Òï ìòï
ÎóÒï
ëòï
í
ïòì
éôëß
õïë õïë
õïë
ïðß ëß
ï
ïòì
Õïð Õïï
Õï èé Õì èé èé èé Õî èé
èë íð èë íð èë íð èë íð èë íð
ÕÝ
ÓóÒï
ÓóÞï ïòî
ïòî
ÎóÊï ÎóÊï íòë
Øßï
íï íï
ïòë íòï
Úîéïêç
12 SECTION 55 - ELECTRICAL SYSTEM
ï ç ï ç ï ç ï é ç
ï ð ï ð ï ð ï ð Øï
ë ïð ë ïð ë ïð ë ïð
Òï êòï
ÔóÙï
ïòî
ÎóÊï
îòë
Ííð
ï
Èíê
Þ·¼·®»½¬·±²¿´
ÐÉÓ
Ü®·ª»® ÛÊïî
ÛÊë ÛÊí
ÛÊï
ÍÌí
íï íï
îòë ìòï
Úîéìêì
SECTION 55 - ELECTRICAL SYSTEM 13
Ô×ÙØÌÍ ÍÝØÛÓßÌ×Ý
îòë
ÎñÒï ÎñÒï ÎñÒï éòì
ÍÌî
îð ïë íð
îð
ïð
ìð
ïð
ë îë ï ê è ç
ð ï ð ï î
íð
ëð
ÓÐØ
í î ïð
Õ³ñ¸
»´ »½ ¬®± ²· ½ Íïð Íç
ßóÊï éòï
ÔóÒï éòï
ÔóÙï éòï
ÙñÎï ÙñÎï
éòï
Òï
îòë
ÊóÒïòë éòï
Ííï
Õïî
õ Õë èé
íß íß Ô Ý
ëï èòí
èë íð
ó
ÕÝ î ëð
ïòì éòë
îòë
Ýï
Íìî
íòë
íï íï ëòï
Úîéìêë
14 SECTION 55 - ELECTRICAL SYSTEM
ÎóÒï
îòë
Ííî Ííí
ìòë
Ôï
ßï
ìòë
Îï
ÚïÝ
ïðß
õïë
ìòî
ïï
ìòî
ïð ëî èòì
ÕÝ
Ùï èòí
Øì Øê
Øë
ìòë
íï íï êòï
Úîéìêê
SECTION 55 - ELECTRICAL SYSTEM 15
íòë
ÎóÒï ÎóÒï ÎóÒï éòï
íòë
ÝñÒï ÝñÒï ÝñÒï éòï
íòë
ÝñÞï
ï ê è ç ï ê è ç
ð ï î ð ï î
í î ïð í î ïð
Íïï Íïî
íòë
Òï Òï Òï éòï
ïðß
èé èé èé èé
èë íð èë íð èë íð èë íð
ÕÝ
ëòë
íï íï éòï
Úîéïéí
16 SECTION 55 - ELECTRICAL SYSTEM
êòë
ÎóÒï ÎóÒï ÎóÒï èòï ìòë
ÎñÒï
ÝñÒï
êòë
Øïë Øïê
î ê é ç ï ç
ï ð
Ó Ó
Íìï
í ë ïð ë ïð
Íïì Íïë
êòë
Òï
ßóÊï
ìòë
ÔóÒï
ìòë
ìòë ÔóÙï
ìòë
ÙñÎï
ìòë
ÊóÒïòë
ÚéÝ
éôëß ïðß
õïë
ïëß
ëð
ìòì
ÕÝ
Óê Óé
Óç ëí¿ ëí¿
ëí Ó ëí¾ Ó Ó ëí Ó ëí¾
íï¾ íï¾
íï íï
íï íï
êòë èòï
Úîéìêé
SECTION 55 - ELECTRICAL SYSTEM 17
ëòë
Ùï
ÑÚÚ
ð
Íìí ÑÒ
Øïè
ÞÍï
ïòï
ÎóÒï ÙñÒï
éòî ïòë
ÎóÒïòë
ïòë
Ííë
ëï ëî
ìòì ëòî
ÕÝ
íï
éòë
Úîéïéë
18 SECTION 55 - ELECTRICAL SYSTEM
ÝÑÒÌÎÑÔÔÛÎ
ÎÛÔßÇ
Úîéïéê
SECTION 55 - ELECTRICAL SYSTEM 19
Í×ÜÛ ×ÒÍÌÎËÓÛÒÌ
S2 6 Tachometer Hz ððððð ðð ¸
• 15 9 Positive (• Key)
10 NC
ë ê ì í î ï îð ïï
L10 Service lamp Int. õïë
ç Ôï Ôî Ôí Ôì
ÚËÛÔ ÔÛÊÛÔ ÌßÝØÑÓÛÌÛÎ
11 NC ÙßËÙÛ
Íî ÙßËÙÛ
Íï Íì
ÚÎÑÒÌ ×ÒÍÌÎËÓÛÒÌ
Ôë Ôê Ôé Ôè
î
ÙÒÜ
õ×ÔÔ
ïð ç è é
ê
Úîéïèð
SECTION 55 - ELECTRICAL SYSTEM 21
ï
í
Ó
ó õ
ïð ïï
ç
ì
Ô Ó Ø
î
× Ø ÓÔ Ý
ß Í
ïî
ë
Úîéïèï
Ð×ÔÑÌ ÍÝØÛÓßÌ×Ý
ÔÊÝ Î×ÙØÌ
ÖÑÇÍÌ×ÝÕ
Õï èê èé
èë íð
ÔÛÚÌ
ÖÑÇÍÌ×ÝÕ
íï íï
Úîéïèî
SECTION 55 - ELECTRICAL SYSTEM 23
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
K1 Safety relay
S1 Pilot on/off switch 8 way connector
S2 Pattern change switch 8 way connector
X1 Pattern valve “1” 2 way connector
X2 Pattern valve “2” 2 way connector
X4 Left joystick 2 way connector
Left stabilizer pressure switch 2 way
X11
connector
Right stabilizer pressure switch 2 way
X12
connector
X13 Right tower line 5 way connector
X14 Right joystick 6 way connector
X17 Manifold power 2 way connector
X20 LVC unit 23 way connector
X23 Safety switch 2 way connector
X24 Left stabilizer joystick 6 way connector
X27 Horn jumper connection 2 way connector
X72 Pilot control cable 1 way connector
XL Left stabilizer joystick 3 way connector
XR Right stabilizer joystick 3 way connector
YP3 Plug 3 left down 2 way connector
YP4 Plug 4 left up 2 way connector
YP5 Plug 5 right down 2 way connector
YP6 Plug 6 right up 2 way connector
YP7 Plug 7 extend 2 way connector
YP8 Plug 8 retract 2 way connector
YP9 Plug 9 reverse speed aux 2 way connector
YP10 Plug 10 forward 2 way connector
24 SECTION 55 - ELECTRICAL SYSTEM
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
F1A Rear windshield wiper and rear windshield washer (15 A) Õïî
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A) Õïð Õïï
F1C Stop lights switch (10 A)
Instruments power supply, switches lamps, brake oil ÞÆï
F2A
level sensor, seat, buzzer (15 A)
F2B Conditioner (15 A) Õî
Üê
Üì
F2C Pilot control (15 A)
Rear right/front left side lights, instruments illumination,
F3A
conditioner switch illumination (3 A)
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, Glide Ride control, double delivery (10
F3C
A), grab 4x1 switches
Õí
EGS power supply, clutch shut off button, 4WD switch
F4A
(7.5 A)
Õì
F4B Rear hammer button, grab level valve and sensor (10 A)
Rear excavator lock, rear translation lock, rear work
F4C
light (10 A) Õë
F5A Front inner work lights (15 A)
F5B Traffic lights (10 A) Õê
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
XC3 On board 21 way connector
XC4 On board 21 way connector
XC5 On board 17 way connector
XC6 On board 13 way connector
XD Fuel shut off diode 2 way connector
XX Diodes 5 way connector
XY Safety seat switch 2 way connector
SECTION 55 - ELECTRICAL SYSTEM 29
ÛÒÙ×ÒÛ Ô×ÒÛ
ÍÌï
ïë
ïð îð
Íïé ÊóÞï ë îë
Æï
ÙóÎï Î ÐÓ ¨ ïðð íð
ßóÙï »´ »½¬®± ²· ½
ððð ðð ðð ¸
ÔóÞï
ÎóÒïòë èòï
ÙñÒï èòí
ÓóÞï
îòì
Íëï
ÓóÒï îòì
Íïè
ÔóÙï
íòï
ßîòë
ßîòë
ßîòë
õïë
í
Îê îòí
õíð
ï îòí
Õí èé
î
ìòí
èë íð
õïë
ÚïÞ ÚîÝ
éôëß ïëß
Õïí
ÕÝ
ÙóÊïòë èòì
ÙÎ×Ü ØÛßÌÛÎ
ÌÑ ÝÑÔÜ
ÍÌßÎÌ Õ×Ì
ÞóÒï
Õðï
èê èé èê èé
èë íð èë íð
ÚÙî
ïðß
Îïê
Îéð
Ùï
Óï Óïð
ï îÊ ½½
Ùî Îî Îí
íð
Ó
ëð
Íìç Ó
Üõ
É
Íîð Íîï Íìè Íîì Íîë
íð Ù
° í ° ° ¬ ° ¬
Ë
¬
Íìé íï
íï
îòï
Úîéìêè
30 SECTION 55 - ELECTRICAL SYSTEM
ÎóÒï ëòï
ÎñÒï ìòï
Òï
ìòï
Ýï ìòì
ÓóÊï
ï
î ê ï ë ç ï ç ï ç ï é î è ïð
î ï ð ï ð ï ð
Íëð
ÛÙÍ
Íî ì è í é ïð
Íí
ë ïð
Íìé ë ïð ë ê ç
Õïì
èê èé¿ èé
èë íð
ßóÞï
ìòï
éð
ëòî
õïë õïë ï
ïòì
õïë
ëß ïðß
í
ïòì
Õïð Õì Õî
èé èé èé
èë íð èë íð èë íð
ÕÝ
ÎóÊï ÎóÊï
íòë ÓóÒï
ïòî
ïòî
ÓóÞï
ÛÊé ÛÊî
Íîê Íîç
Øßï
ïòë
íï íï íòï
Úîéïèë
SECTION 55 - ELECTRICAL SYSTEM 31
ï ç ï ç ï ç ï é ç
ï ð ï ð ï ð ï ð Øï
ë ïð ë ïð ë ïð ë ïð
Íì Íë Íé Íè
Òï êòï
ÔóÙï
ïòî
îòí
ÎóÊï
Ííð
Þ·¼·®»½¬·±²¿´
ÐÉÓ
Ü®·ª»® ÛÊïî
ÛÊë ÛÊí
ÛÊï
ÛÊïï
ÍÌí
íï íï
îòë ìòï
Úîéìêç
32 SECTION 55 - ELECTRICAL SYSTEM
Ô×ÙØÌÍ Ô×ÒÛ
ÍÌî
îð ïë íð
îð
ïð
ìð
ïð
ë îë ï ê è ç
ð ï ð ï î
íð
ëð
ÓÐ Ø
í î ïð
Õ³ñ¸
» ´» ½¬®±² ·½
Íïð Íç
ßóÊï éòï
ÔóÒï
éòï
ÔóÙï
éòï
ÙñÎï ÙñÎï
éòï
Òï
îòë
ÊóÒïòë éòï
Ííï
Õïî
õ Õë èé
íß íß ëï
Ô Ý èòî
èë íð
ó
ÞÆï
ÕÝ î ëð
ïòì éòë
îòë
Ýï
ßóÞï
îòí
Øî Øí
Øßî
íòë
íï íï ëòï
Úîéìéð
SECTION 55 - ELECTRICAL SYSTEM 33
ÎóÒï
îòë
Ííî Ííí
ìòë
Ôï
ßï
ìòë
Îï
ÚïÝ
ïðß
õïë
éð
îòî
éï éòì
ìòî ïï
Õïï
ìòî
ïð ëî èòí
ÕÝ
Ùï èòí
Øì Øê
Øë
íï íï
ìòë êòï
Úîéìéï
34 SECTION 55 - ELECTRICAL SYSTEM
íòë
ÎóÒï ÎóÒï ÎóÒï éòï
íòë
ÝñÒï ÝñÒï ÝñÒï éòï
íòë
ÝñÞï
ï ê è ç ï ê è ç
ð ï î ð ï î
í î ïð í î ïð
Íïï Íïî
íòë
Òï Òï Òï éòï
ïðß
èé èé èé èé
èë íð èë íð èë íð èë íð
ÕÝ
ëòë
íï íï éòï
Úîéïéí
SECTION 55 - ELECTRICAL SYSTEM 35
Øïë Øïê
ð ï Î
× î ê é ç ð ï ç
ð ï ð Ó Ó
Ô
Íìï
í ë ïð ë ïð
Íïì Íïë
Òï
êòë
ìòë
ßóÊï
ìòë
ÔóÒï
ìòë
ÔóÙï
ìòë
ÙñÎï
ìòë
ÊóÒïòë
éôëß ïðß
õïë
ïëß
ìòì
ëð
ÕÝ
Óç ëí¿ ëí¿
ëí Ó ëí¾ Ó Ó ëí Ó ëí¾
íï¾ íï¾
íï íï
íï íï
êòë èòï
Úîéïéì
36 SECTION 55 - ELECTRICAL SYSTEM
ØÛßÌÛÎ Ô×ÒÛ
ëòë
Ùï
ÑÚÚ
ð
Íìí ÑÒ
Øïè
ÞÍï
ïòï
ÎóÒï ÙñÒï
éòî ïòë
ÎóÒïòë
ïòë
Ííë
ëï ëî
ìòì ëòî
ÕÝ
íï
éòë
Úîéïéë
SECTION 55 - ELECTRICAL SYSTEM 37
ÝÑÒÌÎÑÔÔÛÎ
ÎÛÔßÇ
Úîéïéê
38 SECTION 55 - ELECTRICAL SYSTEM
Í×ÜÛ ×ÒÍÌÎËÓÛÒÌ
S2 6 Tachometer Hz ððððð ðð ¸
• 15 9 Positive (• Key)
10 NC
ë ê ì í î ï îð ïï
L10 Service lamp Int. õïë
ç Ôï Ôî Ôí Ôì
ÚËÛÔ ÔÛÊÛÔ ÌßÝØÑÓÛÌÛÎ
11 NC ÙßËÙÛ
Íî ÙßËÙÛ
Íï Íì
ÚÎÑÒÌ ×ÒÍÌÎËÓÛÒÌ
Ôë Ôê Ôé Ôè
î
ÙÒÜ
õ×ÔÔ
ïð ç è é
ê
Úîéïèð
40 SECTION 55 - ELECTRICAL SYSTEM
ï
í
Ó
ó õ
ïð ïï
ç
ì
Ô Ó Ø
î
× Ø ÓÔ Ý
ß Í
ïî
ë
Úîéïèï
Ð×ÔÑÌ Ô×ÒÛ
ÔÊÝ Î×ÙØÌ
ÖÑÇÍÌ×ÝÕ
Õï èê èé
èë íð
ÔÛÚÌ
ÖÑÇÍÌ×ÝÕ
íï íï
Úîéïèî
42 SECTION 55 - ELECTRICAL SYSTEM
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
K1 Safety relay
S1 Pilot on/off switch 8 way connector
S2 Pattern change switch 8 way connector
X1 Pattern valve “1” 2 way connector
X2 Pattern valve “2” 2 way connector
X4 Left joystick 2 way connector
Left stabilizer pressure switch 2 way
X11
connector
Right stabilizer pressure switch 2 way
X12
connector
X13 Right tower line 5 way connector
X14 Right joystick 6 way connector
X17 Manifold power 2 way connector
X20 LVC unit 23 way connector
X23 Safety switch 2 way connector
X24 Left stabilizer joystick 6 way connector
X27 Horn jumper connection 2 way connector
X72 Pilot control cable 1 way connector
XL Left stabilizer joystick 3 way connector
XR Right stabilizer joystick 3 way connector
YP3 Plug 3 left down 2 way connector
YP4 Plug 4 left up 2 way connector
YP5 Plug 5 right down 2 way connector
YP6 Plug 6 right up 2 way connector
YP7 Plug 7 extend 2 way connector
YP8 Plug 8 retract 2 way connector
YP9 Plug 9 reverse speed aux 2 way connector
YP10 Plug 10 forward 2 way connector
SECTION 55 - ELECTRICAL SYSTEM 43
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
F1A Rear windshield wiper and rear windshield washer (15 A)
Õïî
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A)
Õïð Õïï
F1C Steering unit, steering switch (10 A)
Instruments power supply, switches lamps, brake oil ÞÆï
F2A
level sensor, seat, buzzer, stop lights switch (15 A)
F2B Conditioner (15 A) Õî
Üê
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
K2 Speed alarm, hand brake relay Õïî
K3 Starting relay Õïð Õïï
K4 Grab level solenoid valve relay
K5 Traffic and main beam lights relay ÞÆï
K6 Inner front work lights relay
Õî
K7 Inner rear work lights relay Üê
Üì
Õì
Õë
Õê
Õé
Õè
Õç
Úîéïèí
SECTION 55 - ELECTRICAL SYSTEM 45
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
X93 4WS enable solenoid valve 2 way connector
X94 2WS enable solenoid valve 2 way connector
X95 Steering unit 12 way connector
X96 Steering unit 8 way connector
X97 Front axle sensor 3 way connector
X98 Rear axle sensor 3 way connector
X102 Controller 10 way connector
X103 Relay 2 way connector
XA Horn 2 way connector
XC1 On board 11 way connector
XC2 On board 7 way connector
XC3 On board 21 way connector
XC4 On board 21 way connector
XC5 On board 17 way connector
XC6 On board 13 way connector
XD Fuel shut off diode 2 way connector
XX Diodes 5 way connector
XY Safety seat switch 2 way connector
48 SECTION 55 - ELECTRICAL SYSTEM
ÛÒÙ×ÒÛ Ô×ÒÛ
ÍÌï
ïë
ïð îð
Íïé ÊóÞï ë îë
Æï
ÙóÎï Î ÐÓ ¨ ïðð íð
ßóÙï »´ »½ ¬®± ²· ½
ðð ððð ðð ¸
ÔóÞï
ÎóÒïòë èòï
ÙñÒï èòí
ÓóÞï
îòì
Íëï
ÊóÞï
ìòï
ßîòë
ßîòë
ßîòë
õïë
ßîòë
í
Îê îòí
õíð
ï
îòí
Õí èé
î
ìòí
èë íð
õïë
ÚïÞ ÚîÝ
éôëß ïëß
Õïí
ÕÝ
ÙóÊïòë èòì
é
Èï
ÙÎ×Ü ØÛßÌÛÎ
ÌÑ ÝÑÔÜ
ÍÌßÎÌ Õ×Ì
ÞóÒï
Õðï
èê èé èê èé
èë íð èë íð
ïðß
Îïê
Îéð
Ùï
Óï Óïð
ï îÊ ½½
Ùî Îî Îí
íð
Ó
ëð
Ííê Ó
Üõ
É
Íîð Íîï Íìè Íîì Íîë
íð Ù
° í ° ° ¬ ° ¬
Ë
¬
Íìç íï
íï
îòï
Úîéïèç
SECTION 55 - ELECTRICAL SYSTEM 49
ÎóÒï ëòï
ÎñÒï ìòï
Òï ìòï
Ýï ìòì
ÓóÊï
ï
î ê ï ë ç ï ç ï é î è ïð
î ï ð ï ð
ÛÙÍ
ì è í é ïð ë ïð ë ê ç Íëð
Íî Íí
Õïì
èê èé¿ èé
èë íð
ßóÞï ìòï
éð ëòî
éôëß
õïë õïë ï
ïòì
õïë
ëß ïðß
ïòì í
èé èé èé
èë íð èë íð èë íð
ÕÝ
ÓóÒï
ïòî
ÓóÞï
ïòî
è
Èïð
íï íï
ïòë íòï
Úîéïçð
50 SECTION 55 - ELECTRICAL SYSTEM
ÎóÒï ÎóÒï
êòï
ÝñÒï ÝñÒï êòï
ÝñÞï ÝñÞï êòî
ï ð
ï ç
ï ð
ï ç
ï ð
ï ç
ï ð
ï é ç Øï ï
ð
î
Þ Ý Ú
ë ïð ë ïð ë ïð ë ïð
Íì Íë Íé Íè Íìé ß Û
ÎóÙï
ìòï
Òï êòï
ßóÎï ìòï
ÊñÒï ìòï
ÔóÙï
ïòî
ÔñÎï
ìòî
ÍñÒï
ìòî
ØñÒï ìòî
ÓñÞï ìòí
Þ·¼·®»½¬·±²¿´
ÐÉÓ
Ü®·ª»® ÛÊïî
ÍÌí
îòë
íï íï ìòï
Úîéïçï
SECTION 55 - ELECTRICAL SYSTEM 51
Ô×ÙØÌÍ Ô×ÒÛ
ÍÌî
îð ïë íð
îð
ïð
ìð
ïð
ë îë ï ê è ç
ð ï ð ï î
íð
ëð
ÓÐØ
í î ïð
Õ³ñ¸
»´ »½ ¬®± ²· ½
Íïð Íç
ßóÊï éòï
ÔóÒï éòï
Òï
îòë
íòë
ÎóÙï
ÞñÎï
ëòï
õ
èé
íß íß ëï
Ô Ý èòî
èë íð
ó
ÕÝ î ëð
ïòì éòë
íòë
ÓñÞï
îòí
ßóÞï
îòë
Ýï
íòë
ØñÒï
ÊóÞï
ïòì ÍñÒï
íòë
íòë
ÊñÒï íòë
ÔñÎï
íòë
ßóÎï
Øî Øí
ÕÍ
íï íï
íòë ëòï
Úîéìéî
52 SECTION 55 - ELECTRICAL SYSTEM
îòë
ÎóÒï
ìòë
ÞñÎï
ìòë Ôï
ìòë
ßï
Îï
éð
îòî
éï
éòì
ìòî
ïï
Õïï
ìòî
ïð ëî èòí
ÕÝ
Ùï èòí
Øì Øê
Øë
ìòë
íï íï êòï
Úîéìéí
SECTION 55 - ELECTRICAL SYSTEM 53
íòë
ÎóÒï ÎóÒï ÎóÒï éòï
íòë
ÝñÒï ÝñÒï ÝñÒï éòï
íòë
ÝñÞï
ï ê è ç ï ê è ç
ð ï î ð ï î
í î ïð í î ïð
Íïï Íïî
íòë
Òï Òï Òï éòï
ïðß
èé èé èé èé
èë íð èë íð èë íð èë íð
ÕÝ
íï íï
ëòë éòï
Úîéïéí
54 SECTION 55 - ELECTRICAL SYSTEM
êòë
ÎóÒï ÎóÒï ÎóÒï èòï ìòë
ÎñÒï
êòë
ÝñÒï
î ê é ç
Øïë Øïê
× ð ð ï î Î
ð ï ç
ï ð Ó Ó
Ô
í ë ïð
Íïì Íìï
ë ïð
Íïë
êòë
Òï
ìòë ßóÊï
ìòë
ÔóÒï
ÔóÙï
ìòë
ÙñÎï
ìòë
ÊóÒïòë
ìòë
ÚéÝ
Úêß ÚíÝ
éôëß ïðß
éï
ëòí
õïë
Úïß
ïëß
ìòì
ëð
ÕÝ
Óì Óê Óé
Óç ëí¿ ëí¿
ëí
Ó ëí¾ Ó Ó ëí
Ó ëí¾
íï¾ íï¾
íï íï
íï íï
êòë èòï
Úîéìéì
SECTION 55 - ELECTRICAL SYSTEM 55
ØÛßÌÛÎ Ô×ÒÛ
ëòë
Ùï
ÑÚÚ
ð
Íìí ÑÒ
Øïè
ÞÍï
ïòï
ÎóÒï ÙñÒï
éòî ïòë
ïòë
ÎóÒïòë
Ííë
ìòì
ëï ëòî
ëî
ÕÝ
éòë
íï
Úîéïéë
56 SECTION 55 - ELECTRICAL SYSTEM
ÝÑÒÌÎÑÔÔÛÎ
ÎÛÔßÇ
Úîéïéê
SECTION 55 - ELECTRICAL SYSTEM 57
Í×ÜÛ ×ÒÍÌÎËÓÛÒÌ
S2 6 Tachometer Hz ððððð ðð ¸
• 15 9 Positive (• Key)
10 NC
ë ê ì í î ï îð ïï
L10 Service lamp Int. õïë
ç Ôï Ôî Ôí Ôì
ÚËÛÔ ÔÛÊÛÔ ÌßÝØÑÓÛÌÛÎ
11 NC ÙßËÙÛ
Íï
Íî
Íì
ÙßËÙÛ
ÚÎÑÒÌ ×ÒÍÌÎËÓÛÒÌ
L7 8 NC
L6 9 NC
L5 10 NC í ïï ïî ë ì
õïî
L1 11 Direction lamp - ï
Ôï Ôî Ôí Ôì
Íï
L2 12 Brake level oil lamp -
Ôë Ôê Ôé Ôè
î
ÙÒÜ
õ×ÔÔ
ïð ç è é
ê
Úîéïçì
SECTION 55 - ELECTRICAL SYSTEM 59
ï
í
Ó
ó õ
ïð ïï
ç
ì
Ô Ó Ø
î
× Ø ÓÔ Ý
ß Í
ïî
ë
Úîéïèï
Ð×ÔÑÌ Ô×ÒÛ
ÔÊÝ Î×ÙØÌ
ÖÑÇÍÌ×ÝÕ
Õï èê èé
èë íð
ÔÛÚÌ
ÖÑÇÍÌ×ÝÕ
íï íï
Úîéïèî
SECTION 55 - ELECTRICAL SYSTEM 61
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
K1 Safety relay
S1 Pilot on/off switch 8 way connector
S2 Pattern change switch 8 way connector
X1 Pattern valve “1” 2 way connector
X2 Pattern valve “2” 2 way connector
X4 Left joystick 2 way connector
Left stabilizer pressure switch 2 way
X11
connector
Right stabilizer pressure switch 2 way
X12
connector
X13 Right tower line 5 way connector
X14 Right joystick 6 way connector
X17 Manifold power 2 way connector
X20 LVC unit 23 way connector
X23 Safety switch 2 way connector
X24 Left stabilizer joystick 6 way connector
X27 Horn jumper connection 2 way connector
X72 Pilot control cable 1 way connector
XL Left stabilizer joystick 3 way connector
XR Right stabilizer joystick 3 way connector
YP3 Plug 3 left down 2 way connector
YP4 Plug 4 left up 2 way connector
YP5 Plug 5 right down 2 way connector
YP6 Plug 6 right up 2 way connector
YP7 Plug 7 extend 2 way connector
YP8 Plug 8 retract 2 way connector
YP9 Plug 9 reverse speed aux 2 way connector
YP10 Plug 10 forward 2 way connector
62 SECTION 55 - ELECTRICAL SYSTEM
ÒßÓÛ ÜÛÍÝÎ×ÐÌ×ÑÒ
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A)
Õïî
F1C Stop lights switch (10 A)
Õïð Õïï
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat, buzzer (15 A) Õï
ÞÆï
F2C Pilot control (15 A)
Rear right/front left side lights, instruments illumination Õî
F3A
(3 A) Üê
Üì
ÛÒÙ×ÒÛ Ô×ÒÛ
ÍÌï
ïë
ïð îð
Íïé ÊóÞï ë îë
Æï
ÙóÎï Î ÐÓ ¨ ïðð íð
ßóÙï »´ »½ ¬®± ²· ½
ððð ðð ðð ¸
ÔóÞï
ÎóÒïòë èòï
ÙñÒï èòì
ÓóÞï
îòí
Íëð
ÓóÒï îòì
Íïè
ÔóÙï
íòï
ßîòë
ßîòë
ßîòë
õïë
í îòë
Îê
õíð
ï îòí
Õí
èé
î
ìòí
èë íð
õïë
ïëß
Õïí
ÕÝ
é
Èï
ÍÌßÎÌ Õ×Ì
ÞóÒï
Õðï
èê èé èê èé
èë íð èë íð
ïðß
Îïê
Îéð
Ùï
ï îÊ ½½ Óï
ëð Ùî Íìè Îî Îí
íð
Ó
Üõ
É
Íîð Íîï Íîì Íîë
íð Ù
í ° ° ¬ ° ¬
Ë
¬
íï
íï
îòï
Úîéïçê
SECTION 55 - ELECTRICAL SYSTEM 67
ÎñÒï ìòï
ÓóÊï
î ê ï ë ç ï ç × Ú Ò Î ÒÑ
ï
î ï ð × Ú
ð
Î
Íî
ì è í é ïð ë ïð
Íìð õ õ Ò×
Íí
ÓñÞï
ï î í ì
Ýï ìòì
Òï ìòï
ÎóÒï ëòï
ï
Èç
ïòì
í
éôëß
õïë õïë
õïë
ïðß ëß
ïòì
ï
Õï Õì Õïð Õïï Õî
èé èé èé èé èé
èë íð èë íð èë íð èë íð èë íð
ÕÝ
ÓóÒï
ÓóÞï ïòî
ïòî
ÎóÊï ÎóÊï
íòë
Íîê Íîé
íï íï
ïòë íòï
Úîéïçé
68 SECTION 55 - ELECTRICAL SYSTEM
ï ç ï ç ï ç ï é ç
ï ð ï ð ï ð ï ð Øï
ë ïð ë ïð ë ïð ë ïð
Íì Íë Íé Íè
Òï êòï
ïòî
ÔóÙï
îòë
ÎóÊï
Ííð
Þ·¼·®»½¬·±²¿´
ÐÉÓ
Ü®·ª»®
ÛÊïî
íï íï
îòë ìòï
Úîéìéë
SECTION 55 - ELECTRICAL SYSTEM 69
Ô×ÙØÌÍ Ô×ÒÛ
îòë
ÎñÒï ÎñÒï ÎñÒï éòì
ÍÌî
îð ïë íð
îð
ïð
ìð
ïð
ë îë ï ê è ç
ð ï ð ï î
íð
ëð
ÓÐØ
í î ïð
Õ³ñ¸
»´ »½ ¬®± ²· ½
Íïð Íç
ÔñÒï
Ôï
ßï
éòï
Ííï
Õïî
õ
èé
íß íß ëï
Ô Ý èòí
èë íð
ó
ÞÆï
ÕÝ î ëð
ïòì éòë
îòë
Ýï
Øî Øí
Íìî Øßî
íòë
íï íï ëòï
Úîéìéê
70 SECTION 55 - ELECTRICAL SYSTEM
îòë
ÎóÒï
Ííî Ííí
ìòë
Ôï
ìòë
ßï
Îï
ÚïÝ
ïðß
õïë
ìòî ïï
ïð ëî
ìòî èòì
ÕÝ
Øì Øê
Øë
ìòë
íï íï êòï
Úîéìéé
SECTION 55 - ELECTRICAL SYSTEM 71
íòë
ÎóÒï ÎóÒï ÎóÒï éòï
íòë
ÝñÒï ÝñÒï ÝñÒï éòï
íòë
ÝñÞï
ï ê è ç ï ê è ç
ð ï î ð ï î
í î ïð í î ïð
Íïï Íïî
íòë
Òï Òï Òï éòï
ïðß
èé èé èé èé
èë íð èë íð èë íð èë íð
ÕÝ
ëòë
íï íï éòï
Úîéïéí
72 SECTION 55 - ELECTRICAL SYSTEM
ÝÑÒÌÎÑÔÔÛÎ
ÎÛÔßÇ
Úîéïéê
SECTION 55 - ELECTRICAL SYSTEM 73
Í×ÜÛ ×ÒÍÌÎËÓÛÒÌ
S2 6 Tachometer Hz ððððð ðð ¸
• 15 9 Positive (• Key)
10 NC
ë ê ì í î ï îð ïï
L10 Service lamp Int. õïë
ç Ôï Ôî Ôí Ôì
ÚËÛÔ ÔÛÊÛÔ ÌßÝØÑÓÛÌÛÎ
11 NC Íï
ÙßËÙÛ
Íî
Íì
ÙßËÙÛ
ÚÎÑÒÌ ×ÒÍÌÎËÓÛÒÌ
L8 7 NC
L7 8 NC
L6 9 NC
L5 10 NC í ïï ïî ë ì
õïî
ï
L1 11 Direction lamp - Ôï Ôî Ôí Ôì
Íï
Ôë Ôê Ôé Ôè
î
ÙÒÜ
õ×ÔÔ
ïð ç è é
ê
Úîéïèð
SECTION 55 - ELECTRICAL SYSTEM 75
ÞÛßÝÑÒ Ô×ÒÛ
êòë
ÎóÒï ÎóÒï ÎóÒï èòï ìòë
ÎñÒï
êòë
ÝñÒï
Øïë Øïê
ð ïî Î
ð ï ç
ï ð Ó Ó
Ô
Íìï
ë ïð
Íïë
êòë
Òï
ìòë ßï
ÔñÒï
Ôï
ÙñÎï
ìòë
ÊóÒïòë
ìòë
ÚéÝ
Úêß ÚíÝ
éôëß ïðß
õïë
Úïß
ïëß
ìòì
ëð
ÕÝ
íï íï
êòë èòï
Úîéìéè
76 SECTION 55 - ELECTRICAL SYSTEM
ÎóÒï ÙñÒï
éòî ïòë
ÎóÒïòë
ïòë
õíð õïë
ëï ëî
ìòì ëòî
ÕÝ
éòë
íï
Úîéîðî
SECTION 55 - ELECTRICAL SYSTEM 77
èò SPEEDOMETER (optional)
The speedometer shows travel speed in kilom- ÒÑÌÛæ when manual mode is no longer required,
eters per hour (kmh) and miles per hour (mph). place the control in OFF position to return to auto-
çò DIFFERENTIAL LOCK SWITCH (Powershift matic gear shifting.
transmission)
This switch is used to lock or unlock the differen-
tial.
ïðò ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off (if fitted).
ïïò LIGHT SWITCH
The switch has three positions:
the first position is OFF,
the second position powers the gauge cluster,
the parking lights with relevant warning light (3)
and the rear red lateral lights. The third position
powers the beam lights and the relevant warn-
ing light (4).
ïîò HAZARD LIGHT SWITCH
Press the control down to locked position. The
direction indicators and the control will flash si-
multaneously.
Press down again for the direction indicators
and control lamp to go out.
ïíò HAND-HELD AUXILIARY HYDRAULIC TOOL
CONTROLS (optional)
ïìò 2/4 WHEEL DRIVE SWITCH
This switch is used to engage or disengage four
wheel drive.
The switch has three positions:
OFF = front axle drive disengaged, with braking
on all 4 wheels.
ON, 2nd position = the switch lamp goes out and
the front axle drive is disengaged (2 wheel drive
operation).
ON, 3rd position = the switch lamp lights up and
the front axle drive is engaged (4 wheel drive op-
eration).
ïïò ENGINE TACHOMETER AND HOUR METER ïçò REAR WORK LIGHT SWITCH
The tachometer shows the engine speed in rev- This switch has 3 positions:
olutions per minute. The figures shown on the 1st position = OFF
dial are to be multiplied by 100. 2nd position = the two rear outer working lights
Each individual graduation corresponds to 10 turn on.
rpm. 3rd position = the two rear inner working lights
The hour meter shows the number of hours and turn on.
tenths of hours the engine has been functioning. The lights switch turns on only in the second and
It also makes it possible to determine when third position.
servicing operations are due. Never use the working lights during road travel.
ïîò ENGINE COOLANT TEMPERATURE WARN- îðò BACKHOE ATTACHMENT SIDESHIFT CAR-
ING LAMP (Diagnosis optional) RIAGE LOCKING AND UNLOCKING SWITCH
This lamp lights up when the engine coolant (Sideshift version)
temperature is too high. If the lamp comes on This switch has 2 positions.
when the machine is working, move the ma- This switch is used to lock or unlock the back-
chine to a place of safety, stop the engine, re- hoe attachment carriage to allow lateral shifting.
move the ignition switch key and find the cause îïò BACKHOE ATTACHMENT LOCKING SWITCH
of the problem. (optional)
ïíò ENGINE COOLANT SOLUTION TEMPERA- This switch has 2 positions.
TURE INDICATOR The switch is used to lock or unlock the backhoe
This indicator shows the temperature of the en- attachment locking plate in preparation for road
gine coolant solution. When the temperature is travel.
normal the needle is in the green area. If the nee- îîò REAR WINDSHIELD WIPER AND WASHER
dle is in the red area the audible warning sounds. The wiper is activated when the switch is de-
Move the machine to a place of safety, stop the pressed and will remain in function until the
engine, remove the ignition switch key and switch is returned to the OFF position.
check the coolant solution level. Make sure that The washer is operated by further depressing
the radiator and oil cooler are perfectly clean and and holding switch. When the switch is released
that all the thermostats function correctly. the wash will stop and return to the wipe posi-
ïìò FRONT WORK LIGHT SWITCH tion.
This switch has 3 positions: îíò LOADER ATTACHMENT LOCKING SWITCH
1st position = OFF (optional)
2nd position = the two frontal outer working lights When operated, this switch is for preventing any
turn on. movement of the loader attachment during trav-
3rd position = the two front inner working lights el.
turn on.
The lights switch turns on only in the second and
third position.
ïëò HYDRAULIC SPEED CONTROL SWITCH
ïêò SWITCH FOR OPTIONAL EQUIPMENT
ïéò SWITCH FOR OPTIONAL EQUIPMENT
ïèò GLIDE RIDE SYSTEM CONTROL SWITCH
(optional)
The glide ride system control improves the ma-
chine behaviour during travel, regardless of the
type of terrain and with the loader bucket full or
empty. It reduces forward and rearward pitching
when moving to the rear or forwards and when
carrying loads, at the same time increasing pro-
ductivity and operator comfort. It also minimizes
impact forces to which the machine may be sub-
jected.
SECTION 55 - ELECTRICAL SYSTEM 81
ÌÑÌßÔ ØÑËÎÍ
0.0 h
1st record 0h 0h 0h 0h 0h
SAVE ERROR
START MENU
Error Time
CANCEL
Out Out
ÓßÔÚËÒÝÌ×ÑÒ ÛÈßÓÐÔÛ
* Filter
Úîèêêë
Úîèêêê
ÐÑÉÛÎÍØËÌÌÔÛ
ÐÑÉÛÎÍØ×ÚÌ
Úîèêêé
ìò ÍÌßÎÌ×ÒÙ ÍÇÍÌÛÓ
ìòï ÜÛÍÝÎ×ÐÌ×ÑÒ ßÒÜ ÑÐÛÎßÌ×ÑÒ
The motor does not start if the ignition key is operated and the transmission is in the neutral position.
Does the reverse travel lever switch operate correctly? ÒÑ Replace the switch
ÇÛÍ
Check the main power
Are the indicators on the instrument panel correctly lighted supply between the battery
after operating the key switch? ÒÑ
and the starter motor key
ÇÛÍ switch. Pin 2 (red wire) of
the ignition key connector.
Are the cable wires of the key switch connected correctly?
ÇÛÍ ÒÑ
ÌÛÝØÒ×ÝßÔ ÍÐÛÝ×Ú×ÝßÌ×ÑÒÍ
Manufacturer............................................................................................................................................. Denso
Voltage ......................................................................................................................................................... 12 V
Rated power............................................................................................................................................. 2.7 kW
Starting system ....................................................................................................................................... Positive
Operating time ..............................................................................................................................................30 s
Direction of rotation.................................................................................... Clockwise seen from the pinion side
Weight ........................................................................................................................................................8.4 kg
Maximum consumption without load at 11 V and 3000 rpm minimum...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm 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
Óß×Ò ÝÑÓÐÑÒÛÒÌÍ
ïò Motor
îò Induction coils
íò Armature
ìò Commutator
ëò Brush assembly
êò Pinion gear
éò Intermediate pinion
èò Solenoid
çò Clutch
ïðò Drive pinion
90 SECTION 55 - ELECTRICAL SYSTEM
SECTION 55 - ELECTRICAL SYSTEM 91
ïò Washer
îò Bearing
íò Armature
ìò Bearing
ëò Coils housing
êò Protection
éò Brush spring
èò Brush assembly
çò Brush bracket
ïðò Protective cover
ïïò Screw and washer
ïîò Screw
ïíò Drain
ïìò Screw and washer
ïëò Solenoid hood
ïêò Union
ïéò Spring washer
ïèò Nut
ïçò Push-rod
îðò Connection assembly
îïò Screw
îîò Connection assembly
îíò Nut
îìò Retaining ring
îëò Roller
îêò Cage
îéò Pinion
îèò Ball
îçò Spring
íðò Drain
íïò Screw
íîò Flat washer
ííò O-ring
íìò Box
íëò Pinion, rings and spring assembly
íêò Union
íéò Bearing
íèò Bearing
íçò Spring
ìðò Shaft pinion
ìïò Solenoid housing
ìîò Clutch assembly
92 SECTION 55 - ELECTRICAL SYSTEM
ß®³¿¬«®»
The surface of the commutator must be clean and
without traces of burns. If necessary, remove trac-
es of burns using fine sandpaper. Do not use em-
ery cloth. Then, clean the commutator with a cloth
soaked in gasoline.
After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in
gasoline.
Ú·»´¼ ½±·´-
To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Ü®·ª» °·²·±²
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.
ÚßËÔÌ Ú×ÒÜ×ÒÙ
Wear on pinion gear or ring gear Replace clutch and ring gear.
teeth tips
Field coil loss Pinion gear disengagement fault Replace magnetic switch.
caused by a coil layer short in the
Magnetic switch coil burn, etc. magnetic switch
SECTION 55 - ELECTRICAL SYSTEM 95
ëò ßÔÌÛÎÒßÌÑÎ
ëòï ÌÛÝØÒ×ÝßÔ ÍÐÛÝ×Ú×ÝßÌ×ÑÒÍ
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
Direction of rotation.................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 °C ......................................................................... 14.2 - 14.8 V
Maximum load that can be applied at terminal L ........................................................................ 12 V, 3.4 W x 6
ïò Alternator
îò Output winding of the rotor
íò Rectifier
ìò Regulator
ëò Starter motor
êò Battery
éò Key switch
èò Charge indicator
çò Tachometer
SECTION 55 - ELECTRICAL SYSTEM 97
ëòí ÝÑÓÐÑÒÛÒÌÍ
ëòì ÎÛÓÑÊßÔ
ÐÎÛÔ×Ó×ÒßÎÇ ÝØÛÝÕÍ
Before undertaking an electrical inspection, check
the charging circuit and the electrical circuit carefully.
Check the state of cables and the tightening of con-
nections.
ÐÎÛÔ×Ó×ÒßÎÇ ÌÛÍÌÍ
The preliminary tests may be carried out without re-
moving the charging circuit components, these tests
help check the following items:
Connections of the alternator cables
Charging current and regulated voltage of the alter-
nator
Voltage lowers in the alternator charging circuit
Maximum flow of the alternator
λ¯«·®»¼ ¼»ª·½»-æ
Voltmeter (0-30 V, moving coil)
Millivoltmeter (0-1 V)
Ammeter (0-110 A, moving coil)
Variable resistance of 1.5 Ohm, 110 A
Required devices:
12 V battery
Multimeter
2.2 W test lamp
êò ÞßÌÌÛÎÇ
For the loader backhoe models two different kinds of installation are provided:
with a battery.
with two batteries (for harsh climates).
Í·²¹´» ¾¿¬¬»®§
Voltage:........................................................................................................................................................ 12 V
Capacity (20 h):.......................................................................................................................................... 95 Ah
Discharge current:...................................................................................................................................... 900 A
Weight with electrolyte: ...............................................................................................................................25 kg
ܱ«¾´» ¾¿¬¬»®§
Voltage:........................................................................................................................................................ 12 V
Capacity (20 h):.......................................................................................................................................... 60 Ah
Discharge current:...................................................................................................................................... 600 A
Weight with electrolyte: ...............................................................................................................................17 kg
ÉßÎÒ×ÒÙ
A spark or flame can cause the hydrogen in a battery
to explode. To prevent any risk of explosion, observe
the following instructions:
Place the battery master switch key in the OFF po-
sition (disconnected).
When disconnecting the battery cables, always dis-
connect the negative cable (-) first.
When reconnecting the battery cables, always con-
nect the negative (-) cable last.
Never short-circuit the battery terminals with metal
objects.
Do not weld, grind or smoke near a battery.
ÉßÎÒ×ÒÙ
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.
ÉßÎÒ×ÒÙ
Before carrying out any welding on the machine or
repair work on the electrical circuit, disconnect the
battery and disconnect the B+ and D+ wires on the
alternator. When reconnecting, check the wire mark-
ings.
ÉßÎÒ×ÒÙ
Always store batteries in a safe place, out of the
reach of children.
ÉßÎÒ×ÒÙ
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
SECTION 55 - ELECTRICAL SYSTEM 111
ÉßÎÒ×ÒÙ
Never reverse the battery terminals. Connect the
positive cable to the positive terminal (+) and the
negative cable to the negative terminal (-).
112 SECTION 55 - ELECTRICAL SYSTEM
êòì Óß×ÒÌÛÒßÒÝÛ
ÉßÎÒ×ÒÙ
When a battery is being charged an explosive gas is
produced. Do not smoke or use an exposed flame
when checking the electrolyte level and ensure the
charger is switched off before connecting or discon-
necting to avoid sparks which could ignite the gas.
114 SECTION 55 - ELECTRICAL SYSTEM
êòë ÌÛÍÌÍ
Before commencing battery tests check the battery ing system to determine the cause of the low
for clogged vents, corrosion, raised vent plugs or a battery charge.
cracked case.
Test equipment required: ÒÑÌÛæ if distilled water has recently been added the
Hydrometer. battery should be recharged for a short period oth-
Battery starter tester (High rate discharge tester). erwise accurate hydrometer readings will not be ob-
Thermometer. tained.
Battery Charger.
If the battery has been charged under static condi-
ÍÐÛÝ×Ú×Ý ÙÎßÊ×ÌÇ tions, denser electrolyte will accumulate at the bot-
This test will determine the state of battery charge. tom of the cells. The battery should be shaken
ïò With the float in the vertical position take the periodically to mix the electrolyte, this will improve
reading. the charge rate and provide a more accurate hy-
îò Adjust the hydrometer reading for electrolyte drometer reading when tested.
temperature variations by subtracting 4 points
ÐÛÎÚÑÎÓßÒÝÛ ÌÛÍÌ
(0.004 specific gravity) for every 5.5 °C below
the temperature at which the hydrometer is cal- The performance test is to determine if the battery
ibrated and by adding 4 points (0.004 specific has adequate capacity to turn the engine. The volt-
gravity) for every 5.5 °C above this temperature. age reading obtained is used to determine the bat-
The following examples are calculated using a hy- tery condition. Prior to testing, ensure the electrolyte
drometer calibrated at 30 °C. level is correct and the open circuit voltage is 12.5 V
or more. The battery may be tested on or off the
Example 1: tractor.
Temperature below 30 °C ïò Set the current control switch of the battery
Electrolyte temperature .................................. 19 °C starter tester (high rate discharge tester) to the
Hydrometer reading ....................................... 1.270 “off” position and the voltage selector switch
Subtract (11.0 / 5.5) x 0.004........................... 0.008 equal to, or slightly higher than, the rated battery
Corrected specific gravity............................... 1.262 voltage. Connect the tester positive leads to the
battery positive terminal and the negative leads
Example 2: to the negative battery terminal.
Temperature above 30 °C îò Turn the current control knob until the ammeter
Electrolyte temperature .................................. 40 °C reading is half the CCA rating of the battery and
Hydrometer reading ....................................... 1.220 take the voltage reading.
Add (10.0 / 5.5) x 0.004.................................. 0.007 If the reading is 9.6 volts or more after 15 seconds,
Corrected specific gravity............................... 1.227 the battery has an acceptable output capacity and
íò Use the following table to determine the state of will readily accept a normal charge.
charge. If however the reading is below 9.6 volts, the bat-
tery is considered unsatisfactory for service and
ͬ¿¬» ±º ݱ®®»½¬» ݱ®®»½¬» ߪ»®¿¹» should be test charged as described below.
ݸ¿®¹» ¼ -°»½·º·½ ¼ -°»½·º·½ ¾¿¬¬»®§
¹®¿ª·¬§ à ¹®¿ª·¬§ à ª±´¬¿¹» ÝßËÌ×ÑÒ
ïë pÝ îë pÝ
Do not leave the high discharge load on the battery
100% 1.295 1.287 2.76 for periods longer than 15 seconds.
75% 1.253 1.246 12.52
50% 1.217 1.210 12.30
25% 1.177 1.170 12.06
Discharged 1.137 1.130 11.84
ÉßÎÒ×ÒÙ
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.
ÉßÎÒ×ÒÙ
Connecting jumper cables wrongly or short-circuiting
battery terminals can cause an accident. Connect
the jumper cables following the instructions in this
manual.
Open the battery box and then remove the tool box.
Remove the terminal covers.
Connect the positive (+) jumper cable to the posi-
tive (+) terminal of the machine’s battery.
Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Start the engine.
First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Install the terminal covers.
Install the tool box and close the battery box.
ÉßÎÒ×ÒÙ
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 windows
are locked.
SECTION 55 - ELECTRICAL SYSTEM 117
éò ÝÑÓÐÑÒÛÒÌ ÌÛÍÌ×ÒÙ
éòï ÙÛÒÛÎßÔ ×ÒÌÎÑÜËÝÌ×ÑÒ
Úîèíéê
Úîèíéé
Úîèíéè
SECTION 55 - ELECTRICAL SYSTEM 119
Úîèìðë
Úîèíèð
Úîèíèï
120 SECTION 55 - ELECTRICAL SYSTEM
Key start
ïò Not used
îò Off
íò Ignition “ON”
ìò Engine start
ÍÉ×ÌÝØ ó Èéï
Èéï
Ì»-¬ °®±½»¼«®»
Voltage: ëæ ÝÓæßæîòë
êæ ÝÓæßæîòë
ÝÓæßæîòë
з² Õ»§ -©·¬½¸ °±-·¬·±² éæ ÝÓæÞóÒæïòë
Ò±ò ÑÚÚ Ð±-ò × Ð±-ò ×× Ð±-ò ××× çæ ÝÓæÓóÒæïòë
ÝÓæÓñÒæï
9 0V 0V 12 V 12 V
7 0V 0V 0V 12 V ìæ ÝÓæÓóÒæïòë
ÝÓæÓóÒæïòë
4 0V 0V 12 V 12 V ïæ ÝÓæÎæïòë
ÝÓæÎæïòë
5-6 0V 12 V 12 V 12 V îæ ÝÓæÎæê Úîèíèí
2 12 V 12 V 12 V 12 V
Continuity:
ÍÌßÎÌÛÎ ÓÑÌÑÎ ó Óï
Ì»-¬ °®±½»¼«®»
Úîèíèì
Ì»-¬ °®±½»¼«®»
ÚËÍÛÍ ó èð ß ó ÚÙï
The main fuses have been designed to protect the
whole electrical system. Fuses fitted are dependent
on models.
Ì»-¬ °®±½»¼«®»
Battery voltage should be found both sides of fuse at
all times.
Úîçëìé
122 SECTION 55 - ELECTRICAL SYSTEM
ßÔÌÛÎÒßÌÑÎ ó Ùî
This sends a square wave signal, the frequency of
which varies between 142.52 855 Hz (480 - 3060
rpm) to the instrument panel.
With the engine running, the warning light should go
out. If not, disconnect the wire connected to the ter-
minal D+ (pink wire).
When D+ is not connected and the warning light
goes out, there is a fault with the alternator. If it does
not go out, then check the bulb and the wiring loom.
Úîèíèè
ÍóÒæï
Úîèíèç
ÌÎßÒÍÓ×ÍÍ×ÑÒÍ
ÐÑÉÛÎÍØËÌÌÔÛ Ü×ÍÝÑÒÒÛÝÌ ó Èîí ñ Èîè
Energizes the transmission dump solenoid at 12 V.
Ì»-¬ °®±½»¼«®»
Continuity should be found between pin 1 and pin 2 Èîí
when switch is operated.
îæ ÎÓæßóÎæï
ïæ ÎÓæÞóÎæï
Èîè
ïæ ÎÓæßóÎæï
ìæ ÎÓæÝóÒæï
ïæ ÎÓæÞóÎæï
íæ ÎÓæÒæï
Úîèíçï
124 SECTION 55 - ELECTRICAL SYSTEM
Ì»-¬ °®±½»¼«®»
Test procedure of the speed sensor refer to the next
page.
Ì»-¬ °®±½»¼«®»
Test between pin indicated in the left hand column
and either pin H or M as detailed in the table below.
Úîèíçì
ÜÛÍÝÎ×ÐÌ×ÑÒ
з²
Ø Ó
Ò±ò
A 27.5 -
B 27.5 -
C 27.5 -
D 27.5 -
E 27.5 -
F 27.5 - Úîèíçë
G - 14
K - 31
Úîèíçì
Ì»-¬ °®±½»¼«®»
з²
Êï Êî
Ò±ò
A 0.6 - 0.8 1.3 - 1.5
The special tool connects to pin A speed sensor plus
output, and pin J speed sensor/temperature sensor
ground.
Úîèíçé
Ü»-½®·°¬·±²
A Speed sensor +
B FWD request
C Disconnect request input ß
Þ Ó
D Speedometer output
Ý Ò Ô
E Diagnostic link input Ð Ë
F Analogue Input 1 Ü Ê Õ
G Analogue Input 0 Î Ì
H - Û Í Ö
J - Ú Ø
Ù
K PWM solenoid supply
L Solenoid 3
M PWM 1 Úîèíçè
N Range solenoid 27
P Forward solenoid
R Solenoid 2
S Solenoid 1
T VCS
U Ground
V Battery +
126 SECTION 55 - ELECTRICAL SYSTEM
Ì»-¬ °®±½»¼«®»
Continuity should be found between pin 1 and pin 2
when switch is operated.
éæ ÆñÒï
ëæ Òï
Úîèìðð
Úîèìðî
Ì»-¬ °®±½»¼«®»
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
з²
Í»²¼»® λ-·-¬¿²½» ÆóÞæï
Ò±ò
1 12 V at low pressure 0.3 Òæï
Úîèìðí
SECTION 55 - ELECTRICAL SYSTEM 127
Úîèìðì
Ì»-¬ °®±½»¼«®»
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
з²
Í»²¼»® λ-·-¬¿²½» ÆóÞæï
Ò±ò
1 12 V at low pressure 0.3 Òæï
Úîèìðí
Ì»-¬ °®±½»¼«®»
Brake engaged:
switch closed warning light illuminated.
Íïè
Brake disengaged:
switch open warning light off. ïæ ÚÓæÙóÎæï
ïæ ÚÓæÒæï
Úîèìðé
128 SECTION 55 - ELECTRICAL SYSTEM
ÝßÞ
ÚÎÑÒÌ ×ÒÍÌÎËÓÛÒÌ ÐßÒÛÔ ó Èéð ïî Ð×Ò
The front instrument panel is sent signals from the
brake oil level sender, transmission speed sensor,
light switch and indicator switch.
At the rear of the panels are connectors that are at-
tached to the vehicle harness system.
These connectors and functions are listed on the fol-
lowing pages.
Úîèìðè
Úîèìðç
ìÉÜ ÍÉ×ÌÝØ ó Íî
Ì»-¬ °®±½»¼«®»
ݱ²¬·²«·¬§
Í©·¬½¸ ÑÚÚ Ð±-·¬·±² ï б-·¬·±² î
Pin 7 to pin 5 Pin 5 to pin 3 Pin 1 to pin 3
Pin 6 to pin 8 Pin 4 to pin 6 Pin 2 to pin 4
ʱ´¬¿¹»æ
Ignition ON: Pin 3 = 12 V
Pin 6 = 9 V
Úîèìïé
Ì»-¬ °®±½»¼«®»
ݱ²¬·²«·¬§æ
Brakes not applied: no continuity.
Brakes applied: continuity, between the two centre
pins of each switch.
Both brake pedals must be applied to allow 12 V to
relay.
Úîèìïç
ʱ´¬¿¹»æ
Left switch:
White / red wire 12 V continuous with ignition ON
Red wire 12 V pedal depressed
0 V pedal released
Right switch:
Red wire 12 V pedal depressed
ïæ Îæï ïæ Îæï
0 V pedal released
Red - Black wire 12 V pedal depressed îæ ÎóÒæï îæ ÞñÎæï
0 V pedal released
Úîèìîð
SECTION 55 - ELECTRICAL SYSTEM 133
Ì»-¬ °®±½»¼«®»æ
Continuity:
With the fluid level correct there should be no conti-
nuity through the switch. Continuity should be seen
when the level is low or the test button pushed.
Voltage:
With the Ignition ON there should be 12 V at the ïæ ÙóÎæï
Red/Black terminal.
îæ ÎñÒæï
Úîèìîî
ï î
Úîèìîì
Ì»-¬ °®±½»¼«®»
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 3
and 2 and 8.
Úîèìïé
134 SECTION 55 - ELECTRICAL SYSTEM
Úîèìîé
Ì»-¬ °®±½»¼«®»
7 - to pins 2/3/5
Úîèìîè
Õïð Õïî
Õïï
õÞÆï
ÈÝï ÈÝî Õî
ÚïñÝ ÚîñÝ
Úîèìíð
ݱ²¬·²«·¬§
Úîèìíï
SECTION 55 - ELECTRICAL SYSTEM 135
Úîèìíí
î
Úîèìíë
Ì»-¬ °®±½»¼«®»
Ì»-¬ °®±½»¼«®»
With ignition ON
ÝóÙ
ß
Úîèìíè
SECTION 55 - ELECTRICAL SYSTEM 137
Þ«¦¦»® ±°»®¿¬·±²
Buzzer operation depends on setting of pin 2 of the
12 way connector:
Pin 2 not connected (North America only). If 12 km/
h is exceeded in crab mode, the buzzer sounds.
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.
Úîèììí
A 12 V 12 V 12 V
B - - -
C - - - ßæ ÎÓæÔñÒæï
Þæ ÎÓæÒæï
Ýæ ÎÓæÎñÒæï
Úîèììì
Úîèììë
Èçé
з² îÉÍ ìÉÍ ÝÎßÞ
A 12 V 12 V 12 V
B - - -
C - - - ßæ ÎÓæØóÔæï
Þæ ÎÓæÒæï
Ýæ ÎÓæßñÊæï
Úîèììê
140 SECTION 55 - ELECTRICAL SYSTEM
ÍÌÛÛÎ×ÒÙ ÍÑÔÛÒÑ×ÜÍ
Energized at 12 V but governed by the steering proc-
essor.
Úîèììé
ÌÛÍÌ ÐÎÑÝÛÜËÎÛ
Èçï
з² Ò±ò ͱ´»²±·¼ λ-·-¬¿²½»
Èçî
1 0V 5.0
ïæ ÎÓæÔñÎæï
îæ ÎÓæÒæï
ïæ ÎÓæÍñÒæï
îæ ÎÓæÒæï
Úîèììç
ÌÛÍÌ ÐÎÑÝÛÜËÎÛ
Èçí
з² Ò±ò ͱ´»²±·¼ λ-·-¬¿²½»
Èçì
1 0V 5.0
ïæ ÎÓæØñÒæï
îæ ÎÓæÒæï
ïæ ÎÓæÓñÞæï
îæ ÎÓæÒæï
Úîèìëð
SECTION 55 - ELECTRICAL SYSTEM 141
Ì»-¬ °®±½»¼«®»
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity should be found between pins 1 and 5.
ïæ ÓñÞï
ëæ ÝóÞï
Úîèìëî
ïæ ÎÓæÝÔæï
îæ ÎÓæÒæï
Úîèìëí
142 SECTION 55 - ELECTRICAL SYSTEM
ÔÑßÜÛÎ
ÙÔ×ÜÛ Î×ÜÛ ÝÑÒÌÎÑÔ ó Íë
Designed to reduce loader bounce when travelling
with an unladen bucket.
ÉßÎÒ×ÒÙ
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF.
If the switch is ON, upon engine start up the vehicle
will fall to the ground without any control.
Ì»-¬ °®±½»¼«®»
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 5.
ïæ ÝñÒï
ëæ ßóÒï
Úîèìëê
ïæ ÎÓæßóÒæï
îæ ÎÓæÒæï
Úîèìëé
SECTION 55 - ELECTRICAL SYSTEM 143
Úîèìëç
Úîèìïé
Ì»-¬ °®±½»¼«®»
ïæ ÎÓæÒæï
îæ ÎÓæÝóÔæï
Úîèìêï
Ì»-¬ °®±½»¼«®»
(Switch off)
Continuity should not be found between any pins.
(Switch on)
Continuity shoud be found between pins 1 and 5.
ïæ ÝñÒï
ëæ ÔóÙï
Úîèìêì
ïæ ÎÓæÒæï
îæ ÎÓæÝóÔæï
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ÞßÝÕØÑÛ
Í×ÜÛÍØ×ÚÌ ÔÑÝÕ ÍÉ×ÌÝØ ó Íé
At key start switch should have 12 V to release/en-
gage sideshift clamps.
Úîèìêé
Ì»-¬ °®±½»¼«®»
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity should be found between pins 1 and 5.
ïæ ÝñÞï
ëæ ÞóÒï
Úîèìêè
SECTION 55 - ELECTRICAL SYSTEM 145
ïæ ÎÓæÒæï
îæ ÎÓæÝóÔæï
Úîèìêç
Úîèìéï
Ì»-¬ °®±½»¼«®»
(Switch Off) - X25
Continuity should be found between pins 1 and 5.
(Switch On)
Continuity should be found between pins 5 and 7.
ïæ ÝóÞï
éæ ÔñÙï
ëæ ÝñÞï
Úîèìéî
ïæ ÎóÊæï
îæ Òæï
Úîèìéí
146 SECTION 55 - ELECTRICAL SYSTEM
Úîèìéë
îæ ÎóÊ
ïæ ÎóÊæï
Úîèìéê
ïæ ÎóÊæï
îæ Òæï
Úîèìéí
SECTION 55 - ELECTRICAL SYSTEM 147
Úîèìéè
ïæ ÝóÞï
ëæ ÝñÞï
Úîèìéç
ïæ ØóÒ
îæ Òæï
Úîèìèð
148 SECTION 55 - ELECTRICAL SYSTEM
Úîèìèî
ïæ ÝñÒï
ëæ Êï
Úîèìèí
Úîèìèë
îæ Êæï
ïæ Òæï
Úîèìèê
SECTION 55 - ELECTRICAL SYSTEM 149
Úîèìèé
ÓñÞ
Ò
Úîèìèè
Úîèìèç
Ì»-¬ °®±½»¼«®»
Approximate resistance:
Úîèìçð
150 SECTION 55 - ELECTRICAL SYSTEM
ÒÑÌÛæ
LB90.B
LB95.B
LB110.B
LB115.B
SECTION 82 - LOADER
The loader assy consists essentially of an arm hinged to the loader backhoe chassis, on which is installed a
linkage moving the bucket frontally.
Two kinds of loader arm are provided:
Rotate the bell crank (1) till it touches the tube (2)
on the loader arm. Make sure the lower bell crank
arm is directing upwards.
Adjust the length of the vertical rod (3) so that when
re-connected, the end of the loader arm tube re-
mains in contact with the bell crank.
Securely tighten locknuts on vertical rod.
8 SECTION 82 - LOADER
2WS
Return to dig is an electrically activated feature
which enables the operator to automatically return
the bucket to a level digging position for a further
work cycle with one simple movement of the loader
control lever (3).
Whenever the bucket is rolled forward to dump the
return to dig electrical circuit is completed and the so-
lenoid on the bucket spool is energized.
When the loader bucket control lever (3) is moved di-
agonally left to the return to dig position (2) the elec-
tromagnet will hold the bucket spool in the roll back
position until the bucket is in the level digging posi-
tion at which time the indicator on the rod of the buck-
et self leveling linkage will pass in front of the sensor
which de-energizes the electromagnet on the bucket
spool enabling the spool to return to the neutral posi-
tion.
4WS
Return to dig is an electrically activated feature
which enables the operator to automatically return
the bucket to a level digging position for a further
work cycle with one simple movement of the loader
control lever (3).
Whenever the bucket is rolled forward to dump the
return to dig electrical circuit is completed and the so-
lenoid on the bucket spool is energized.
When the loader bucket control lever (3) is moved di-
agonally left to the return to dig position (2) the elec-
tromagnet will hold the bucket spool in the roll back
position until the bucket is in the level digging posi-
tion at which time the indicator on the rod of the buck-
et linkage will pass in front of the sensor which de-
energizes the electromagnet on the bucket spool en-
abling the spool to return to the neutral position.
LOCKED POSITION
Raise the loader attachment completely, stop the en-
gine and remove the ignition switch key.
Remove the retaining pin and split pin.
Place the strut on the cylinder rod and install the pin
and split pin in the holes in the strut.
UNLOCKED POSITION
Remove the retaining pin and split pin.
Swing the strut against the lift arm and install the pin
and split pin in the holes in the strut and the retaining
lug.
Start the engine and lower the loader attachment.
LOCKED POSITION
Raise the loader attachment completely, stop the en-
gine and remove the ignition switch key.
Remove the pins and the safety strut from the loader
arm. Put the pins back in place.
Place the strut on the cylinder rod and install the re-
taining strap.
UNLOCKED POSITION
Remove the strut from the cylinder rod.
Install the safety strut with the pins on the loader arm.
Start the engine and lower the loader attachment.
12 SECTION 82 - LOADER
REMOVAL
Park the machine on flat, level ground.
Lower the bucket to the ground in dump position (tilt-
ed completely forward).
Stop the engine and remove the ignition switch key.
If the machine is fitted with a 4x1 bucket, release the
pressure in the bucket circuit.
Remove the linkage pin retaining bolts and then re-
move the linkage pins (1).
(4x1 bucket) disconnect and plug the hydraulic sup-
ply lines.
Start the engine.
Operate the attachment controls so as to release the
bucket.
Reverse the machine from the bucket.
INSTALLATION
Make sure all bushings are completely clean.
Remove any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Install the arm/bucket linkage pins (1) and then in-
stall the linkage pin retaining bolts.
Use the bucket controls to align the connecting rod
holes with the bucket lugs.
Shut down the engine and remove the ignition switch
key.
(4x1 bucket) release the pressure in the bucket cir-
cuit.
Install the connecting rod/bucket linkage pins (1) and
then install the linkage pin retaining bolts.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic supply lines.
SECTION 82 - LOADER 13
REMOVAL
Park the machine on flat, level ground.
Lower the bucket to the ground in dump position (tilt-
ed completely forward).
Stop the engine and remove the ignition switch key.
If the machine is fitted with a 4x1 bucket, release the
pressure in the bucket circuit.
Remove the snap rings and retaining pins and then
drive out the linkage pins (1).
(4x1 bucket) disconnect and plug the hydraulic sup-
ply lines.
Start the engine.
Operate the attachment controls so as to release the
bucket.
Reverse the machine from the bucket.
INSTALLATION
Make sure all bushings are completely clean.
Remove any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Install the arm/bucket linkage pins (1) and then in-
stall the retaining pins and snap rings.
Use the bucket controls to align the connecting rod
holes with the bucket lugs.
Shut down the engine and remove the ignition switch
key.
(4x1 bucket) release the pressure in the bucket cir-
cuit.
Install the connecting rod/bucket linkage pins (1) and
then install the retaining pins and snap rings.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic supply lines.
14 SECTION 82 - LOADER
INSTALLATION
Installation follows removal procedure in reverse.
When installing the retaining bolts tighten them to
500 Nm.
SECTION 82 - LOADER 17
Remove the safety rings (2) and the pins and then
drive out the pins (1). Lower the lift cylinders carefully
onto the chassis.
Remove the snap rings (3) and drive out the pins (4).
Lower the arms onto the lift cylinders.
Remove the safety ring and pins and then pull out the
pin (8).
INSTALLATION
Installation follows removal procedure in reverse.
LB90.B
LB95.B
LB110.B
LB115.B
SECTION 84 - BACKHOE
STANDARD CONFIGURATION
Backhoe boom and backhoe attachment swing left-
hand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (A): the backhoe boom lowers.
Position (B): the backhoe boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.
ISO CONFIGURATION
Lever 1:
Push the lever forward - dipstick crowds in.
Push the lever back - dipstick crowds out.
Lever 2:
Push the lever forward - boom lifts.
Push the lever back - boom lowers.
Lever 3:
Push the lever forward - bucket curls in.
Push the lever back - bucket curls out.
Lever 4:
Push the lever forward - boom swings right.
Push the lever back - boom swings left.
SECTION 84 - BACKHOE 11
STABILIZER CONTROLS
These controls are located on the left-hand control
arm and may be used to operate the stabilizers inde-
pendently or simultaneously.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Remove the snap ring (4), slide out the pin (5) and by
means of an hammer remove the pin (6) of swing cyl-
inder.
Repeat the operation with both swing cylinders. Re-
move snap ring (7).
Slide out the pin (8) and by means of an hammer re-
move the lower pin (9) from swing support.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Úíðííî
Remove the snap ring (4), slide out the pin (5) and by
means of an hammer remove the pin (6) of swing cyl-
inder.
Repeat the operation with both swing cylinders. Re-
move snap ring (7).
Slide out the pin (8) and by means of an hammer re-
move the lower pin (9) from swing bracket.
DIPPER REMOVE
Park the machine on a level, firm surface and posi-
tion the backhoe on the ground.
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Procedure No. 1
Procedure No. 2