87643850B Linked PDF

REPAIR MANUAL
BACKHOE LOADER
B90B
B95B
B95BLR
B95BTC
B110B
B115B
TIER 3
Bur • Issued 01Feb 08

Printed in U.S.A. • Book/Form Number 87643850B NA
Copyright © 2008. CNH America, LLC. All Rights Reserved.
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not
necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.
This unit first became available 02-2008

REVISION HISTORY
Issue Issue Date Applicable Machines Remarks
First Edition 01Feb 08 B90B, B95B, B95BLR, B95BTC, B110B, B115B Tier 3 Backhoe Loader 87643850B NA
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT
TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY.
Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows:
● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.
The color associated with Danger is RED.
● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious
injury. The color associated with Warning is ORANGE.
● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.
If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:
● The first panel indicates the nature of the hazard.
● The second panel indicates the appropriate avoidance of the hazard.
● Background color is YELLOW
● Prohibition symbols such as and STOP if used, are RED.
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS
MACHINE, MAKE CERTAIN THAT EVERY OPERATOR:
❷ Is instructed in safe and proper use of the machine.
❷ Reads and understands the Manual(s) pertaining to the machine.
❷ Reads and understands ALL Safety Decals on the machine.
❷ Clears the area of other persons.
❷ Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job
site.
It is your responsibility to observe pertinent laws and regulations and follow instructions on machine operation and
maintenance.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects,
and other reproductive harm.
Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
TECHNICAL MANUALS
Manuals are available from your Dealer for the operation, service, and repair of your machine.
Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for
Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.
Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your
machine so your Dealer can provide the correct manuals for your machine.
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America LLC. Carol Stream, IL 60188 U.S.A.
1
TO READER
This manual has been printed for a kilful engineer CNH AMERICA LLC
to supply necessary technical information to carry 245 E North Avenue
out service operations on this machine. Carol Stream, II 60188 U.S.A.
Read carefully this manual to collect correct infor-

mation relevant to repair procedures.
For any question or remark, or in case of any error

relevant the contents of this manual, please con-
tact:
REFERENCE
Beyond this Service Manual, also refer to
documents hereunder listed:
Z Operator’s Manual
Z Parts Catalogue
COMPLETE HANDBOOK FOR INSTRUCTIONS The Service Manuals for “Loader backhoe” and
AND REPAIRS “Engine” contain the necessary technical informa-
The complete Service Manual consists of two 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
Z B90B-B95B-B95BLR-B95BTC-B110B-B115B procedures for connection, disconnection, disas-
Service Manual “Loader backhoe” sembly and assembly of parts.
Z B90B-B95B-B95BLR-B95BTC-B110B-B115B
Service Manual “Engine” The complete Service Manual which covers the
loader backhoe models B90B-B95B-B95BLR-
B95BTC-B110B-B115B consists of the following
volumes, which can be identified through their
print no. as stated below:
VOLUME MACHINE TYPE PRINT NUMBER

Service Manual - “Loader backhoe” B90B-B95B-B95BLR-B95BTC-B110B-B115B 87643850B
Service Manual - “Engine” B90B-B95B-B95BLR-B95BTC-B110B-B115B 87659057A
2
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.
S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.
CNH AMERICA LLC

245 E North Avenue
Carol Stream, II 60188 U.S.A.
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
3
LOADER BACKHOE MODELS

The complete range of Loader Backhoe models described in this manual are identified below:
B90B B95B - B95BTC B110B B115B

B95BLR
Powershift / / /
Powershuttle /
Cab
Rops / /
2WD / / /
4WD
4WS / / / /
Pilot control
Mechanical control
Engine Iveco 72 kW - 97 HP model
/ / / /
F4GE9424C*601 (mechanical)
/ / /
F4HE0484G*J102 (electronic)
/ / / /
F4HE9484C*J102 (electronic)
Engine Iveco 82 kW - 110 HP (4WS) model
/ / / /
Short dipper / /
Long dipper /
4
1
INDEX
SECTION 00 - SAFETY PRECAUTIONS
SECTION 01 - MAINTENANCE
SECTION 02 - TECHNICAL SPECIFICATIONS

1. LOADER BACKHOE MODELS .................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
3.1 DIESEL ENGINE ................................................................................................................................... 5
3.2 TRANSMISSION.................................................................................................................................... 7
3.3 AXLES ................................................................................................................................................... 8
3.4 BRAKES ................................................................................................................................................ 8
3.5 STEERING............................................................................................................................................. 9
3.6 HYDRAULIC SYSTEM .......................................................................................................................... 9
3.7 FRONT COUNTERWEIGHT ................................................................................................................. 9
3.8 NOISE AND VIBRATION LEVELS ...................................................................................................... 10
3.9 BUCKETS ............................................................................................................................................ 10
3.10 TYRES ............................................................................................................................................... 12
4. DIMENSIONS AND PERFORMANCE........................................................................................................ 13
4.1 DIMENSIONS - 2WS - B90B - B95B - B95BLR - B110B..................................................................... 13
4.2 DIMENSIONS - 2WS - B95BTC .......................................................................................................... 14
4.3 DIMENSIONS - 4WS - B115B ............................................................................................................. 15
4.4 LOADER ATTACHMENT PERFORMANCE........................................................................................ 16
4.5 PERFORMANCE OF LOADER ATTACHMENT WITH FORKS .......................................................... 28
4.6 BACKHOE ATTACHMENT PERFORMANCE..................................................................................... 32
5. BACKHOE ATTACHMENT LIFTING CAPACITY ....................................................................................... 53
6. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 57
SECTION 17 - TORQUE CONVERTERS

1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................ 3
1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION ......................................................................................................................................... 4
1.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION ......................................................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2
SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025”.................................................... 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
1.12 FAULT FINDING ................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 94
2.2 TRANSMISSION CONTROLS............................................................................................................. 95
2.3 LUBRICATION ................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER................................................................................................................ 108
2.6 TRANSMISSION HYDRAULIC DIAGRAM ........................................................................................ 109
2.7 OPERATION ...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION / ENGINE REMOVAL FROM LOADER ............................................................... 133
2.11 TRANSMISSION COMPONENTS ................................................................................................... 138
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 156
2.13 SPECIAL TOOLS............................................................................................................................. 265
2.14 FAULT FINDING .............................................................................................................................. 266
2.15 FAULT FINDING .............................................................................................................................. 268
SECTION 25 - FRONT AXLES

1. FRONT AXLE 2WD “CARRARO” ................................................................................................................. 3
1.3 FAULT FINDING .................................................................................................................................. 24
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 26
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING .................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.3 FAULT FINDING ................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
3
SECTION 27 - REAR AXLE

1. REAR AXLE 2WS ......................................................................................................................................... 3
1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.4 FAULT FINDING.................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.3 FAULT FINDING.................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
SECTION 33 - BRAKE SYSTEM

2. HAND BRAKE............................................................................................................................................... 6
2.1 HAND BRAKE ADJUSTMENT .............................................................................................................. 7
3. BRAKE MASTER CYLINDERS .................................................................................................................... 8
3.1 BRAKE RESERVOIR........................................................................................................................... 13
3.2 BRAKE BLEEDING PROCEDURE...................................................................................................... 13
SECTION 35 - HYDRAULIC SYSTEM

1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3
1.1 HYDRAULIC DIAGRAM - 2WS MECHANICAL MODELS CENTER PIVOT -
B90B - B95B - B95BLR - B110B............................................................................................................ 3
1.2 HYDRAULIC DIAGRAM - 2WS PILOT MODELS CENTER PIVOT - B90B - B95B - B95BLR - B110B 5
1.3 HYDRAULIC DIAGRAM - 2WS MECHANICAL MODELS CENTER PIVOT - B95BTC ........................ 7
1.4 HYDRAULIC DIAGRAM - 2WS PILOT MODELS CENTER PIVOT - B95BTC ..................................... 9
1.5 HYDRAULIC DIAGRAM - 4WS MECHANICAL MODELS CENTER PIVOT - B115B ......................... 11
1.6 HYDRAULIC DIAGRAM - 4WS PILOT MODELS CENTER PIVOT - B115B ...................................... 13
1.7 HYDRAULIC DIAGRAM - QUICK COUPLER FOR B95BTC .............................................................. 15
2. HYDRAULIC PUMP.................................................................................................................................... 16
2.1 DESCRIPTION AND OPERATION...................................................................................................... 16
2.3 LOAD SENSING VALVE ..................................................................................................................... 19
2.4 REMOVAL ........................................................................................................................................... 21
2.5 COMPONENTS ................................................................................................................................... 22
3. CONTROL VALVES ................................................................................................................................... 27
3.1 CONTROL VALVES “HUSCO” (B90B - B95B - B95BLR - B95BTC - B110B
MECHANICAL MODELS) .................................................................................................................... 27
3.2 CONTROL VALVES “REXROTH” (B115B MECHANICAL MODELS) ................................................ 64
3.3 CONTROL VALVES “REXROTH” (B90B - B90BLR - B95BLR - B110B - B115B PILOT MODELS) .. 80
3.4 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE
(WITH HYDRAULIC CONTROL) ......................................................................................................... 88
3.5 ACCUMULATOR “GLIDE RIDE” PARKER.......................................................................................... 91
3.6 SYSTEM RELIEF VALVES.................................................................................................................. 94
4. HYDRAULIC SWING SYSTEM ................................................................................................................ 104
4.1 DESCRIPTION AND OPERATION.................................................................................................... 104
4.2 HYDRAULIC OIL FLOW .................................................................................................................... 105
4.3 PRECISION SWING CONTROL ....................................................................................................... 107
4
5. HYDRAULIC CYLINDERS........................................................................................................................ 110

5.1 LOADER CYLINDER ......................................................................................................................... 111
5.2 LOADER BUCKET CYLINDER.......................................................................................................... 118
5.3 4X1 BUCKET CYLINDER .................................................................................................................. 127
5.4 BACKHOE BOOM CYLINDER .......................................................................................................... 130
5.5 BACKHOE DIPPER CYLINDER ........................................................................................................ 134
5.6 BACKHOE BUCKET CYLINDER....................................................................................................... 138
5.7 TELESCOPIC CYLINDER ................................................................................................................. 142
5.8 STABILIZERS CYLINDER ................................................................................................................. 146
5.9 SWING CYLINDER............................................................................................................................ 150
5.10 SPECIAL TOOLS............................................................................................................................. 154
6. PILOT HYDRAULIC CONTROL LEVERS ................................................................................................ 155
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 155
6.4 PILOT HYDRAULIC CONTROL VALVE............................................................................................ 162
7. FAULT FINDING ....................................................................................................................................... 165
7.1 PRELIMINARY CHECKS................................................................................................................... 165
7.2 FAULT FINDING (WITH “HUSCO” CONTROL VALVES) ................................................................. 166
7.3 FAULT FINDING (WITH “REXROTH” CONTROL VALVES)............................................................. 171
SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS............................................................................................... 5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 8
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS........................................................................... 9
2.5 TIGHTENING TORQUES .................................................................................................................... 11
SECTION 41 - STEERING SYSTEM

1. STEERING SYSTEM 2WS ........................................................................................................................... 4
3. POWER STEERING ................................................................................................................................... 12
3.2 COMPONENTS ................................................................................................................................... 15
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING .................................................................................................................................. 33
SECTION 50 - CAB HEATING AND AIR CONDITIONING

2. CAB HEATING.............................................................................................................................................. 5
3. AIR CONDITIONING................................................................................................................................... 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 27
5
3.5 FLUSHING THE SYSTEM................................................................................................................... 45

3.6 EVACUATING THE SYSTEM.............................................................................................................. 47
3.7 CHARGING THE SYSTEM.................................................................................................................. 48
3.8 COMPONENTS OVERHAUL .............................................................................................................. 49
3.9 COMPRESSOR ................................................................................................................................... 54
3.10 SPECIAL TOOLS............................................................................................................................... 68
SECTION 55 - ELECTRICAL SYSTEM

1. GENERALITIES............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B90B) ............................................................ 5
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B90B)............................................................. 22
2.3 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B95B - B110B) ............................................ 42
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B95B - B110B)............................................... 56
2.5 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (B110B)................................................................. 73
2.6 ELECTRICAL DIAGRAMS - POWERSHIFT 4WS CAB (B115B) ........................................................ 89
3. CONTROLS AND INSTRUMENTS .......................................................................................................... 106
3.1 FRONT INSTRUMENT PANEL ......................................................................................................... 106
3.2 CALIBRATION OF SPEEDOMETER ................................................................................................ 108
3.3 SIDE INSTRUMENT PANEL (B90B) ................................................................................................. 109
3.4 SIDE INSTRUMENT PANEL (B95B - B110B - B115B) ..................................................................... 111
3.5 SIDE INSTRUMENT CLUSTER (B90B) ............................................................................................ 113
3.6 SIDE INSTRUMENT (B95B - B110B - B115B).................................................................................. 115
3.7 IMMOBILISER SYSTEM.................................................................................................................... 117
4. DIAGNOSTICS DISPLAY (B95B - B110B - B115B)................................................................................. 118
4.1 SYMBOLS.......................................................................................................................................... 120
4.2 SETUP MENU ................................................................................................................................... 121
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 122
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 123
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 124
4.6 WORK HOURS.................................................................................................................................. 125
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 126
4.8 MAINTENANCE................................................................................................................................. 132
4.9 WARNING MESSAGES .................................................................................................................... 133
5. STARTING SYSTEM ................................................................................................................................ 139
5.2 FAULT FINDING................................................................................................................................ 140
5.3 STARTER MOTOR............................................................................................................................ 143
6. ALTERNATOR.......................................................................................................................................... 149
6.3 COMPONENTS ................................................................................................................................. 151
6.4 REMOVAL ......................................................................................................................................... 152
6.5 PRELIMINARY CHECK AND TESTS................................................................................................ 153
6.6 FAULT FINDING................................................................................................................................ 162
6
7. BATTERY.................................................................................................................................................. 163
7.3 REMOVAL AND INSTALLATION ...................................................................................................... 164
7.4 MAINTENANCE ................................................................................................................................. 166
7.5 TESTS................................................................................................................................................ 168
7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 170
7.7 BATTERY MASTER SWITCH ........................................................................................................... 170
8. COMPONENT TESTING .......................................................................................................................... 171
8.1 GENERAL INTRODUCTION ............................................................................................................. 171
8.2 COMPONENT TESTING ................................................................................................................... 172
8.3 GROUND POINTS............................................................................................................................. 172
8.4 KEY-START AND STOP SWITCH .................................................................................................... 174
8.5 ALTERNATOR ................................................................................................................................... 175
8.6 TRANSMISSIONS ............................................................................................................................. 175
8.7 PARKING BRAKE SWITCH............................................................................................................... 179
8.8 CAB.................................................................................................................................................... 180
8.9 4WD SWITCH .................................................................................................................................... 185
8.10 BRAKE PEDAL SWITCHES ............................................................................................................ 185
8.11 BRAKE OIL LEVEL LAMP ............................................................................................................... 186
8.12 FRONT WORK LAMP SWITCH - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH ......... 186
8.13 HAZARD SWITCH ........................................................................................................................... 187
8.14 FLASHER RELÈ .............................................................................................................................. 187
8.15 MULTI FUNCTION SWITCH............................................................................................................ 188
8.16 FRONT WIPER MOTOR (1) - REAR WIPER MOTOR (2) .............................................................. 188
8.17 4WS -STEERING SELECTOR SWITCH ......................................................................................... 189
8.18 STEERING CONTROL UNIT........................................................................................................... 190
8.19 4WS REAR AXLE STEERING SENSOR......................................................................................... 192
8.20 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 192
8.21 STEERING SOLENOID VALVE....................................................................................................... 193
8.22 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 194
8.23 LOADER .......................................................................................................................................... 195
8.24 BACKHOE........................................................................................................................................ 197
8.25 REVERSING BUZZER..................................................................................................................... 200
8.26 FUEL LEVEL INDICATOR ............................................................................................................... 201
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS ......................................................................................................... 4
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 7
3. LOADER ATTACHMENT SAFETY STRUT ................................................................................................ 10
4. LOADER BUCKET REMOVAL ................................................................................................................... 13
4.1 REPLACING BUCKET TEETH ............................................................................................................ 18
5. LOADER ARM REMOVAL.......................................................................................................................... 19
5.1 LOADER ARM REMOVAL (B90B - B95B - B110B)............................................................................. 19
5.2 LOADER ARM REMOVAL (B95BTC - B115B).................................................................................... 21
7
SECTION 84 - BACKHOE
2. BACKHOE ATTACHMENT MECHANICAL CONTROLS ............................................................................. 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS .............................................................................. 15
4. REMOVAL AND INSTALLATION ............................................................................................................... 17
4.1 BACKHOE BUCKET REMOVAL ......................................................................................................... 19
5. TELESCOPIC DIPPER (HED) REVISION.................................................................................................. 24
8
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 00 - SAFETY PRECAUTIONS

2 SECTION 00 - SAFETY PRECAUTIONS
SECTION 00 - SAFETY PRECAUTIONS 3
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”, “WARN-
ING”, and “DANGER”) followed by specific instructions. These precautions are intended for the personal safety
of you and those working with you. Please take the time to read them.
SCAUTION
THE WORD “CAUTION” IS USED WHERE A SAFE BEHAVIORAL PRACTICE ACCORDING TO OPERAT-
ING AND MAINTENANCE INSTRUCTIONS AND COMMON SAFETY PRACTICES WILL PROTECT THE
OPERATOR AND OTHERS FROM ACCIDENT INVOLVEMENT.
SWARNING
THE WORD “WARNING” DENOTES A POTENTIAL OR HIDDEN HAZARD WHICH HAS A POTENTIAL FOR
SERIOUS. IT IS USED TO WARN OPERATORS AND OTHERS TO EXERCISE EVERY APPROPRIATE
MEANS TO AVOID A SURPRISE INVOLVEMENT WITH MACHINERY.
SDANGER
THE WORD “DANGER” DENOTES A FORBIDDEN PRACTICE IN CONNECTION WITH A SERIOUS HAZ-
ARD.
FAILURE TO FOLLOW THE “CAUTION”, “WARNING” AND “DANGER” INSTRUCTIONS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH.
MACHINE SAFETY
Additional precautionary statements (“ATTENTION” and “IMPORTANT”) are followed by specific instructions.
These statements are intended for machine safety.
ATTENTION: the word “ATENTION” is used to warn the operator of potential machine damage if a certain pro-
cedure is not followed.
IMPORTANT: the word “IMPORTANT” is used to inform the reader of something he needs to know to prevent
minor machine damage if a certain procedure is not followed.
SAFETY RULES
Z Carefully follow specified repair and maintenance Z For electrical heaters, battery-chargers and similar
procedures. equipment use exclusive auxiliary power supplies
Z Do not wear rings, wristwatches, jewels, unbut- with a efficient ground to avoid electrical shock
toned or flapping clothing such as ties, torn hazard.
clothes, scarves, open jackets or shirts with open Z Always use lifting equipment and similar of appro-
zips which could get hold into moving parts. priate capacity to lift or move heavy components.
We advise to use approved safety clothing such as Z Pay special attention to bystanders.
anti-slipping footwear, gloves, safety goggles, hel- Z Never pour gasoline or diesel oil into open, wide
mets, etc. and low containers.
Z Never carry out any repair on the machine if some- Z Never use gasoline, diesel oil or other flammable
one is sitting on the operator’s seat, except if they liquids as cleaning agents. Use non-flammable
are certified operators to assist in the operation to non-toxic proprietary solvents.
be carried out. Z Wear protection goggles with side guards when
Z Never operate the machine or use attachments cleaning parts using compressed air.
from a place other than sitting at the operator’s Z Do not exceed a pressure of 2.1 bar (30 psi), in ac-
seat. cordance with local regulations.
Z Never carry out any operation on the machine Z Do not run the engine in a closed building without
when the engine is running, except when specifi- proper ventilation.
cally indicated. Z Do not smoke, use open flames, cause sparks in
Z Stop the engine and ensure that all pressure is re- the nearby area when filling fuel or handling highly
lieved from hydraulic systems before removing flammable liquids.
caps, covers, valves, etc. Z Do not use flames as light sources when working
Z All repair and maintenance operations should be on a machine or checking for leaks.
carried out with the greatest care and attention. Z Move with caution when working under a Machine,
Z 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.
Z Disconnect the batteries and label all controls to Z 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.
Z 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 on
near open flames as such fluids are flammable. an incline cannot be avoided, first block the Ma-
Z 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- Z Ruined or plied cables and chains are unreliable.
trol using blocks or similar devices. Do not use them for lifting or trailing. Always han-
Z The fuel filling gun should remain always in contact dle hem wearing gloves of proper thickness.
with the filler neck. Z 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.
Z Use exclusively specified towing points for towing Z 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. Z 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
Z 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-
Z 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 Z 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
Z 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, Z 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 Z Some fluid slowly coming out from a very small
persons standing in the vicinity of the welding pro- port can be almost invisible and be strong enough
cess 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
Z 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
Z Handle all parts with the greatest caution. Keep result.
your hands and fingers far from gaps, moving Z 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 TIRES
Z Check that the tires are correctly inflated at the
START UP
pressure specified by the manufacturer. Periodi-
Z Never run the engine in confined spaces which are cally check possible damages to the rims and tires.
not equipped with adequate ventilation for exhaust Z Keep off and stay at the tire side when correcting
gas extraction. the inflation pressure.
Z Never bring your head, body, arms, legs, feet, Z Check the pressure only when the machine is un-
hands, fingers near fans or rotating belts. loaded and tires are cold to avoid wrong readings
due to over-pressure. Do not reuse parts of recov-
ENGINE ered wheels as improper welding, brazing or heat-
Z Always loosen the radiator cap very slowly before ing may weaken the wheel and make it fail.
removing it to allow pressure in the system to dis- Z Never cut, nor weld a rim with the inflated tire as-
sipate. Coolant should be topped up only when the sembled.
engine is stopped or idle if hot. Z To remove the wheels, block both front and rear
Z Do not fill up fuel tank when the engine is running, Machine wheels. Raise the Machine and install
mainly if it is hot, to avoid ignition of fires in case of safe and stable supports under the Machine in ac-
fuel spilling. cordance with regulations in force.
Z Never check or adjust the fan belt tension when the Z Deflate the tire before removing any object caught
engine is running. Never adjust the fuel injection into the tire tread.
pump when the machine is moving. Z Never inflate tires using flammable gases as they
Z Never lubricate the machine when the engine is may originate explosions and cause injuries to by-
running. standers.
ELECTRICAL SYSTEMS REMOVAL AND INSTALLATION

Z If it is necessary to use auxiliary batteries, cables Z Lift and handle all heavy components using lifting
must be connected at both sides as follows: (+) to equipment of adequate capacity. Ensure that parts
(+) and (-) to (-). Avoid short-circuiting the termi- are supported by appropriate slings and hooks.
nals. GAS RELEASED FROM BATTERIES IS Use lifting eyes provided to this purpose. Take
HIGHLY FLAMMABLE. During charging, leave the care of the persons near the loads to be lifted.
battery compartment uncovered to improve venti- Z Handle all parts with great care. Do not place your
lation. Avoid checking the battery charge by hands or fingers between two parts. Wear ap-
means of “jumpers” made by placing metallic ob- proved protective clothing such as safety goggles,
jects across the terminals. Avoid sparks or flames gloves and footwear.
near the battery area. Do not smoke to prevent ex- Z Do not twist chains or metal cables. Always wear
plosion hazards. protection gloves to handle cables or chains.
Z Prior to any service, check for fuel or coolant leaks.
Remove these leaks before going on with the work.
Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent acci-
IMPORTANT ECOLOGICAL CONSIDERATIONS

The following are recommendations which may be
of assistance:
Z Become acquainted with and ensure that you un-
derstand the relative legislation applicable to your
country.
Z Where no legislation exists, obtain information
from suppliers of oils, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and
nature and how to safely store, use and dispose of
these substances.
Helpful hints
Z Avoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
Z In general, avoid skin contact with all fuels, oils, ac-
ids, solvents, etc. Most of them contain substances
which can be harmful to your health.
Z Modern oils contain additives. Do not burn contam-
inated fuels and/or waste oils in ordinary heating
systems.
Z Avoid spillage when draining off used engine cool-
ant mixtures, engine, transmission and hydraulic
oils, brake fluids, etc. Do not mix drained brake flu-
ids or fuels with lubricants. Store them safely until
they can be disposed of in a proper way to comply
with local legislation and available resources.
Z Modern coolant mixtures, i.e. antifreeze and other
additives, should be replaced every two years.
They should not be allowed to get into the soil but
should be collected and disposed of safely.
Z Do not open the Air-Conditioning system yourself.
It may contain gases which should not be released
into the atmosphere. Your air conditioning special-
ist has special equipment for discharging and
charging the system.
Z Repair any leaks or defects in the engine cooling or
hydraulic system immediately.
Z Do not increase the pressure in a pressurized sys-
tem as this may lead to a catastrophic failure of the
system components.
Z Protect hoses during welding as penetrating weld
splatter may burn a hole or weaken them, causing
the loss of oils, coolant, etc.
B90B
B95B - B95BLR
B95BTC
B110B
B115B
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 abrasive dust can re- When repairing O-ring face seal connectors, the fol-
duce the efficient working life of a component and lowing procedures should be observed.
lead to costly replacement.
Time spent on the preparation and cleanliness of S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. Refer to the following torque chart.
HOSES AND TUBES NOTE: to ensure a leak-free joint is obtained, it is

Always replace hoses and tubes if the cone end or important that the fittings are not over or under
the end connections on the hose are damaged. torqued.
When installing a new hose, loosely connect each
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, mea-
After hose replacement to a moving component, sure them individually using a micrometer 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-
tivity of the components being served. Connectors ROTATING SHAFT SEALS
which show signs of movement from the original To correctly install rotating shaft seals, observe the follow-
swagged position have failed and will ultimately sep- ing instructions:
arate completely. Z let the seal soak into the same oil as it will seal for
A hose with a chafed outer cover will allow water en- at least half an hour before mounting;
try. Concealed corrosion of the wire reinforcement Z thoroughly clean the shaft and ensure that the
will subsequently occur along the hose length with shaft working surface is not damaged;
resultant hose failure.
Z place the sealing lip towards the fluid. In case of a

hydrodynamic lip, consider the shaft rotation direc- NOTE: a torque wrench is necessary to properly
tion and orient grooves in order that they deviate torque hardware.
the fluid towards the inner side of the seal;
Z coat the sealing lip with a thin layer of lubricant (oil
rather than grease) and fill with grease the gap be- NOTES FOR SPARE PARTS
tween the sealing lip and the dust lip of double lip Only genuine parts guarantee same quality, life,
seals; safety as original components as they are the same
Z insert the seal into its seat and press it down using as mounted in production. Only the genuine spare
a flat punch. Do not tap the seal with a hammer or parts can offer this guarantee.
a drift; All spare parts orders should be complete with the
Z take care to insert the seal perpendicularly to its following data:
seat while you are pressing it. Once the seal is set- Z machine model (commercial name) and chassis
tled, ensure that it contacts the thrust element if re- number;
quired.; Z engine type and number;
Z to prevent damaging the sealing lip against the Z part number of the ordered part, which can be
shaft, place a suitable protection during installa- found on the “Spare Parts Catalogue”, which is the
tion. base for order processing.
O-RINGS NOTES FOR EQUIPMENT

Lubricate the O-rings before inserting them into their Equipment which proposes and shows in this man-
seats. This will prevent the O-rings from rolling over ual are as follows:
and twisting during mounting which will jeopardize Z studied and designed expressly for use on compa-
sealing. ny machines;
Z necessary to make a reliable repair;
Z accurately built and strictly tested to offer efficient
BEARINGS and long-lasting working means.
It is advisable to heat the bearings to 80 to 90 °C be- Z we also remind the repair personnel that having
fore mounting them on their shafts and cool them these equipment means:
down before inserting them into their seats with ex- Z work in optimal technical conditions;
ternal tapping. Z obtain best results;
Z save time and effort;
Z work more safely.
SPRING PINS
When mounting split socket spring pins, ensure that
the pin notch is oriented in the direction of the effort NOTICES
to stress the pin. Wear limits indicated for some details should be in-
Spiral spring pins should not be oriented during intended as advised, but not binding values. The
stallation. words “front”, “rear”, “right hand”, and “left hand” re-
ferred to the different parts should be intended as
seen from the operator’s seat oriented to the normal
HARDWARE TORQUE VALUES sense of movement of the machine.
Check the tightness of hardware periodically.
Use the following charts to determine the correct
torque when checking, adjusting or replacing hard- HOW TO MOVE THE MACHINE WITH THE
BATTERY REMOVED
ware on the Backhoe loader.
Cables from the external power supply should be
IMPORTANT: DO NOT use the values listed in the connected exclusively to the respective terminals of
charts if a different torque value or tightening proce- the Machine positive and negative cables using pli-
dure is specified in this manual for a specific appli- ers in good condition which allow proper and steady
cation. Torque values listed are for general use only. contact.
Make sure fastener threads are clean and not dam- Disconnect all services (lights, wind-shield wipers,
aged. etc.) before starting the Machine.
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
power supply off before disconnecting the cables.
O-RING FLAT FACE SEAL FITTING
O-RING FLAT SEAL FITTING TORQUE VALUES

Nominal Thread size Swivel nut torque
Dash size
O.D. (inch) Tube (mm) (inch) lbf·ft Nm
0.250 6.35 -4 9/16-18 12 16
0.375 9.52 -6 11/16-16 18 24
0.500 12.70 -8 13/16-16 37 50
0.625 15.88 -10 1-14 51 69
0.750 19.05 -12 1 3/16-12 75 102
0.875 22.22 -14 1 3/16-12 75 102
1.000 25.40 -16 1 7/16-12 105 142
1.250 31.75 -20 1 11/16-12 140 190
1.500 38.10 -24 2-12 160 217
MINIMUM HARDWARE TIGHTENING TORQUES lfb·ft (Nm)
INCH HARDWARE AND LOCKNUTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS
Nominal Unplated Plated Unplated Plated Unplated Plated Gr.B with Gr.C with Nominal
Size or plated with or plated with zinc- or plated with zinc- Grade 5 Grade 8 Size
silver zinc- silver chrome silver chrome bolt bolt
chrome gold gold
gold
1/4 55* (6.2) 72* (8.1) 86* (9.7) 112* (13) 121* (14) 157* (18) 61* (6.9) 86* (9.8) 1/4
5/16 115* (13) 149* (17) 178* (20) 229* (26) 250* (28) 324* (37) 125* (14) 176* (20) 5/16
3/8 17 (23) 22 (30) 26 (35) 34 (46) 37 (50) 48 (65) 19 (26) 26 (35) 3/8
7/16 27 (37) 35 (47) 42 (57) 54 (73) 59 (80) 77 (104) 30 (41) 42 (57) 7/16
1/2 42 (57) 54 (73) 64 (87) 83 (113) 91 (123) 117 (159) 45 (61) 64 (88) 1/2
9/6 60 (81) 77 (104) 92 (125) 120 (163) 130 (176) 169 (229) 65 (88) 92 (125) 9/16
5/8 83 (112) 107 (145) 128 (174) 165 (224) 180 (244) 233 (316) 90 (122) 127 (172) 5/8
3/4 146 (198) 189 (256) 226 (306) 293 (397) 319 (432) 413 (560) 160 (217) 226 (306) 3/4
7/8 142 (193) 183 (248) 365 (495) 473 (641) 515 (698) 667 (904) 258 (350) 364 (494) 7/8
1 213 (289) 275 (373) 547 (742) 708 (960) 773 (1048) 1000 (1356) 386 (523) 545 (739) 1
METRIC HARDWARE AND LOCKNUTS

CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT
Nominal Unplated Plated with Unplated Plated with Unplated Plated with CL.8 with
Size zinc- zinc-chrome zinc-chrome Class 8.8
chrome bolt
M4 15* (1.7) 19* (2.2) 23* (2.6) 30* (3.4) 33* (3.7) 42* (4.8) 16* (1.8)
M6 51* (5.8) 67* (7.6) 79* (8.9) 102* (12) 115* (13) 150* (17) 56* (6.3)
M8 124* (14) 159* (18) 195* (22) 248* (28) 274* (31) 354* (40) 133* (15)
M10 21 (28) 27 (36) 32 (43) 41 (56) 45 (61) 58 (79) 22 (30)
M12 36 (49) 46 (63) 55 (75) 72 (97) 79 (107) 102 (138) 39 (53)
M16 89 (121) 117 (158) 137 (186) 177 (240) 196 (266) 254 (344) 97 (131)
M20 175 (237) 226 (307) 277 (375) 358 (485) 383 (519) 495 (671) 195 (265)
M24 303 (411) 392 (531) 478 (648) 619 (839) 662 (897) 855 (1160) 388 (458)
NOTE: there is no note on the page that * indicates lb·in and not lb·ft.
SEALANTS
Description P/N CNH Typical Applications

General locking and sealing of metallic threads-medium
strength.
THREAD LOCK
82995773 Oil tolerant.
AND SEAL 24 ml
Resists vibration, seals against corrosion and leakage.
Can be dismantled with standard tools.
General purpose instant non drip gel adhesive Ideal for
repair of cab trim, mats, external trim etc.
SUPER GLUE
82995778 Bonds most materials including wood, rubber, metals,
GEL 20 gm
most plastics.
Not absorbed by porous materials.
Replaces pre-cut gasket materials.
FLEXIBLE Use on hydraulic lift cover joint, transmission to axle joint
GASKET 82995770 and all rigid machined faces.
SEALANT 50 ml Anaerobic sealant cures on assembly.
Will not cure and block oil ways etc.
General purpose metallic thread and pipe sealant.

THREAD SEAL
82995768 Use on fuel system, hydraulics, air lines etc.
50 ml
Replaces pastes, hemp, pipe tape etc.
Clear, flexible adhesive and sealant.

CLEAR
ADHESIVE 50 ml 82995775 Suitable for glass, metal, wood etc., seals and bonds
gaps to 6 mm.
AND SEALANT 82995776
310 ml Use to seal glazing and windshields, vehicle lamps,
electrical boxes, sump joints etc.
Non hardening sealant-enhances sealing of all types of

pre cut gaskets.
GASKET
82995774
DRESSING 60 ml Holds gasket in place-assists assembly.
Dries slowly, sets to pliable film for easy dismantling.
General high strength metallic locking and sealing of all

threaded fasteners and studs.
STUD AND
Retains cylindrical parts, e.g. bushes, bearings, gears to
BEARING LOCK 82995772
shafts etc.
24 ml
Resists severe vibration loosening. Seals against
corrosion
All purpose cleaner and degreaser.
SOLVENT
Specially designed for parts to be lubricated, bonded or
CLEANER AND
82995779 sealed leaving no film or residue.
DEGREASER
400 ml Removes grease, oil and dirt from electrical parts, tools
etc.
MISCELLANEOUS
Description P/N CNH Typical Applications

Spray on fast action foaming gasket remover.
Removes old heat hardened gasket residue without
GASKET
82995782 damaging metal surfaces.
REMOVER 300 ml
Removes all Loctite gaskets and gasket residue.
Removes carbon deposits from cylinder heads etc.
Natural hand cleaner made from citrus oil.
CITRUS HAND Removes ground in dirt, grease, grime, paint, glue oil
CLEANER 400 ml 82995780 and tar.
3 liter 82995781 Contains premium skin conditioners.
Use with or without water.
NOTE:
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 02 - TECHNICAL
SPECIFICATIONS
1. LOADER BACKHOE MODELS .................................................................................................................... 3

2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3.1 DIESEL ENGINE ................................................................................................................................... 5
3.2 TRANSMISSION.................................................................................................................................... 7
3.3 AXLES ................................................................................................................................................... 8
3.4 BRAKES ................................................................................................................................................ 8
3.5 STEERING............................................................................................................................................. 9
3.6 HYDRAULIC SYSTEM .......................................................................................................................... 9
3.7 FRONT COUNTERWEIGHT ................................................................................................................. 9
3.8 NOISE AND VIBRATION LEVELS ...................................................................................................... 10
3.9 BUCKETS ............................................................................................................................................ 10
3.10 TYRES ............................................................................................................................................... 12
4. DIMENSIONS AND PERFORMANCE........................................................................................................ 13
4.1 DIMENSIONS - 2WS - B90B - B95B - B95BLR - B110B..................................................................... 13
4.2 DIMENSIONS - 2WS - B95BTC .......................................................................................................... 14
4.3 DIMENSIONS - 4WS - B115B ............................................................................................................. 15
4.4 LOADER ATTACHMENT PERFORMANCE........................................................................................ 16
4.5 PERFORMANCE OF LOADER ATTACHMENT WITH FORKS .......................................................... 28
4.6 BACKHOE ATTACHMENT PERFORMANCE..................................................................................... 32
5. BACKHOE ATTACHMENT LIFTING CAPACITY ....................................................................................... 53
6. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 57
2 SECTION 02 - TECHNICAL SPECIFICATIONS
1.
SECTION 02 - TECHNICAL SPECIFICATIONS 3
1. LOADER BACKHOE MODELS
B95B -
B90B B95BTC B110B B115B
B95BLR
Powershift / / /
Powershuttle /
Cab
Rops / /
2WD / / /
4WD
4WS / / / /
Pilot control
Mechanical control
/ / / /
F4GE9424C*601 (mechanical)
/ / /
F4HE0484G*J102 (electronic)
/ / / /
Engine Iveco 82 kW - 110 HP (4WS) model
/ / / /
Short dipper / /
Long dipper /
2. IDENTIFICATION OF MAIN COMPONENTS
1. Loader bucket 8. Backhoe attachment boom

2. Loader arm 9. Backhoe dipper or telescopic dipper
3. Front axle 10. Backhoe bucket
4. Fuel tank 11. Stabilizers
5. Rear axle 12. Battery box
6. Operator's compartment - Cab 13. Hydraulic reservoir
7. Engine guard 14. Swing cylinders
3. TECHNICAL SPECIFICATIONS
3.1 DIESEL ENGINE
72 kW - 97 HP ENGINE (B90B)
Specifications (EEC 88/195) ................................................................................... 72 kW - 97 HP @ 2200 rpm
Model ....................................................................................................................................... F4GE9484C*601
Type ....................................................................................................................................... diesel, mechanical
No. of cylinders ................................................................................................................................................. 4
Valves per cylinder............................................................................................................................................ 2
Bore .............................................................................................................................................. 104 mm (4 in)
Stroke......................................................................................................................................... 132 mm (5.2 in)
Displacement ................................................................................................................... 4485 cm3 (237.69 in3)
Compression ratio..................................................................................................................................... 17.5:1
Maximum torque (EC).......................................................................................400 Nm (295 lbf·ft) @ 1400 rpm
Low idle speed at no load ............................................................................................................ 1000 ± 50 rpm
High idle speed at no load (engine not installed) ......................................................................... 2430 ± 50 rpm
High idle speed at no load (engine not installed on the vehicle).................................................. 2380 ± 60 rpm
Maximum speed at full load ................................................................................................................. 2200 rpm
Air intake .................................................................................................... TAA (turbocharged with aftercooler)
Supply
Type ............................................................................................................................................. direct injection
Injection pump..............................................................................................BOSCH ROTARY VE 4/12 F1100L
Injection sequence ...................................................................................................................................1-3-4-2
Cold-start device ............................................................................................................. “Grid heater” (optional)
Cooling
Pump type.......................................................................................................................................... H2O pump
Pump drive............................................................................................................................................ belt drive
Temperature switch (opening start) ......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)
72 kW - 97 HP ENGINE (B95B)
Specifications (EEC 88/195) ................................................................................... 72 kW - 97 HP @ 2200 rpm
Model ..................................................................................................................................... F4HE0484G*J102
Type ......................................................................................................................................... diesel, electronic
No. of cylinders ................................................................................................................................................. 4
Bore............................................................................................................................................... 104 mm (4 in)
Stroke......................................................................................................................................... 132 mm (5.2 in)
Compression ratio ..................................................................................................................................... 17.5:1
Maximum torque (EC) .......................................................................................453 Nm (334 lbf·ft) @ 1400 rpm
Low idle speed at no load .............................................................................................................. 950 ± 50 rpm
High idle speed at no load (engine not installed on the vehicle) .................................................. 2380 ± 60 rpm
Supply
Type .........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................. CP3 high-pressure pump
Control unit.................................................................................................................................................EDC7
Cooling
Pump type .......................................................................................................................................... H2O pump
Pump drive ............................................................................................................................................belt drive
82 kW - 110 HP ENGINE (B110B - B115B)

Specifications (EEC 88/195) ................................................................................. 82 kW - 110 HP @ 2200 rpm
Model (B110B) ....................................................................................................................... F4HE9484C*J102
Model (B115B) ....................................................................................................................... F4HE9484C*J103
Type ......................................................................................................................................... diesel, electronic
No. of cylinders ................................................................................................................................................. 4
Bore............................................................................................................................................... 104 mm (4 in)
Stroke......................................................................................................................................... 132 mm (5.2 in)
Compression ratio ..................................................................................................................................... 17.5:1
Maximum torque (EC) .......................................................................................516 Nm (380 lbf·ft) @ 1400 rpm
Low idle speed at no load .............................................................................................................. 950 ± 50 rpm
High idle speed at no load (engine not installed on the vehicle) .................................................. 2380 ± 60 rpm
Supply
Type .........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................. CP3 high-pressure pump
Control unit.................................................................................................................................................EDC7
Cooling
Pump type .......................................................................................................................................... H2O pump
Pump drive ............................................................................................................................................belt drive
3.2 TRANSMISSION
2WD/2WS TRANSMISSION - POWERSHUTTLE (B90B)

Model ................................................................................................................................ Turner COM-T4-2025
Type (4x4)..................................................................................................4 forward and 4 reverse travel gears
Torque converter ratio.................................................................................................................................. 2.38
Transmission ratios:
1st forward travel .................................................................... gear 4.824:1 reverse travel gear 4.020:1
2nd forward travel ................................................................... gear 2.998:1 reverse travel gear 2.496:1
3rd forward travel .................................................................... gear 1.408:1 reverse travel gear 1.173:1
4th forward travel .................................................................... gear 0.792:1 reverse travel gear 0.660:1
4WD/2WS TRANSMISSION - POWERSHUTTLE (B90B - B95B - B110B)

Model ................................................................................................................................ Turner COM-T4-2025
Torque converter ratio.................................................................................................................................. 2.38
3rd forward travel .................................................................... gear 1.408:1 reverse travel gear 1.173:1
4th forward travel .................................................................... gear 0.792:1 reverse travel gear 0.660:1
4WD/2WS TRANSMISSION - POWERSHIFT (B110B)

Model .............................................................................................................................................Dana T16000
Torque converter ratio................................................................................................................................ 2.261
(upper output)
3rd forward travel .................................................................... gear 1.284:1
4th forward travel .................................................................... gear 0.679:1
(lower output)
4WD/4WS TRANSMISSION - POWERSHIFT (B115B)

Model .............................................................................................................................................Dana T16000
Torque converter ratio................................................................................................................................ 2.261
(upper output)
(lower output)
3.3 AXLES
FRONT AXLES
Front 2WD/2WS axle (B90B)

Model ...................................................................................................................................... CARRARO 26.00
Type ....................................................................................................................................................... steering
Front 4WD/2WS axle (B90B - B95B - B110B)

Model ...................................................................................................................................... CARRARO 26.16
Type ....................................................................................................................................................... steering
Front 4WD/4WS axle (B115B)

Model ...................................................................................................................................... CARRARO 26.28
Type ....................................................................................................................................................... steering
REAR AXLES
Rear 2WS axle (B90B - B95B - B110B)

Model ................................................................................................................................................... CNH D46
Type ............................................................................................................................................................. rigid
Differential lock (powershuttle axle) .................................................................................................. mechanical
Differential lock (powershift axle) .......................................................................................................... electrical
Rear 4WS axle (B115B)

Model ................................................................................................................................... CARRARO 26.32M
Type ....................................................................................................................................................... steering
Differential lock...................................................................................................................................... electrical
3.4 BRAKES
BRAKES (B90B - B95B - B110B)
Service brake
Type ........................................................................................................wet multi-discs, 8 x axle (4 x half axle)
Braking surface ..................................................................................................................... 1440 cm2 (223 in2)
Parking brake
Type ......................................................................................................................... single disc on transmission
BRAKES (B115B)
Service brake
Type ........................................................................................................wet multi-discs, 6 x axle (3 x half axle)
Braking surface ......................................................................................................1440 cm21440 cm2 (223 in2)
Parking brake
Type ......................................................................................................................... single disc on transmission
3.5 STEERING
2WS ............................................................................................................................................... 2 wheel steer

4WS ............................................................................................................................................... 4 wheel steer
System pressure ...................................................................................................... 177 ± 3 bar (2566 ± 44 psi)
POWER STEERING
2WS
Model ......................................................................................................................... DANFOSS OSPC 125 LS
Displacement ............................................................................................................. 125 cm3/rev (7.63 in3/rev)
Shock valve adjustment ......................................................................................................... 225 bar (3262 psi)
Pressure relief valve adjustment............................................................................................ 170 bar (2465 psi)
4WS
Model ......................................................................................................................... DANFOSS OSPC 160 LS
Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev)
Shock valve adjustment ......................................................................................................... 225 bar (3262 psi)
Pressure relief valve adjustment............................................................................................ 170 bar (2465 psi)
3.6 HYDRAULIC SYSTEM
HYDRAULIC PUMP
72 kW - 97 HP pump (B90B - B95B)

Model ...........................................................................................................CASAPPA KP 30.34 - 05 S6 - LMF
Type ..............................................................double gear pump: hydraulic system and priority steering system
Displacement .............................................................................. 35.427 + 35.427 cm3/rev (2.16 + 2.16 in3/rev)
82 kW - 110 HP pump (B110B - B115B)

Model ...........................................................................................................CASAPPA KP 30.38 - 05 S6 - LMF
Type ..............................................................double gear pump: hydraulic system and priority steering system
Displacement .............................................................................. 40.258 + 35.427 cm3/rev (2.45 + 2.16 in3/rev)
3.7 FRONT COUNTERWEIGHT
COUNTERWEIGHT - 2WS
Standard .................................................................................................................................. 125.5 kg (276 lb)
Medium .................................................................................................................................... 366.5 kg (806 lb)
Big............................................................................................................................................. 475 kg (1045 lb)
Extra (optional)............................................................................................................................ 125 kg (275 lb)
COUNTERWEIGHT - 4WS
Standard .................................................................................................................................. 125.5 kg (276 lb)
Medium ....................................................................................................................................... 333 kg (733 lb)
Extra (optional)............................................................................................................................ 125 kg (275 lb)
3.8 NOISE AND VIBRATION LEVELS
NOISE LEVEL
Certified by the Manufacturer.
In compliance with European Directive 2000/14/EC - Stage II.
Internal noise level (LpA) ........................................................................................................................... 77 db
External noise level (LwA) (B90B - B95B) ............................................................................................... 102 db
External noise level (LwA) (B110B - B115B) ........................................................................................... 103 db
VIBRATION LEVEL INSIDE THE CAB

Upper limbs .................................................................................................. level lower than 2.5 m/s2 (8.2 ft/s2)
Abdomen...................................................................................................... level lower than 0.5 m/s2 (1.6 ft/s2)
3.9 BUCKETS
LOADER BUCKETS
Type 0.88 m3 (31.1 ft3) 1 m3 (35.3 ft3) 4x1 6x1 (with forks)
standard standard
Heaped
capacity 0.88 m3 (31.1 ft3) 1.0 m3 (35.3 ft3) 1.0 m3 (35.3 ft3) 1.0 m3 (35.3 ft3)
2WS
2250 mm 2250 mm 2250 mm 2250 mm
Width
(88.58 in) (88.58 in) (88.58 in) (88.58 in)
Weight 310 kg (682 lb) 400 kg (880 lb) 750 kg (1650 lb) 950 kg (2090 lb)
Heaped
capacity
- 1.15 m3 (40.6 ft3) 1.15 m3 (40.6 ft3) 1.15 m3 (40.6 ft3)
4WS 2350 mm 2350 mm 2350 mm

Width -
(92.52 in) (92.52 in) (92.52 in)
Weight - 415 kg (913 lb) 770 kg (1694 lb) 970 kg (2134 lb)
BACKHOE BUCKETS
“HEAVY DUTY” buckets
mm
Width 305 (12) 457 (17.99) 610 (24.01) 762 (30) 914 (35.98)
(in)
m3 0.0775 0.1143 0.2475

Struck capacity 0.159 (5.61) 0.203 (7.17)
(ft3) (2.73) (4.03) (8.74)
m3 0.323
Heaped capacity 0.088 (3.10) 0.138 (4.87) 0.199 (7.02) 0.261 (9.21)
(ft3) (11.40)
“HIGH CAPACITY” buckets
mm
Width 305 (12) 457 (17.99) 610 (24.01) 762 (30) 914 (35.98)
(in)
m3 0.0933 0.299
Struck capacity 0.138 (4.87) 0.192 (6.78) 0.245 (8.65)
(ft3) (3.29) (10.56)
m3 0.312 0.388
Heaped capacity 0.105 (3.71) 0.165 (5.82) 0.238 (8.40)
(ft3) (11.02) (13.70)
“EXTRA HEAVY DUTY” buckets
mm
Width 457 (17.99) 610 (24.01)
(in)
m3
Struck capacity 0.138 (4.87) 0.192 (6.78)
(ft3)
Heaped capacity m3 0.165 (5.82) 0.238 (8.40)

3.10 TYRES
TYRE TYPES
Tyres - 2WS
Front tyres Rear tyres
19.5L-24 R4 10PR
16.9-24 R4 10PR
2WD 11L-16 F3 10PR 17.5L-24 R4 10PR
16.9-28 R4 10PR
21L-24 R4 12PR
19.5L-24 L4 14PR
19.5L-24 R4 10PR
12-16.5 R4 10PR
17.5L-24 R4 10PR
4WD 16.9-24 R4 10PR
16.9-28 R4 10PR
14-17.5 R4 10PR 21L-24 R4 12PR
19.5L-24 R4 10PR
Tyres - 4WS
Front and rear tyres
16.9-24 R4 12PR
16.9-28 R4 12PR
NUT TORQUES
Front nuts (2WS)................................................................................................................... 330 Nm (243 lbf·ft)
Rear nuts (2WS) ................................................................................................................... 540 Nm (398 lbf·ft)
Front and rear nuts (4WS) .................................................................................................... 700 Nm (516 lbf·ft)
4. DIMENSIONS AND PERFORMANCE

4.1 DIMENSIONS - 2WS - B90B - B95B - B95BLR - B110B
Front tyres..........................................................................................................................................12-16.5 R4
Rear tyres ........................................................................................................................................19.5L-24 R4
Standard loader bucket............................................................................................................ 0.88 m3 (31.1 ft3)
“High Capacity” backhoe bucket ................................................................................................. 305 mm (12 in)
A Overall machine length 7030 mm (276.77 in)

B Loader bucket reach 1930 mm (75.98 in)
C Wheel base 2175 mm (85.63 in)
D Backhoe bucket dimensions 2925 mm (115.16 in)
E Rear wheel base - backhoe attachment swing support 1120 mm (44.09 in)
F Maximum machine height 3815 mm (150.19 in)
G Stabilizer width 2300 mm (90.55 in)
H Cab height 2870 mm (112.99 in)
I Loader bucket width 2250 mm (88.58 in)
4.2 DIMENSIONS - 2WS - B95BTC
Front tyres ......................................................................................................................................... 12-16.5 R4

Rear tyres........................................................................................................................................ 19.5L-24 R4
Standard loader bucket ............................................................................................................0.88 m3 (31.1 ft3)
“High Capacity” backhoe bucket ................................................................................................. 305 mm (12 in)
A Overall machine length 7325 mm (288.38 in)

B Loader bucket reach 2225 mm (87.59 in)
C Wheel base 2175 mm (85.63 in)
D Backhoe bucket dimensions 2925 mm (115.16 in)
H Cab height 2870 mm (112.99 in)
4.3 DIMENSIONS - 4WS - B115B
Front and rear tyres ..........................................................................................................................16.9-28 R4

Standard loader bucket............................................................................................................ 1.15 m3 (40.6 ft3)
“High Capacity” backhoe bucket ............................................................................................ 610 mm (24.01 in)
A Overall machine length 7080 mm (278.74)

B Loader bucket reach 1970 mm (77.56)
C Wheel base 2200 mm (86.61)
D Backhoe bucket dimensions 2910 mm (114.56)
H Cab height 3065 mm (120.67)
4.4 LOADER ATTACHMENT PERFORMANCE
B90B, B95B, B95BLR AND B110B (WITH STANDARD BUCKET 1 m3/35.3 ft3)
Front counterweight F. Loader attachment reach when lowered with re-

A. Maximum height/dimensions tracted bucket
B. Maximum height of loader bucket pin/pivot G. Attachment reach in digging position
C. Maximum dumping height H. Attachment reach when lowered
D. Digging depth α. Angle of lowered closed bucket
E. Loader attachment reach when raised in dump-
ing position β. Angle of closed bucket at maximum height
χ. Dumping angle
Front tyres 11L-16 F3 11L-16 F3 11L-16 F3 11L-16 F3 11L-16 F3 12-16.5 L5

Rear tyres 19.5L-24 R4 16.9-24 R4 17.5L-24 R4 16.9-28 R4 21L-24 R4 19.5L-24 L4
A 4235 (166.73) 4238 (166.85) 4247 (167.20) 4218 (166.06) 4225 (166.34) 4250 (167.32)
B 3408 (134.17) 3410 (134.25) 3420 (134.64) 3391 (133.50) 3397 (133.74) 3422 (134.72)
C 2671 (105.16) 2675 (105.31) 2690 (105.90) 2644 (104.09) 2654 (104.49) 2687 (105.78)
D 175 (6.89) 172 (6.77) 160 (6.29) 196 (7.71) 189 (7.44) 160 (6.29)
E 801 (31.53) 795 (31.29) 771 (30.35) 842 (33.15) 827 (32.56) 797 (31.38)
F 1461 (57.52) 1459 (57.44) 1453 (57.20) 1471 (57.91) 1467 (57.75) 1453 (57.20)
G 1411 (55.55) 1413 (55.63) 1420 (55.90) 1398 (57.20) 1402 (55.19) 1412 (55.59)
H 1539 (60.59) 1538 (60.55) 1534 (60.39) 1546 (60.87) 1544 (60.79) 1530 (60.23)
α 41° 41.1° 41.4° 40.5° 40.7° 40.7°
β 49.4° 49.6° 50.3° 48.2° 48.7° 49.5°
χ 43.9° 43.7° 43.1° 45.1° 44.7° 43.8°

mm (in)
Front tyres 12-16.5 R4 12-16.5 R4 12-16.5 R4 14-17.5 14-17.5 R4 14-17.5 R4

Rear tyres 19.5L-24 R4 17.5L-24 R4 16.9-24 R4 19.5L-24 R4 16.9-28 R4 21L-24 R4
A 4253 (166.73) 4265 (167.91) 4256 (167.56) 4293 (169.01) 4296 (169.13) 4302 (169.37)
B 3425 (134.84) 3437 (135.31) 3428 (134.96) 3465 (136.42) 3468 (136.53) 3474 (136.77)
C 2691 (105.94) 2711 (106.73) 2696 (106.14) 2737 (107.75) 2734 (107.64) 2743 (107.99)
D 156 (6.14) 140 (5.51) 153 (6.02) 113 (4.45) 114 (4.49) 106 (4.17)
E 789 (31.06) 758 (29.84) 783 (30.82) 762 (30) 790 (31.10) 775 (30.51)
F 1451 (57.12) 1444 (56.85) 1450 (57.08) 1431 (56.34) 1430 (56.29) 1427 (56.18)
G 1414 (55.67) 1423 (56.02) 1416 (55.75) 1422 (55.98) 1414 (55.67) 1418 (55.82)
H 1529 (60.19) 1524 (60) 1528 (60.15) 1505 (59.25) 1499 (59.01) 1497 (58.93)
α 40.8° 41.2° 40.9° 40.3° 39.6° 39.8°
β 49.8° 50.6° 49.9° 50.5° 49.7° 50.1°
χ 43.6° 42.7° 43.4° 42.8° 43.6° 43.2°

mm (in)
B90B, B95B, B95BLR AND B110B (WITH 4x1 BUCKET 1 m3/35.3 ft3)
Front counterweight F. Loader attachment reach when lowered with re-

χ. Dumping angle

A 4387 (172.71) 4390 (172.83) 4399 (173.19) 4370 (172.05) 4376 (172.28) 4402 (173.31)
B 3408 (134.17) 3410 (134.25) 3420 (134.64) 3391 (133.50) 3397 (133.74) 3422 (134.72)
C 2697 (106.18) 2702 (106.38) 2719 (107.05) 2667 (105) 2678 (105.43) 2714 (106.85)
D 223 (8.78) 220 (8.66) 207 (8.15) 244 (9.60) 236 (9.29) 208 (8.19)
E 989 (38.94) 982 (38.66) 958 (37.72) 1030 (40.55) 1015 (39.96) 984 (38.74)
F 1594 (62.75) 1592 (62.68) 1586 (62.44) 1605 (63.19) 1601 (63.03) 1587 (62.48)
G 1497 (58.94) 1499 (59.01) 1506 (59.29) 1484 (58.42) 1489 (58.62) 1498 (58.97)
H 1657 (65.23) 1655 (65.16) 1651 (65) 1664 (65.51) 1661 (65.39) 1647 (64.84)
α 40.2° 40.3° 40.6° 39.7° 39.9° 39.9°
β 47.3° 47.5° 48.2° 46.1° 46.5° 47.4°
χ 32.2° 32° 31.3° 33.3° 32.9° 32°

mm (in)

A 4405 (173.42) 4417 (173.89) 4408 (173.54) 4444 (174.96) 4448 (175.12) 4453 (175.31)
B 3425 (134.84) 3437 (135.31) 3428 (134.96) 3465 (136.42) 3468 (136.53) 3474 (136.77)
C 2719 (107.05) 2741 (107.91) 2724 (107.24) 2767 (108.94) 2761 (108.70) 2772 (109.13)
D 204 (8.03) 188 (7.40) 200 (7.87) 161 (6.34) 161 (6.34) 153 (6.02)
E 977 (38.46) 945 (37.20) 970 (38.19) 949 (37.36) 978 (38.50) 962 (37.87)
F 1585 (62.40) 1577 (62.08) 1583 (62.32) 1565 (61.61) 1565 (61.61) 1562 (61.49)
G 1500 (59.05) 1509 (59.41) 1502 (59.13) 1508 (59.37) 1500 (59.05) 1505 (59.25)
H 1646 (64.80) 1641 (64.60) 1645 (64.76) 1623 (63.89) 1618 (63.70) 1616 (63.62)
α 40° 40.4° 40.1° 39.5° 38.8° 39°
β 47.6° 48.5° 47.8° 48.4° 47.6° 48°
χ 31.8° 31° 31.7° 31.1° 31.9° 31.4°

mm (in)
B95BTC (WITH STANDARD BUCKET 1 m3/35.3 ft3)
Front tyres F. Loader attachment reach when lowered with re-

χ. Dumping angle

A 4237 (166.81) 4240 (166.93) 4252 (167.40) 4214 (165.90) 4223 (166.26) 4252 (167.40)
B 3287 (129.41) 3290 (129.53) 3303 (130.04) 3265 (128.54) 3273 (128.86) 3302 (130)
C 2363 (93.03) 2368 (93.23) 2388 (94.01) 2329 (91.69) 2341 (92.16) 2380 (93.70)
D 314 (12.36) 311 (12.24) 298 (11.73) 336 (13.23) 328 (12.91) 299 (11.77)
E 1161 (45.71) 1155 (45.47) 1135 (44.68) 1195 (47.05) 1183 (46.57) 1157 (45.55)
F 1370 (53.94) 1368 (53.86) 1361 (53.58) 1383 (54.45) 1378 (54.25) 1368 (53.86)
G 1668 (65.67) 1670 (65.75) 1679 (66.10) 1653 (65.08) 1659 (65.31) 1670 (65.75)
H 1894 (74.56) 1892 (74.49) 1888 (74.33) 1902 (74.88) 1899 (74.76) 1885 (74.21)
α 72.6° 72.7° 72.8° 72.4° 72.4° 72.2°
β 64.4° 64.6° 65.2° 63.3° 63.7° 64.5°
χ 45.3° 45.1° 44.4° 46.4° 46° 45.1°

mm (in)

A 4256 (167.56) 4271 (168.15) 4259 (167.68) 4299 (169.25) 4298 (169.21) 4306 (169.53)
B 3306 (130.16) 3322 (130.79) 3310 (130.31) 3349 (131.85) 3349 (131.85) 3356 (132.12)
C 2386 (93.94) 2410 (94.88) 2391 (94.13) 2436 (95.90) 2428 (95.59) 2440 (96.06)
D 295 (11.61) 278 (10.94) 291 (11.45) 251 (9.88) 252 (9.92) 244 (9.60)
E 1151 (45.31) 1124 (44.25) 1145 (45.08) 1127 (44.37) 1151 (45.31) 1139 (44.84)
F 1366 (53.78) 1357 (53.42) 1364 (53.70) 1356 (53.38) 1363 (53.66) 1359 (53.50)
G 1672 (65.82) 1683 (66.26) 1675 (65.94) 1682 (66.22) 1672 (65.83) 1677 (66.02)
H 1883 (74.13) 1878 (73.94) 1882 (74.09) 1860 (73.23) 1856 (73.07) 1854 (72.99)
α 72.3° 72.5° 72.3° 71.5° 70.8° 70.9°
β 64.7° 65.5° 64.9° 65.3° 64.6° 65°
χ 44.9° 44.1° 44.7° 44.2° 45° 44.5°

mm (in)
B95BTC (WITH 4x1 BUCKET 1 m3/35.3 ft3)

χ. Dumping angle

A 4349 (171.22) 4353 (171.38) 4365 (171.85) 4327 (170.35) 4335 (170.67) 4365 (171.85)
B 3287 (129.41) 3290 (129.53) 3303 (130.04) 3265 (128.54) 3273 (128.86) 3302 (130)
C 2515 (99.01) 2519 (99.17) 2536 (99.84) 2485 (97.83) 2496 (98.27) 2531 (99.64)
D 329 (12.95) 326 (12.83) 313 (12.32) 351 (13.82) 343 (13.50) 314 (12.36)
E 944 (37.16) 938 (36.93) 915 (36.02) 982 (38.66) 968 (38.11) 940 (37.01)
F 1341 (52.79) 1339 (52.71) 1332 (52.44) 1352 (53.23) 1348 (53.07) 1337 (52.64)
G 1418 (55.82) 1420 (55.90) 1429 (56.26) 1403 (55.23) 1409 (55.47) 1420 (55.90)
H 1653 (65.08) 1651 (65) 1647 (64.84) 1661 (65.39) 1658 (65.27) 1644 (64.72)
α 70.8° 70.9° 71° 70.6° 70.7° 70.4°
β 62.1° 62.3° 63° 61° 61.4° 62.2°
χ 47.5° 47.4° 46.7° 48.7° 48.3° 47.4°

mm (in)

A 4368 (171.97) 4384 (172.59) 4372 (172.12) 4411 (173.66) 4411 (173.66) 4419 (173.97)
B 3306 (130.16) 3322 (130.78) 3310 (130.31) 3349 (131.85) 3349 (131.85) 3356 (132.12)
C 2536 (99.84) 2558 (100.71) 2541 (100.04) 2584 (101.73) 2579 (101.53) 2589 (101.93)
D 310 (12.20) 293 (11.53) 306 (12.05) 266 (10.47) 267 (10.51) 259 (10.19)
E 933 (36.73) 904 (35.59) 927 (36.49) 908 (35.75) 934 (36.77) 920 (36.22)
F 1335 (52.56) 1326 (52.20) 1333 (52.48) 1321 (52.01) 1325 (52.16) 1322 (52.05)
G 1422 (55.98) 1433 (56.42) 1425 (56.10) 1432 (56.38) 1422 (55.98) 1427 (56.18)
H 1642 (64.64) 1637 (64.45) 1641 (64.60) 1620 (63.78) 1616 (63.62) 1613 (63.50)
α 70.5° 70.7° 70.5° 69.7° 69° 69.1°
β 62.4° 63.3° 62.6° 63.1° 62.3° 62.7°
χ 47.2° 46.3° 47° 46.4° 47.2° 46.8°

mm (in)
B115B (WITH STANDARD BUCKET 1.15 m3/40.6 ft3)

χ. Dumping angle
Front and rear tyres 16.9-24 R4 16.9-28 R4

A 4293 (169.01) 4344 (171.02)
B 3436 (143.15) 3487 (137.28)
C 2625 (103.34) 2676 (105.35)
D 169 (6.65) 118 (4.64)
E 723 (28.46) 666 (26.22)
F 1328 (52.28) 1235 (48.62)
G 1275 (50.19) 1218 (47.95)
H 1402 (55.19) 1308 (51.49)
α 44.1° 43.9°
β 59.6°
χ 50.3°
mm (in)
B115B (WITH 4x1 BUCKET 1.15 m3/40.6 ft3)

χ. Dumping angle

A 4425 (174.21) 4476 (176.22)
B 3436 (135.27) 3487 (137.28)
C 2595 (102.16) 2646 (104.17)
D 196 (7.71) 145 (5.71)
E 888 (34.96) 830 (32.68)
F 1436 (56.53) 1346 (52.99)
G 1376 (54.17) 1318 (51.89)
H 1521 (59.88) 1428 (56.22)
α 44.2° 44°
β 59.6°
χ 42.3°
mm (in)
4.5 PERFORMANCE OF LOADER ATTACHMENT WITH FORKS
B90B, B95B, B95BLR AND B110B
Front counterweight C. Height of loader bucket pin/pivot with lowered

A. Maximum height of loader bucket pin/pivot with forks
lifted forks D. Fork reach when raised
B. Fork maximum height E. Fork reach when lowered

3133 3137 3149 3111 3120 3149
A (standard bucket)
(123.34) (123.50) (123.97) (122.48) (122.83) (123.97)
3296 3299 3310 3277 3284 3311
A (6x1 bucket)
(129.76) (129.88) (130.31) (129.01) (129.29) (130.35)
2695 2698 2711 2673 2681 2710
B (standard bucket)
(106.10) (106.22) (106.73) (105.23) (105.55) (106.69)
2899 2902 2912 2879 2887 2914
B (6x1 bucket)
(114.13) (114.25) (114.64) (113.34) (113.66) (114.72)
C (standard bucket) 479 (18.86)
C (6x1 bucket) 437 (17.20)
D (standard bucket) 2485 (97.83) 2477 (97.52) 2447 (96.34) 2535 (99.80) 2517 (99.09) 2479 (97.59)
D (6x1 bucket) 2328 (91.65) 2320 (91.34) 2288 (90.08) 2382 (93.78) 2362 (92.99) 2322 (91.42)
2757 2755 2750 2767 2764 2749
E
(108.54) (108.46) (108.27) (108.94) (108.82) (108.23)
mm (in)

3153 3168 3156 3195 3195 3203
A (standard bucket)
(124.13) (124.72) (124.25) (125.79) (125.79) (126.10)
3315 3328 3317 3355 3357 3364
A (6x1 bucket)
(130.51) (131.02) (130.59) (132.08) (132.16) (132.44)
2714 2730 2717 2757 2757 2764
B (standard bucket)
(106.85) (107.48) (106.97) (108.54) (108.54) (108.82)
2917 2931 2920 2958 2960 2966
B (6x1 bucket)
(114.84) (115.39) (114.96) (116.45) (116.53) (116.77)
C (6x1 bucket) 437 (17.20)
D (standard bucket) 2470 (97.24) 2432 (95.75) 2462 (96.93) 2437 (95.94) 2471 (97.28) 2453 (96.57)
D (6x1 bucket) 2312 (91.02) 2272 (89.45) 2304 (90.71) 2277 (89.64) 2314 (91.10) 2294 (90.31)
2748 2740 2746 2727 2726 2722
E
(108.19) (107.87) (108.11) (107.36) (107.32) (107.16)
mm (in)
B115B
Front tyres C. Height of loader bucket pin/pivot with lowered

A. Maximum height of loader bucket pin/pivot with forks
lifted forks D. Fork reach when raised
B. Fork maximum height E. Fork reach when lowered
Front and rear tyres 16.9x24 R4 16.9-28 R4

A 3436 (135.27) 3487 (137.28)
B (standard bucket) 3048 (120) 3099 (122.01)
B (6x1 bucket) 3044 (119.84) 3095 (121.85)
C (6x1 bucket) 432 (17.01)
D (standard bucket) 2277 (89.64) 2219 (87.36)
D (6x1 bucket) 2250 (88.58) 2192 (86.29)
E (standard bucket) 2581 (101.61) 2494 (98.19)
E (6x1 bucket) 2556 (100.63) 2469 (97.20)
mm (in)
4.6 BACKHOE ATTACHMENT PERFORMANCE
B90B AND B95B (WITH SHORT STANDARD DIPPER)
A. Maximum digging height F. Maximum reach when loaded

B. Maximum height at full load G. Maximum digging reach with lowered bucket
C. Maximum digging depth α. Bucket digging angle
D. Digging depth (L = 2438.4 mm/96 in)
E. Digging reach at maximum height
“High Capacity” backhoe bucket

A 5585 (219.88) 5569 (219.25) 5506 (216.77) 5690 (224.01) 5652 (222.52) 5587 (219.96)
B 3599 (141.69) 3582 (141.02) 3520 (138.58) 3704 (145.82) 3666 (144.33) 3600 (141.73)
C 4412 (173.70) 4429 (174.37) 4491 (176.81) 4305 (169.49) 4345 (171.06) 4411 (173.66)
D 4032 (158.74) 4048 (159.37) 4109 (161.77) 3928 (154.64) 3966 (156.14) 4031 (158.70)
E 1557 (61.29) 1573 (61.93) 1633 (64.29) 1455 (57.28) 1492 (58.74) 1568 (61.73)
F 1026 (40.39) 1037 (40.82) 1074 (42.28) 963 (37.91) 986 (38.82) 1034 (40.71)
G 5245 (206.49) 5247 (206.57) 5251 (206.73) 5237 (206.18) 5240 (206.29) 5245 (206.49)
α 204.6°
mm (in)

A 5567 (219.17) 5488 (216.06) 5551 (218.54) 5527 (217.59) 5613 (220.98) 5574 (219.45)
B 3581 (140.98) 3502 (137.87) 3564 (140.31) 3540 (139.37) 3626 (142.75) 3588 (141.26)
C 4431 (174.45) 4509 (177.52) 4447 (175.08) 4471 (176.02) 4385 (172.64) 4423 (174.13)
D 4049 (159.41) 4126 (162.44) 4066 (160.08) 4088 (160.94) 4004 (157.64) 4041 (159.09)
E 1587 (62.48) 1662 (65.43) 1603 (63.11) 1653 (65.08) 1584 (63.36) 1621 (63.82)
F 1045 (41.14) 1093 (43.03) 1055 (41.53) 1087 (42.79) 1044 (41.10) 1067 (42.01)
G 5246 (206.53) 5252 (206.77) 5248 (206.61) 5248 (206.61) 5241 (206.34) 5244 (206.45)
α 204.6°
mm (in)
“Heavy Duty” or “Extra Heavy Duty” backhoe bucket

A 5520 (217.32) 5504 (216.69) 5441 (214.21) 5624 (221.42) 5587 (219.96) 5521 (217.36)
B 3664 (144.25) 3648 (143.62) 3585 (141.14) 3769 (148.38) 3731 (146.89) 3665 (144.29)
C 4347 (171.14) 4364 (171.81) 4426 (174.25) 4240 (166.93) 4279 (168.46) 4346 (171.10)
D 3957 (155.79) 3973 (156.42) 4034 (158.82) 3853 (151.69) 3891 (153.19) 3956 (155.75)
E 1495 (58.86) 1508 (59.37) 1556 (61.26) 1413 (55.63) 1443 (56.81) 1504 (59.21)
F 1112 (43.78) 1123 (44.21) 1160 (45.67) 1048 (41.26) 1072 (42.20) 1120 (44.09)
G 5180 (203.94) 5181 (203.97) 5186 (204.17) 5171 (203.58) 5174 (203.70) 5179 (203.89)
α 204.6°
mm (in)

A 5502 (216.61) 5423 (213.50) 5485 (215.94) 5461 (215) 5548 (218.42) 5509 (216.89)
B 3646 (143.54) 3567 (140.43) 3629 (142.87) 3605 (141.93) 3692 (145.35) 3653 (143.82)
C 4366 (171.89) 4444 (174.96) 4382 (172.52) 4406 (173.46) 4320 (170.08) 4358 (171.57)
D 3974 (156.45) 4051 (159.49) 3991 (157.12) 4013 (157.99) 3929 (154.68) 3966 (156.14)
E 1519 (59.80) 1579 (62.16) 1532 (60.31) 1572 (61.89) 1517 (59.72) 1546 (60.86)
F 1131 (44.53) 1179 (46.41) 1142 (44.96) 1173 (46.18) 1130 (44.49) 1153 (45.39)
G 5181 (203.97) 5187 (204.21) 5182 (204.01) 5183 (204.05) 5176 (203.78) 5179 (203.89)
α 204.6°
mm (in)
B90BLR, B95BLR AND B110B SIDESHIFT (WITH LONG STANDARD DIPPER)


A 5770 (227.16) 5753 (226.49) 5686 (223.86) 5881 (231.53) 5841 (229.96) 5771 (227.20)
B 3786 (149.05) 3768 (148.34) 3703 (145.79) 3895 (153.34) 3856 (151.81) 3786 (149.05)
C 4714 (185.59) 4731 (186.26) 4792 (188.66) 4608 (181.42) 4647 (182.95) 4713 (185.55)
D 4354 (171.42) 4370 (172.05) 4430 (174.41) 4252 (167.40) 4289 (168.86) 4352 (171.34)
E 1799 (70.82) 1816 (71.49) 1877 (73.89) 1693 (66.65) 1732 (68.19) 1811 (71.29)
F 1282 (50.47) 1292 (50.86) 1332 (52.44) 1214 (47.79) 1239 (48.78) 1289 (50.75)
G 5510 (216.93) 5511 (216.97) 5516 (217.16) 5502 (216.61) 5505 (216.73) 5510 (216.93)
α 204°
mm (in)

A 5750 (226.38) 5666 (223.07) 5733 (225.71) 5705 (224.60) 5796 (228.19) 5755 (226.57)
B 3766 (148.27) 3683 (145) 3749 (147.59) 3722 (146.53) 3812 (150.08) 3772 (148.50)
C 4732 (186.29) 4810 (189.37) 4749 (186.97) 4771 (187.83) 4687 (184.53) 4724 (185.98)
D 4371 (172.08) 4447 (175.08) 4387 (172.71) 4409 (173.58) 4326 (170.31) 4362 (171.73)
E 1830 (72.05) 1908 (75.12) 1847 (72.71) 1899 (74.76) 1828 (71.97) 1866 (73.46)
F 1301 (51.22) 1351 (53.19) 1312 (51.65) 1345 (52.95) 1300 (51.18) 1324 (52.12)
G 5511 (216.97) 5516 (217.16) 5512 (217.01) 5513 (217.05) 5506 (216.77) 5509 (216.89)
α 204°
mm (in)

A 5707 (216.81) 5690 (224.01) 5624 (221.42) 5816 (228.97) 5777 (227.44) 5708 (224.72)
B 3851 (151.61) 3833 (150.90) 3768 (148.34) 3960 (155.90) 3921 (154.37) 3851 (151.61)
C 4649 (183.03) 4666 (183.70) 4727 (186.10) 4543 (178.86) 4582 (180.39) 4648 (182.99)
D 4280 (168.50) 4296 (169.13) 4356 (171.49) 4178 (164.49) 4215 (165.94) 4279 (168.46)
E 1733 (68.23) 1749 (68.86) 1810 (71.26) 1629 (64.13) 1667 (65.63) 1745 (68.70)
F 1367 (53.82) 1378 (54.25) 1418 (55.82) 1299 (51.14) 1324 (52.12) 1375 (54.13)
G 5445 (214.37) 5446 (214.41) 5450 (214.56) 5436 (214.01) 5439 (214.13) 5444 (214.33)
α 204°
mm (in)

A 5688 (223.94) 5604 (220.63) 5670 (223.23) 5643 (223.16) 5733 (225.71) 5693 (224.13)
B 3831 (150.82) 3748 (147.56) 3814 (150.16) 3787 (149.09) 3877 (152.64) 3837 (151.06)
C 4667 (183.74) 4745 (186.81) 4683 (184.37) 4706 (185.27) 4622 (181.97) 4659 (183.42)
D 4297 (169.17) 4373 (172.16) 4313 (169.80) 4335 (170.67) 4252 (167.40) 4289 (168.86)
E 1763 (69.41) 1841 (72.48) 1780 (70.08) 1832 (72.12) 1761 (69.33) 1799 (70.82)
F 1387 (54.60) 1438 (56.61) 1398 (55.04) 1432 (56.38) 1386 (54.56) 1410 (55.51)
G 5446 (214.41) 5451 (214.60) 5447 (214.45) 5448 (214.49) 5441 (214.21) 5444 (214.33)
α 204°
mm (in)
B90B AND B95B (WITH SHORT TELESCOPIC DIPPER)

RETRACTED DIPPER
5682 5664 5599 5790 5751 5682
A
(223.70) (222.99) (220.43) (227.95) (226.42) (223.70)
3701 3619 3807 3769 3701
B 3683 (145)
(145.71) (142.48) (149.88) (148.38) (145.71)
4589 4651 4466 4505 4571
C 4572 (180)
(180.67) (183.11) (175.82) (177.36) (179.96)
4204 4220 4280 4101 4138 4202
D
(165.51) (166.14) (168.50) (161.45) (162.91) (165.43)
E 1723 (67.83) 1740 (68.50) 1800 (70.86) 1619 (63.74) 1657 (65.23) 1735 (68.31)
F 1130 (44.49) 1140 (44.88) 1179 (46.42) 1064 (41.89) 1088 (42.83) 1137 (44.76)
5386 5388 5392 5378 5381 5386
G
(212.05) (212.12) (212.28) (211.73) (211.85) (212.05)
α 203.8°
mm (in)
RETRACTED DIPPER
5662 5579 5645 5618 5708 5708
A
(222.91) (219.64) (222.24) (221.18) (224.72) (224.72)
3682 3600 3664 3639 3727 3688
B
(144.96) (141.73) (144.25) (143.27) (146.73) (145.19)
4590 4669 4607 4630 4545 4583
C
(180.71) (183.82) (181.38) (182.28) (178.94) (180.43)
4221 4297 4237 4259 4176 4213
D
(166.18) (169.17) (166.81) (167.68) (164.41) (165.86)
E 1754 (69.05) 1831 (72.08) 1770 (69.68) 1821 (71.69) 1751 (68.94) 1789 (70.43)
F 1149 (45.23) 1198 (47.16) 1160 (45.67) 1193 (46.97) 1148 (45.19) 1172 (46.14)
5387 5393 5388 5389 5382 5385
G
(212.08) (212.32) (212.12) (212.16) (211.89) (212.01)
α 203.8°
mm (in)
EXTENDED DIPPER
6361 6341 6266 6485 6440 6359
A
(250.43) (249.64) (246.69) (255.31) (253.54) (250.35)
4379 4360 4286 4502 4458 4378
B
(172.40) (171.65) (168.74) (177.24) (175.51) (172.36)
5612 5628 5688 5508 5546 5610
C
(220.94) (221.57) (223.94) (216.85) (218.34) (220.86)
5306 5322 5380 5206 5242 5304
D
(208.89) (209.53) (211.81) (204.96) (206.38) (208.82)
2543 2612
E 2524 (99.37) 2406 (94.72) 2449 (96.42) 2537 (99.88)
(100.12) (102.83)
F 1931 (76.02) 1944 (76.53) 1990 (78.34) 1851 (72.87) 1880 (74.01) 1940 (76.38)
6339 6340 6344 6332 6335 6339
G
(249.56) (249.60) (249.76) (249.29) (249.41) (249.56)
α 203.8°
mm (in)
EXTENDED DIPPER
6336 6241 6316 6281 6382 6336
A
(249.45) (245.71) (248.66) (247.28) (251.26) (249.45)
4356 4262 4336 4302 4402 4356
B
(171.49) (167.79) (170.71) (169.37) (173.31) (171.49)
5629 5705 5645 5666 5584 5620
C
(221.61) (224.60) (222.24) (223.07) (219.84) (221.26)
5322 5397 5338 5359 5277 5313
D
(209.53) (212.48) (210.16) (210.98) (207.75) (209.17)
2559 2646 2577 2635 2556 2598
E
(100.75) (104.17) (101.45) (103.74) (100.63) (102.28)
F 1954 (76.93) 2014 (79.29) 1967 (77.44) 2006 (78.97) 1953 (76.89) 1981 (77.99)
6345 6341 6342 6336 6338
G 6340 (249.6)
(249.80) (249.64) (249.68) (249.45) (249.53)
α 203.8°
mm (in)
RETRACTED DIPPER
5621 5604 5539 5729 5690 5622
A
(221.29) (220.63) (218.07) (225.55) (224.01) (221.34)
3766 3748 3684 3873 3834 3766
B
(148.27) (147.56) (145.04) (152.48) (150.94) (148.27)
4507 4524 4586 4401 4440 4506
C
(177.44) (178.11) (180.55) (173.27) (174.80) (177.40)
4129 4146 4206 4027 4128
D 4064 (160)
(162.56) (163.23) (165.59) (158.54) (162.52)
E 1654 (65.12) 1671 (65.79) 1731 (68.15) 1552 (61.10) 1589 (62.56) 1666 (65.59)
F 1217 (47.91) 1227 (48.31) 1266 (49.84) 1150 (45.27) 1174 (46.22) 1224 (48.19)
5321 5322 5327 5312 5315 5320
G
(209.49) (209.53) (209.72) (209.13) (209.25) (209.45)
α 203.8°
mm (in)
RETRACTED DIPPER
5602 5520 5585 5559 5648 5608
A
(220.55) (217.32) (219.88) (218.86) (222.36) (220.79)
3747 3665 3730 3704 3792 3753
B
(147.52) (144.29) (146.85) (145.82) (149.29) (147.75)
4525 4604 4542 4565 4480 4518
C
(178.15) (181.26) (178.82) (179.72) (176.38) (177.87)
4147 4223 4163 4185 4101 4138
D
(163.27) (166.26) (163.89) (164.76) (161.45) (162.91)
E 1685 (66.39) 1761 (69.33) 1701 (66.97) 1751 (68.94) 1682 (66.22) 1719 (67.68)
F 1236 (48.66) 1286 (50.63) 1247 (49.09) 1280 (50.39) 1235 (48.62) 1259 (49.56)
5322 5327 5323 5324 5317 5320
G
(209.53) (209.72) (209.56) (209.60) (209.33) (209.45)
α 203.8°
mm (in)
EXTENDED DIPPER
6300 6280 6206 6424 6379 6299
A
(248.03) (247.24) (244.33) (252.91) (251.14) (247.99)
4425 4351 4568 4523 4443
B 4445 (175)
(174.21) (171.29) (179.84) (178.07) (174.92)
5547 5563 5623 5443 5481 5545
C
(218.38) (219.01) (221.38) (214.29) (215.79) (218.31)
5235 5251 5310 5135 5172 5234
D
(206.10) (206.73) (209.05) (202.16) (203.62) (206.06)
2542
E 2455 (96.65) 2474 (97.40) 2339 (92.08) 2382 (93.78) 2469 (97.20)
(100.08)
F 2018 (79.45) 2031 (79.96) 2078 (81.81) 1937 (76.26) 1967 (77.44) 2027 (79.80)
6274 6275 6279 6266 6269 6273
G
(247.01) (247.05) (247.20) (246.69) (246.81) (246.97)
α 203.8°
mm (in)
EXTENDED DIPPER
6276 6182 6256 6222 6322 6276
A
(247.08) (243.38) (246.29) (244.96) (248.89) (247.08)
4421 4327 4401 4368 4467 4421
B
(174.05) (170.35) (173.27) (171.97) (175.86) (174.05)
5564 5639 5580 5601 5518 5555
C
(219.05) (222.01) (219.68) (220.51) (217.24) (218.70)
5252 5326 5268 5288 5243
D 5207 (205)
(206.77) (209.68) (207.40) (208.19) (206.42)
2576 2565
E 2490 (98.03) 2508 (98.74) 2487 (97.91) 2529 (99.56)
(101.42) (100.98)
F 2041 (80.35) 2101 (82.71) 2054 (80.86) 2094 (82.44) 2040 (80.31) 2069 (81.45)
6275 6279 6276 6276 6270 6273
G
(247.05) (247.20) (247.08) (247.08) (246.85) (246.97)
α 203.8°
mm (in)
B90BLR, B95BLR AND B110B (WITH LONG TELESCOPIC DIPPER)

RETRACTED DIPPER
5768 5751 5684 5880 5840 5769
A
(227.08) (226.42) (223.78) (231.49) (229.92) (227.12)
3788 3771 3705 3898 3858 3789
B
(149.13) (148.46) (145.86) (153.46) (151.89) (149.17)
4722 4738 4800 4616 4655 4721
C
(185.90) (186.53) (188.97) (181.73) (183.27) (185.86)
4361 4377 4437 4259 4296 4360
D
(171.69) (172.32) (174.68) (167.68) (169.13) (171.65)
E 1857 (73.11) 1873 (73.74) 1935 (76.18) 1751 (68.94) 1790 (70.47) 1869 (73.58)
F 1250 (49.21) 1261 (49.64) 1301 (51.22) 1182 (46.53) 1207 (47.52) 1258 (49.53)
5516 5517 5521 5507 5510 5515
G
(217.16) (217.20) (217.36) (216.81) (216.93) (217.12)
α 203.8°
mm (in)
RETRACTED DIPPER
5748 5663 5730 5702 5794 5753
A
(226.29) (222.95) (225.59) (224.49) (228.11) (226.49)
3769 3685 3751 3724 3814 3774
B
(148.38) (145.08) (147.68) (146.61) (150.16) (148.58)
4740 4817 4756 4779 4694 4732
C
(186.61) (189.64) (187.24) (188.15) (184.80) (186.29)
4378 4454 4394 4416 4333 4370
D
(172.36) (175.35) (172.99) (173.86) (170.59) (172.05)
E 1888 (74.33) 1966 (77.40) 1904 (74.96) 1956 (77.01) 1885 (74.21) 1923 (75.71)
F 1270 (50) 1320 (51.97) 1281 (50.43) 1314 (51.73) 1268 (49.92) 1293 (50.90)
5516 5522 5518 5519 5512 5515
G
(217.16) (217.40) (217.24) (217.28) (217.01) (217.12)
α 203.8°
mm (in)
EXTENDED DIPPER
6442 6421 6344 6569 6523 6440
A
(253.62) (252.79) (249.76) (258.62) (256.81) (253.54)
4461 4441 4366 4587 4541 4460
B
(175.63) (174.84) (171.89) (180.59) (178.78) (175.59)
5760 5776 5835 5657 5695 5758
C
(226.77) (227.40) (229.72) (222.71) (224.21) (226.69)
5459 5475 5533 5359 5396 5457
D
(214.92) (215.55) (217.83) (210.98) (212.44) (214.84)
2663 2681 2751 2543 2587 2676
E
(104.84) (105.55) (108.31) (100.12) (101.85) (105.35)
F 2056 (80.94) 2069 (81.45) 2117 (83.34) 1974 (77.71) 2004 (78.89) 2065 (81.29)
6469 6470 6474 6462 6465 6469
G
(254.68) (254.72) (254.88) (254.41) (254.53) (254.69)
α 203.8°
mm (in)
EXTENDED DIPPER
6416 6319 6396 6360 6462 6415
A
(252.59) (248.78) (251.81) (250.39) (254.41) (252.56)
4437 4341 4416 4382 4483 4436
B
(174.68) (170.90) (173.86) (172.52) (176.49) (174.64)
5777 5852 5793 5814 5731 5768
C
(227.44) (230.39) (228.07) (228.89) (225.63) (227.08)
5475 5549 5491 5511 5430 5466
D
(215.55) (218.46) (216.18) (216.97) (213.78) (215.19)
2698 2786 2716 2775 2695 2738
E
(106.22) (109.68) (106.93) (109.25) (106.10) (107.79)
F 2080 (81.89) 2140 (84.25) 2093 (82.40) 2133 (83.97) 2078 (81.81) 2107 (82.95)
6470 6475 6471 6472 6466 6468
G
(254.72) (254.92) (254.76) (254.80) (254.56) (254.64)
α 203.8°
mm (in)
RETRACTED DIPPER
5709 5691 5625 5819 5779 5709
A
(224.76) (224.05) (221.45) (229.09) (227.52) (224.76)
3853 3836 3770 3963 3923 3854
B
(151.69) (151.02) (148.42) (156.02) (154.45) (151.73)
4657 4673 4735 4551 4590 4656
C
(183.34) (183.97) (186.42) (179.17) (180.71) (183.31)
4288 4304 4364 4185 4223 4286
D
(168.82) (169.45) (171.81) (164.76) (166.26) (168.74)
E 1788 (70.39) 1804 (71.02) 1865 (73.42) 1683 (66.26) 1721 (67.75) 1799 (70.82)
F 1337 (52.64) 1348 (53.07) 1388 (54.64) 1268 (49.92) 1293 (50.90) 1345 (52.95)
5450 5451 5456 5442 5445 5450
G
(214.56) (214.60) (214.80) (214.25) (214.37) (214.56)
α 203.8°
mm (in)
RETRACTED DIPPER
5689 5604 5671 5644 5734 5694
A
(223.97) (220.63) (223.27) (222.20) (225.75) (224.17)
3834 3750 3816 3789 3879 3839
B
(150.94) (147.64) (150.23) (149.17) (152.71) (151.14)
4674 4752 4691 4714 4629 4667
C
(184.01) (187.08) (184.68) (185.59) (182.24) (183.74)
4305 4381 4321 4343 4259 4296
D
(169.49) (172.48) (170.12) (170.98) (167.68) (169.13)
E 1818 (71.57) 1896 (74.64) 1835 (72.24) 1886 (74.25) 1816 (71.49) 1853 (72.95)
F 1357 (53.42) 1408 (55.43) 1368 (53.86) 1402 (55.19) 1356 (53.38) 1380 (54.33)
5451 5457 5452 5453 5446 5449
G
(214.60) (214.84) (214.64) (214.68) (214.41) (214.53)
α 203.8°
mm (in)
EXTENDED DIPPER
6382 6361 6285 6508 6462 6380
A
(251.26) (250.43) (247.44) (256.22) (254.41) (251.18)
4526 4506 4431 4652 4606 4525
B
(178.19) (177.40) (174.45) (183.15) (181.34) (178.15)
5695 5711 5770 5592 5630 5693
C
(224.21) (224.84) (227.16) (220.16) (221.65) (224.13)
5389 5405 5463 5289 5325 5387
D
(212.16) (212.79) (215.08) (208.23) (209.64) (212.08)
2593 2612 2681 2607
E 2475 (97.44) 2518 (99.13)
(102.08) (102.83) (105.55) (102.64)
F 2143 (84.37) 2156 (84.88) 2204 (86.77) 2061 (81.14) 2091 (82.32) 2152 (84.72)
6404 6405 6409 6397 6399 6403
G
(252.12) (252.16) (252.32) (251.85) (251.93) (252.08)
α 203.8°
mm (in)
EXTENDED DIPPER
6357 6260 6336 6301 6403 6356
A
(250.27) (246.45) (249.45) (248.07) (252.08) (250.23)
4502 4406 4482 4447 4548 4501
B
(177.24) (173.46) (176.45) (175.08) (179.05) (177.20)
5712 5787 5728 5749 5666 5703
C
(224.88) (227.83) (225.51) (226.34) (223.07) (224.53)
5405 5479 5421 5441 5360 5396
D
(212.79) (215.71) (213.42) (214.21) (211.02) (212.44)
2628 2716 2647 2705 2625 2668
E
(103.46) (106.93) (104.21) (106.49) (103.34) (105.04)
F 2167 (85.31) 2228 (87.71) 2180 (85.82) 2221 (87.44) 2165 (85.23) 2195 (86.42)
6405 6409 6406 6406 6401 6403
G
(252.16) (252.32) (252.20) (252.20) (252.01) (252.08)
α 203.8°
mm (in)
B115B (WITH LONG STANDARD DIPPER)


A 5904 (232.44) 5853 (230.43)
B 3917 (154.21) 3866 (152.20)
C 4579 (180.27) 4630 (182.28)
D 4218 (166.06) 4269 (168.07)
E 1853 (72.95)
F 1316 (51.81)
G 5492 (216.22) 5499 (216.49)
α 204°
mm (in)
“Heavy Duty or Extra Heavy Duty” backhoe bucket

A 5788 (227.87) 5839 (229.88)
B 3931 (154.76) 3982 (156.77)
C 4565 (179.72) 4514 (177.71)
D 4195 (165.16) 4144 (163.15)
E 1787 (70.35)
F 1402 (55.19)
G 5433 (213.89) 5427 (213.66)
α 204°
mm (in)
B115B (WITH LONG TELESCOPIC DIPPER)

RETRACTED DIPPER
A 5848 (230.23) 5899 (232.24)
B 3869 (152.32) 3920 (154.33)
C 4638 (182.59) 4587 (180.59)
D 4276 (168.34) 4225 (166.34)
E 1911 (75.23)
F 1285 (50.59)
G 5504 (216.69) 5498 (216.45)
α 203.8°
mm (in)
EXTENDED DIPPER
A 6512 (256.38) 6563 (258.38)
B 4533 (178.46) 4584 (180.47)
C 5674 (223.38) 5623 (221.38)
D 5372 (211.49) 5321 (209.49)
E 2724 (107.24)
F 2098 (82.59)
G 6459 (254.29) 6454 (254.09)
α 203.8°
mm (in)
RETRACTED DIPPER
A 5788 (227.87) 5839 (229.89)
B 3934 (154.89) 3985 (156.89)
C 4573 (163.42) 4522 (178.03)
D 4202 (165.43) 4151 (163.42)
E 1841 (72.48)
F 1372 (54.01)
G 5439 (214.13) 5432 (213.86)
α 203.8°
mm (in)
EXTENDED DIPPER
A 6454 (254.09) 6405 (252.16)
B 4598 (181.02) 4649 (183.03)
C 5609 (220.82) 5558 (218.82)
D 5302 (208.74) 5251 (206.73)
E 2654 (104.49)
F 2185 (86.02)
G 6397 (251.85) 6392 (251.65)
α 203.8°
mm (in)
5. BACKHOE ATTACHMENT LIFTING CAPACITY

LIFTING CAPACITY - MODELS B90B, B95B AND
B95BLR
Lifting capacity in normal operating mode - SAE

rated
The following table reports the lifting capacities of the
dipper (A) and the boom (B).
NOTE: the capacities indicated may slightly vary

from one machine to another, according to the ac-
cessories mounted, the pressure settings and the
market requirements.
Lifting capacities are given in kg (lb) for a standard

dipper and a telescopic dipper.
Dipper Telescopic dipper (retracted) Telescopic dipper (extended) Height/Depth

Dipper A Boom B Dipper A Boom B Dipper A Boom B m (ft)
590 (1300) +5.4 (18)
1160 (2560) 1085 (2390) 880 (1945) +4.9 (16)
1545 (3405) 1445 (3185) 1510 (3330) 1015 (2235) +4.3 (14)
2640 (5820) 1665 (3675) 2585 (5705) 1555 (3430) 1605 (3540) 1080 (2380) +3.6 (12)
2615 (5770) 1695 (3735) 2505 (5520) 1575 (3470) 1655 (3655) 1110 (2450) +3.0 (10)
2665 (5880) 1680 (3710) 2550 (5625) 1560 (3440) 1680 (3705) 1125 (2475) +2.4 (8)
2915 (6425) 1660 (3665) 2790 (6155) 1530 (3375) 1755 (3865) 1125 (2480) +1.8 (6)
3700 (8155) 1630 (3590) 3555 (7840) 1495 (3300) 1850 (4080) 1125 (2480) +1.2 (4)
6080 (13410) 1600 (3525) 5910 (13030) 1460 (3225) 2075 (4575) 1120 (2470) +0.6 (2)
1570 (3460) 1430 (3155) 3235 (7135) 1115 (2455) 0 (ground)
1545 (3410) 1400 (3090) 5787 (12755) 1110 (2450) -0.6 (2)
1530 (3370) 1380 (3045) 1110 (2450) -1.2 (4)
1525 (3360) 1370 (3025) 1115 (2455) -1.8 (6)
1540 (3400) 1380 (3045) 1125 (2480) -2.4 (8)
1610 (3550) 1435 (3170) 1150 (2540) -3.0 (10)
1920 (4230) 1710 (3770) 1210 (2670) -3.6 (12)
1350 (2985) -4.2 (14)
1990 (4390) -4.8 (16)
LIFTING CAPACITY - MODELS B95BTC

rated



580 (1275) +5.4 (18)
1225 (2700) 1030 (2270) 810 (1785) +4.9 (16)
1495 (3295) 1330 (2930) 1680 (3710) 955 (2110) +4.3 (14)
2700 (5955) 1655 (3655) 2435 (5370) 1440 (3175) 1585 (3500) 1020 (2250) +3.6 (12)
2575 (5680) 1675 (3700) 2325 (5125) 1450 (3195) 1555 (3435) 1045 (2310) +3.0 (10)
2660 (5870) 1655 (3655) 2380 (5245) 1425 (3145) 1590 (3505) 1055 (2330) +2.4 (8)
3070 (6770) 1615 (3565) 2650 (5850) 1390 (3070) 1690 (3730) 1055 (2330) +1.8 (6)
5365 (11830) 1575 (3475) 3745 (8265) 1355 (2990) 1915 (4225) 1045 (2310) +1.2 (4)
1535 (3390) 5405 (11920) 1315 (2905) 2475 (5460) 1035 (2290) +0.6 (2)
1500 (3310) 1280 (2830) 4960 (10935) 1030 (2270) 0 (ground)
1470 (3240) 1250 (2760) 1020 (2250) -0.6 (2)
1445 (3190) 1230 (2710) 1015 (2240) -1.2 (4)
1435 (3170) 1215 (2680) 1015 (2240) -1.8 (6)
1455 (3205) 1220 (2695) 1025 (2265) -2.4 (8)
1545 (3410) 1275 (2875) 1055 (2330) -3.0 (10)
1690 (3725) 1460 (3220) 1120 (2470) -3.6 (12)
1325 (2925) -4.2 (14)
1670 (3680) -4.8 (16)
5.1 LIFTING CAPACITY - MODELS B110B

rated



590 (1300) +5.4 (18)
1160 (2560) 1085 (2390) 880 (1945) +4.9 (16)
1545 (3405) 1445 (3185) 1510 (3330) 1015 (2235) +4.3 (14)
2640 (5820) 1665 (3675) 2585 (5705) 1555 (3430) 1605 (3540) 1080 (2380) +3.6 (12)
2615 (5770) 1695 (3735) 2505 (5520) 1575 (3470) 1655 (3655) 1110 (2450) +3.0 (10)
2665 (5880) 1680 (3710) 2550 (5625) 1560 (3440) 1680 (3705) 1125 (2475) +2.4 (8)
2915 (6425) 1660 (3665) 2790 (6155) 1530 (3375) 1755 (3865) 1125 (2480) +1.8 (6)
3700 (8155) 1630 (3590) 3555 (7840) 1495 (3300) 1850 (4080) 1125 (2480) +1.2 (4)
6080 (13410) 1600 (3525) 5910 (13030) 1460 (3225) 2075 (4575) 1120 (2470) +0.6 (2)
1570 (3460) 1430 (3155) 3235 (7135) 1115 (2455) 0 (ground)
1545 (3410) 1400 (3090) 5787 (12755) 1110 (2450) -0.6 (2)
1530 (3370) 1380 (3045) 1110 (2450) -1.2 (4)
1525 (3360) 1370 (3025) 1115 (2455) -1.8 (6)
1540 (3400) 1380 (3045) 1125 (2480) -2.4 (8)
1610 (3550) 1435 (3170) 1150 (2540) -3.0 (10)
1920 (4230) 1710 (3770) 1210 (2670) -3.6 (12)
1350 (2985) -4.2 (14)
1990 (4390) -4.8 (16)
5.2 LIFTING CAPACITY - MODELS B115B

rated



545 (1205) +5.4 (18)
1085 (2390) 1005 (2215) 835 (1840) +4.9 (16)
1485 (3275) 1385 (3050) 1500 (3305) 975 (2150) +4.3 (14)
2620 (5775) 1625 (3580) 2425 (5610) 1510 (3330) 1600 (3525) 1050 (2315) +3.6 (12)
2560 (5645) 1660 (3660) 2450 (5400) 1540 (3395) 1615 (3560) 1090 (2400) +3,0 (10)
2620 (5775) 1660 (3660) 2505 (5525) 1535 (3385) 1640 (3615) 1105 (2435) +2.4 (8)
2875 (6340) 1645 (3625) 2750 (6065) 1515 (3340) 1730 (3815) 1115 (2460) +1.8 (6)
3700 (8155) 1620 (3570) 3550 (7825) 1490 (3285) 1870 (4120) 1120 (2470) +1.2 (4)
6280 (13845) 1600 (3525) 6075 (13395) 1460 (3220) 2120 (4675) 1120 (2470) +0.6 (2)
1575 (3475) 1435 (3165) 3660 (8070) 1115 (2460) 0 (ground)
1555 (3430) 1410 (3110) 5745 (12665) 1115 (2460) -0.6 (2)
1545 (3405) 1400 (3085) 1120 (2470) -1.2 (4)
1550 (3415) 1395 (3075) 1125 (2480) -1.8 (6)
1580 (3485) 1415 (3120) 1145 (2525) -2.4 (8)
1670 (3680) 1500 (3305) 1180 (2600) -3.0 (10)
2070 (4565) 1855 (4090) 1250 (2755) -3.6 (12)
1430 (3150) -4.2 (14)
2230 (4915) -4.8 (16)
6. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS

NEW QUANTITY
RECOMMENDED FLUIDS AND INTERNATIONAL
HOLLAND MODELS
APPLICATION Specifications Liters Us gal
Specifications
ENGINE - OIL API CI-4 2WS - with filter 14 3.70
NH 330 H
Ambra Master Gold HSP (15W40) CH-4/SL, ACEA E5 4WS - with filter 12.8 3.40
COOLING SYSTEM
Ambra Agriflu NH 900 A CUNA NC 956-16 ALL
24 6.30
antifreeze 50% water 50%
HYDRAULIC SYSTEM ISO VG 46, ALL 118 31.10
NH 410 C
Ambra Mastertran 10W-20
Ambra Multi BIO-S Biodegradeable ISO 32/46, ALL 118 31.10
NH410 BS
10W-30, GL4
For Cold Weather Operation,
See your Dealer
POWERSHUTTLE TRANSMISSION ISO VG 46,
NH 410 C ALL 18 4.70
POWERSHIFT TRANSMISSION
NH 530 B ATF ALL 14 3.70
Ambra Hydrodex 3
FRONT AXLE (2WS) ISO VG 46,
NH 410 C 2WD (ea) 0.2 0.10
Differential 6.5 1.70
4WD Wheel hub
0.7 0.20
(ea)
FRONT AXLE (4WS) API CI-4
NH 410 B Differential 10.5 2.80
Ambra Multi G ISO VG 32/46
Wheel hub (ea) 1.3 0.34
REAR AXLE (2WS) ISO VG 46,
NH 410 C 21 5.60
AOA Brake oil additive, P/N 87304782 0.8 0.20
REAR AXLE (4WS) API CI-4
NH 410 B Differential 11 2.90
Ambra Multi G ISO VG 32/46
Wheel hub (ea) 1.3 0.34
BRAKE MASTER CYLINDER
Ambra LHM
NH 610 A ISO 7308 ALL 1 0.26
Mineral Oil
Do not use vegetable based brake fluid
FUEL No. 2 Diesel
ALL 135 35.50
Decanted and filtered Diesel Fuel Cetane 40 (min)
GENERAL LUBRICATION JOINTS
NH 720 A NLGI 2 ALL As required
Ambra GR 75 MD grease
TELESCOPIC DIPPER (HED)
Graphite Spray
LUBRICATION NLGI 00 ALL As required
or Dry Molycoat
PN FP404DS
AIR CONDITIONING COMPRESSOR
ALL 240 cc
PAG Oil SP 20
NOTE:
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 17 - TORQUE CONVERTERS
1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................ 3

1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION ......................................................................................................................................... 4
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION ......................................................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2 SECTION 17 - TORQUE CONVERTERS
SECTION 17 - TORQUE CONVERTERS 3
1. POWERSHUTTLE TORQUE CONVERTER

1.1 DESCRIPTION AND OPERATION
The torque converter is the connection between the

engine and the transmission and is hydraulically ac-
tuated. The main parts of the torque converter (A)
are the impeller (pump), the turbine, the stator and
the front and rear covers. The impeller is integral
with the rear cover and is driven by the engine fly-
wheel by means of a drive plate.
The stator, is splined to a stationary shaft (stator
support) through a one-way clutch that permits the
stator to rotate only in the same direction as the im-
peller. All of the converter parts are enclosed in an
oil-filled housing. The front and rear cover, being
welded together, form the housing.
The turbine (2), splined to the front input shaft, is
splined to a stationary shaft (stator support) through
a one-way clutch that permits the stator (3) to rotate
only in the same direction as the impeller (1). All of
the converter parts are enclosed in an oil-filled hous-
ing. The front and rear cover, welded together, form
the housing. When the engine is running, the oil in
the converter flows from the impeller (1) to the tur-
bine (2) and back to the impeller through the stator
(3). This flow produces a maximum torque increase.
When enough oil flow is developed by the impeller,
the turbine begins to rotate, driving the front input
shaft. The torque multiplication gradually decreases
as turbine speed approaches impeller speed, and
becomes 1 to 1 when the turbine is being driven at
nine tenths impeller speed.
When the turbine (2) is rotating at approximately
nine tenths impeller speed, the converter stops mul-
tiplying torque because the oil is now acting on the
rear face of the stator blades (4). The action of the
oil on the rear face of the stator unlocks the one-way
clutch (5), permitting the stator to rotate in the same
direction as the turbine (2) and impeller (1). Through
this action the converter becomes an efficient fluid
coupling by transmitting engine torque from the im-
peller to the turbine. To achieve optimum operation
the engine performance, transmission ratios, hy-
draulic power delivery and converter torque multipli-
cation are all “Matched” to provide the necessary
vehicle drive torque when required. When the tur-
bine is rotating less than nine tenths impeller speed
(1), the converter is multiplying torque through the
action of the stator (3). This action, produced by oil
acting on the front face of the stator blades, tends to
rotate the stator in the opposite direction of the im-
peller (1) and turbine (2). However, the one-way
clutch prevents this opposite rotation and allows the
stator to direct oil back to the impeller, thereby pro-
ducing torque multiplication. Maximum torque multi-
plication is achieved when the impeller is driven at
stall speed and the turbine is stationary.
1.2 TECHNICAL SPECIFICATIONS
Torque converter ratio............................................................................................................................... 2.38:1

Weight ..................................................................................................................................... 17.4 kg (38.3 lbs)
Torque of retaining screws for transmission ............................................................................. 58 Nm (43 lbf·ft)
Torque of retaining screw for flywheel ...................................................................................... 41 Nm (30 lbf·ft)
Torque of screw for drive plate to the convertor........................................................................ 53 Nm (39 lbf·ft)
Torque of screw for drive plate to the flywheel.......................................................................... 41 Nm (30 lbf·ft)
Hydraulic tests
Tachometer setting .......................................................................................................................2000 revs/min
Test temperature, oil ........................................................................................................80-85 °C (176-185 °F)
Cold start valve (For reference only).......................................................................................... 26 bar (377 psi)
System pressure test ...............................................................................................13.7-15.2 bar (198-220 psi)
Torque converter............................................................................................................. 7-11 bar (101-159 psi)
Sealant
Gasket sealant .................................................................................................................................... 82995774
Thread sealant .................................................................................................................................... 82995768
1.3 OVERHAUL
The torque converter, is a welded unit and cannot be

disassembled. The only maintenance performed on
the converter, other than the stall test, is cleaning
and visual inspection. A commercial torque convert-
er cleaner may be used to clean the converter. How-
ever, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.
Z Drain as much oil as possible from the hub of the

converter by tilting the converter in all directions.
Z Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning sol-
vent specified for cleaning transmissions.
Z Plug the opening in the hub, then circulate the sol-
vent inside the converter by rotating and shaking.
Z Drain the solvent from the converter.
Z Repeat previous steps, as required, until the sol-
vent that is drained from the converter is clean.
1.4 INSPECTION
Inspect the splines on the converter hub for wear or

damage and the weld joints for cracks. If the hub is
worn or damaged and/or the weld joints cracked, a
new converter must be installed. A new drive plate
should also be installed if it is warped.
1.5 DISASSEMBLY AND ASSEMBLY
Z Secure the drive plate (3) to the torque converter

(5), with the attaching bolts and flat washers (1).
Z Tighten bolts to 53 Nm (39 lbf·ft).
Z Prior to fitting the transmission place the torque
converter carefully over the transmission shaft and
into the transmission housing.
Z With the transmission bolted to the engine secure
the drive plate to the flywheel (6) accessed through
the starter motor aperture, with the attaching bolts
and washers (2). Tighten bolts to 41 Nm (30 lbf·ft).
1.6 STALL TEST
The purpose of this test is to determine if the torque

converter and hydraulic clutch assemblies are oper-
ating satisfactorily.
For the test to be conclusive, the transmission hy-
draulic pump and pressure regulating valve must be
operating correctly.
They can be checked by performing the “Line Pres-
sure Test”.
The engine and brakes must also be in good working
order.
Z Check the coolant level in the radiator and the oil
level in the transmission. If low, add fluid as re-
quired to bring to the proper level.
Z With the gearshift lever and the shuttle lever in neu-
tral, start the engine and run at 800-1000 revs/min
until the transmission temperature reaches 85° -
95 °F (29° - 35 °C).
Z Lock the brakes and shift into fourth gear, increase
engine speed to approximately 900 revs/min, then
shift the power reversing lever to the forward posi-
tion. This will position the control valve so as to di-
rect high pressure oil to the front clutch.
Z Ensure the brakes are firmly locked so the unit will
not move, gradually depress the foot accelerator
and note the maximum engine speed obtained.
Move the power reversing lever to the neutral posi-
tion. The stall speed should be:
Engine 97 HP............................... 1750 ÷ 1850 rpm
Engine 110 HP............................. 1900 ÷ 2100 rpm
IMPORTANT: to prevent the transmission from

overheating, do not allow the engine to operate at
maximum rpm for more than fifteen seconds.
Z Allow the transmission oil to cool to 29°-35 °C (85°-

95 °F). Check the rear hydraulic clutch by repeating
previous steps, but with the power reversing lever
in the rearward position. Again, cool the transmis-
sion oil by allowing the engine to run at approxi-
mately 1000 revs/min for one minute.
Z The engine speed noted previously (stall speed) for
both the front and rear clutch assemblies should be
within 150 revs/min of each other. If the stall speed
is not within these limits, refer to the diagnosis
guide for possible causes.
Z With the gearshift lever and power reversing lever
in neutral, set the engine speed at 600-800 revs/
min, then shift into any gear ratio. If the gears clash,
either the front or rear hydraulic clutch assembly is
transmitting power, even though the power revers-
ing lever is in neutral.
NOTE: if the unit creeps forward and the gears

clash, the front clutch is at fault. The rear clutch is at
fault if the unit creeps backward. If the unit does not
creep and the gears still clash, use the stabilizers to
raise the rear wheels off the ground, move the power
reversing lever to neutral and shift into first gear.
Check the rear wheels for rotational direction - if the
wheel rotate rearward, then the rear clutch is at fault.
1.7 FAULT FINDING
PROBLEM CAUSE ACTION

Low stall speed Hydraulic clutch not releasing Replace torque converter.
Stator support broken Replace torque converter.
Defective torque converter Replace torque converter.
Low engine power Check and correct output.
High stall speed Hydraulic clutch not applying or is Replace.
slipping
Low line pressure Check pump output.
Sealing rings on rear input shaft
broken Replace seals.
2. POWERSHIFT TORQUE CONVERTER

Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the hydraulic torque converter and is the primary component which starts
the oil flowing to the other components which results in torque multiplication. This element can be compared
to a centrifugal pump in that it picks up fluid at its center discharges at its outer diameter. The torque converter
turbine is mounted opposite the impeller and is connected to the turbine shaft or directional clutch shaft. This
element receives fluid at its outer diameter and discharges at its center. The stator of the torque converter is
located between and at the center 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 the balding (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 multiplication is increasing. In the impeller cover a splined shaft is fitted which runs inside and
through the turbine shaft to drive a hydraulic pump which is fitted at the back of the transmission. Since the
shaft is connected to the center of the impeller cover, the pump speed will be the same as engine speed. The
rear side of the impeller cover has a tanged drive which drives the transmission charging pump located in the
converter housing. The transmission charging pump speed is also the same as the engine speed.
TORQUE CONVERTER AND LUBRICATION PRESSURE TEST PORTS
1. System pressure port 4. Oil temperature converter out port

2. Torque converter in port 5. Oil temperature cooler out port
3. Torque converter out port 6. Lubrication pressure port
Torque converter ratio............................................................................................................................... 2.38:1

Torque of retaining screws for transmission ............................................................................. 26 Nm (19 lbf·ft)
Torque of retaining screw for flywheel ...................................................................................... 43 Nm (32 lbf·ft)
Torque of screw for drive plate.................................................................................................. 43 Nm (32 lbf·ft)
Hydraulic tests
Tachometer setting .......................................................................................................................2200 revs/min
Torque converter relief valve...................................................................................................... 10 bar (145 psi)
Oil temperature converter out:
Normal operating range .........................................................................................80-90 °C (175-193 °F)
Maximum temperature ..................................................................................................... 120 °C (284 °F)
Sealant
Gasket sealant .................................................................................................................................... 82995774
Thread sealant .................................................................................................................................... 82995768
2.3 OVERHAUL
The torque converter, is a welded unit and cannot be

disassembled. The only maintenance performed on
the converter, other than the stall test, is cleaning
and visual inspection. A commercial torque convert-
er cleaner may be used to clean the converter. How-
ever, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.
Z Drain as much oil as possible from the hub of the

converter by tilting the converter in all directions.
Z Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning sol-
vent specified for cleaning transmissions.
Z Plug the opening in the hub, then circulate the sol-
vent inside the converter by rotating and shaking.
Z Drain the solvent from the converter.
Z Repeat previous steps, as required, until the sol-
vent that is drained from the converter is clean.
2.4 INSPECTION
Inspect the splines on the converter hub for wear or

damage and the weld joints for cracks. If the hub is
worn or damaged and/or the weld joints cracked, a
new converter must be installed. A new drive plate
should also be installed if it is warped.
DISASSEMBLY
Remove the drive plate screws.
Remove the drive plates.
Remove the torque converter.

ASSEMBLY
Install the torque converter assy on input shaft.
Install the drive plates on the converter.
Install the drive plates screws and the lock washers

and tighten the screws to the specified torque 43 Nm
(32 lbf·ft).
2.6 STALL TEST
The purpose of this test is to determine if the torque

converter and hydraulic clutch assemblies are oper- NOTE: if the unit creeps forward and the gears
ating satisfactorily. clash, the front clutch is at fault. The rear clutch is at
For the test to be conclusive, the transmission hy- fault if the unit creeps backward. If the unit does not
draulic pump and pressure regulating valve must be creep and the gears still clash, use the stabilizers to
operating correctly. raise the rear wheels off the ground, move the pow-
They can be checked by performing the “Line Pres- er reversing lever to neutral and shift into first gear.
sure Test”. Check the rear wheels for rotational direction - if the
The engine and brakes must also be in good work- wheel rotate rearward, then the rear clutch is at
ing order. fault.
Z Check the coolant level in the radiator and the oil
level in the transmission. If low, add fluid as re-
quired to bring to the proper level.
Z With the gearshift lever and the shuttle lever in
neutral, start the engine and run at 800-1000 revs/
min until the transmission temperature reaches
85° - 95 °F (29° - 35 °C).
Z Lock the brakes and shift into fourth gear, increase
engine speed to approximately 900 revs/min, then
shift the power reversing lever to the forward posi-
tion. This will position the control valve so as to di-
rect high pressure oil to the front clutch.
Z Ensure the brakes are firmly locked so the unit will
not move, gradually depress the foot accelerator
and note the maximum engine speed obtained.
Move the power reversing lever to the neutral po-
sition. The stall speed should be:
Engine 97 HP............................... 1750 ÷ 1850 rpm
Engine 110 HP............................. 1990 ÷ 2140 rpm
IMPORTANT: to prevent the transmission from

overheating, do not allow the engine to operate at
maximum rpm for more than fifteen seconds.
Z Allow the transmission oil to cool to 29°-35 °C (85°-

95 °F). Check the rear hydraulic clutch by repeat-
ing previous steps, but with the power reversing le-
ver in the rearward position. Again, cool the
transmission oil by allowing the engine to run at ap-
proximately 1000 revs/min for one minute.
Z The engine speed noted previously (stall speed)
for both the front and rear clutch assemblies
should be within 150 revs/min of each other. If the
stall speed is not within these limits, refer to the di-
agnosis guide for possible causes.
Z With the gearshift lever and power reversing lever
in neutral, set the engine speed at 600-800 revs/
min, then shift into any gear ratio. If the gears
clash, either the front or rear hydraulic clutch as-
sembly is transmitting power, even though the
power reversing lever is in neutral.
2.7 FAULT FINDING

Low stall speed Hydraulic clutch not releasing Replace torque converter.
Stator support broken Replace torque converter.
Low engine power Check and correct output.
High stall speed Hydraulic clutch not applying or is Replace.
slipping
Low line pressure Check pump output.
Sealing rings on rear input shaft
broken Replace seals.
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 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
1.12 FAULT FINDING................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.2 TRANSMISSION CONTROLS............................................................................................................. 95
2.3 LUBRICATION................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER ............................................................................................................... 108
2.6 TRANSMISSION HYDRAULIC DIAGRAM ........................................................................................ 109
2.7 OPERATION...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION / ENGINE REMOVAL FROM LOADER............................................................... 133
2.11 TRANSMISSION COMPONENTS................................................................................................... 138
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 156
2.13 SPECIAL TOOLS............................................................................................................................. 265
2.14 FAULT FINDING.............................................................................................................................. 266
2.15 FAULT FINDING.............................................................................................................................. 268
2 SECTION 21 - TRANSMISSION
SECTION 21 - TRANSMISSION 3
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025”

This transmission is used on powershuttle loader
backhoes models B90B - B95B - B95BLR - B95BTC
- B110B.
The transmission consists of a torque converter, an
internal rotor-type hydraulic pump, an oil distributor,
a solenoid control valve assembly, two hydraulically
operated clutches, a 4-speed synchromesh
geartrain, transmission case and oil cooler tubes.
NOTE: a conventional clutch is not used with this

transmission.
The transmission case serves as an oil tank for the

torque converter and hydraulic clutch assemblies.
The transmission receives power from the engine (1)
by a fluid coupling in the torque converter (2) and hy-
draulic clutch assemblies in the transmission (3).
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
COLD START BY-PASS VALVE SPRING

Free length............................................................................................53.4 mm ± 0.96 mm (2.10 in ± 0.038 in)
FORWARD CLUTCH SPRING

Free length............................................................................................................................ 76.6 mm (3.017 in)
CLUTCH PISTON SPRING

Free length.............................................................................................................................. 75.9 mm (2.99 in)
DETENT SPRING
Free length (Approximately)................................................................................................ 42.06 mm (1.656 in)
END FLOAT
Input forward Primary Shaft ............................................................................0.0508-0.41 mm (0.002-0.016 in)
Input reverse Primary Shaft ............................................................................0.0508-0.41 mm (0.002-0.016 in)
Output shaft......................................................................................1st Gear - 0.33-0.508 mm (0.013-0.020 in)
....................................................................................................... 2nd Gear - 0.35-0.558 mm (0.014-0.022 in)
........................................................................................................ 3rd Gear - 0.38-0.838 mm (0.015-0.033 in)
........................................................................................................ 4th Gear - 0.20-0.558 mm (0.008-0.022 in)
Four Wheel Drive Shaft.....................................................................................0.050-0.28 mm (0.002-0.011 in)
Bearing End Floats..........................................................................................0.025-0.076 mm (0.001-0.003 in)
Bearing End Float Shims available ................................................... 0.050/0.076/0.127/0.177/0.381/0.508 mm
........................................................................................................... (0.002/0.003/0.005/0.007/0.015/0.020 in)
HYDRAULIC TESTS
Tachometer Setting........................................................................................................................2000revs/min
Cold Start Valve (For reference only)......................................................................................... 26 bar (377 psi)
System Pressure Test..............................................................................................13.7-15.2 bar (198-220 psi)
Torque Converter .............................................................................................................7-11 bar (101-159 psi)
Reverse Clutch.........................................................................................................13.7-15.2 bar (198-220 psi)
Forward Clutch.........................................................................................................13.7-15.2 bar (198-220 psi)
Four Wheel Drive Supply .........................................................................................13.7-15.2 bar (198-220 psi)
COOLER FLOW TEST

Oil temperature 80-85 °C (176-185 °F) ........................ Revs/min ................... Oil Flow Liters/min (gallons/min)
...............................................................................................700 ........................... 12.5 liters (3.3 US Gallons)
.............................................................................................1000 ........................... 18.2 liters (4.8 US Gallons)
............................................................................................ 1500 ........................... 22.1 liters (5.8 US Gallons)
.............................................................................................2500 ........................... 25.0 liters (6.6 US Gallons)
1.2 TIGHTENING TORQUES
Strainer bolts............................................................................................................18 to 31 Nm (13 to 23 lbf·ft)

Pump retaining bolts ................................................................................................18 to 31 Nm (13 to 23 lbf·ft)
Output Yoke bolts ....................................................................................................68 to 88 Nm (50 to 65 lbf·ft)
Pressure test plugs ..................................................................................................41 to 54 Nm (30 to 40 lbf·ft)
Main transmission case bolts...................................................................................45 to 64 Nm (33 to 47 lbf·ft)
Shift detent plug .......................................................................................................41 to 54 Nm (30 to 40 lbf·ft)
Shift fork screws.......................................................................................................18 to 25 Nm (13 to 18 lbf·ft)
Shift lever assembly screws.....................................................................................16 to 24 Nm (12 to 18 lbf·ft)
Drain plugs...............................................................................................................34 to 54 Nm (25 to 40 lbf·ft)
Converter relief valve ...............................................................................................23 to 30 Nm (17 to 22 lbf·ft)
Pressure regulator valve ..........................................................................................46 to 60 Nm (34 to 44 lbf·ft)
Cold start valve ........................................................................................................46 to 60 Nm (34 to 44 lbf·ft)
4WD solenoid valve spool........................................................................................20 to 27 Nm (15 to 22 lbf·ft)
4WD Solenoid coil retaining nut..................................................................................................5.4 Nm (4 lbf·ft)
Directional control valve retaining screws...............................................................6.8 to 8.5 Nm (5 to 6.3 lbf·ft)
4WD hydraulic pipe connections...........................................................................6.8 to 10.2 Nm (5 to 7.5 lbf·ft)
Filter housing bolts...................................................................................................45 to 64 Nm (33 to 47 lbf·ft)
Oil filter........................................................................................................................7 to 10 Nm (5 to 7.5 lbf·ft)
Temperature sender ................................................................................................20 to 27 Nm (15 to 20 lbf·ft)
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 expansion plug...................................................................................................... Loctite 649
1.3 TRANSMISSION CONTROLS
4X4 POWERSHUTTLE TRANSMISSION CONTROLS
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 NOTE: in reverse gear an audible alarm device
this switch which disengages transmission sounds.
drive, select the required gear with the gear le-
ver and release the switch to re-engage drive. 6. WARNING HORN BUTTON
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 equalises or foot brakes are
applied.
Transmission
The transmission is fully synchronised providing four
forward and four reverse speeds allowing gear ratio
changes on the move. A torque converter is used to
connect the engine to the transmission and the col-
umn mounted powershuttle lever (4) enables shifts
between forward and reverse travel without disen-
gaging gear ratios.
A device for “transmission disconnect” is activated
by pushing button (2), placed on the gearshift lever
(1) or by pushing button (5), placed on the loader
control lever (3).
S WARNING
Always apply the parking brake whenever the ma-
chine is parked as the machine is free to roll even
though the transmission gearshift lever and power
reversing lever may be “In Gear” and the engine is
turned “OFF”.
Gearshift Lever
The single gearshift lever (1) is used to select any
one of the four gear ratios. The transmission discon-
nect button (2) is depressed and held as the lever is
shifted from one gear to another and then released
to re-connect transmission drive.
Forward/reverse powershuttle lever

To select forward travel, engage the required gear
ratio with the gearshift lever, then with the engine
idling lift the powershuttle lever from the neutral lock
position (1) and move to the forward position (2). Use
the foot accelerator to control the engine and ground
speed.
To reverse the direction of travel, reduce engine
speed and move the power reversing from neutral
lock position (1) and rearwards (3) for reverse travel
an audible alarm device sounds.
IMPORTANT: the powershuttle lever is equipped

with a neutral lock to prevent inadvertent engage-
ment of the transmission. With this design the power
reversing lever moves through a “T” slot for the for-
ward and reverse positions.
IMPORTANT: when operating in low ambient tem-

peratures with cold transmission oil, allow the oil to
warm up before attempting to shift the powershuttle
lever. The transmission can be shifted normally after
the oil warms up.
NOTE: the horn will sound if the powershuttle lever

is operated (forward or reverse) with the handbrake
engaged.
NOTE: the powershuttle lever can be shifted at any

engine speed, however, for safe, smooth operation
the engine speed should be reduced to approximate-
ly 1200 rpm.
This action is easily controlled by using the foot ac-
celerator to control engine and ground speed.
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.
S WARNING
To avoid personal injury do not use the disconnect
switch control to coast down hill. Excessive speed
may cause loss of control, personal injury to a by-
stander or failure of the transmission.
To make upward gear ratio changes simply depress

and hold the button (2) on the gearshift lever (1),
while moving the lever from one gear ratio to anoth-
er. When the desired gear ratio has been selected
release the button and allow the unit to gain engine
speed and ground speed. If another higher ratio is re-
quired repeat the procedure.
IMPORTANT: to avoid possible damage to the

transmission hydraulic clutches never use the dis-
connect switch for inching the machine forward.
Inching the machine forward with the button will
cause the clutches to slip excessively and overheat.
To make downward gear ratio changes or reduce

ground speed, simply lower the engine speed, de-
press and hold the gearshift lever button and down-
shift the transmission.
When the desired gear ratio has been selected re-
lease the button and adjust the engine speed to suit
ground speed required.
Operating the machine in a too high gear or under a
too heavy load will cause the torque converter to slip
excessively and overheat. If the machine is over-
loaded, the engine speed will not exceed a range of
1800-2200 rpm at maximum accelerator and the
torque converter will “stall” bringing the machine to a
complete stop.
If “stall” does occur, there is still sufficient engine
power to operate the loader however, to prevent the
transmission from overheating, either reduce the
load on the machine or select a lower gear ratio.
IMPORTANT: operating at a “stall” for more than 20

seconds can cause the transmission to overheat and
can possibly damage the transmission. If the trans-
mission overheats, the needle (1) reaches the red
field. Shift both the power reversing and gearshift le-
vers to neutral. Let the engine run idle (1000 rpm) un-
til transmission oil cools down enough to have the
needle (1) return to correct position. Once the needle
is returned to its position, all operations can be re-
sumed.
DIFFERENTIAL LOCK PEDAL

In conditions inducing wheel slip, hold down the dif-
ferential lock pedal (1) with your heel until the lock is
felt to engage. The lock will automatically disengage
when traction at the rear wheels equalizes. If a rear
wheel spins at speed, reduce the engine speed to
idle before engaging the differential lock to minimize
shock loads on the rear axle.
S WARNING
Never use the differential lock at speeds above 8 km/h
(5 mph) or when turning the machine.
When engaged the lock will prevent the machine turn-
ing and personal injury could result.
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.
Oil level checking

The oil level should be checked daily and corrected if necessary.
The oil level must be checked with the engine idling and with the transmission oil cold.
In this condition the oil level should fall between the Max and Min marks on the dipstick.
At normal operating temperature, (80°C) (176°F) the oil level will rise to 20 - 30 mm (0.79-1.18 in) above the
Max. mark on the dipstick.
Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the
churning action of the gears. Early breakdown of the oil will result in heavy sludge deposits that block oil ports
and build up on splines and bearings. Overfilling may also cause oil leaks.
Oil changes
An initial oil change and flush is recommended after the transmission is placed in actual service.
This change should be made at any time following 50 hours in service, but should not exceed 100 hours.
When changing the oil it is essential to renew the oil filter and clean out the suction strainer.
The object in draining the oil is to eliminate possible bearing surface abrasion and attendant wear. Minute par-
ticles of metal, the result of normal wear in service are deposited in and circulated with the oil. Oil changes are
best carried out when the transmission is thoroughly warm.
S WARNING
To prevent oil starvation and possible seizure of the transmission whilst towing the vehicle, it is imperative that
the propeller shafts are disconnected.
Failure to observe this precaution may result in extensive damage to the transmission.
Oil capacity: 18 liters (4.7 US Gallons)
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°C (from -4 to 104°F):
Ambra Mastertran NH 410 C
1.5 TRANSMISSION OIL FLOW AND SUPPLY
F29967
Pressure oil
Disengaged
Lubrication
OIL FLOW AND SUPPLY IN NEUTRAL POSITION
1 2 3 4 5
16
F R
15
6
14
13
12
11 10 9 8
F29968
Pump pressure Lubrication

Return to Sump Suction
Torque converter flow
1. Shuttle control solenoid valve oil 14 bar (203 5. FWD - Low pressure system oil supply received
psi). from the filter at 14 bar (203 psi) and fed by ex-
2. Torque Converter - Receives low pressure sys- ternal tube to rear of transmission to the FWD.
tem oil at maximum 10 bar (145 psi) and returns 6. Cold Start Pressure protection Valve - Prevents
oil to port (10). system pressure exceeding 26 bar (377 psi) at
3. Backhoe Boom Lock oil flow 14 bar (203 psi). initial cold start.
4. Pressure filter - Mounted to the left of the trans- 7. Oil Pump Port OUT, to oil filter assembly
mission viewed looking forward. through internal drillings.
8. Oil returned from the oil cooler lubricates shafts,
gears and bearings and returns oil to reservoir.
OIL FLOW AND SUPPLY IN FORWARD POSITION
1 2 3 4 5
16
F R
15
6
14
13
12
11 10 9 8
F29969
Pump pressure Lubrication

Return to Sump Suction
Torque converter flow
1. Returned lubrication oil from the pump shaft 6. Torque Converter oil OUT, to oil cooler.
bush to reservoir. 7. Torque Converter pressure regulating valve, re-
2. Torque Converter oil supply IN, received at ceives oil from the sequencing valve (16) and
maximum 10 bar (145 psi). returns oil in excess of 10 bar (145 psi) to reser-
3. Transmission Reservoir/System Capacity: 17 li- voir.
ters (4.50 US Gallons) (2WD) 18 liters (4.70 US 8. System pressure sequencing valve - Maintains
Gallons) (4WD). system oil at 14 bar (203 psi) and supplies a
4. Oil Cooler - Mounted below the engine coolant continuous oil feed to the torque converter reg-
radiator. ulating valve.
5. Oil pump suction port IN, from the reservoir.
TRANSMISSION OIL SUPPLY PORT
Viewed From Front and Rear Housings

1. Oil supply port to Reverse clutch pack, rear cas- 10. System pressure sequencing valve.
ing. 11. Torque converter pressure regulating valve.
2. Oil supply port to forward clutch pack, rear cas- 12. Oil supply from pump to solenoid valve pack.
ing. 13. Oil supply port to Reverse clutch pack, front cas-
3. Oil supply port to pressure test reverse clutch ing.
pack. 14. Oil port to reservoir (dump) from solenoid.
4. Oil supply port too pressure test forward clutch 15. Oil supply port to Reverse clutch pack, front cas-
pack. ing.
5. Front Wheel Drive Solenoid. 16. Oil supply port to forward clutch pack, front cas-
6. System pressure test point, connected to test ing.
block. 17. Oil supply port to forward clutch pack, front cas-
7. Locating Dowel ing.
8. Cold start oil pressure protection valve. 18. Manufacturing drilling only.
9. Torque converter pressure test point, connected 19. FWD oil supply port (front casing)
to test block. 20. FWD oil supply port (rear casing)
TRANSMISSION OIL FLOW THROUGH

SOLENOID VALVE
The solenoid valves forward (1) or reverse (2) fitted
at the top of the transmission housing controls the oil
flow to the forward/reverse clutch packs in the tran-
mission.
On the underside of the solenoid valve are the 4

ports for directional oil flow to and from the solenoid
valve.
1. Oil supply from the valve to the forward clutch
pack.
2. Return oil to reservoir
3. Oil supply from the valve to the reverse clutch
pack.
4. Oil supply from the pump into the valve.
5. Locating Pin
When the shuttle lever in the cab is in neutral position

the solenoid valve spool (1) will be static and oil (2) 1 2
will not flow into either reverse (3) or forward (4)
clutch pack oil gallery.
4 3 F29973
When forward direction is selected on the shuttle le-

ver the solenoid valve spool (1) will move to the left 1 2
(as shown) and the oil (2) will flow into the forward
clutch pack oil gallery (4).
When reverse direction is selected on the shuttle le-
ver the solenoid valve spool (1) will move to the right
(not shown) and the oil (2) will flow into the reverse
clutch pack oil gallery (3).
4 3
F29974
OIL FLOW SOLENOID CONTROL VALVE

OPERATION (FORWARD DRIVE ONLY SHOWN)
The solenoid valve when in neutral position dead
heads the oil flow at the spool (1) from the supply 1
port and no oil is allowed to pass through the valve.
Therefore the oil in the galleries beyond the spool at
the fill time metering valve (2) remains static.
3
F29975
Selection of the forward / reverse shuttle lever in the

cab directs a current flow to the forward or reverse 1
solenoid and the spool (1) will move in the direction
selected, reverse shown. The oil then flows past the
spool to the clutch pack and applies pressure to the
fill time metering valve (2), a small bore allows oil to
flow into the clutch feathering valve.
When valve (2) moves it partially uncovers a port to
the reservoir and also opens the control orifice within 2
the valve. Therefore a precisely metered flow of oil is
fed to the pressure regulating (feathering) piston (3).
As this piston is pushed back against its spring the 3
pressure at the clutch builds up gradually to give a F29976
smooth jerk free clutch engagement.

When the piston reaches the end of its travel, clutch
pressure quickly builds up to full system pressure ei- 1
ther side of valve (2) so the light spring pushes the
valve covering the port to the reservoir.
The oil is dead headed at system pressure at the
clutch so ensuring full torque can be transmitted by
the clutch.
3
F29977
NOTE: the control valve also includes a pressure Regulated Pressure Oil
regulating (feathering) valve and a fill time metering Return Oil
valve for the reverse clutch pack. Pressure Oil
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS
NOTE: all pressure test ports are 9/16 in UNF thread

size.
1. Cold Start oil pressure relief valve 10. Torque converter pressure regulating valve
26 bar (377 psi) reference only 7-11 bar (101-159 psi)
2. Forward Solenoid valve 11. Oil in from cooler, test port
13.7-15.2 bar (198-220 psi) 3.5 bar (50 psi)
3. Test port for reverse clutch pack 12. Backhoe Boom Lock supply
13.7-15.2 bar (198-220 psi) 13.7-15.2 bar (198-220 psi)
4. Test port for forward clutch pack 13. System pressure test point
13.7-15.2 bar (198-220 psi) 13.7-15.2 bar (198-220 psi)
5. System pressure sequencing valve 14. Converter pressure oil test port
13.7-15.2 bar (198-220 psi) 7-11 bar (101-159 psi)
6. Oil flow OUT to cooler 15. Front Wheel Drive Solenoid
7. Oil OUT to cooler, test port 13.7-15.2 bar (198-220 psi)
6.5 bar (94 psi) 16. System Oil Filter
8. Front Wheel Drive test point 17. Reverse Solenoid valve
13.7-15.2 bar (198-220 psi) 13.7-15.2 bar (198-220 psi)
9. Oil flow IN from cooler
1.7 TRANSMISSION POWER FLOW
When neutral is selected on the shuttle lever (1), the

transmission forward (3) and reverse hydraulic
clutch packs or (4) are free to rotate and hence there
is no drive in the transmission.
With Forward or Reverse selected on the shuttle le-

ver (1) power will be directed through the clutch
packs (3) or (4) to the gear train and selection of gear
on lever (2) will result in engagement of gears to the
output shafts.
Power for all four forward gear ratios is transmitted

from the front hydraulic clutch (3) on the input shaft.
The input shaft then transmits power to the counter
shaft forward gear and the countershaft in turn trans-
mits power to the output shaft.
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.
Because power is being transmitted through the re-

verse idler gear, the countershaft and output shaft
will rotate in the opposite direction as for forward
gear ratios. The rear input shaft will also rotate in the
opposite direction.
F29980
Input
Intermediate
Output
NOTE: 4WD shown.

NOTE: 4WD version shown.

1.8 TRANSMISSION 2WD COMPONENTS
F27510
F27511
1. Front gear case assembly 68. Clutch pack retaining clip

2. Rear gear case assembly 69. Clutch pack retaining plate
3. Plug and O-ring 70. Clutch plate
4. Cold start spring housing 71. Clutch plate (friction)
5. Bolt 72. Circlip
6. Sealing cap 73. Spring retainer
7. Bolt 74. Piston return spring
8. Reverse shift hub sleeve 75. Piston
9. Synchronizer assembly 76. Piston sealing ring outer
10. Sealing ring 77. O-ring
11. Copper washer 78. Piston sealing ring inner
12. Thrust bearing 79. O-ring
14. Thrust washer 80. Breather plug
17. Ball 81. Capscrew
18. Cold start spring 82. Breather
19. O-ring 83. Needle bearing spacer
20. Plug 84. Bolt
21. Oil filter housing 85. Needle bearing
22. Flywheel housing 86. Temperature sender
23. Washer 87. Output yoke washer
24. Filter housing gasket 88. O-ring
25. Bolt 89. Screw
26. Cover plate 90. O-ring
27. Setscrew 91. End yoke assembly
28. 4th gear output shaft 92. Pump assembly
29. 3rd gear output shaft 93. Pump sealing ring
30. 2nd gear output shaft 94. O-ring
31. 1st gear output shaft 95. Detent ball
32. Spacer 96. Detent spring
33. Bearing 97. 1st/2nd shift fork
34. 1st gear bearing spacer 98. 3rd/4th shift fork
35. 1st gear bearing sleeve 99. 1st/2nd shift rod
36. Circlip 100. 3rd/4th shift rod
37. Expansion plug 101. Shift fork screw
38. Directional valve 102. Gearshift lever
40. O-ring 103. Bolt
43. 4th gear thrust washer 104. Gear lever seating
44. Bearing spacer 105. Pin
45. Shim 106. Rubber boot
50. Shim 107. O-ring
51. Bearing 108. Suction strainer
52. Output shaft 109. Pressure regulator valve
53. Bearing 110. Plastic clip
54. Bearing spacer 111. Plastic clip
55. Shim 112. Plug
58. Shim 113. Converter relief valve
59. Support washer 114. Setscrew
60. Bearing 115. Oil seal
61. Bearing 116. Oil filter
62. Thrust washer 117. Oil filter adapter
63. Countershaft 118. Drain plug
64. Reverse idler gear 120. Dowel
65. Input shaft assembly 121. Strainer cover plate
66. Forward primary gear 127.Plug
67. Reverse primary gear
1.9 TRANSMISSION 4WD COMPONENTS
F27512
1. Front gear case assembly 70. Clutch plate - steel

2. Rear gear case assembly 71. Clutch plate - friction
3. Plug assembly 72. Circlip
4. Bolt 73. Spring retainer
5. Bolt 74. Piston return spring
7. Bolt 75. Clutch piston
8. Reverse shift hub sleeve 76. Piston sealing ring
9. Synchronizer assembly 77. O-ring
10. Sealing ring 78. Piston sealing ring
11. Copper washer 79. O-ring
12. Thrust bearing 80. Brake caliper bolt
13. 4WD piston sealing ring 81. End yoke
14. Support washer 82. Spacer ring
15. Torque converter 83. Needle bearing spacer
16. O-ring 4WD piston 84. Bolt
17. Circlip 85. Needle bearing
18. Clutch collar 86. Bearing
19. Spring 4WD 87. Output flange washer
21. Spring support 89. Screw
22. Flywheel housing 90. O-ring
23. Parking brake assembly 91. Brake flange assembly
24. 4WD shaft 92. Pump assembly
25. 4WD gear 93. Sealing ring
26. Converter drive plate 94. Sealing ring
27. Thrust washer 95. Detent ball
28. 4th gear output shaft 96. Detent spring
29. 3rd gear output shaft 97. 1st/2nd shift fork
30. 2nd gear output shaft 98. 3rd/4th shift fork
31. 1st gear output shaft 99. 1st/2nd shift rod
32. 4WD gear output shaft 100. 3rd/4th shift rod
33. Bearing 1st gear output shaft 101. Shift fork screw
34. Bearing spacer 102. Gear stub lever
35. Bearing sleeve 103. Bolt
36. Circlip 104. Gear lever seating
37. Sealing ring 4WD shaft 105. Pin
38. Bearing spacer 106. Rubber boot
39. Shim 107. Washer
42. Shim 109. Hydraulic pipe nut
43. Thrust washer 110. Plastic clip
44. Bearing spacer 111. Plastic clip
45. Shim 112. Plug
50. Shim 113. Converter relief valve
51. Bearing 114. Setscrew
52. Output shaft 115. Banjo bolt washer
53. Bearing 116. 4WD clutch supply pipe
54. Bearing spacer 118. Drain plug assembly
55. Shim 119. Hydraulic pipe sleeve
58. Shim 120. Bearing spacer
59. Bearing 121. Shim
60. Bearing 124. Shim
61. Bearing 125. Cold start spring housing
62. Thrust washer 126. Coaxial drive shaft
63. Countershaft 127. Capscrew
64. Reverse idler gear 128. Pressure regulator valve
65. Input shaft assembly coaxial 129. 4WD solenoid valve
66. Forward primary gear 130. Directional control valve
67. Reverse primary gear 131. Oil filter
68. Clutch pack retaining ring 132. Oil filter adapter
69. Clutch pack retaining plate 134. Dowel
135. Oil seal

136. Sealing cap
137. Suction strainer
138. O-ring suction strainer
139. Support washer
140. Strainer cover plate
141. Setscrew
142. Breather
143. O-ring
146. O-ring
149. Expansion plug
150. Brake caliper nut
151. Pump mounting stud
152. Oil filter housing
153. Filter housing gasket
154. Bolt
155. O-ring
156. Cold start spring
157. Ball
158. Setscrew
160. Setscrew
161. Copper washer
162. Banjo bolt
163. Remote test port assembly
164. Remote test port pipe
165. Remote test port pipe
168. Pump mounting stud nut
170. 4WD gear bearing
171. Spacer 4WD gear bearings
SOLENOID VALVE COMPONENTS
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
1.10 TRANSMISSION REMOVAL
Remove the transmission and engine as a complete

unit from the vehicle and place on a suitable stand for
disassembly.
NOTE: prior to disassembly drain the oils into suit-

able containers for disposal.
Prior to separating the transmission from the engine.

Remove the starter motor (1).
Engine timing tab (2).
Torque converter back plate attaching bolts through
the starter motor aperture (1).
Bell housing attachment bolts (3).
IMPORTANT: prior to positioning the transmission

vertically remove the vehicle system oil pump (4)
and torque converter unit (5) from the transmission
bell housing.
Using eye bolts (1), 1 per side capable of lifting a

weight of 250 kg (550 lbs) hoist the transmission ver-
tically and place in a safe, clean and suitable work-
shop environment.
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 gearshift lever as-
sembly.
Remove the plastic plugs and 4 cap screws and

withdraw the direction control valve.
Remove the converter relief valve.

Remove the pressure regulator valve.
Remove the cold start housing, the spring and the

ball.
Remove the temperature sender.
Remove the bolt, the washer and the O-ring and

withdraw the output yoke.
Remove the bolt, the washer and the O-ring and the
withdraw the 4WD yoke and spacer (only fitted on
4WD model).
Remove 17 screws and using a suitable hoist take

off the rear transmission case.
Lever slots are provided to assist removal.
NOTE: the bearing cones and shims may fall from

the rear case during removal.
IMPORTANT: for proper reassembly, take note and

mark which bearings and shims come from which lo-
cations.
Remove the 4WD shaft assembly (only fitted on

4WD model).
Tilt the countershaft and withdraw the input shaft as-

sembly.
Remove the reverse idler shaft assembly.
Remove the outer detent plug, the spring and the

ball.
Ensure both synchronizers are in the neutral posi-

tion then remove the 1st/2nd shift fork screw.
Withdraw the 1st/2nd shift rod from the housing.

Then using a magnetic probe remove the interlock
ball from the detent, bore.
Remove the 3rd/4th shift fork screw.
NOTE: before attempting to remove the 3/4th shift

rail, replace the detent plug as the ball and spring
may shoot out and cause injury.
Turn the 3rd/4th shift rod through 90 degrees and

withdraw from the housing.
Remove the detent plug, the inner detent ball and

the spring.
Remove the counter shaft assembly.

Remove the 1st/2nd and 3rd/4th shift forks.
Remove the output shaft assembly.
Remove the 4th gear lock out screw (if fitted).
Remove 2 screws and withdraw the strainer cover,

the O-ring, the spacer and the strainer.
Using a strap wrench remove and discard the oil fil-

ter.
Remove 2 bolts and take of the oil filter housing and

the gasket.
Remove the 4WD solenoid coil and retaining nut

(only fitted on 4WD model).
Remove the 4WD solenoid spool (only fitted on 4WD

model).
Remove and discard the expansion plug from the

shimming access hole.
Invert the case. Remove 4 screws and copper wash-

ers then withdraw the pump assembly and the seal-
ing ring.
INPUT SHAFT DISASSEMBLY

Position the shaft in a soft jawed vice as shown.
Remove and discard the 3 sealing rings.
Using the appropriate bearing puller 380002683 re-

move the rear bearing.
Remove the thrust washer and the needle bearing.

Remove the reverse primary gear.
Remove the bearing, the spacer, the bearing and

the thrust washer.
Remove the clutch pack retaining ring.
Remove the clutch pack retaining plate.

Remove the clutch pack.
Using the appropriate tool 380002689 compress the

piston spring and release the circlip.
Remove the circlip, the retainer and the spring.
Using pliers pull the piston out of the drum.

Invert the shaft and remove the sealing ring.

Repeat steps 3 to 2 to dismantle the forward clutch
pack.
Remove and discard the piston sealing rings and the

O-rings.
INPUT SHAFT ASSEMBLY

Re-new the piston sealing rings and the O-rings.
To assist assembly bend the inner sealing ring into
a heart shape as shown.
Using transmission fluid to lubricate the seals push

the piston into the drum.
Replace the spring, the retainer and the circlip as

shown.
Using the tool 380002689 compress the spring and

locate the circlip into its groove.
Replace an externally splined (plain) disc and then

an internally splined (friction) disc alternately until six
of each have been replaced.
Replace the clutch pack retaining plate and refit the

retaining clip.
Replace the thrust washer, the bearing, the spacer

and the bearing.
Line up the clutch plate splines and replace the pri-

mary gear. Then replace the needle bearing and the
thrust washer.
NOTE: the needle bearing should be fitted with the

closed side of its cage against the gear.
Using an appropriately sized tube replace the bear-

ing.
Invert the shaft and repeat previous steps. Then fit a

new sealing ring.
Finally fit 3 new sealing rings to the rear of the shaft.

(To avoid damage the sealing rings should be left off
until all shimming operations have been completed).
DISASSEMBLY AND ASSEMBLY OF THE

COUNTERSHAFT
The countershaft assembly.
Using the appropriate bearing pullers 380002691

and 380002687 remove the countershaft front and
rear the bearings.
Using an appropriately sized tube replace the coun-

tershaft front and the rear bearings.
DISASSEMBLY AND RE-ASSEMBLY OF THE

REVERSE IDLER SHAFT
The reverse idler assembly.

move the front and the rear bearings.
Using an appropriately sized tube replace the front

and rear the bearings.
OUTPUT SHAFT DISASSEMBLY

Position the shaft assembly in a soft jawed vice.

move the front bearing.
Remove the thrust washer and the 4th gear.
Remove the 3rd/4th synchro assembly.

Remove the circlip and the synchro hub.
Remove the 3rd gear.
Invert the shaft and using the appropriate bearing

puller 380002687 remove the rear bearing.
Remove the 4WD gear. (On 2WD model a spacer is

fitted in place of a gear.)
Remove the 1st gear.
Remove the needle bearings and the spacer.
Remove the 1st/2nd synchronizer assembly.
Using a suitable bearing puller or press.

Remove the bearing sleeve, the synchro hub and
the 2nd gear.
Remove the bearing sleeve, the synchro hub and

the 2nd gear.
OUTPUT SHAFT ASSEMBLY

Replace the 2nd gear and the synchro hub.
Using an appropriately sized tube refit the 1st gear

bearing sleeve.
Replace the 1st/2nd synchronizer assembly.
Replace the 1st gear needle bearings and the spac-

er.
Replace the 1st gear.
Replace the 4WD gear using Loctite 649 spline lock

or equivalent.
NOTE: the gear should be fitted with the fluted boss

against the 1st gear. (On 2WD models a spacer is fit-
ted in place of the gear).
Using an appropriately sized tube refit the rear bear-

ing.
Invert the shaft and refit the 3rd gear, the synchro
hub and the circlip.
Refit the 3rd/4th synchronizer assembly.
Refit the 4th gear and the thrust washer.
Using an appropriately sized tube replace the front

bearing.
HYDRAULIC DOG CLUTCH 4WD DISASSEMBLY

The hydraulic dog clutch 4WD assembly.
Position the shaft in a soft jawed vice and remove

the sealing ring.

move the rear bearing.
Remove the thrust washer.

Remove the 4WD gear.
Remove the two needle bearings and the spacer.
Invert the shaft and using the appropriate bearing

puller 380002685 remove the front bearing.

spring and release the circlip.
Remove the circlip, the retainer and the spring.
Remove the piston drum assembly.
Remove the piston seal and the O-ring from the

shaft and discard.
Remove and discard the piston seal and the O-ring

from the piston drum.
HYDRAULIC DOG CLUTCH 4WD ASSEMBLY

Fit a new O-ring and sealing ring to the shaft.
Fit a new O-ring and sealing ring into the piston.

Bend the sealing ring into a heart shape to assist as-
sembly.
Lubricate the seals with a light grease and refit the

piston to the shaft.
Replace the piston spring and the clip retainer.


spring and retainer and refit the circlip.
Using an appropriately sized tube refit the front bear-

ing.
Invert the shaft and refit the two needle bearings and
spacer.
Replace the 4WD gear.

Replace the thrust washer.
Using an appropriately sized tube replace the rear

bearing.
Fit a new sealing ring. (To avoid damage the sealing

ring should be left off until all shimming operations
have been completed.)
PERMANENT 4WD SHAFT DISASSEMBLY

The permanent 4WD shaft.

move the front and the rear bearings.

PERMANENT 4WD SHAFT ASSEMBLY

Replace the 4WD gear using Loctite 649, or equiva-
lent, on the shaft splines.
Then using a suitably sized tube refit the front and
the rear bearings.
HYDRAULIC MULTI PLATE CLUTCH 4WD SHAFT

DISASSEMBLY
The hydraulic multiplate clutch 4WD shaft assembly.
Mount the shaft assembly in a suitable soft jawed

vice and remove the rear sealing ring.
Using the appropriate tool 380002685 remove the

rear bearing.
Remove the thrust washer and the needle bearing.

Remove the needle bearings and the spacer.
Remove the needle bearing and the thrust washer.
Remove the clutch pack retaining clip.

Remove the clutch pack retaining plate.
Remove the clutch pack.

piston return spring and release the circlip.
Remove the clip retainer and the spring.

Remove the piston from the drum.
Remove and discard the piston sealing rings.
Invert the shaft and remove the front bearing using

the appropriate tool 380002685.
HYDRAULIC MULTI PLATE CLUTCH 4WD SHAFT

ASSEMBLY
Using an appropriately sized tube refit the front bear-
ing.
Re-new the piston sealing rings to assist assembly

the seals may be warmed in lukewarm water prior to
assembly.
NOTE: the outer seal must be fitted with the open

edge facing away from the clutch pack.

piston sealing rings. The seals should be left in the
tool 380002684 for a minimum of 30 minutes prior to
assembly into the clutch drum.

piston into the clutch drum. Then replace the spring,
retainer and circlip.

piston return spring and locate the circlip into its
groove.
Replace an externally splined (plain) disc then an in-

ternally splined (friction) disc alternately until 8 plain
discs and 8 friction discs have been fitted.
Replace the retaining plate and fit a new retaining

clip.
Refit the thrust washer and the needle bearing.

Refit the 4WD gear.
Refit the needle bearings and the spacer.
Refit the needle bearing and the thrust washer.
Using an appropriately sized tube refit the rear bear-

ing.
Refit a new sealing ring and lubricate with a light

grease. (To avoid damage the sealing ring should be
left off until all shimming operations have been com-
pleted.)
THE OIL PUMP DISASSEMBLY AND ASSEMBLY

Individual components of the oil pump are non ser-
viceable. The pump may, however, be stripped for
cleaning and examination purposes.
View showing a dismantled pump assembly.
The pump oil seal may be replaced using an appro-

priately sized tube.
DIRECTION CONTROL VALVE DISASSEMBLY

AND ASSEMBLY
Disassembly of the control valve is not generally rec-
ommended as, with the exception of the solenoids,
individual parts are non serviceable. It may however
be dismantled for cleaning and examination.
The valve fitted may be either the modulated type or
the non-modulated type.
The retaining nut, the coil and the washer removed.
The modulation components removed.
There are 4 O-rings fitted to the underside of the

valve which may be renewed if necessary.
GEAR LEVER HOUSING DISASSEMBLY AND

ASSEMBLY
Remove the plastic ties from the rubber gaiter and
pull the assembly apart.
Before re-assembly remove all traces of old sealant

from the joint faces.
Apply a bead of RTV joint compound (Loctite 5900)

to the sealing face.
Lubricate the ball seating with a light grease and

push the two halves of the assembly together. Se-
cure the rubber boot with two new plastic ties.
TRANSMISSION ASSEMBLY
All nylon patch bolts may be re-used 5 to 6 times pro-
vided a prevailing thread torque of 20 to 25 Nm (15
to 18 lbf·ft) is recorded.
All shafts and bearings should be lubricated with
transmission fluid prior to assembly.
To prevent possible contamination of hydraulic parts
lint or cotton rags should not be used.
Position the front case as shown and using a suit-

ably sized tube fit a new 4WD output shaft oil seal to
a depth of 6 mm (0.24 in) below the housing face. Fill
the seal lip with light grease. (Only fitted on 4WD
model)
If previously removed, replace the two plug and the

O-ring assemblies and tighten to a torque of 41 to 54
Nm (30 to 40 lbf·ft).
Refit the oil pump assembly and sealing ring. Tight-

en 4 bolts to a torque of 18 to 31 Nm (13 to 23 lbf·ft).
New copper washers must be fitted under the bolt
heads. Finally check for free rotation of pump rotor.
Invert the case and then refit the bearing cups if pre-
viously removed.
Using a suitable tool push the inner detent spring

and ball into the case and secure in place with a
dummy plug.
Dummy the plug in the place.
Replace the countershaft and reverse idler shaft as-

semblies.
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 to 25 Nm (13 to 18 lbf·ft). Hold the forks
and rail in place on the output shaft then refit the
complete assembly into the case. The shift rail
should displace the dummy plug as it enters the
bore.
NOTE: check that the inner detent spring and ball

have not become displaced and remove the loose
dummy plug from the case sump.
Push the interlock ball into the detent bore.
Refit the 1st/2nd shift rail and tighten the shift fork
screw to a torque of 13 to 18 Nm (9.6 to 13 lbf·ft).
Check that the interlock ball is correctly positioned in
between the two rails.
Replace the outer detent ball and the spring.

Tighten the plug to a torque of 41 to 54 Nm (30 to 40
lbf·ft).
Replace the 4WD shaft assembly.

(Only fitted on 4WD models.)
Lubricate the rear seal with a light grease.
Lubricate the input shaft front and rear seals with a

light grease and refit the shaft assembly into the
case.
Rear case with all shaft assemblies fitted.
Position the rear case as shown and using a suitably

sized tube fit a new output shaft oil seal to a depth of
6 mm below the housing face. Fill the seal lip with a
light grease.
Invert the case and replace the shim packs and

bearing cups. The 2 mm (0.08 in) thick spacer shim
should be fitted into the case first, then fit the remain-
ing shims followed by the bearing cup.
A light grease may be used to help hold the cups in
the case.
Refit the rear case, (without sealant at this stage),

and secure with at least 6 equally spaced bolts.
When fitting the rear case be careful to avoid dam-
aging the input shaft sealing rings.
Position a D.T.I. on the end of the input shaft as

shown, and using a suitable pry bar through the side
access hole, measure and note the shaft end float.
NOTE: all shaft assemblies should be rotated sever-

al times to seat the bearings prior to measuring the
end float.
Attach a suitable shimming tool 380002693, (with a

12 mm (0.47 in) thread), to the end of the reverse
idler shaft. Position a D.T.I. as shown, and using a
pry bar lift the shaft, then measure and note the end
float.

12 mm (0.47 in) thread), to the end of the counter-
shaft.
Position a D.T.I., and using a pry bar lift the shaft,
then measure and note the end float.

12 mm (0.47 in) thread), to the end of the output
shaft. Position a D.T.I., and using a pry bar lift the
shaft, then measure and note the end float.

12 mm (0.47 in) thread), to the end of the 4WD shaft.
Position a D.T.I., and using a pry bar lift the shaft,
then measure and note the end float.
Only fitted on 4WD model.
Remove the rear case and add or remove shims as

necessary to give 0.025 to 0.076 mm (0.001 to 0.003
inches) end float on all shafts
Repeat steps 17 to 22 until all shaft end floats are

correct.
Replace the 4 O-rings in the front case. (There are

only 3 fitted on the 2WD model.)
NOTE: the input shaft and 4WD shaft sealing rings

should now be fitted.
Refit the rear case using an approved liquid gasket

(Loctite 5203) taking care not to damage the input
shaft or 4WD shaft sealing rings. Tighten the 17
bolts to a torque of 45 to 64 Nm (33 to 47 lbf·ft).
Replace the shaft end plug and the O-ring assem-

blies. Note the special breather plug is fitted in the
reverse idler position. Tighten to a torque of 41 to 54
Nm (30 to 40 lbf·ft).
Fit a new expansion plug to the shimming access

hole using an approved sealant. (Loctite 649)
Replace the output yoke, the O-ring, the washer and

the bolt. Then tighten to a torque of 68 to 88 Nm (50
to 65 lbf·ft).
Replace the spacer, the 4WD yoke, the O-ring, the

washer and the bolt. Then tighten to a torque of 68
to 88 Nm (50 to 65 lbf·ft).
Refit the cold start ball, the spring and the housing.
Then tighten to a torque of 46 to 60 Nm (34 to 44
lbf·ft).
Lubricate the seals with transmission fluid then refit

the pressure regulator valve and tighten to a torque
of 46 to 60 (34 to 44 lbf·ft).
Lubricate the seals with transmission fluid then refit

the converter regulator valve and tighten to a torque
of 23 to 30 (17 to 22 lbf·ft).
Refit the temperature sender and tighten to a torque

of 20 to 27 Nm (15 to 20 lbf·ft).
Ensure the 4 O-rings are in place then refit the con-

trol valve assembly, tighten the 4 cap screws to a
torque of 6.8 to 8.5 Nm (5.0 to 6.3 lbf·ft). Refit the 4
plastic caps to the capscrew holes.
NOTE: the valve can only be fitted one way round as

it is located by a small dowel pin.
Refit the strainer, the spacer, the O-ring and the cov-
er plate. Then tighten the two screws to a torque of
18 to 31 Nm (13 to 23 lbf·ft).
Refit the drain plug and the O-ring assembly.

Tighten to a torque of 34 to 54 Nm (25 to 40 lbf·ft).
Refit the 4th gear lock out screw, (when this feature
is not required a shorter blanking screw is fitted.) On
some applications an additional sealing plug may be
fitted.
Apply a bead of RTV joint compound (Loctite 5900)

to the gear case as shown.
Refit the gear lever assembly and tighten the three

Refit the filter housing and gasket. Tighten the two

NOTE: do not use sealant on this gasket as it is

graphite coated.
Lubricate the seal with a light grease and screw on

a new oil filter. Tighten to a torque of 7 to 10 Nm (5
to 7 lbf·ft), or a half to three quarters of a turn after
initial seal contact.

4WD solenoid spool.
Tighten to a torque of 20 to 27 Nm (15 to 20 lbf·ft).
(Only fitted on 4WD model).
Refit the 4WD solenoid coil and nut. Tighten to a

torque of 5.4 Nm (4 lbf·ft) maximum. (Only fitted on
4WD model).
If previously removed refit the 4WD clutch supply

pipe, apply sealant (Loctite 542) to threads and tight-
en nuts to a torque of 6.8 to 10.2 Nm (5 to 7.5 lbf·ft).
(Only fitted on 4WD model).
TEST PORT
The transmission oil, should be at an approximate
temperature of 80 °C (176°F) during pressure tests.
All 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.
Oil pump pressure test port. Pressure should be

13.5 to 15.5 bar (196 to 225 psi) at maximum engine
speed. (Approximately 2500 rpm)
Reverse the clutch pressure test point.

Pressure should be 12.5 to 15.5 bar (181 to 225 psi)
at maximum engine speed. (Approximately 2500
rpm)
Forward the clutch pressure test point.

rpm)
4WD pressure test point.

rpm)
Converter relief pressure test point.

Pressure should not exceed 7.5 bar (109 psi) at
maximum engine speed. (Approximately 2500 rpm)
For Coaxial transmissions max pressure should be
10.5 bar (152 psi).
Lubrication pressure test point. Pressure should be

0.5 to 2.5 bar (7 to 36 psi) at maximum engine
speed. (Approximately 2500 rpm).
If a malfunction of the transmission is indicated a
systematic pressure checking procedure should be
followed. These checks should be carried out while
the transmission is still in the vehicle so that true op-
erating conditions are created. Pressure checks are
essential since a failure in the hydraulic system may
not be easily traceable when the transmission is
stripped down on a bench.
All pressure checks should be carried out with the
transmission gear lever in the neutral position, the oil
temperature at 80 to 85 °C (176 to 185°F). and the
engine speed maintained at 2000 to 2500 rpm. As a
safety precaution the vehicles parking brake should
be applied.
All pressure test ports have a 9/16 ins. UNF thread.
A pressure gauge is required that will measure up to
20 bar (290 psi).
For test port locations refer to illustrations at page
15.
PARKING BRAKE
The caliper assembly is mounted directly onto the
rear face of the transmission housing.
1. Mounting face
2. Locknut
3. Mounting bolt
4. Outer locknut
1 2 A
A. Adjust the two mounting bolts and locknuts to
leave a 0.25/1.50 mm (0.01/0.06 in) gap be-
tween the locknut and sleeve.
Then torque locknuts against mounting surface
to 155 Nm (110 lbf·ft).
B. Adjust this nut until pads are in contact with the
brake pads.
Then back off 4 to 5 flats.
Finally torque outer locknut to 60-70 Nm (45 - 55
lbf·ft).
B 4
F27714
Brake pad replacement

Remove the retaining spring clip.
Withdraw the friction pads.

1.12 FAULT FINDING
FAULT POSSIBLE CAUSES

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.
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.
No drive from 4WD 4WD solenoid valve or coil not operating.
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.
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.
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.
Low Pump Pressure Worn or broken pump.

Leaking pump sealing ring.
Blocked oil strainer or filter.
Blockage in oil ports between transmission sump and oil pump.
Pressure regulator valve stuck open.
Cold start valve stuck open.
High pump pressure Pressure regulator valve faulty.
Has normal operating oil temperature been reached?
Low forward or reverse clutch Faulty direction control valve.
pack pressure Piston seal or O-ring leaking.
Input shaft sealing ring leaking.
High forward/reverse clutch Pressure regulator valve faulty.
pack pressure
Converter pressure low Converter relief valve faulty.
Leak in converter, oil cooler or connecting hoses.
Very hot oil.
Converter pressure high Converter relief valve faulty.
Blockage or restriction in oil cooler.
Very cold oil.
Low 4WD clutch pack 4WD piston seals leaking.
pressure 4WD shaft sealing ring leaking.
Leak from 4WD clutch supply pipe.
Faulty 4WD solenoid.
Blockage or restriction in 4WD clutch supply pipe.
High 4WD clutch pack Pressure regulator valve faulty.
pressure
Low lubrication pressure Blockage or restriction in oil cooler.
Input shaft front sealing ring leaking.
Very hot oil.
FAULT DIAGNOSIS MECHANICAL SYSTEM
FAULT POSSIBLE CAUSES

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.
Gearshift stub lever worn or damaged.
Incorrect grade of oil in transmission.
Low oil level.
Jumping out of gear Detent springs worn or broken.
Synchronizer or gear dog teeth worn or damaged.
Synchronizer assemblies worn or damaged.
Shift forks worn, loose or twisted.
Restriction or wear in gear linkage or stub lever assy.
not allowing gears to be fully selected.
Excess end float on output shaft assembly or gears.
1.13 SPECIAL TOOLS
P/N CNH DESCRIPTION

380002683 Input and reverse idler shaft bearing removal collect
380002684 Piston seal sizing ring (hydraulic 4WD only)
380002685 4WD shaft front/rear and Coaxial input shaft front bearing removal collect
380002686 Output shaft front bearing removal collect
380002687 C/shaft and output shaft rear bearing removal collect
380002689 Input shaft spring compressor
380002690 4WD shaft spring compressor (hydraulic multiplate 4WD only)
380002691 C/shaft front bearing removal collect
380002692 Coaxial input shaft and hydraulic dog clutch 4WD shaft spring compressor
380002693 Shimming adapter
2. POWERSHIFT TRANSMISSION “DANA T16000”

This transmission is used only on powershift loader backhoes models B110B - B115B.
A B
1
F27718
HYDRAULIC SPECIFICATIONS
Suitable for operation from ambient to 120 °C (248°F) continuous operating temperature.
Must withstand 20 bar (290 psi) continuous pressure and with 40 bar (580 psi) intermittent surges.
Conform SAE J1019 and SAE J517, 100RI.
Weight ....................................................................................................................................... 290 kg (639 lbs)
BOLT TORQUES
Output flanges.....................................................................................................339 - 407 Nm (250 - 300 lbf·ft)
Filter torque ..............................................................................................................30 - 38 Nm (22.1 - 28 lbf·ft)
Control valve, connector nut to cover............................................................................6 - 8 Nm (4.4 - 5.9 lbf·ft)
ELECTRICAL SPECIFICATIONS
Solenoid (forward reverse, high/low, 2nd/1st, modulation, disconnect) coil resistance28 Ω ± 2 Ω at 20 °C (68 °F)
Electronic controlled modulation valve, coil resistance .......................3.55 Ohm (± 0.25 Ohm) at 20 °C (68 °F)
Speed sensor:
- type ................................................................................. magneto resistive sensor with 7/14 mA current loop
- frequency ......................................................................................................................................0 - 25000 Hz
- sensing distance ...........................................................................................................0 - 2.5 mm (0 - 0.01 in)
2.2 TRANSMISSION CONTROLS
4X2 POWERSHIFT TRANSMISSION CONTROL
1. TRANSMISSION POWERSHIFT GEARSHIFT 5. TRANSMISSION DISCONNECT BUTTON

AND DIRECTION LEVER: Four gears are 6. KICKDOWN SWITCH: If the machine is in 2nd
selectable for the required ground speed in gear and 1st is required for loader work
forward and 2 two gears for reverse travel. engaging kickdown instantly drops the gear from
2nd to 1st. When reverse is selected the
IMPORTANT: the gearshifts and direction of travel transmission reverts to 2nd gear.
are governed by the micro processor to maintain 7. ROLLER FOR THE PROPORTIONAL
smooth and safe changes, irrespective of gear se- CONTROL OF LOADER BUCKET 4X1
lected. Therefore Upshifting, downshifting or direc-
tion of travel through the gears will only occur when
the monitored machine speed is safe to do so.
2. DIFFERENTIAL LOCK SELECTION SWITCH:

Depressing the spring loaded switch will lock
both rear wheels together giving equal drive and
will disengage when wheel torque equalises or
the foot brakes are applied.
3. WARNING HORN BUTTON
4. LOADER ATTACHMENT CONTROL LEVER
POWERSHIFT 4x2 (EGS) transmission display - Forward travel selection

POWERSHIFT 4x2 (EGS) transmission display - Reverse travel selection

Powershift Lever Display - (LEDs)

LEDs - Numbered 1 through 4:
Indicate the direction of travel by the color of the LED
Forward = Green
Neutral = Red
Reverse = Orange
and also indicate the selected shift lever gear.
STEADY ILLUMINATED LED: indicates selected

transmission gear.
FLASHING LED: indicates the actual transmission
gear engaged (if different from that selected).
LEDs - Numbered 1 through 8: used during test

modes
1 2 3 4 5 6 7 8
LED - Number 8: illuminates green when the ma-

chine is at a standstill (in normal mode).
1 2 3 4 5 6 7 8
LED - Letter T = Self-diagnostic Mode: T

Used in self-diagnostic test mode and will illuminate
during self test.
NOTE: in the event of a fault, (the light will flash),

Contact your Authorized Dealer for assistance.
LED - Letter N Indicates Neutral: N

Illuminates when the transmission is shifted to neutral.
Powershift Lever and Microprocessor Functions

The microprocessor controls the transmission and
self checks its own memory continuously to ensure
that gear selection and range changes are always
performed in a safe manner.
Should a fault occur in the transmission or the micro-
processor, the microprocessor will default to the re-
set mode.
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.
IMPORTANT: if limp home is active, only 1st and

2nd gear will be selectable but without modulation.
Limp home active can be identified by the illumina-
tion of the following LEDs.
- Consult your Dealer.
T - LED N - LED CONDITION

Flashing ON Last fault currently shown on display
Flashing Flashes Slower Input error detected
Flashing Flashes in Phase Non critical output error detected
Flashing Flashes Faster Safety critical output error detected
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.
NOTE: when forward is selected you will not be giv-

en any indication of gear selected, only the maxi-
mum selected gear the transmission will shift too.
The microprocessor is programmed to be an auto-
matic speed based shift system
In addition whether forward actually engages at that
time, depends on the status of the machine, for ex-
ample if on the move, road speed and direction will
be considered before any shift changes take place.
Selecting Reverse
To select reverse travel pull the lever towards you
and the reverse LED will illuminate orange.
NOTE: when reverse is selected you will not be giv-

en any indication of gear selected, only the maxi-
mum selected gear the transmission will shift too.
The microprocessor is programmed to be an auto-
matic speed based shift system.
In addition whether reverse actually engages at that
time, depends on the status of the machine, that is if
on the move road speed and direction will be consid-
ered by the microprocessor.
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.
NOTE: an upshift request after a downshift is de-

layed for 2 seconds. Should an error occur with the
speed sensor the microprocessor will not allow up-
shifts above 2nd gear and will be indicated by the “T”
LED flashing and the “N” LED flashing slower.
NOTE: if climbing up a steep incline select 2nd and

proceed, if speed and power allow upshift into 3rd
and 4th.
Downshifting
S WARNING
If descending down a steep incline select 2nd and
proceed, upshifting only when safe to do so. You can
not downshift to reduce speed if the machine speed
is above 15 km/h (9 mph).
Downshifting to the desired gear is achieved by

twisting the handgrip clockwise (-) in single move-
ments, If held in this position the processor will de-
crease the shift from 4, if the shift lever was in this
gear, through to 1 in 1.5 sec intervals.
NOTE: if the gear requested and the shift attainable

are not the same because of torque converter tur-
bine rpm being too high, the gear position LED (e.g.
LED 4) will flash and the shift lever position will illu-
minate, not flashing, (e.g. LED 2), until the requested
gear is reached. When a gear position LED is flash-
ing this indicates that the machine has to reduce
speed to reach the requested gear.
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
When driving forward in 3rd or 4th gear two respons-

es are possible depending on machine speed.
RESPONSE 1: If the machine speed in forward is

above 15 km/h (9 mph) and reverse is selected
downshift engages but momentum forward remains,
until the speed lowers sufficiently to allow downshift
to take place when reverse is achieved in 2nd gear.
RESPONSE 2: If the machine speed in forward is

less than 15 km/h (9 mph) reverse takes place imme-
diately into 2nd gear.
Should a speed sensor fault be detected while in F3

or F4 a downshift sequence to 2nd gear will take
place and is indicated by the LED “T” flashing fast
and the LED “N” flashing slowly.
NOTE: if the transmission Is in forward 1st gear due

to kickdown the direction change will result in selec-
tion of reverse 2nd gear for efficient pull away. Refer
to Kick down for more information.
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.
Kickdown
The kickdown facility (2nd to 1st gear only) on this
transmission increases torque instantly to the driving
wheels and hence pushing power. For example
when the loader is pushing into a pile and more
torque is required at the wheels.
This is achieved by the instant gearshift from 2nd to
1st by the use of the button (1) without the need to
use the twist grip on the powershift lever.
NOTE: the kickdown facility is only available when

the transmission is in 2nd gear and the kickdown but-
ton (1) is depressed. If kickdown can not be achieved
(machine speed too high) the LED 1 will be illuminat-
ed and LED 2 will be flashing.
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.
NOTE: transmission disconnect is selectable, when

the machine speed is less than 5 km/h (3 mph) and
by depressing the button on the loader lever and re-
mains active until the pedals or switch are released.
Speed Ranges
The microprocessor controlling the powershift trans-
mission is pre-programmed to control the speed at
which the gearshifts take place.
This effectively protects the transmission from ex-
cess forces, should gearshifts be selected at higher
speeds than is desirable.
Shown in the chart opposite with an 18.4 X 26 R4 tire
fitted is the approximate (within 10%) maximum
speed available and at which speed an automatic
shift takes place in each gear.
(...) = Automatic upshift speed
[...] = Automatic downshift speed
As can be seen when downshifting from 4th gear at
maximum speed 39.5 km/h (24 mph) the micropro-
cessor will not allow the downshift to take place until
the speed has lowered to approximately 19.9 km/h
(12 mph). Refer to the chart for complete upshift and
downshift speed change details.
NOTE: in some countries the road speed of 40 km/h

(25 mph) is not allowed. In these circumstances the
transmission is governed to a maximum of 30 km/h
(19 mph) and the shift speed range reduces accord-
ingly.
2.3 LUBRICATION
Oil capacity.................... 14 liters (3.7 US Gallons)

Suggested oil ........... Ambra Mastertran NH 410 C
Daily
Check oil level daily with engine running at idle (600
rpm) and oil at 82 - 93 °C (180 - 200 °F).
Maintain oil level at full mark.
Normal drain period

Normal drain period and oil filter change are for av-
erage environment and duty cycle condition.
Severe or sustained high operating temperature or
very dusty atmospheric conditions will cause accel- 2 1
erated
F27717
deterioration and contamination.
For extreme conditions judgement must be used to 1. Drain plug
determine the required change intervals. 2. Oil level plug
Z Every 1000 hours change oil filter.
Z Every 1000 hours drain and refill system as follows:
drain with oil at 65 - 93°C (150 - 200 °F).
- Drain transmission.
- Oil filter, remove and discard, install new filter.
- Refill transmission (14 liters) (3.7 US Gallons).
- Run engine at idle (600 rpm) to prime converter
and lines.
- When oil temperature is at 82 - 93°C (180 - 200 °F)
adjust oil level to full mark.
NOTE: it is recommended that oil filter be changed

after 100 hours of operation on new, rebuilt or re-
paired unit.
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS
Normal operating temperature 70 - 120 °C (158 - Filter bypass valve set at 4.1 - 5 bar (*) (59 - 73 psi)
248 °F) measured at temperature check port to cool-
er. Lube pressure (*) 0.3 - 0.5 bar (4.3 - 7.3 psi) at 47 l/
min. (12.4 GPM) pump flow (±1800 rpm).
Maximum allowed transmission temperature 120 °C
(248 °F). Internal leakage (*) 1.5 - 3.0 l/min. (0.4 - 0.8 GPM)
for each clutch.
Transmission regulator pressure (*) - (neutral 2nd Max. total leakage 6.8 l/min (1.8 GPM) (clutch leak-
speed). age + range + converter leak + valve leak) without
Z at 600 rpm: 16.5 bar (239 psi). disconnect clutch.
Z at 2200 rpm: 19.6 - 23.1 bar (248 - 335 psi).
Safety valve: cracking pressure (*) 9,5 - 10,5 bar
Pump flow (*) (138 - 152 psi)
Z at 2200 rpm in neutral 2nd speed: 64.9 l/min. min-
imum (17.1 GPM). To cooler (converter out) pressure (*) 2 bar min. (29
Z at 2200 rpm in reverse 1st, 2nd, forward 1st, 2nd psi) at 2000 rpm and max. 5 bar (73 psi) at no load
maximum 3 l/min. (0.8 GPM) less than in neutral governed speed.
2nd.
Z at 2200 rpm in forward 3rd and 4th: maximum 5l/ Converter by-pass valve set at 5 - 7 bar (*) (73 - 102
min. (1.3 GPM) less than in neutral 2nd. psi).
Clutch pressures (*) at 2200 rpm: (*) All pressures and flows to be measured with oil
Z 18.1 - 21,5 bar (263 - 312 psi) clutch activated. temperature of 82 - 93 °C (180 -200 °F).
Z 0 - 0.2 bar (0 - 3 psi) clutch released.
A B
1
F27718
A. Front view 4. Pressure check port forward port forward low

B. Rear view clutch (forward 1st and forward 2nd)
5. To cooler 18.1-21.5 bar (265-312 psi)
1. Dipstick hole M27 x 2.5 6. Pressure check port reverse clutch (reverse 1st
2. Pressure check port forward hi clutch (forward and reverse 2nd) 18.1-21.5 bar (265-312 psi)
3rd and forward 4th) 18.1-21.5 bar (265-312 psi) 7. Pressure check port 1st clutch (forward 1st, for-
3. Pressure check port from cooler (lube pressure) ward 3rd, reverse 1st) 18.1-21.5 bar (265-312 psi)
8. From cooler
C D
13 14
11
10
12
F27719
C. Left side view 11. To cooler

D. Top view 12. Pressure check port 4WD 18.9-27.5 bar (270-
397 psi)
9. Pressure check port converter in 5-11 bar (73- 13. Pressure check port regulator pressure 19.6-
159 psi) 23.7 bar (290-340 psi)
10. Pressure check port 2nd clutch (forward 2nd - 14. Filter plug M22 x 1.5
forward 4th - reverse 2nd) 18.1-21.5 bar (265-
312 psi)
E F
15
16
17
F27720
E. Bottom view 16. Pressure check port converter out to cooler

F. Right side view 1.0625-12 UN2B SAE
17. Pressure before filter
15. Temperature check port converter out to cooler
M10 x 1
2.5 TRANSMISSION COOLER
F27721
1. To cooler from converter

2. Transmission cooler
3. From cooler to transmission lube distributor
COOLER LINES SPECIFICATIONS

Suitable for operation from ambient to 120 °C
(248 °F) continuous operating temperature.
Must withstand 20 bar (290 psi) continuous pressure
and with 40 bar (580 psi) intermittent surges.
Confirm SAE J1019 and SAE J517, 100RI
2.6 TRANSMISSION HYDRAULIC DIAGRAM
1
5
2 3
4
34 32 AA 33
bar bar °C bar
7
71
°C
6
9
8
23 24 25 26 27 28
10 17
31
bar
20
11 12
35 18
bar
19 46
bar
45
bar
44
bar
42
bar
41
bar
47
bar
13
14 21 29 30 31 32 33 34
15
22
16
F27722
X
bar
Pressure check port
X
°C
Temperature check port
1. Operator compartment 19. Pressure booster 0 - 5.5 to 0 - 20 bar (0 - 80 to 0 -

2. Pressure gauge 290 psi)
3. Temperature gauge 20. Electronic controlled modulation valve 5.5 to 0 bar (80
4. Torque converter to 0 psi)
5. Torque converter (pressure difference 4 bar (58 psi)) 21. Modulated pressure 0 to 20 bar (0 to 290 psi)
by-pass valve 22. Clutch pressure 20 bar (290 psi)
6. Cooler 23. Solenoid N/forward
7. Lubrication 24. Solenoid N/reverse
8. Safety valve 10 bar (145 psi) cracking pressure 25. Solenoid high/low
9. Solenoid pressure 5 bar (73 psi) 26. Solenoid 2nd/1st
10. Pressure regulator valve 20 bar (290 psi) 27. Solenoid range modulation
11. By-pass valve pressure difference 4.3 bar (62 psi) 28. Solenoid disconnect
12. Filter 29. Reverse clutch
13. Pump 30. F low clutch
14. Air breather 31. F high clutch
15. Screen 32. 2nd clutch
16. Oil sump 33. 1st clutch
17. Pressure reducer to 5.5 bar (80 psi) 34. Disconnect clutch
18. Accumulator
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 screen and directs
it through the oil filter and pressure regulating valve.
Across the oil filter is a filter by-pass valve which will open if the pressure difference becomes higher than 4.3
bar (62 psi).
The pressure regulating valve maintains pressure for the control valve and clutches at 20 bar (290 psi).
Excess oil volume is bled off into the converter system. A safety valve is fitted between the pressure regulator
and converter.
The valve will open if pressure in this line becomes higher than 10 bar (145 psi).
After entering the converter the oil is directed through the converter blade cavity and exits in the passage be-
tween the turbine shaft and pump drive shaft and flows to the cooler.
After leaving the cooler the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates and cools the transmission bearings and clutches.
The oil then gravity drains back to the transmission sump.
Across the converter and oil cooler is a converter by-pass valve which will open if the pressure difference is
higher than 4 bar (58 psi) (during start up from cold or at high rpm).
Basically the transmission is composed of five main assemblies:
F27723
The converter and pump drive section.

The input or directional clutches.
The range clutches.
The output section.
THE CONVERTER AND PUMP DRIVE SECTION

Engine power is transmitted from the engine fly-
wheel to the impeller through the impeller cover.
This element is the pump portion of the hydraulic
torque converter and is the primary component
which starts the oil flowing to the other components
which results in torque multiplication. This element
can be compared to a centrifugal pump in that it
picks up fluid at its center discharges at its outer di-
ameter.
The torque converter turbine is mounted and dis-
charge opposite the impeller and is connected to the
turbine shaft or directional clutch shaft.
This element receives fluid at its outer diameter and
discharges at its center.
The stator of the torque converter is located be-
tween and at the center 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. F27724
This recirculation causes the converter to multiply The converter and pump drive section
torque.
The converter will multiply engine torque to its de-
signed maximum multiplication ratio when the tur-
bine shaft is at zero rpm (stall).
Therefore we can say that as the turbine shaft is de-
creasing in speed, the torque multiplication is in-
creasing.
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 center of the im-
peller cover, the pump speed will be the same as en-
gine speed.
The rear side of the impeller cover has a tanged drive
which drives the transmission charging pump locat-
ed in the converter housing. The transmission charg-
ing pump speed is also the same as the engine
speed.
THE INPUT OR DIRECTIONAL CLUTCHES

The turbine shaft driven from the turbine transmits
power to the forward or reverse clutches.
These clutches consists of a drum with splines and
a bore to receive a hydraulic actuated piston.
The piston is oil tight by the use of sealing rings.
A steel disc with external splines is inserted into the
drum and rests against the piston.
Next, a friction disc with splines at the inner diameter
is inserted.
Discs are alternated until the required total is
achieved.
A back up plate is then inserted and secured with a
span ring.
A hub with outer diameter splines is inserted into the
splines of discs with teeth on the inner diameter.
The discs and hub are free to increase in speed or
rotate in the opposite direction as long as no pres-
sure is present in that specific clutch.
To engage the clutch, the control valve which is fitted
on the side of the transmission will direct oil under F27725
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.
THE RANGE CLUTCHES

Once a directional clutch is engaged power is trans-
mitted to the range clutches (1st or 2nd).
Operation and actuation of the range clutches is
similar as the directional clutches.
The engagement of the range clutches is also mod-
ulated to enable a smooth engagement.
The modulation for these clutches is achieved by
means of a restrictor valve fitted in the control valve
which is controlled electronically and which limits oil
flow to the clutch during shifts.
In the clutch itself the plate before the end plates is
dished to build up the clamping force of the clutch
gradually.
F27726
The range clutches
THE OUTPUT SECTION

With a range clutch engaged power is finally trans-
mitted to the output shafts.
The transmission can have an upper output or lower
output at the rear side of the unit, and a lower output
at the front side. Output rotation of the rear upper
output is opposite the engine rotation when the for-
ward clutch is engaged, while output rotation of the
lower rear output and the front output is the same as
the engine rotation with the forward clutch engaged.
Ratio between upper and lower output is 0.951:1.
The lower front output has an axle disconnect clutch
to enable 4WD.
The clutch is similar as the other clutches except that
it has no modulation.
The disconnect is controlled electronically. Without
an electrical signal the clutch is always engaged.
F27727
The output section

THE TRANSMISSION CONTROLS (REFER TO

HYDRAULIC DIAGRAM)
The transmission is controlled by an electronic gear
selector (EGS). This unit has a microprocessor
which receives certain inputs (gear selector position,
speed sensor...) which are processed and will give
output signals to the control valve.
The control valve has 6 solenoid, 6 shift spools, a
pressure reducer, an electronic controlled modula-
tion valve, an accumulator, a pressure booster and
a speed sensor.
Operation of the valve is as follows:
Regulated pressure 20 bar (290 psi) is directed to
the shift spools, pressure booster and pressure re-
ducer.
In the pressure reducer, regulated pressure is re-
duced to 5,5 bar (80 psi). This reduced pressure is
used as supply for the solenoid and electronic con-
trolled modulation valve.
When activated, the electronic controlled modulation
valve will give an output pressure curve from 0 to 5 F27728
bar (0 to 80 psi).
The transmission controls
This pressure curve is multiplied in the booster so
that a curve from 0 to 20 bar (0 to 290 psi) is avail-
able for the directional 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.
The pilot pressure will move the modulation shift
spool so that oil supply is fed through a restrictor
which is in by-pass of the valve.
The controlled volume of oil is used to push in the
dished outer plate gradually until the clutch is fully
closed.
This will give a smooth build up of torque. At that mo-
ment the range modulation solenoid is released, so
that the modulation shift spool return to its rest posi-
tion and allowing full oil flow to the clutch.
The control valve also controls the front lower output
disconnect clutch. If the solenoid is not activated full
oil pressure is fed through the disconnect shift spool
to the disconnect clutch.
If the solenoid is activated, pilot pressure will move
the disconnect shift spool to block oil supply to the
disconnect clutch to release it.
The control valve also has a speed sensor. This sen-
sor will pick up upper output gear speed.
This information is used in the electronic gear selec-
tor to determine shift logic.
Since the sensor picks up upper output gear speed,
the signal will be in direct relation of the turbine
speed if any directional clutch is engaged.
Transmission gear Activated solenoids Activated clutches

Forward 4 Forward Forward high, 2nd
Forward 3 Forward, 2nd/1st Forward high, 1st
Forward 2 Forward, Forward high/low Forward low, 2nd
Forward 1 Forward, Forward high/low, 2nd/1st Forward low, 1st
Reverse 1 Reverse, 2nd/1st Reverse, 1st

Reverse 2 Reverse Reverse, 2nd
Disconnect off Disconnect ---------------

Disconnect on --------------- Disconnect
2.8 POWER FLOWS
F27729 F27730
1st speed forward 2nd speed forward
F27731 F27132
3rd speed forward 4th speed forward

F27733 F27734
1st speed reverse 2nd speed reverse

OPERATING VALVES AND SOLENOIDS
F29986
1. Transmission sump 12. High / low solenoid

2. Transmission breather 13. Neutral reverse solenoid
3. Suction strainer 14. 1st gear clutch
4. Gerotor oil pump 15. Accumulator
5. Pressure oil filter 16. Electronic modulation valve 0-5.5 bar (0-80 psi)
6. Filter by-pass valve 4.3 bar (62.4 psi) 17. Pressure reducing valve 5.5 bar (80 psi)
7. System pressure regulating valve 20 bar (290 18. 2nd / 1st shift spool
psi) 19. Range modulation spool
Oil to converter system 20. Range modulation restriction
8. Neutral reverse shift spool 21. Four wheel drive shift spool
9. Pressure booster 0-20 bar (0-292 psi) 22. Four wheel drive solenoid
10. Neutral forward solenoid 23. Range modulation solenoid
11. High / low shift spool 24. 2nd / 1st Solenoid
TORQUE CONVERTER AND COOLER SYSTEM
F29987
Suction oil High Pressure Oil

Return to oil tank Torque Converter and Lubrication Oil
1. Transmission sump 11. Converter system pressure test port 5 bar (73
2. Transmission breather psi)
3. Suction strainer 12. Torque converter
4. Gerotor oil pump 13. Converter oil temperature port
5. Pressure oil filter 14. Oil cooler pressure test port
6. Filter by-pass valve 4.3 bar (62.4 psi) 15. Converter pressure by-pass valve 4 bar (58 psi)
7. System pressure test port 20 bar (290 psi) 16. Oil cooler
8. Oil flow to control valve 17. Oil temperature port after cooler
9. System pressure regulating valve 20 bar (290 18. Lubrication pressure port.
psi) 19. Lubrication galleries.
10. Converter system safety valve 10 bar (145 psi)
SERVO PILOT PRESSURE SYSTEM
F29988
Suction Oil Return to oil tank

High Pressure Oil Pilot Pressure
Torque Converter and Lubrication Oil Modulated Pilot Oil
1. Transmission sump 12. 2nd / 1st Solenoid
2. Transmission breather 13. Range modulation solenoid
3. Suction strainer 14. Four wheel drive solenoid
4. Gerotor oil pump 15. High / Low solenoid
5. Pressure filter 16. Neutral reverse solenoid
6. Filter by-pass valve 4.3 bar (62.4 psi) 17. Neutral forward solenoid
7. System pressure test port 20 bar (290 psi) 18. Electronic modulation valve 0-5.5 bar (0-80 psi)
8. System pressure regulating valve 20 bar 19. Accumulator
(290 psi) 20. Pressure booster 0-20 bar (0-290 psi)
9. Oil flow to converter 21. Modulated pressure to shift spools 0-20 bar (0-
10. Oil flow to shift spools 290 psi)
11. Pressure reducing valve 5.5 bar (80 psi)
SERVO CONTROL FORWARD SECOND GEAR 4WD ENGAGED

System pressure is reduced to 5.5 bar (80 psi) by the pressure reducer this oil then supplies the 6 solenoids
and electronic modulation valve.
When the powershift lever is moved forward and twisted anti clockwise an electrical signal is sent to:
Z The high low solenoid which energizes allowing pilot oil to flow to the shift spool.
Z The neutral forward solenoid which energizes allowing pilot oil to flow to the shift spool.
Z The powershift lever will then reduce the current to the modulation valve which gives an output pressure curve
from 0 to 5.5 bar (0 to 80 psi) to the pressure booster valve.
Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0-20 bar (0-292
psi) is available for the directional clutches.
Between the modulation valve and the booster is accumulator to dampen any hydraulic vibration.
F29989

1. Transmission sump 11. Pressure reducing valve 5.5 bar (80 psi)
2. Transmission breather 12. 2nd / 1st Solenoid
3. Suction strainer 13. Range modulation solenoid
4. Gerotor oil pump 14. Four wheel drive solenoid
5. Pressure filter 20 bar (290 psi) 15. High / Low solenoid
6. Filter by-pass valve 4.3 bar (62.4 psi) 16. Neutral reverse solenoid
7. System pressure test port20 bar (290 psi) 17. Neutral forward solenoid
8. System pressure regulating valve 20 bar (290 18. Electronic modulation valve 0-5.5 bar (0-80 psi)
psi) 19. Accumulator
9. Oil flow to converter 20. Pressure booster 0-20 bar (0-290 psi)
10. Oil flow to shift spools 0-20 bar (0-290 psi) 21. Modulated pressure to shift spools
SERVO CONTROL FORWARD THIRD GEAR 4WD ENGAGED

Z When the powershift lever is moved forward and twisted anti clockwise an electrical signal is sent to:
Z The range modulation solenoid sending pilot pressure to the spool.
Z The 1st 2nd solenoid sending pilot pressure to the spool.
Z Once the 3rd gear has been engaged the range modulation solenoid will be de-energized
Z The high/low solenoid prevents pilot oil to flow to the shift spool.
Z The neutral forward solenoid allowing pilot oil to flow to the shift spool.
Z The powershift electronics will then reduce the current to the modulation valve which gives an output pressure
curve from 0-5.5 bar (0 to 80 psi) to the pressure booster valve.
psi) is available for the directional clutch.
Z The four wheel drive solenoid supplies pilot oil to the shift spool.
F29990

1. Transmission sump 12. 2nd / 1st Solenoid
4. Gerotor oil pump 15. High / Low solenoid
5. Pressure filter 16. Neutral reverse solenoid
8. System pressure regulating valve 20 bar (290 psi) 19. Accumulator
10. Oil flow to shift spools 21. Modulated pressure to shift spools 0-20 bar (0-
11. Pressure reducing valve 5.5 bar (80 psi) 290 psi)
SERVO CONTROL REVERSE FIRST GEAR 4WD ENGAGED

When the powershift lever is moved rearward and twisted clock wise a electrical signal is sent to:
Z The range modulation solenoid sending pilot pressure to the spool.
Z The 1st 2nd solenoid sending pilot pressure to the spool.
Z Once the 1st gear has been engaged the range modulation solenoid will be de-energized
Z The low/high solenoid sends pilot oil to the shift spool.
Z The neutral reverse solenoid allowing pilot oil to flow to the shift spool.
Z The powershift lever microprocessor will then reduce the current to the modulation valve which gives an out-
put pressure curve from 0-5.5 bar (0-80 psi) to the pressure booster valve.
psi) is available for the directional clutches.
F29991
Suction Oil Return to Reservoir

1. Transmission sump 12. 2nd / 1st oil tank
4. Pressure filter 15. High / Low solenoid
5. Gerotor oil pump 16. Neutral reverse solenoid
8. System pressure regulating valve 20 bar (290 psi) 19. Accumulator
10. Oil flow to shift spools 21. Modulated pressure to shift spools 0-20 bar (0-
11. Pressure reducing valve 5.5 bar (80 psi) 290 psi).
CONTROL VALVE OPERATION FORWARD, SECOND GEAR WITH 4WD ENGAGED

Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar (80 psi). 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:
Z Oil flows from the system pressure regulating valve at 20 bar (290psi) through the four wheel drive spool to
engage the 4WD clutch.
Z System pressure also flows through the range modulation valve, then through the 1st 2nd spool to engage
the 2nd gear clutch.
Z 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.
Z 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.
Z 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.
Z 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 (290 psi).
1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar (62.4 psi)
7. System pressure test port
8. System pressure regulating valve 20 bar (290 psi)
9. Oil to converter system
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 (0-80 psi)
31. Accumulator
32. Pressure booster 0-20 bar (0-290 psi)
F29992

CONTROL VALVE OPERATION FORWARD, THIRD GEAR WITH 4WD DISENGAGED

Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar (80 psi). 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:
Z The 4WD solenoid, sending pilot pressure to the shift spool.
This will move the spool preventing oil flowing to the clutch disengaging 4WD.
Z The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
Z The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Z Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
Z 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.
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 (290 psi).
3. Suction strainer
4. Gerotor oil pump
13. 2nd gear clutch
14. 1st gear clutch
27. Reverse clutch
30. Electronic modulation valve 0-5.5 bar (0-80 psi)
31. Accumulator
F29993

CONTROL VALVE OPERATION REVERSE, FIRST GEAR WITH 4WD ENGAGED

Pressure oil from the system regulating valve flows to the pressure reducing valve. The pressure lowers to 5.5
bar (80 psi). 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:
Z The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
Z The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Z Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
Z 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.
ing on the boost valve and it multiplies pilot pressure.
Z 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 (290 psi).
3. Suction strainer
4. Gerotor oil pump
13. 2nd gear clutch
14. 1st gear clutch
27. Reverse clutch
30. Electronic modulation valve 0-5.5 bar (0-80 psi).
31. Accumulator
F29994

PRESSURE TESTING TORQUE CONVERTER AND COOLER SYSTEM.

All pressure and flow testing should be measured with an oil temperature of 82-93 degrees Celsius (180-200
°F). For operating speed refer to each test.
Port 1 System pressure.

Z Engine set to 750 revs/min minimum pressure15bar (218 psi).
Z Engine set to 2200 revs/min 19.6-23.1 bar (284-335 psi).
Port 2 Torque converter in.

Z Engine set to 2200 revs/min oil pressure range 5-11 bar (73-160 psi).
Port 3 Torque converter out.

Z Engine speed 2000 revs/min minimum pressure 2 bar (29 psi).
Z Engine speed 2200 revs/min maximum pressure 5 bar (73 psi).
Port 4 Oil temperature converter out.

Z Normal operating temperature 80-90 °C (176-194°F). Maximum temperature 120 °C (284 °F).
Port 5 Oil temperature cooler out.

Z T.B.A
Port 6 Lubrication pressure

Z Engine speed 2000 revs/min pressure range 0.8-2.0 bar (11.6-29 psi).
HYDRAULIC OIL FLOWS

Oil flows to the pressure regulating valve, maintaining system pressure to the control valve and clutches at 20
bar (292 psi).
Excess oil flow is bleed off to the converter system which is protected by a 10 bar (145 psi) safety valve.
Oil enters the converter through the converter blade cavity and exits in the passage between the turbine shaft
and pump drive.
Oil then flow to the external cooler.
Across the converter and oil cooler system a by-pass valve is fitted if the pressure difference is more than 4
bar (58 psi) the valve will open. Directing excess oil to the lubrication system.
This protects the system during start up from cold oil or at high revs/min.
After leaving the cooler the oil is directed via a single fitting on the rear of the transmission to a series of tubes
and passages, to lubricate and cool the transmission bearings and clutches.
Oil is drawn up from the sump, via an internal strainer, through the inlet port of the hydraulic pump.
Oil is pumped out to the pressure filter.
Across the oil filter is a filter by-pass valve which will open if the
pressure difference becomes higher than 4.3 bar (62.5 psi).
Oil then drains back by gravity to the transmission sump.
2.9 GEAR AND CLUTCH LAY OUT
t
Ou
In
t
Ou
F27735
Forward low
Forward high
Reverse and 1st
2nd
Disconnect
Input shaft
2.10 TRANSMISSION / ENGINE REMOVAL FROM LOADER
REMOVAL
S 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. Lower the backhoe to the ground, switch off engine and release any pressure in the system.
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. Pull main hydraulic cooler over radiator tabs.
8. Remove all attaching bolts from radiator.
9. Disconnect transmission cooler pipes.
10. Remove radiator, taking care not to damage the fan or hydraulic oil cooler.
11. Remove air filter assembly.
12. Disconnect all electrical connections.
13. Disconnect hydraulic pipe clamps.
14. Disconnect the fuel tank feed and return pipes.
15. Disconnect the foot accelerator cable at the fuel injection pump.
16. Remove the cab mat.
17. Remove the cab floor access panel.
18. Disconnect the 12 pin connector from the trans-

mission valve chest mounted to the left hand
side of the of the transmission.
19. Disconnect the transmission to lock out valve
pipe.
20. Disconnect lock out return pipe and plug the hole
(oil will leak out of transmission).
F27736
21. Remove front drive shaft (where fitted) and re-

move rear drive shaft.
22. Disconnect the hand brake cable.
23. Disconnect and pull back hydraulic pump (leav-
ing all pipes attached). Check that the oil pump
drive shaft does not slide out with the pump.
24. Check return from steering motor is on the out-
side of transmission oil level tube.
F27737
25. With the engine supported and using a “hoist”

capable of supporting a total weight of 800 kg
(1764 lbs) loosen and remove the engine and
transmission mounting bolts.
IMPORTANT: if the hydraulic oil pump is removed

from the transmission / engine assembly the bal-
ance of the assembly when hoisted will be front end
heavy.
26. Using lifting tool for engine-trasmission assy (1)

380300030 very carefully raise and guide the
engine/transmission assembly from the vehicle.
SEPARATING ENGINE FROM TRANSMISSION

WITH ASSEMBLY REMOVED FROM THE
VEHICLE
1. Place the engine/transmission assembly on a
suitable splitting stand.
2. Remove the starter motor assembly.
F27739
3. Remove the torque converter attaching bolts ac-

cessed through the starter motor aperture (1). 1
4. Remove the engine timing tab (2).
5. Remove the bell housing bolts.
6. Gently slide the transmission with the torque
converter from the engine.
2
F27740
INSTALLATION
Place a stud in one tang of the flexi plate and as the
transmission is assembled up to the engine guide
the stud through a bolt hole of the flywheel, remove
the stud and refit a bolt.
Refit the attaching bolts which couple the transmis-
sion to engine.
Turn the engine crankshaft using a torque bar to ex-
pose in turn each attaching bolt hole of the flywheel
through the flexi plate and refit all of the bolts.
Hoist the engine / transmission assembly back into
the vehicle and centralize in the machine using a
measure between the chassis and center 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.
TRANSMISSION TO ENGINE INSTALLATION

PROCEDURE
Remove all burrs from flywheel (1) mounting face
and nose pilot bore (3). Clean drive plate surface
1
with solvent.
A
Check engine flywheel (4) and housing (1).
Measure and record engine crankshaft end play.
Install two (2.50 inch) 63.500 mm long transmission
to flywheel housing guide studs in the engine fly-
wheel housing as shown. Rotate the engine flywheel
to align a drive plate mounting screw hole with the 3
flywheel housing access hole (3).
Install a (4.00 inch) 101.60 mm long drive plate lo- 4

cating stud fine thread in a drive plate nut. Align the
locating stud in the drive plate with the flywheel drive
plate (5) mounting screw hole.
(Does not apply to units having 3 intermediate drive
plates).
Rotate the transmission torque converter to align the

locating stud in the drive plate with the flywheel drive
plate mounting screw hole (3). Locate transmission
on flywheel housing (1).
Aligning drive plate to flywheel and transmission to 2

flywheel housing guide studs, install transmission to
flywheel housing screws. Tighten screws to speci-
fied torque. Remove transmission to engine guide 5
studs. Install remaining screws and tighten to speci- F27742
fied torque.
Remove drive plate locating stud.
Install drive plate attaching screw and washer. 6

Snug screw but do not tighten. Some engine fly-
wheel housings have a hole located on the flywheel
housing circumference in line with the drive plate
screw access hole. A screwdriver or pry bar used to
hold the drive plate against the flywheel will facilitate
installation of the drive plate screws. Rotate the en- 7
gine flywheel and install the remaining seven fly-
wheel to drive plate attaching screws. Snug screws
8
but do not tighten.
After all eight screws are installed torque one torque
35 - 39 Nm (26 to 29 lbf·ft). This will require tighten-
ing each screw and rotating the engine flywheel until
the full amount of eight screws have been tightened
to specified torque. F27743
Measure engine crankshaft end play after transmis-

sion has been completely installed on engine fly-
wheel.
This value must be within 0.025 mm (0.001 in) of the
end.
6. Special stud, washer and self locknut furnished
by engine manufactured
7. Impeller cover
8. Intermediate drive plate
2.11 TRANSMISSION COMPONENTS
CONVERTER HOUSING AND TRANSMISSION

ITEM DESCRIPTION QUANTITY

1 Plug 11
2 O-ring plug 11
3 O-ring plug 3
4 Plug 3
5 Ball 1
6 Spring 1
7 Plug 1
8 O-ring plug 1
9 Spring safety valve 1
10 Ball 1
11 O-ring plug 1
12 Plug 1
13 O-ring converter housing to transmission case 2
14 O-ring converter housing to transmission case 2
15 Gasket converter housing to transmission case 1
16 Housing converter 1
17 Lock washer - converter housing to transmission case screw 14
18 Screw - converter housing to transmission case 14
19 O-ring filter adaptor 1
20 O-ring filter adaptor 1
21 Filter - adaptor 1
22 Lock washer - filter adaptor screw 3
23 Screw - filter adaptor 3
24 Assembly - filter 1
25 Oil seal - output shaft front 1
30 Clip - suction tube 1
31 Lock washer - suction tube screw 1
32 Screw - suction tube 1
33 O-ring suction tube 1
34 Retainer - suction tube 1
35 Assembly - tube and screen 1
36 Baffle - oil 1
37 Lock washer - oil baffle mounting screw 3
38 Screw - oil baffle mounting 3
39 Nut - oil baffle mounting screw 5
40 Lock washer - oil baffle mounting screw 5

41 Baffle - oil 1
42 Screw - oil baffle mounting 5
43 Plate - oil baffle 1
44 Plate - oil baffle 1
45 Pin - transmission case to converter dowel 2
48 Case - transmission 1
49 O-ring plug 1
50 Plug 1
51 Plug 11
52 O-ring plug 11
53 Seal upper output 1
56 Plug - magnetic drain 1
57 Snap ring - output shaft rear bearing 1
58 Plug - output shaft bore 1
59 Sealing ring - plug 1
60 Plug 1
61 Plug 1
62 Plug 1
INPUT SHAFT, TORQUE CONVERTER, PUMP DRIVE, INTERNALSHARGING PUMP AND DRIVE PLATE

1 Screw - drive plate mounting 6
2 Lock washer - drive plate mounting screw 6
3 Ring - drive plate 1

4 Plate - drive 2
5 Assembly - drive plate 1
6 Bushing - converter pilot 1
7 Assembly - torque converter 1
8 Oil seal - charging pump 1
9 Screw - pump mounting 6
10 Seal washer - pump mounting screw 6
11 Assembly - charging pump 1
12 O-ring charging pump 1
13 Ring - piston 1
14 Bearing - input shaft front 1
15 Snap ring 1
16 Snap ring 8
17 Gear - forward low and reverse drive 9
18 Snap ring 1
19 Shaft - input 1
20 Snap ring 1
21 Gear - forward high drive 1
22 Bearing - input shaft rear 1
23 Ring - piston 1
24 Assembly - pump drive shaft and sleeve 1
25 Ring - piston 1
26 Bearing - pump drive shaft 1
27 Snap ring 1
28 Retaining ring 1
29 Gasket - permanent pump adapter cover 1
30 Cover - permanent pump adapter 1
31 Lock washer - permanent pump adapter cover screw 4
32 Screw - permanent pump adapter cover 4
FOWARD LOW AND FOWARD HIGH SHAFT
18
17
5
4
2 3
1
16
15
14
13
12
11
10
9
8
7
6 32
31
30
29
28
27
26
25
50
24
49
23 48
22 47
46
21
20 45
19
44
43
42
41
40
39
38
37
36
34 35
33
F27746

1 Bearing - front FWD low/FWD high shaft 1
2 Gear - forward driven 1
3 Snap ring 1

4 Bearing - clutch gear 1
5 Retaining ring - clutch gear bearing 1
6 Gear forward low clutch 1
7 Ring - clutch gear piston 1
10 Snap ring 1
11 Snap ring 1
12 Washer 1
13 Snap ring - backing plate 1
14 Plate - clutch disc backing 1
15 Disc - outer half 1
16 Disc - outer 8
17 Disc - inner 9
19 Ring - retaining 1
20 Retainer spring 1
21 Spring - piston return 1
22 Plate spring - clutch piston wear 1
23 Assembly - clutch piston and seals 1
24 Seal - clutch piston - outer 1
25 Seal - clutch piston - inner 1
26 Assembly forward low/forward high, shaft drum and plug 1
29 Assembly clutch piston and seals 1
30 Plate spring clutch piston wear 1
31 Spring piston return 1
33 Spacer clutch spring fwd high 1
36 Disc - inner 4
37 Disc - outer 3
40 Spacer - clutch disc backing plate Fwd/high 1
41 Snap ring spacer 1
42 Thrust washer 1
43 Thrust bearing 1

44 Bearing - needle 1
45 Gear - forward high clutch 1
46 Bearing - needle 1
47 Thrust bearing 1
48 Thrust washer 1
49 Bearing - rear Fwd low/Fwd high shaft 1
50 Ring - piston 3
REVERSE / 1ST SHAFT AND GEARS
9
8
7
6
5
4
2 3
18
1 16 17
15
14 32
13
12
11
31
10
30
29
27 28
26
47
25
46
24 45
23 44
22 43
21
42
20
19
41
40
39
37 38
36
34 35
33
F27747

1 Bearing - front reverse: 1st shaft 1
2 Gear - reverse driven 1
3 Snap ring 1
6 Gear forward low clutch 1
7 Ring - clutch gear piston 1
10 Snap ring 1
11 Snap ring 1
12 Washer 1
13 Snap ring - backing plate 1
16 Disc - outer 8
17 Disc - inner 9
26 Assembly reverse / 1st, shaft drum and plug 1
29 Assembly clutch piston and seals 1
30 Plate clutch piston wear 1
31 Assembly - spring disc 1
34 Disc - inner 9
35 Disc - outer 8
37 Modulation spring 1
39 Snap ring - clutch disc backing plate 1
40 Bearing clutch gear 1

42 Gear - 1st clutch 1
45 Snap ring 1
46 Bearing - rear reverse / 1st shaft 1
47 Ring - piston 3
2ND SHAFT
7
6
5
4
3
2
15
14
1 13
12
11
10
9
8
23
22
21
20
31
19
30
18 29
17
28
16
27
26
25
24
F27748

1 Ring - piston 2
2 Bearing - front 2nd shaft 1
3 Washer - bearing support 1
5 Retaining - ring clutch gear bearing 1
6 Gear - 2nd clutch 1
11 Modulation spring 1
13 Disc - outer 8
14 Disc - inner 9
16 Ring retaining 1
18 Spring clutch - piston return 1
23 Assembly - 2nd shaft, drum and plug 1
24 Snap ring - gear retainer 1
25 Gear - lower output drive 1
26 Gear - upper output 1
27 Bearing rear - 2nd shaft 1
28 Flange yoke 1410 - upper output 1
29 O-ring - flange 1
30 Washer - flange nut 1
31 Nut - flange 1
OUTPUT SHAFT WITH INTERNAL DISCONNECT
13
12
11
10
8
7
5
4
22
3 21
2
1 20
19
18
17
16
15
32
31
30
29
28
14
27
26
25
24
23
F27749

1 Nut - flange 1
2 Washer - flange nut 1
3 O-ring - flange 1

4 Output flange front yoke 1410 with brake pads 1
5 Bearing - output shaft front 1
7 Disconnect hub 1
9 Assembly - output shaft front 1
10 Bushing 2
12 Spacer 1
13 Plate clutch disc backing 1
15 Disc - outer 11
16 Disc - inner 12
25 Assembly - output shaft rear, drum and plug 1
27 Gear lower output 1
28 Snap ring gear retainer 1
29 Snap ring - rear bearing 1
30 Bearing - output shaft rear 1
31 Snap ring - rear bearing 1
32 Ring - piston 3
PARKING BRAKE
19
20
3
19
2 18
1
17
21
15
16
14
12 13
11
10
9
8
7
6
5
4
F27750

1 Screw - brake mounting 2
2 Assembly - caliper 1
3 Nut - brake mounting screw 2
4 Nut - jam adjustment 1
5 Nut - adjustment 1
6 Washer - hardened 1
7 Washer - stainless steel 1
8 Washer - thrust 1
9 Lever 1
10 Boot 1
11 Cam 1
12 Id seal 1
13 Ball bearing 3
14 Plastic retainer 1
15 Cam 1
16 Torque plate - front 1
17 Carrier and lining assembly 2
18 Torque plate - rear 1

19 Sleeve mounting 2
20 Bolt - Adjusting 1
21 Spring 1
ELECTRICAL CONTROL VALVE
6 3
5 F27751

1 Control valve assembly 1
2 Control valve mounting screws 17
3 Control valve protection cover gasket 1
4 Control valve protection cover 1
5 Protection cover screw 20
6 Air breather 1
ASSEMBLY INSTRUCTIONS
1 10 6 7
3
14 6
15
2
4
5
10
2
13
15
2
10
10 3
16 11
12
3
15
11
3
8
F27752
1. Add some grease to O-ring before assembly.

2. Add some grease to piston rings before assembly slots of piston rings are not allowed to pass bores in
housings.
3. Teflon seals must be sized prior to assembly, add • Assembly see (6)
some grease to inner and outer diameter of clutch • Clearance:
drum before assembly. min. clearance = 3.66 mm (0.14 in)(for carbon
4. Pump must be filled up with test oil prior to assembly. plates)
5. Pump drive shaft must be installed after torque con- max. clearance = 6.78 mm (0.27 in)(for carbon
verter. plates)
6. Fl, Rev, 1st, and 2nd clutch: 9 separator plates with in- If clearance is more than 5,66 mm (0.22 in), add one
ner splines. 8 friction plates (friction material both separator plate upon last separator plate.
sides) with outer splines, 2 1-side friction plates (fric- 9. • Installation force of disc spring is 3280 N (737 lbf).
tion material 1 side) with outer splines. 10. Be sure that shielded and sealed bearings are
Start with one 1-side friction plate, metal against pis- mounted as shown.
ton, then alternately separator and friction plate. 11. Seals must be pressed in perpendicular upon shaft
End with a 1-side friction plate, metal side against end axis from bearing side. Except lower rear output.
plate or disc spring. 12. Plug to be screwed in and torqued but without Loctite.
Be sure disc spring is mounted as shown. 13. First clutch springs concave side of first disc spring to
• Clearance: Forward low and Reverse: be placed against clutch piston wear sleeve.
min. clearance = 2.79 mm (0.11 in)(for carbon Remaining 10 springs to be stacked alternately re-
plates) versed as shown.
max. clearance = 5.21 mm (0.21 in)(for carbon 14. Shipping strap: only used during shipment of the indi-
plates) vidual transmission.
If clearance is more than 4.79 mm (0.18 in), add one
separator plate upon last separator plate. NOTE: check if safety valve and valve block are tested
• Clearance: First and second: before assembly.
min. clearance = 2.54 mm (0.10 in)
max. clearance = 5.41 mm (0.22 in) 15. Heat gears up to 150 °C (302 F) before assembling.
If clearance is more than 4.54 mm (0.18 in), add one 16. Parking brake.
separator plate upon last separator plate. 17. Mounting: tighten locking nuts with 0.25 to 1.25 mm
7. • Fh clutch: 4 separator plates, 3 friction plates and (0.01 to 0.05 in) clearance between nuts and sleeves.
two 1-side friction plates. Adjustment: loosen the (2) adjustment locking nuts (1
• Assembly see (6) and 2). Put lever in correct position.
• Clearance: Tighten inner adjustment nut (2) with 11 Nm (8 lbf.ft).
min. clearance = 1.24 mm (0.05 in)(for carbon Back off inner adjustment nut (2) with 4 or 5 flats.
plates) Tighten outer locking nut (1) against inner adjustment
max. clearance = 2.76 mm (0.11 in)(for carbon nut (2). Clearance must be from 0.8 to 1.1 mm (0.03
plates) to 0.04 in).
8. • Disconnect clutch: 12 separator plates, 11 friction
plates and two 1-side friction plates.
F27753
DISASSEMBY TRANSMISSION
Remove the oil filter.
Remove the filter adapter screws.
Remove the filter adapter with the O-ring.
Remove the drive plate screws.

Remove the drive plates.
Remove the torque converter assy.
Remove the charging pump screws.
Use a bearing puller to remove the charging pump.

Remove the charging pump assy, remove the O-

ring.
Remove the parking brake mounting screws.
Remove the parking brake assy.
Remove the upper output nut, the washer, the O-

ring and the flange.
Remove the air breather.
Remove the control valve protection cover mounting

screws.
Remove the wiring connector mounting nut.
Remove the control valve protection cover and the

gasket.
Remove the control valve mounting screws.
Remove the control valve assy: remove the bypass

valve spool and the spring in the meantime.
Remove the auxiliary pump hole cover screws.
Remove the auxiliary pump hole cover and the gas-

ket.
Remove the pump drive shaft rear bearing locating

ring.
Remove the pump drive shaft and the bearing assy.
Remove the upper output nut, the washer, the O-

ring and the flange.
Remove the converter housing to transmission case

screws and the lock washers.
Remove the transmission case plug.
Transmission case plug and gasket removed.
Spread ears on output shaft rear bearing retaining

ring. Holding snap ring open, tap on output shaft and
transmission case to remove case from converter
housing.
Lift transmission case from converter housing (using
lifting bracket).
Transmission case removed all drums and shafts

remain in converter housing.
Remove the transmission case to converter housing

gasket.
Remove the output shaft sealing rings.
Remove the output shaft rear bearing retaining ring.
Use bearing puller to remove the output shaft rear

bearing.
Output shaft rear bearing removed.
Using bearing puller to remove the 2nd shaft rear

bearing.
2nd shaft rear bearing removed.
Using bearing puller to remove the input shaft rear

bearing.
Input shaft rear bearing removed.
Remove the reverse and 1st shaft sealing rings.
Using bearing puller to remove the reverse and 1st

shaft rear bearing.
Reverse and 1st shaft rear bearing removed.

Remove the forward low and forward high shaft

sealing rings.
Using bearing puller to remove the forward low and

the forward high shaft rear bearing.
Forward the low and forward high shaft rear bearing

removed.
Use bearing puller to remove the forward high gear

from the input shaft.
Forward high gear removed.
Remove the baffle plates screws, remove the baffle

plates.
Remove the oil baffle to converter housing screws,

do not remove the oil baffle from the output shaft.
Remove the output shaft, the 2nd shaft and the oil
baffle at the same time.
Loosen the suction tube retainer screw.
Remove the suction tube retainer screw and the lock

washer.
Remove the suction tube retainer ring.
Remove the suction tube O-ring and the washer.

Remove the output shaft front bearing retainer ring.
Remove the output shaft front assembly.
Remove the input shaft, the reverse and the forward

shaft at the same time.
Remove the safety valve plug, the spring and the

ball.
Remove the by-pass plug, the spring and the ball.

FORWARD HIGH CLUTCH DISASSEMBLY

Remove the clutch shaft sealing rings.
Remove the thrust washer and the thrust bearing.
Remove the clutch gear outer needle bearing.
Remove the clutch gear.

Remove the clutch gear inner needle bearing.
Remove the thrust washer and the thrust bearing.
Remove the backing plate retaining ring.
Remove the clutch plate spacer.

Remove the clutch disc backing plate.
Remove one outer half disc.
Remove the inner and the outer discs.

Compress spring to remove spring retainer snap

ring.
Remove the spring retainer snap ring.
Remove the clutch spring spacer.
Remove the clutch piston spring retainer.

Remove the clutch piston spring.
Remove the clutch piston wear plate.
Remove the clutch piston assy.

FORWARD LOW CLUTCH DISASSEMBLY

Use bearing puller to remove the front bearing and
gear.
Front bearing and gear removed.
Remove the gear retainer ring.
Use a bearing puller to remove the clutch gear and

the outer bearing.
Clutch gear and outer bearing removed.
Remove the spacer snap ring.
Remove the spacer.

Use a bearing puller to remove the clutch gear inner

bearing
Clutch gear inner bearing removed.

Remove the clutch gear inner bearing locating ring.
Compress the spring to remove the spring retainer

snap ring.


FORWARD LOW CLUTCH ASSEMBLY

Install the clutch piston outer seal.
NOTE: ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with out-
er diameter of piston.
Install the clutch piston inner seal.

Install the clutch piston in clutch drum, use caution
as not to damage the sealing rings.
Install the clutch piston wear plate on the piston.
Install the clutch piston spring.

Install the clutch piston spring retainer.
Install the clutch spring retainer snap ring.
Use a sleeve with the proper diameter to fit over

shaft and against retainer ring. A sharp blow with a
soft hammer will compress spring and seat retainer
ring.
Be sure ring is in full position in groove.
Install one outer half disc, with friction material away

from the piston.
Install one steel disc. Alternate friction and steel

discs until the proper amount of discs are installed.
First and last discs are steel.
Install one outer half disc with friction material down.
Install the backing plate.
Install the backing plate snap ring.

Install the spacer.
Install the spacer snap ring.
Install the inner bearing snap ring.
Install the clutch gear inner bearing.

Tap inner bearing into place.
Install the clutch gear bearing locating rings.
Install the clutch gear sealing ring. Install the clutch

gear in clutch drum. Align splines on clutch gear with
all internal teeth of steel discs. Do not force this op-
eration. Gear splines must be in full position with in-
ternal teeth of all inner discs.
Install the clutch gear outer bearing.

Be sure that bearing shield is on the outside.
Tap the outer bearing into the place.
Install the outer bearing snap ring.
Warm the gear to 150 °C (302 °F), install the gear.
Warm the front bearing to 120 °C (248 °F), install the

bearing.
FORWARD HIGH CLUTCH ASSEMBLY

Install the clutch outer seal.

Install the piston inner seal and install the clutch pis-
ton in clutch drum; use caution as not to damage the
sealing rings.
Install the clutch piston wear plate on the piston.
Install the clutch piston return spring.

Install the piston return spring retainer.
Install the spring retainer spacer.

soft hammer will compress the spring and the seat
retainer ring.
Install one outer half disc with friction material away

from the piston.

discs until the proper amount of discs are installed,
first and last discs are steel.

Install the backing plate spacer.
Install the backing plate spacer retainer ring.
Install the thrust washer and the thrust bearing.
Install the clutch gear inner needle bearing.

Install clutch gear in clutch drum. Align splines on

clutch gear with internal teeth of steel discs.
Do not force this operation. Gear splines must be in
full position with internal teeth of all inner discs.
Install the clutch gear outer needle bearing.
Install the thrust washer and the thrust bearing.
Install the clutch shaft sealing rings.

FIRST CLUTCH DISASSEMBLY

Remove the clutch gear bearing retainer ring.

the outer bearing.
Clutch the gear and the outer bearing removed.

Remove the backing plate retainer ring.
Remove the backing plate.
Remove the modulation spring.
Use bearing puller to remove the clutch gear inner

bearing.

Compress the clutch piston belleville washer spring.

Remove the spring snap ring.
NOTE: force of disc spring is 3280N.
Spring retainer ring removed.
Remove the disc belleville washer spring.
Remove the clutch piston wear sleeve.


REVERSE CLUTCH DISASSEMBLY

Use a bearing puller to remove the gear and the front
bearing.
Gear and front bearing removed.
Remove the clutch gear bearing retaining ring.

the clutch gear outer bearing.
Clutch gear and outer bearing removed.
Remove the spacer snap ring.
Remove the spacer.

Use a bearing puller to remove the clutch gear inner

bearing.

Remove the inner bearing locating ring.
Compress the spring to remove the spring retainer

snap ring.


REVERSE CLUTCH ASSEMBLY


Install the clutch piston inner seal. Install the clutch

piston in the clutch drum, use caution as not to dam-
age the sealing rings.
Install the piston wear plate on the piston.

Install the clutch piston spring retainer.

soft hammer will compress the spring and the seat
retainer ring.
Install one outer half disc, with friction material away

from the piston.


Install the spacer.
Install the spacer snap ring.
Install the inner bearing snap ring.
Install the clutch gear inner bearing.

Tap the inner bearing into the place.
Install the clutch gear bearing locating rings.
Install the clutch gear sealing ring. Install the clutch

gear in the clutch drum. Align splines on clutch gear
with internal teeth of steel discs. Do not force this
operation. Gear splines must be in full position with
internal teeth of all inner discs.
Install the clutch gear outer bearing.
S WARNING
Install the outer bearing snap ring.

bearing.
FIRST CLUTCH ASSEMBLY


Install the piston inner seal. Install the clutch piston

in the clutch drum. Use caution as not to damage the
sealing rings.
Install the clutch piston wear sleeve.
Install the piston return disc springs. First spring with

large diameter of bevel toward wear sleeve.
Alternate eleven (11) springs.
Install the disc belleville washer spring retainer ring.
Compress the spring to install the spring retainer

ring.

from the piston.

Install the modulation spring with large diameter up

to the backing plate.

Install the clutch disc hub inner bearing.
Tap the inner bearing into the place.
Install the clutch hub bearing locating rings. Install

the clutch gear in the clutch drum. Align splines on
clutch gear witch internal teeth of steel discs. Do not
force this operation. Gear splines must be in full po-
sition with internal teeth of all steel discs.
Install the clutch hub outer bearing.

Tap the outer bearing into the clutch hub.
Install the outer bearing retaining ring.

2ND CLUTCH DRUM DISASSEMBLY

Press the upper output gear from the 2nd shaft.
Press the gear from the 2nd shaft.
Remove the gear retaining ring.

Use bearing puller to remove the clutch hub and the

front bearing.
Remove the clutch shaft front bearing.
Remove the bearing washer.
Remove the clutch hub and the outer bearing.

Use a bearing puller to remove the clutch hub inner

bearing.
Remove the clutch hub inner bearing.
Remove the backing plate snap ring.

Remove the modulation spring.

Compress the spring to remove the spring retaining

ring.
Remove the spring retaining ring.
Remove the spring retainer.
Remove the clutch piston return spring.

Remove the piston wear plate.

2ND CLUTCH DRUM ASSEMBLY

Install the piston outer seal.


Install the clutch piston in the clutch drum.
Use caution as not to damage the sealing rings.
Install the piston wear plate.
Install the piston return spring.

Install the spring retainer.
Install the spring retainer snap ring.
Use a sleeve with the proper inner diameter to fit the

over shaft and against retainer ring. A sharp blow
with a soft hammer will compress spring and seat re-
tainer ring. Be sure ring is in full position in groove.

from the piston.

Install the modulator spring with large diameter up to

the backing plate.

Install the backing plate retainer ring.
Install the clutch hub inner bearing.
Tap the clutch gear inner bearing into the place.
Install the clutch hub bearing locating rings. Install

the clutch gear in the clutch drum. Align splines on
clutch gear with internal teeth of steel discs. Do not
force this operation.
Gear splines must be in full position with internal
teeth of all steel discs.
Install the clutch hub outer bearing.
S WARNING
Install the bearing washer.

bearing.
Install the gear retaining ring.
Warm the upper output gear to 150 °C (302 °F) in-

stall the gear.
OUTPUT SHAFT DISASSEMBLY

Remove the oil baffle screws and the nuts.
Remove the oil baffle.
Remove the output shaft sealing rings.
Remove the output shaft gear retaining ring.

Press the output gear from the shaft.
Remove the output gear.
Remove the oil baffle from the output shaft.
Remove the gear retaining ring.

Remove the backing plate snap ring.
Remove the backing plate spacer.

Compress the spring to remove the spring retaining

ring.
Remove the spring retaining ring.

Remove the spring retainer.
Remove the piston wear plate.
Remove the piston assy.

OUTPUT SHAFT ASSEMBLY

Install the piston outer seal.


Install the clutch piston in the clutch drum.
Use caution as not to damage the sealing rings.
Install the piston wear plate on the piston.

Install the spring retainer.
Install the spring retainer snap ring. Use a sleeve

with the proper inner diameter to fit over shaft and
against snap ring. A sharp blow of a soft hammer will
compress spring and seat retainer ring. Be sure ring
is in full position in groove.

from the piston.

Install one half disc with friction material down.
Install the backing plate spacer.

Install the oil baffle on the output shaft.
Install the output gear retaining ring.
Install the output gear retaining ring.

Install the output shaft sealing rings.
Install the rear oil baffle on the output shaft.
Install the oil baffle mounting screws, the washer

and the nuts and tighten nuts to the specified torque
(Use Loctite 243).
DISCONNECT SHAFT DISASSEMBLY

Use bearing puller to remove the disconnect shaft
front bearing.
Remove the front bearing.
Remove the front bearing retaining ring.
Remove the clutch hub from the shaft.

Remove the clutch hub locating ring from the shaft.

DISCONNECT SHAFT ASSEMBLY

Install the bushing if necessary.
Install the clutch hub locating ring.
Install the clutch hub on the shaft.
Install the front bearing retaining ring.

Install the front bearing on the shaft.
Tap the bearing on the shaft.

PUMP DRIVE SHAFT DISASSEMBLY

Remove the rear bearing snap ring.
Use bearing puller to remove the rear bearing.
Remove the rear bearing from the shaft.
Remove the sealing ring from the shaft.

PUMP DRIVE SHAFT ASSEMBLY

Install the sealing ring on the shaft
Install the rear bearing on the shaft.
Tap the bearing into the place.
Install the rear bearing retainer ring.

INPUT SHAFT DISASSEMBLY

Remove the input shaft rear sealing ring.
Remove the forward high gear retaining ring.
Remove the forward low gear retaining ring.
Remove the input shaft front sealing ring.

Use bearing puller to remove the input shaft front the

bearing.
Remove the input shaft front bearing.
Remove the input shaft front bearing retaining ring.
Remove the forward low gear retaining ring.

Press the forward low gear from the shaft.

INPUT SHAFT ASSEMBLY

Install the forward low gear retaining ring.
Install the forward low gear retaining ring.
Install the input shaft front bearing retaining ring.

Install the input shaft front sealing ring.
Warm the input shaft front bearing to 120 °C

(248 °F), install the bearing.
Turn the shaft and install the input shaft forward high
gear retaining ring.
Install the input shaft rear sealing ring.

CONVERTER HOUSING ASSEMBLY

Install the safety valve ball spring and the plug.
Install the by-pass valve ball spring and the plug.
Install the output shaft front oil seal.
Using suitable seal installer, tap the seal in the

place.
Install the input shaft into housing and in the

meantime install reverse and first shaft (they have to
be installed together). Using caution as not to
damage any of the first shaft sealing rings.
Install the forward low shaft and the high shaft into
housing. Using caution as not to damage any seal-
ing rings.
Install the disconnect shaft assembly into the hous-

ing.
Open the bearing retaining ring. Tap the shaft into

the place. Be sure ring is in groove.
Install the upper and the lower output at the same

time.
Do not force this operation, be sure discs of
disconnect are in full position. Using caution as not
to damage any of the lower shaft sealing rings.
Install the baffle plate, the mounting screws, the

washers and the nuts. Tighten the nuts to the spec-
ified torque. (Use Loctite 243).
Install the baffle plate, the mounting screws, the

washers and the nuts. Tighten nuts to the specified
torque. (Use Loctite 243).
Install the oil baffle, the mounting screws and the

washers. Tighten the screws to the specified torque.
(Use Loctite 243).
Install the O-ring, the spacer and the snap ring on

suction tube. Install suction tube into housing. Be
sure ring is in groove.
Install the suction tube retainer, mounting the screw

and the lock washer (Use Loctite 243).
Tighten the mounting screw to the specified torque.
Install the output shaft rear bearing retaining ring.

Warm the forward high gear to 150 °C (302 °F), in-

stall the gear.
Warm the upper output rear bearing to 120 °C

Warm the reverse and 1st shaft rear bearing to

120 °C (248 °F), install the bearing.
Warm the input shaft rear bearing to 120 °C (248 °F),

install the bearing.
Warm the forward low and the high shaft rear bear-
ing to 120 °C (248 °F), install the bearing.
Warm the lower output shaft rear bearing to 120 °C

Install the output shaft rear bearing retaining ring.
Install the gasket and the clutch pressure O-rings (4)

into the O-ring grooves.
TRANSMISSION ASSEMBLY
Remove the lower output bore plug. Position the
transmission case on the converter housing (using
the lifting bracket).
Using the spreading type snap ring pliers, the

spread ears on the output shaft rear bearing retain-
ing ring. Holding snap ring open. Tap the transmis-
sion case into the place.
Tap the dowel pin in the transmission case and the

converter housing.
Install the transmission case to the converter hous-

ing mounting the screws and the lock washers.
Tighten the mounting screws to the specified torque.
Using the spreading type snap ring plier, the spread

ears on output shaft rear bearing retaining ring. Hold
snap ring open, pry or lift output shaft. Be sure re-
taining ring is complete in bearing groove. (Using a
lifting eye or screw M12).
Install the hole plug and the gasket.
Tighten the plug to 13.6 - 20.3 Nm (10 -15 lbf·ft).
Position the lower output bore plug and tap the bore
plug into the place.
Position the upper output seal.
Tap the seal into the place.
Install the upper output flange, the O-ring, the wash-

er and the nut and tighten the nut to 339 - 407 Nm
(200 - 300 lbf·ft).
Install the pump drive shaft assembly into the hous-

ing.
Install the pump drive shaft rear bearing retaining

ring.
Install the pump hole cover, the gasket, the screws

and the lock washers.
Tighten the pump hole cover screws.
Install the pump and the O-ring into the converter

housing.
Install the pump mounting screws and the lock

washers and tighten the screws.
Install the converter assy on the input shaft.
Install the drive plates on the converter.
Install the drive plates screws and the lock washers

and tighten the screws.
Install the filter adapter, the O-ring, the lock washers

and mounting the screws.
Tighten the screws.
Install the oil filter and tighten to 30 - 38 Nm (22.1 -

28 lbf·ft).
Install the output shaft front flange, the O-ring, the

washer and the nut. Tighten the nut to 339 - 407 Nm
(250 - 300 lbf·ft).
Position the parking brake, install the mounting

screws (See packing brake adjustment).
Install the by-pass valve spool into the solenoid

housing and spring into transmission case, position
control valve on transmission case.
Install the control valve mounting screws and the

lock washers, tighten the screws.
Position the wiring connector in the valve protection

cover.
Install the gasket and the valve protection cover

mounting screws and tighten the screws.
Install the air breather and tighten to 34 - 41 Nm (25

- 30 lbf·ft).
Install the wiring connector nut and tighten to 6 - 8 Nm

(4.4 - 5.9 lbf·ft).
Replacement and adjustment of parking brake
19
20
3
19
2 18
1
17
21
15
16
14
12 13
11
10
9
8
7
6
5
4
F27750
Z Loosen two adjustment locking nuts (4 and 5) enough to slide each torque plate (16 and 18) away from disc
far enough to provide clearance to remove old carrier and lining assemblies and install new ones. (It may be
necessary to remove one or both nuts).
Z Collapse lining retraction spring (21) and remove from brake head assembly.
Z Slide torque plates (16 and 18) away from disc, move carrier and lining assemblies (17) out of pockets, and
remove from the brake head assembly from the side.
Z Install new carrier and lining assemblies (17) in each torque plate (16 and 18).
Z Install lining retention spring (21) into brake head assembly. Be sure spring’s “feet” are positioned properly in
holes in both lining carrier assemblies (17).
Z Tighten inner adjusting nut (5) until firm contact is made with the disc by the linings. Torque to 11 Nm (8 lbf.ft)
make certain lever is in proper operating position for application.
Z Back off inner adjusting nut 4 (5) to 5 flats and check that disc is free to move (total clearance 0.8 - 1.1 mm
(0.031 - 0.043 in)).
Z Tighten outer locking nut (4) against inner adjusting nut to lock adjustment bolt in place. Torque to (45 to 55
lbf-ft.) 61 - 75 Nm.
2.13 SPECIAL TOOLS
P/N CNH DESCRIPTION

380000676 Lifting tool
2.14 FAULT FINDING
STALL TEST
Use a stall test to identify transmission, converter, or
engine problems.
TRANSMISSION PRESSURE CHECKS

Transmission problems can be isolated by the use of
pressure tests. When the stall test indicates slipping
clutches, then measure clutch pack pressure to de-
termine if the slippage is due to low pressure or
clutch plate friction material failure.
In addition, converter charging pressure and trans-
mission lubrication pressure may also be measured.
MECHANICAL AND ELECTRICAL CHECKS

Prior to checking any part of the system for hydraulic
function (pressure testing), the following mechanical
and electrical checks should be made:
Z Check the parking brake for correct adjustment.
Z Be sure all lever linkage is properly connected and
adjusted in each segment and at all connecting
points.
Z The controls are actuated electrically. Check the
wiring and electrical components.
Z Be sure that all components of the cooling system
are in good condition and operating correctly.
The radiator must be clean to maintain the proper
cooling and operating temperatures for the engine
and transmission. Air clean the radiator, if neces-
sary.
Z The engine must be operating correctly. Be sure
that it is correctly tuned and adjusted to the correct
idle and maximum no-load governed speed specifi-
cations.
HYDRAULIC CHECK
Also, before checking the transmission clutches,
torque converter, charging pump, and hydraulic sys-
tem for pressure and rate of oil flow, it is important to
make the following transmission fluid check:
Check oil level in the transmission. The transmission
fluid must be at the correct (full level). All clutches
and the converter and its fluid system lines must be
fully charged (filled) at all times. See note below.
NOTE: the transmission fluid must be at operating

temperature of 82 - 93 °C (180 - 200 °F) to obtain
correct fluid level and pressure readings. Do not at-
tempt to make these checks with cold oil.
To raise the oil temperature to this specification it is

necessary to either operate (work) the vehicle or run
the engine with converter at “stall”. (Refer to convert-
er stall procedure).

Low clutch pressure Low oil level Fill to proper level.
Clutch pressure regulating valve Clean valve spool and housing.
stuck open Replace pump.
Faulty charging pump Replace sealing rings.
Broken or worn clutch shaft or
piston sealing rings
Low charging pump output Low oil level Fill to proper level.
Suction screen plugged Clean section pump.
Defective charging pump Replace pump.
Overheating Worn oil sealing rings Remove, disassemble, and rebuild
Worn charging pump converter assembly.
Low oil level Replace.
Dirty oil cooler Fill to proper level.
Restriction in cooler lines Clean cooler.
Change cooler lines.
Noisy converter Worn charging pump Replace.
Worn or damaged bearings A complete disassembly will be
necessary to determine what
bearing is faulty.
Lack of power Low engine R.P.M. at converter Tune engine check governor.
stall Make corrections as explained in
See “Overheating” and make “Overheating”.
same checks
2.15 FAULT FINDING
Before attempting any fault finding ensure you have

a suitable multimeter for checking component conti-
nuity. When fault finding remember that with an elec-
trical concern it is often a minor fault that may have
occurred and could be as simple as:
Z Poor continuity between connector pins.
Z Condensation in the connectors.
Z Disconnected cables.
Z Damaged or broken wires all of which could result
in a no drive situation but easily remedied when
found and corrected.
It should also be remembered that mechanical prob-
lems could result in fault codes appearing on the F28292
LED display
INDICATION OF FAULTS
In case a fault is present during normal operation
and is detected by the microprocessor, both the T-
LED and N-LED may be blinking in some way as
F N R T N
shown in the table below.
NOTE: that on an open circuit or connection to bat-

tery plus on ON/OFF outputs can only be detected 1 2 3 4 5 6 7 8
while the corresponding output is in the OFF posi-
tion. 1 2 3 4
Also a short to ground is only detected while the out-
put is on.
F28358
T-LED N-LED CONDITION SITUATION

(Orange) (Red)
Off Off Normal operation -
Off On Normal operation - N selected -
Off Blinks Blinks Normal operation - N selected/speed -
too high
On Off Diagnostic mode was activated at power up -
On On Controller in RESET -malfunction Fault
On Blinks Self calibration in progress -
Blinks On Last fault is currently shown on display Fault
Blinks Blinks slower Input fault detected Fault
Blinks Blinks in phase Non critical output fault detected Fault
Blinks Blinks faster Safety critical output fault detected Fault
Blinks fast Blinks out of phase System shutdown - Neutral till power down Fault
LED DISPLAYED FAULTS

If a fault is, or there have been (intermittent faults)
present, a detailed fault display can be selected by
placing: the powershift lever in neutral position and
pressing the kickdown button. The indicated fault on
the LED display can then be localized by using the
table below, until power down.
FAULT GROUP
The faults are displayed using 2 LEDs on the 8 LED
display. Faults are displayed as 3 subgroups - F N R T N
Group A:
FAULT SUB GROUP A GROUP INDICATION

Input related LED 1 blinks red 1 2 3 4 5 6 7 8
Output related LED 2 blinks red
Other LED3 blinks red
A B
Within each group several faults are possible. The F28359
second LED’s position - Group B, indicates the fault

area, where the color indicates the fault type.
Typically an open circuit condition is shown using an
orange LED where a short circuit condition is indicat-
ed with a red LED.
Once the fault code has been determined proceed to
fault codes.
FAULT GROUP FAULT GROUP FAULT FAULT CODE

LED (A) LED (B)
None None No fault active -
1 Red 4 Orange Shift lever input fault F1
1 Red 5 Orange Speed sensor open circuit F2
1 Red 5 Red Speed sensor short circuit F3
1 Red 7 Green Battery over voltage F4
2 Red 4 Orange Open circuit on one or both direction outputs F5
2 Red 4 Red Direction output forced to plus - Critical fault F6
2 Red 5 Orange Other output open circuit F7
2 Red 5 Red Red Other output short circuit F8
2 Red 6 Orange Modulation output open circuit F9
2 Red 6 Red Modulation output short circuit F10
3 Red 5 Red Start-up fault - Limp home mode selected F11
SHIFT LEVER INPUT FAULT CODE F1
Perform input test

This test is used to verify operation of the shift lever F N R T N
and its inputs. Blinks Slower
Blink
In this mode driving is possible.
Blinks Blinks
NOTE: the gear position indicators on the micropro-

1 2 3 4 5 6 7 8
cessor top cover are used to display the test infor-
mation.
1 2 3 4
F28360
INPUT TEST REQUIREMENTS: powershift lever to

be in forward position, twist to upshift (keep the shift
lever in this position during power up) and turn the F
ignition on, this will place the microprocessor in the
input test mode.
As shown in the table below placing the shift lever in
different positions in this mode illuminates its re-
spective LED (only 2 at the same time).
IMPORTANT: self test modes can only be started

WHILE POWERING UP (ignition on). Leaving the
self test mode is done by switching OFF the power R
of the Microprocessor (ignition off). F12046
POWERSHIFT LEVER POSITIONS - WITH UP LED - LED COLOR - DISPLAYED = Okay

AND DOWNSHIFT SELECTION NUMBER
Neutral 2 RED
Neutral and upshift 3 RED
Neutral and downshift 1 RED
Forward 2 GREEN
Forward and upshift 3 GREEN
Forward and downshift 1 GREEN
Reverse 2 ORANGE
Reverse and upshift 3 ORANGE
Reverse and downshift 1 ORANGE
Operate disconnect button on loader lever 5 (*) (**) GREEN
Operate 4WD switch on instrument panel 6 (*) (**) GREEN
Foot brake test + 4WD 6 (**) GREEN
Foot brake test + 4WD 7 (*) RED
Transmission in automatic mode 7 (*) RED
Temperature and speed sensor: too test 8 RED
disconnect lead on the sensor and short to ground
*= Auto transmission only

**= Auto/Manual override
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
Select neutral and push

kickdown button:
= LED 1 red
NO Other input fault
= LED 4 orange
YES YES
Input fault: forward/reverse Check through
Replace the powershift F2, F3, F4 or F11
Lever unit
YES
Test with new powershift
lever unit fitted
SPEED SENSOR / FAULT CODE F2 AND F3

A fault indication on the display is given to warn of
this problem.
F N R T N
If a speed sensor fault is detected the microproces-
Blinks Slower
sor will modify its behaviour in the following areas: Blinks
Blink
Z no upshifts will be allowed above 2nd gear Blinks 5

Z direction change while in F3 or F4: the actual rever-
sal is preceded by a downshift sequence until 2nd 1 2 3 4 5 6 7 8
gear is obtained.
Z 4WD braking remains operative. 1 2 3 4
NOTE: the system response in this case is identical
to the response in case of a power supply overvolt- F28361
age.
Speed sensor test using the turbine speed dis-

play Turbine RPM LED
0 1 blinks
NOTE: a lamp test is performed prior to the speed
sensor test and monitors all LEDs are operational. 0 - 249 1 on
250 - 499 2 on
SPEED SENSOR TEST REQUIREMENTS: power-
shift lever to be in reverse position, twist to upshift 500 - 749 3 on
(keep the shift lever in this position during power up) 750 - 999 4 on
turn the ignition on and start the engine.
With engine running return powershift lever to neu- 1000 - 1249 5 on
tral position and then place lever in forward and twist 1250 - 1499 6 on
to upshift. Increase engine speed and compare with
the table opposite. 1500 - 1749 7 on
1750 - 1999 8 on
IMPORTANT: self test modes can only be started
WHILE POWERING UP (ignition on). Leaving the above 2000 8 blinks
self test mode is done by switching OFF the power
to the Microprocessor (ignition off).
In this mode, driving is possible.

The LED corresponding with the table opposite illu-
minates to indicate the torque converter turbine
speed and increases with engine revs.
NOTE: application of the foot brakes during this test

will reduce the turbine speed to zero.
Speed sensor test okay NO Key start ON

YES YES
End T-LED Blinks

NO No input fault
N-LED Blinks Slower
YES

kickdown button:
= LED 1 red = LED 1 red
NO NO Other input fault
= LED 5 orange (F2) = LED 5 red (F3)
YES YES YES
Check wires from speed sensor CV pin A to powershift Refer to F1, F4
Repair NO lever unit pin A or CV pin J to pin U, and continuity test. or F11.
Does it test OK.
YES
Check speed sensor has it failed.
NO
CV15 (A) CV07 (J)

Change lever unit NO
100 Ω
If static is 0.6 - 0.8 V
or 1.3 - 1.5 V
+ 12 V
YES F28371
Replace sensor
If static is not 0.6 - 0.8 V
or 1.3 - 1.5 V
F28370
FAULT CODE F4 / BATTERY OVERVOLTAGE (17

V PLUS)
Over voltage F N R T N
Even power supply levels up to 30V will not damage Blinks Slower
Blink
system components.
Above a power supply of 17 V DC: Blinks
Blinks
Group Fault 1 - Fault code 7.
1 2 3 4 5 6 7 8
NOTE: the speed sensor system will not operate
when an over voltage is present. 1 2 3 4
F28362
Above a power supply of 24 V DC:

the analogue signals are not reliable to convert any
more.
Over voltage: when the voltage exceeds 17 V DC. F N R T N
Action of the Microprocessor:
Z no upshifts above 2nd gear
Z direction change while in Forward 3 or Forward 4:
the actual reversal is preceded by a downshift se- 1 2 3 4 5 6 7 8
quence until 2nd gear is obtained.
1 2 3 4
+ 24 VDC F28363
Z brake switch activation always engages four wheel

drive.
NOTE: voltages below 8 V DC the microprocessor F N R T N

enters the reset mode.
Intermittent power loss

1 2 3 4 5 6 7 8
After power is restored, the microprocessor goes
through the reset mode.
1 2 3 4
- 8 VDC F28364
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
Select neutral and push Other input fault

kickdown button: NO Check through F1, F2,
1 red - 7 green F3 or F11
YES
Check battery voltage
NO
above 17.7 V
YES
Check dual battery connection Disconnect and reconnect
is parallel and okay NO correctly
YES YES
Check alternator output is
Repair or replace NO it correct
YES
FAULT CODE F5 AND F6 / OPEN CIRCUIT

DIRECTION OUTPUTS
Direction selection related outputs (E06-Pin P, F N R T N

E07-Pin N): Blinks Faster
Blink
A short to plus is considered as a critical fault. Shorts
to plus usually result in being blocked in either For- Blinks Blinks
ward or Reverse. If both are on simultaneously, the

transmission Behaviour depends on the state of a 1 2 3 4 5 6 7 8
mechanical interlock inside the transmission.
1 2 3 4
F28365
In this case the Microprocessor normally turns on

the pressure modulator (E03-Pin T). This results in
immediate selection of neutral regardless of the ori-
1 2
gin of the fault. Indeed even in case the short to plus A
B M
is applied externally, this response effectively blocks
C N L
the transmission in neutral. P U
If however at the time the fault was detected a fault D V K
was also present on the pressure modulator, the mi- R T
croprocessor reverts to shutdown mode and re- E S J
mains this way until power is removed. Shutdown F H
G
mode is a state in which power is removed from the
microprocessor outputs by opening the internal re-
dundant shutdown path. F4288
This only helps if the fault was caused by the micro-

processor internally.
Additionally, during program execution, critical vari-
ables are continuously checked for contents integri-
ty.
Gearshifts
low/high solenoid:
inactive = forward high is selected
active = forward low is selected
SHIFT FORWARD REVERSE

DIAGRAM -
SOLENOIDS
1 2 3 4 1 2
reverse/n X X
forward/n
low/high X X X X
1st/2nd X X X
During the output test LEDs 1234567 one by one are used and by
color 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
OUTPUT FAULT - STATUS BY LED COLOR

OUTPUT TEST REQUIREMENTS: powershift lever
to be in forward position, twist clockwise to downshift
and turn ignition on.
In this mode, driving is not possible, since all micro-
processor outputs remain off until the test mode is
left.
The color and number of the LED indicates its sta-
tus:
COLOR STATUS
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)
Output test - Fault by LED Number
The LED numbers correspond to the connector out-

put wires as follows:
Example:
LED 1 = Forward solenoid - color
Orange = (Output not connected or shorted to bat-
tery plus)
LED OUTPUT OUTPUT

NUMBER WIRE FUNCTION 1 2
A
B M
1 E06 Forward solenoid
C N L
2 E07 Reverse solenoid P U
D V K
R T
E S J
F H
G
F4288
Key start ON
YES
T-LED Blinks
NO Safety critical output
N-LED Blinks Faster
YES
Select neutral and push Other output fault

kickdown button (F5) open NO forced to plus (F6) NO
circuit 2 red - 4 orange 2 red - 4 red
YES YES
All LEDs green Perform output test - fault Other LEDs are
NO NO
and OK found? orange
YES YES YES
Led 1 orange Led 2 orange Proceed to F7, F8,
YES YES F9 or F10
Check forward Check reverse wire
wire to powershift to powershift lever is
Repair or YES lever is it faulty it faulty
replace NO YES NO
Check forward solenoid Check reverse solenoid

Repair or YES resistance - is it faulty resistance - is it faulty
replace NO YES NO
Check internal wires in forward Check internal wires in reverse

Repair or YES solenoid is it faulty solenoid is it faulty
replace
NO YES NO
Change powershift
lever unit
F28372
FAULT CODE F7 AND F8 / OUTPUT FAULT -

STATUS BY LED COLOR
OUTPUT TEST REQUIREMENTS: powershift lever
to be in forward position, twist clockwise to downshift
F N R T N
Blinks Blinks
and turn ignition on. Blinks
in Phase
In this mode, driving is not possible, since all micro- Blinks 5

processor outputs remain off until the test mode is
left. 1 2 3 4 5 6 7 8
The color and number of the LED indicates its sta-
tus: 1 2 3 4
COLOR STATUS
F28367
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)
Output test - Fault by LED Number

The LED numbers correspond to the connector out-
put wires as follows:
Example:
LED color Red and numbered 3 = 1/2 solenoid out-
put shorted to ground.
LED OUTPUT OUTPUT

NUMBER WIRE FUNCTION 4 5
A
B M
3 E04 1/2 Solenoid
C N L
4 E05 Forward Low/High P U
solenoid D V K
R T
5 E09 AWD/RWD E S J
solenoid F H
G
3
F4293
Key start ON
YES
T-LED Blinks
NO Non critical output
N-LED Blinks in phase
fault
YES
Select neutral and push Other output fault

kickdown button (F7) open NO (F8) short NO
circuit 2 red - 5 orange circuit 2 red - 5 red
YES YES
All LEDs green
NO Perform output test - fault found? NO Other LEDs are
and OK
YES YES YES orange
Led 3 orange or red Led 4 orange or red Led 5 orange or red YES
YES YES YES Proceed to
F9 or F10
Check 1/2 Check AWD/RWD
Repair YES solenoid is it faulty solenoid is it faulty
Check Lo/HI
or NO solenoid is it YES NO
replace YES faulty
NO
Check internal and
external wiring of
affected solenoids are
Repair or
replace YES they faulty
NO
Change powershift
lever unit
5
F28373
FAULT CODE F9 AND F10 / DIRECTION

MODULATION OUTPUT SHORT OR OPEN
CIRCUIT
A fault on this output is considered as a problem po- F N R T N
Blinks Blinks
tentially reducing transmission life. in Phase
Blinks
For this reason while a fault is persistent, the allow-
able direction change speed limit is decreased grad-
Blinks 6
ually (10%) each time a direction change was 1 2 3 4 5 6 7 8
inhibited, down to a minimum of 20% of the maxi-
mum allowable shift speed. 1 2 3 4
After a while this can result in severely degraded
performance (only low speed reversals are possi-
ble), but it has the advantage that the driver cannot F28368
be surprised by a sudden performance loss which

could constitute a safety hazard in itself.
Direction Modulation Solenoid (E03) Pin T
The variable Current solenoid for direction modula-

tion is connected to the modulation Common Plus A
B M
(Pin K) at one side and to (Pin T) at the other side. 1
A programmable current is increased or reduced to C N L
P U
the solenoid controlling the modulating pressure. D V K
No current corresponds to maximum pressure. R T
S
2
Approximately 1 Amp corresponds with no pressure. E J
F H
G
F4296
Key start ON
YES
T-LED Blinks
NO No fault
N-LED Blinks in phase
YES
Other non
kickdown button (F9) (F10)
NO critical output
2 red - 5 orange 2 red - 6 red NO
fault, F7 or F8
YES YES
All LEDs green Direction modulator Direction modulator
NO
and OK open circuit short circuit
YES YES
Check solenoid Check solenoid
Repair YES resistance - is it faulty resistance - is it faulty
or
NO YES NO
replace
Repair or Check internal and external wiring of the

replace YES direction modulation solenoid is it faulty
NO
Change powershift
lever unit
F28374
FAULT CODE F11 / START UP FAULT LIMP

HOME SELECTED
Internal faults F N R T N
Blinks Slower
Blink
At power up a series of integrity checks is done.
If a fault is detected: Blinks
Blinks
Z and the fault prevent operation as a transmission
1 2 3 4 5 6 7 8
controller: the microprocessor locks itself in a reset
state.
Z and controlling the transmission is still possible: the 1 2 3 4
microprocessor reverts to limp home mode.
F28369
Limp Home mode
Defaulted to if an internal problem is detected at

power up.
This models automatically selected at power up if the
integrity tests show that EPROM parameters are cor-
rupt, but the microprocessor can still function as a
transmission controller (other component’s integrity
are intact).
In this mode the user can operate the transmission in
either direction in 1st. and 2nd. There are no protec-
tions; all shifts are unmodulated.
Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks slower
YES
NO kickdown button (F11) Other output fault 2 red - 6 red
3 red - 5 red NO Refer F1, F2, F3 or F4
YES
Change powershift
lever unit
FAULTS OTHER F12

NOT IDENTIFIED BY THE LEDS
There may be situations when an individual compo-
nent develops a fault but it is not highlighted by the
LEDs. If a component is in doubt proceed to input
test as follows:
Perform Input test:
This test is used to verify the inputs.

In this mode driving is possible.
NOTE: the gear position indicators on the micropro-

cessor top cover are used to display the testinforma-
tion.
INPUT TEST REQUIREMENTS: powershift lever to

be in forward position, twist to upshift and turn the ig-
nition on, this will place the microprocessor in the in-
put test mode.
As shown in the table below placing the shift lever in
different positions in this mode illuminates its respec-
tive LED.
IMPORTANT: selftest modes can only be started

WHILE POWERING UP (ignition on). Leaving the
selftest mode is done by switching OFF the power of
the microprocessor.
CHECKING OF INPUT REQUESTS LED - LED COLOR -

NUMBER DISPLAYED
Confirm input test is okay (lever forward, neutral, reverse) and in order check as below:
1. Operate disconnect button on loader lever 5 GREEN = OKAY
2. Operate 4WD switch on instrument panel and foot brakes 6 GREEN = OKAY
3. Foot brake test on later models 7 RED = OKAY
4. Temperature and speed sensor: too test disconnect lead on 8 RED = OKAY
the sensor and short to ground
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
LIMP HOME LEAD

In the event of a total failure of the microprocessor 1
such as a serious cab or loom fire the vehicle can be
moved by using the limp home lead to bypass the
microprocessor.
Tool No - 380000715
F38338
Mounted to the left hand side and to the top of the

transmission is the microprocessor loom connector.
Disconnect the damaged loom and connect the limp 1
home lead in its place.
F11834
Connect the plug end into the 12 V auxiliary socket

or any available 12 V supply.
F11835
When seated in the cab start the engine and ensur-

ing that all personnel are clear of the machine select
either forward or reverse on the switch and the ma-
chine will move as requested.
NOTE: when using the limp home lead only 2nd

gear (forward or reverse) is selectable no other
gearshift or modulation is available.
NOTE:
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 25 - FRONT AXLES
1. FRONT AXLE 2WD “CARRARO” ................................................................................................................. 3

1.3 FAULT FINDING.................................................................................................................................. 24
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 26
2.3 FAULT FINDING.................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.3 FAULT FINDING................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
2 SECTION 25 - FRONT AXLES
SECTION 25 - FRONT AXLES 3
1. FRONT AXLE 2WD “CARRARO”

TYPE
Front steering axle, model 26.00
F27349
DESCRIPTION POSITION
Oil filling and level plug 1
Air breather 2
Oil drain plug 3
Filling, level and drain plug of epicyclic reduction gear oil 4
Greasing points 5
Before draining the oil from axle housing, use the

breather (2) to release possible internal pressure.
SWARNING
Risk of violent oil ejection.
To drain the oil remove the level plug (1) and the
drain plug (4).
SWARNING
Drain all oil.

Clean the drain plug (4) and tighten to the requested
torque.
Always use the oil breather (2) to release possible

internal pressure.
Unscrew the level plug (1) and fill to the bottom of
the level plug hole with the specified oil.
Wait to allow the oil to flow through the axle. Check
oil level and fill to the specified level if necessary.
Screw the level plug (1) to the prescribed torque.
Before draining the oil from the wheel hub, rotate it

so that the plug (3) is in the lowest possible position
and partially unscrew the plug to release any possi-
ble internal pressure.
Remove the plug and drain the oil.
FRONT AND REAR SUPPORTS
1
7
6 2 9
4
5
8
15 3
13
1
11
10
14
12
8
F27351
Disassembly
Remove the rear support (10) from the differential

support.
10
F27352
Remove the O-ring (11) from the rear support (10).
NOTE: this is a destructive operation for the O-ring.
11
10
F27353
Remove the bolt (8) with the lube nibble (9).

Remove the bush (12) from the rear support (10).
12
10
8
9
F27354
Remove the bushes (1) from the rear support (10).

1
10
F27355
Remove the bush (13) and the thrust washer (14)

from the differential support only if necessary.
NOTE: it is advisable to heat the bush (13) to make

easy this operation; this is a destructive operation
for the bush. 14
13
F27356
Take the front support (2) out from the axle housing
(6).
2
6
F27357
Remove the bolt (8) with the lube nibble (9).

Remove the bush (3) from the front support (2).
1
Remove the bushes (1) from the front support (2).
2
8
3
9
F27358
Remove the bush (4) and the thrust washer (5) from
the axle housing (6) only if necessary. 6 5

for the bush.
4
F27359
Assembly
Insert the thrust washer (14) into the differential sup-

port.
Heat the bush (13) at 110÷120°C (230÷248°F) than
assemble it to the differential support.
NOTE: if necessary assemble the bush (13) with a 14

pad and a hammer. 13
F27356
Apply sealant on the bushes (1) contact surface.

Assemble the bushes (1) to the rear support (10) 1
with a pad and a hammer.
10
F27355
Assemble the bush (12) in the rear support (10).
SWARNING
Align the bush hole with the bolt (8) hole.
Assemble the bolt (8).

12
10
8
F27360
Lubricate with grease a new O-ring (11).

Insert the O-ring (11) in the rear support (10).
11
10
F27353
Insert the rear support (10) on the differential sup-

port.
SWARNING
Do not damage the O-ring when inserting the rear 10
support on the axle housing.
Tighten the bolt (8) to the request torque and tighten

the lube nibble (9). 8
9 F27361
Insert the thrust washer (5) into the front support

seat. 6 5
assemble it to the axle housing (6).
NOTE: if necessary assemble the bush (4) with a

pad and a hammer. 4
F27359

Assemble the bushes (1) to the front support (2) with
a pad and a hammer.
1
F27362
Assemble the bush (3) into the front support (2) with
a suitable driver and a hammer.
SWARNING
2
8
Assemble the bolt (8). 3
F27363
Insert the front support (2) on the axle housing (6).

Tighten the bolt (8) to the request torque and tighten
the lube nibble (9). 2
6
8
9
F27364
STEERING CYLINDER
19
12
11
21 10
17
20
15
18
16 7
14 8 9
6
13
5
4
3
2 1
F27227
Disassembly
Loosen the nut (1) with enough turns till it is protrud-

ing over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel hous-
ing (2).
SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3
NOTE: this is a destructive operation for the nut (1). 1

2
F27228
Repeat the whole sequence at the other side.

Remove the tie rods (3) and (12) by loosing the nuts
(4) and (12) with a suitable wrench, then check them 11
conditions.
Unscrew the fastening screws (6) and take the
6
steering cylinder (7) out of its housing, if necessary 12
use a rubber hammer.
4
Remove only parts that need to be overhauled and/ 10
or replaced. 7
3 5
F27229
Remove the cylinder head (15) from the cylinder

body (19) and remove it from the rod (17). 21
Remove the rod (17) from the cylinder body (19). 19
Remove all the seals and O-rings (13, 14, 16, 18, 20
and 21) from the cylinder case (19), the cylinder 16 20
head (15), and the rod (17). 14
13
18
17
15
F27230
Assembly
Assemble new seals and O-rings (13, 14, 16, 18, 20

and 21) on the cylinder head (15), on the rod (17) 21
and on the cylinder body (19). 19
16
14 20
13
18
17
15
F27231
Assemble the cylinder head (15) on the rod (17).

Slide the pre-assembled rod (17) into the cylinder
body (19).
17
15
19
F27232
Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod 11
(17), then tighten to the requested torque.
6
12
4
10
7
17
3 5
F27233
Install the steering cylinder (7) already assembled

on the central body. 6
Assemble and tighten the screws (6) to the request-
ed torque.
F27504
Align the swivel housing (8) with the axle.

Screw the tie rod (12) so that its ball joint can be in- 11 12
serted into the swivel housing (8).
NOTE: it is important to unscrew the locknut (11) to

carry out this operation.
Repeat the whole sequence of the mentioned oper-

ations to the other side.
8
F27235
Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). 3
Assemble and tighten the locknut (1) to the request-
ed torque.
1
F27236
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been 11 12
carried out.
F27238
WHEEL HUB
19
12
18
11
18
20
21
10
9 17
8
7 16
6
5
4 22
3 15
13 14
2 12
F27365
Disassembly
Unscrew and remove the fastening screws (1) of the

cover (2). Remove the cover (2) and the O-ring (6).
6
F27366
Unscrew and remove the screws (3). Remove the

thrust washer (4).
Remove the wheel hub (7) using levers and a ham-

mer to facilitate the operation.
NOTE: collect the bearing (5). 7
F27368
Position the wheel hub (7) on a flat surface and re-

move the seal ring (9) with a lever.
NOTE: destructive operation for the seal ring (9). 7

5
Remove the bearing cups (5) and (8) using a ham-
mer and a suitable drift.
9
Remove the bearing (8) from the swivel housing
end, using a suitable extractor. 8
F27255
Unscrew and remove the fastening bolts (12) from

the upper (11) and lower (13) king pin. 12
SWARNING 11 13
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-
10
rent safety regulations to guarantee operator’s safe-
ty.
Remove the king pins (11) and (13).

F27370
Remove the swivel housing (10) from the axle

beam.
10
F27371
Remove the thrust washers (16) and (19) with the

bushes (17) and (18). 19
18
17
16
F27372
Assembly
If it has been previously removed, reassemble the

steering stop composed by the screw (15) and the
nut (14).
15
NOTE: do not tighten the nut (14) until the steering 14
angle adjustment has been done.
F37953
Insert the thrust washers (16) and (19) and the

bushes (17) and (18). 19
18
17
16
F27372
If ball joints (21) and (22) have been previously re-

moved, reassembly them on the upper king (11) and
the lower king pin (13).
22 21
13 11
F27374
Secure the swivel housing (10) with a belt or a rope

to a hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal 10
ring.
Assemble the swivel housing (10) on the axle beam.
F27371
Assemble the king pins, the lower (13) and the up-
per (11), and tighten the retaining screws (12) to the
requested torque.
12
11 13
F27375
Insert both bearing cups (5) and (8) to their wheel

hub (7) housings using the special tool 380002663
under a press or with a hammer.
Insert the seal ring (9) into the wheel hub (7) with the 5 8
special tool 380002227 and a hammer. 9
7
NOTE: do not lubricate the seal ring (9). 7
F27376
Assemble the bearing (8) on the swivel housing

(10). 10 7
Assemble the wheel hub (7) on the swivel housing
(10) and insert the bearing (5). 8 5
F27377
Assemble the thrust washer (4). Screw the screws

(3).
Assemble a new O-ring (6). Assemble the cover (2)

and screws two screws (1). Tighten the screws (1)
to the requested torque.
6
F27366
TOE-IN / STEERING ANGLE
11
1 2 3 11
3 2 1
5 5
4 4
F27339
Toe-in
Put two equal one-meter-long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.
SWARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm 500 mm
F27340
Measure the distance in mm M between the bars

ends with a tapeline.
NOTE: keep the minimum value, swinging the mea-

surement point.
F27341
Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the
requested tolerance range. A -02
The nominal toe-in value (A) is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be relat-
ed to the ratio between length of the bar and flange
diameter:
0 0 A
nominal toe-in = A - 2 measured toe-in = M - 5
M -05
F27342
If toe-in is incorrect, operate with two wrenches on

the steering rods (1) screwing in and out the two
1 3
joint tie rods (3) equally till the toe-in is within the re-
quested tolerance.
3 1
F27343
After adjusting, screw in the locknuts (2) of the

steering rods (1) to the requested tightening torque.
1 2
F27344
Steering angle adjustment
Use the same bars assembled for the toe-in adjust-

ment and a long bar perfectly leaned over the ma-
chined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.
F27345
Adjust a protractor to the requested angle and posi-

tion it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.
F27346
Adjust the mechanical steering stop, screwing in or

out the stop screw (4), locking them with the nut (5)
to the requested tightening torque.
5 4
F27347
Steer completely towards the other side and repeat

the same operation.
F27348
1.3 FAULT FINDING
PROBLEMS POSSIBLE CAUSES
1 2 3 4 5 6 7 8 9
Wheel vibration; front tire resistance; half shaft
breakage
Steering is difficult; vehicle goes straight while its
turning
Transmission excessively noisy
Uneven wear of tire
Friction noise
Vibration during forward drive, intermittent noise
1. Incorrect installation / defective axle

Correct installation or repair or replace the differential in case it does not survive any one of the test phases.
2. Overloading / incorrect weight distribution

Remove excessive weight and redistribute load, following instructions related to the vehicle.
3. Different rotation radius of the tires

If one tire has a smaller radius, it will cause partial wheel slipping when force is applied.The other tire with big-
ger radius will have to support all the work. Replace the tire or adjust pressure to have same radius on both tire.
4. Broken half shaft

It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few meters away only.
5. Bent half shaft

Replace half shaft.
6. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.
7. Spoiled or worn out axle parts

Check the condition bearings etc. Replace when ever necessary.
8. Contamination in the axle box or incorrect assembly of parts

Look for foreign particles. Check assembly of the various parts of the axle.
9. Incorrect use of the product

See the vehicle producer’s instructions once again.

Axle beam body bent Vehicle over loaded Replace axle beam body.
Vehicle’s accident
Load bump
Worn out or pitted bearings Insufficient lubrication Replace bearings.
Contaminated oil Use correct lubrication fill up, to the

right level and replace at
recommended intervals.
Excessive use
Normal wear out

Oil leakage form gaskets and Prolonged functioning at high Replace the gasket or seal and
seals temperature of the oil matching surface if damaged.
Oil gasket assembled incorrectly Use correct lubrication and replace

at recommended intervals.
Seal lip damaged
Contaminated oil
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.
2. FRONT AXLE 4WD “CARRARO”

TYPE
F27203
POWER SHIFT POWER SHUTTLE RATIO

• • 12.8
• / 12.333
/ • 13.714
/ • 14.308
LUBRICATION AND GREASING
Differential oil capacity 6.5 liters (1.70 US Gallon)

Epicyclic reduction gear oil capacity each side 0.7 liters (0.20 US Gallon)
Oil specification:
use recommended oil enriched in additives. Ambra
Note: do not use synthetic or vegetable oil without consent of the axle Mastertran NH 410 C
manufacturer
3 5 1 4 5 3
5 2 5
5 4 5
F27205
Air breather 2
Oil drain plug 4
Greasing points 5
Before draining the oil from axle housing, use the oil
breather (2) to release possible internal pressure. 2
SWARNING
F27206
drain plug (4).
SWARNING
Drain all oil.

torque.
1 4
F27207

internal pressure.
Screw the plug (1) to the prescribed torque.
1
F27208
Before draining the oil from wheel end rotate the

wheel end so that the plug (3) is at the highest posi-
tion [pos.A] and partially unscrew to release possi-
ble pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [pos.B].
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil.
Tighten the plug (3) to the requested torque.
TIGHTENING TORQUES
165 Nm
95 Nm 120 Nm 8 Nm 150 Nm 95 Nm 13 Nm
80 Nm 25 Nm 120 Nm 8 Nm 300 Nm 120 Nm 169 Nm
120 Nm
266 Nm 57 Nm
165 Nm
10 Nm 8 Nm 84 Nm 60 Nm 8 Nm 84 Nm
F27211
FRONT AND REAR SUPPORT
21
18
20
15 17
16 19
14
12
9
6 8
3 5 13
11
10
7
4
2
1
F27212
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1) from the pinion shaft end (14).
14
1 2
F27213
Loosen the bolt (4).

Take the rear support (5) out from the differential
support.
4
F27214
Remove the O-ring (6) from the bush (8) in rear sup-
port (5).
5
7
F27215
Remove the bolt (4).

5 8
4
F27216

6
F27217
Remove the cover (11) from differential support with

a lever.
11
F27218
Remove the O-ring (12) and the seal ring (13) from
the cover (11). 13
NOTE: destructive operation for the seal rings. 12
11
F27219

from differential support only if necessary.

for the bush. 10
9
F27220
Loosen the bolt (19).

Take the front support (20) out from the axle hous-
ing (15). 20
15
19
F27221
Remove the bolt (19).

Remove the bush (18) from the front support (20). 21
Remove the bushes (21) from front support (20).
20
18
19
F27222

from axle housing (15) only if necessary. 15 16

for the bush.
17
F27223
Assembly
Insert the thrust washer (10) into the differential sup-

port.
assemble it to the differential support.
If necessary assemble the bush (9) with a pad and
a hammer. 10
9
F27220
Assemble the seal ring (13) to the cover (11) with

the special tool 380002432 and a hammer. 13
Assemble the new O-ring (12) to the cover (11).
Lubricate the O-ring (12) and the seal ring (13). 12
11
F27219
Assemble the cover (11) to the differential support.
11
F27218
Apply sealant on bushes (6) contact surface.

Assemble the bushes (6) to the rear support (5) with 6
a pad and a hammer.
F27217
SWARNING

5 8
4
F27216

5
7
F27215
Insert the rear support (5) on the differential support.
SWARNING
Do not damage the O-ring when inserting the rear
support on the central body. 5
Tighten the bolt (4) to the requested torque.
4
F27214
Assemble the flange (2) to the pinion shaft end (14).

Lock the flange (1) with the bolt (2) and the nut (3).
Tighten the nut (3) to the requested torque.
14
1 2
F27213
Insert the thrust washer (16) into the front support

seat. 15 16
Heat the bush (17) at 110÷120 °C (230÷248°F) than
assemble it to the axle housing (15).

pad and a hammer.
17
F27223

Assemble the bushes (21) into the front support (20) 21
20
F27224
Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.
20
SWARNING 18
19
F27225
Insert the front support (20) on the body axle.

20
19
F27226
STEERING CYLINDER
19
12
11
21 10
17
20
15
18
16 7
14 8 9
6
13
5
4
3
2 1
F27227
Disassembly

ing (2).
SWARNING

2
F27228

conditions.
Unscrew the fastening screws (6) and take the
6
steering cylinder (7) out of its housing, if necessary 12
use a rubber hammer.
4
or replaced. 7
3 5
F27229

and 21) from the cylinder case (19), the cylinder 16 20
13
18
17
15
F27230
Assembly

and on the cylinder body (19). 19
16
14 20
13
18
17
15
F27231

body (19).
17
15
19
F27232
and (10), the nuts (4) and (11) to the ends of the rod 11
(17), then tighten to the requested torque.
6
12
4
10
7
17
3 5
F27233

on the central body. 6
Assemble and tighten the screws (6) to the request-
ed torque.
F27234

serted into the swivel housing (8).


8
F27235
Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). 3
ed torque.
1
F27236
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been 11 12
carried out.
F27238
EPICYCLIC REDUCTION GEAR
10
9
8
7
6
5
4
2
1
3
F27239
Disassembly
Drain the oil completely from the planetary carrier.
F27240
Unscrew and remove both fastening screws (3) of

the planetary carrier (1). 3
1
F27241
Remove the planetary carrier (1) from the wheel hub

and collect the relative O-ring (5). 1 5
Position the planetary carrier (1) on a workbench
and check its wear conditions.
F27242
If required replace the planetary gears as follows:

Z remove the snap rings (10) on every pin (4); 7
Z remove the triangular plate (9); 6
Z take the planetary gears (8) out of the pins;
Z collect the roller bearings (7), checking their condi-
tions;
Z collect the thrust washer (6).
10
NOTE: with new planetary gears is advisable to as- 9
sembly new roller bearings. 8
4
F27243
Assembly
Collect all epicyclic reduction gear parts: the plane-

tary carrier (1), the thrust washers (6), the needle 7
bearings (7), the planetary gears (8), the triangular 6
plate (9) and the snap rings (10) of every pin.
NOTE: with new planetary gears is advisable to as-

sembly new roller bearings.
10
9
8
1
F27244
Position the planetary carrier (1) on a workbench.

Insert the thrust washers (6) and the epicyclic gears 9
1 1 10
(8) in the planetary carrier pins.
Insert the needle bearings (7) in the epicyclic gears
(8).
NOTE: grease well the needles.
Assemble the triangular plate (9) and the related

snap rings (10).
6 7 8
F27245
Assemble a new O-ring (5) on the planetary carrier

(1). 1
Assemble the planetary carrier (1) on the wheel hub. 5 1
F27246
Assemble the screws (3) and tighten to the

requested torque. 3
1
F27241
Top up the oil on the wheel hub.

Assemble the plug (2) on the planetary carrier (1) 2
and tighten to the requested torque.
F27247
WHEEL HUB
28
19
27
18
24
14
22
13
26
12
25
23
11
10
9
8 15
7 21
4 16 20
3 17
2 5 6
F27248
Disassembly
Insert a lever between the swivel housing (14) and

the axle beam and fit it into the cardan shaft.
With the lever push the double U-Joint in the direc-
tion of the wheel hub to allow the lock ring removal.
SWARNING
Do not damage the cardan shaft.
14
F27249
Remove the snap ring (1) from the cardan shaft.

Collect the cardan shaft washers (2) and (3). 3 2
F27250
Unscrew and remove the fastening screws (5) from

the ring gear carrier (7).
7
F27251
In order to remove the wheel carrier group from its

housing, screw two of the just removed screws (5) 5
in the threaded extraction holes.
Extract and remove the ring gear carrier (7) together 7
with the ring gear (4).
4
F27253
Remove the steel lock ring (8) and disjoin the ring
gear carrier (7) from the epicyclic ring gear (4). 8
Only if necessary, remove the bushes (6) from the
wheel carrier with a hammer and the special tool 6
380002223.
7
F27252

mer to facilitate the operation. 15
F27254

move the seal ring (13) with a lever.

5
Remove the bearing cups (9) and (12) using a ham-
mer and a suitable drift.
9
end using a suitable extractor. 8
F27255
Unscrew and remove the fastening bolts (19) and

(17) from the upper (18) and lower (16) king pin.
17 19
SWARNING 16 18
rent safety regulations to guarantee operator’s safe- 14
ty.

F27256
Remove the swivel housing (14) from the axle beam

and from the short shaft of the cardan shaft.
14
F27257
Remove the spacer (27) from the upper king pin

housing.
27
F27258
Position the swivel housing (14) on a flat surface

and take the seal ring (23) out with a lever.
NOTE: destructive operation for the seal ring (23).

22
Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.
14 23
F27259
Assembly

steering stop composed by the screw (21) and the
nut (20).
NOTE: do not tighten the nut (20) until the steering

20 21
F27260
Insert the bush (22) into the swivel housing (14) with
the special tool 380002660 and a hammer or a
23 14
press.
Assemble the seal ring (23) on the swivel housing
22
(14) with the special tool 380002661 and a hammer.
Grease carefully the seal ring (23).
F27261
Assemble the spacer (27) in the upper king pin

housing.
27
F27258
If the cone (15) of the spherical joint has been pre-

viously removed, reassemble it to the lower king pin
(16) using the special tool 380002662 under a
15
press.
Grease carefully the seats of king pin (16) and (18)
16 28
25
with specific grease.
Position the belleville washers (25) and (28) on the 18 25
king pin (16) and (18) housings.
F27262

ring.
Assemble the swivel housing (14) on the axle beam.
F27257
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19
16 18
F27263
Assemble both bearing cups (9) and (12) to their

wheel hub (11) housings using the special tool
380002663 under a press or with a hammer.
Insert the seal ring (13) into the wheel hub (11) with
the special tool 380002227 and a hammer. 9 12 13
11 11
NOTE: do not lubricate the seal ring (13).
F27264

(14) end. 14
(14) and fit the bearing (9). 12 9
F27265
Position the ring gear carrier (7) on a workbench

and force the bushes (6) to the ring gear carrier (7) 6 7
surface level with the special tool 380002223.
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins.
F37835
Preassemble the ring gear carrier (7) and the ring

gear (4) with the lock ring (8). 8
7
4
F27267
Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub.
F27268
Insert all the hub dowel bushes (6) completely with

the special tool 380002223 and a hammer. 6 5
Apply sealant on the screw (5) thread.
Assemble the ring gear carrier (7) with the screws 7
(5) and tighten to the requested torque.
F27269
The special operation “Set Right” of the bearings (9)

and (12) does not require preload or backlash ad-
justment. Anyway, before assembling new compo-
nents check the indicated dimensions.
A= 11.975 ÷ 12.025 C A C
B= 52.229 ÷ 52.279
C= 20.000 ÷ 20.100
B
F27270
Insert a lever between the swivel housing and the

axle beam and fit it into the cardan shaft.
With the lever push the cardan shaft in the direction
of the wheel hub to make easier the lock ring inser-
tion.
F27271
Slide the thrust washers (2) and (3) onto the cardan
shaft end. 3 2
Insert the snap ring (1) at the end of the splined hub
and push it into its seat.
NOTE: check that the snap ring (1) is correctly fitted

1
in its seat.
Push the cardan shaft thoroughly.
F27250
CARDAN SHAFTS
1 2
4
5
6
F27272
Disassembly
Remove the cardan shaft (6) from the axle beam (1).
1
6
F27273
Remove the seal rings (5) from the axle beam.
NOTE: destructive operation for the seal rings (5).

4
Remove the bush (4) from the axle beam only if the 5
wear conditions require this.
SWARNING
Be careful not to damage the bush seat.
5
F27274
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.
F27275
Assembly
Cool the upper king pin bush (2) and the ball bearing
cup (3) at a temperature lower than -100 °C (-148°F)
with liquid nitrogen.
2
SWARNING
Wear safety gloves.
Assemble the bush (2) on the upper king pin seat with
the special tool 380002664 and a hammer. 3
Assemble the ball bearing cup (3) on the lower king pin
seat with the special tool 380002662 and a hammer.
F27276
Assemble the bush (4) on the axle beam (1) with the
special tool 380002665 and a hammer.
Assemble the seal ring (5) on the axle beam with the
1
4
NOTE: grease carefully the seal rings. 5
F27277
Assemble the seal ring (5).
SWARNING 5
Positioning the seal ring (5) as in figure
F27278
Insert the cardan shaft (6) inside the axle beam (1).
SWARNING
Be careful not to damage the seal ring.
1
6
F27273
DIFFERENTIAL SUPPORT
9 8 13
12
11
10
7
6
14
8
5
4
2 3
1
F27282
Disassembly
Drain the oil completely from the differential.

Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).
14
SWARNING
Support the differential support with a rope or other 2
appropriate means.
1
F27283
Loosen and remove the screws (9) to take out the

two ring nut retainers (8). 9 9
8 8
F27284
Before removing the bolts, mark both half-collars

(11) and the differential support with permanent ref-
erence marks to avoid inverting them during re-as-
sembly. Mark the area between the ring nuts (3) and 11
(7) and the differential support (1) as well.
3
F27285
Unscrew the adjuster ring nuts (3) and (7) using

tools 380000406 and a wrench.
F27286
Remove the 4 screws (12) and remove both half-

collars (11).
NOTE: check that the bushes (10) remains in their 12

housings.
11
10
F27287
Remove the differential group (5).

The bearing (4) and (6) are removed together with
the differential group.
4
SWARNING 6
Do not invert the bearings if they are not replaced.
5
F27288
Assembly
Assemble the bearings (4) and (6) on the differential

group (5).
SWARNING
4
6
5
F27289
Position the complete differential group with bear-

ings on the differential carrier.
SWARNING
Check the right side of the bevel crown assembly.
F27290
Move the differential group so to place the bevel

crown gear on the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using 12
the previously traced reference marks.
Lock both half-collars with the screws (12).
11
10
F27291
Assemble the adjuster ring nuts (3) and (7) to the

differential support.
Tighten both ring nuts (3) and (7) with special tools
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded. 3
Check that the differential bearings are well settled; 7
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.
F27292
Position a magnetic-base dial gauge on the differen-

tial support, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle.
F27293
Lock the pinion and move the crown gear alterna-

tively and note the pinion-ring gear backlash, mea-
sured with the comparator.
Repeat the operation on 2 or more points (teeth), ro-
tating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.18÷0.25 mm (0.007÷0.010 in)
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27294
Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the giv-
en tolerance range, unscrew the adjuster ring A A
nut (3) and screw in the adjuster ring nut (7) by
the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the B B
same measure.
F27295
Once the adjustment of the pinion-ring gear back-

lash has been carried out, check also that there is a
minimum preloading on the differential box bear-
ings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
F27293
Once the pinion-ring gear backlash has been estab-

lished, measure the total preloading (T) of the bear-
ings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion
splined end. The measured value should be within
the following range:
T = (P+3.90) ÷ (P+5.90) daN
T = (P+8.77) ÷ (P+13.3) lbf
where P is the effectively measured pinion preload-
ing.
See section “Pinion assembly”.
F27296
SWARNING
All preloadings must be measured without seal ring.
If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of A A
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion-
ring gear backlash value unchanged. B B
(B)- if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (3) and
ring gear backlash value unchanged. F27297
Once all the adjustment operations have been com-

pleted, fit the ring nut retainers (8) and their screws 9
(9), tightening them to the requested torque.
8
F27298
Tighten the bolts (12) of both half collars (11) to the

requested torque.
12
13
F27299
Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with ap- 13
propriate detergents.
Spread a film of adhesive on the contact surface be-
tween the axle beam (14) and the differential carrier. 14
NOTE: check that two dowel pins (13) are in their 13
housing.
F27300
Position the differential support (1) on the axle hous-

ing (14), and tighten the retaining screws (2) to the
requested torque.
14
F27301
Bevel gear marking test
To test the marks of the bevel gear teeth, paint the

ring gear with red lead paint.
The marking test should be always carried out on
the ring bevel gear teeth and on both sides.
F27302
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
Z
OK
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in or-
der to adjust the backlash. X
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in or-
der to adjust the backlash.
F27303
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
1
F27304
DIFFERENTIAL GROUP
Disassembly
Use an extractor to remove the bearing (12).
12
F27306
F27307
Unscrew all fastening screws (1) of the bevel gear

crown (11). 11
SWARNING 1
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
F27308
Remove the bevel gear crow (11) by means of a

mallet.
11
F27309
Check marking points (3) and (10) that will be useful

during the assemblage.
10
F27310
Disassemble the two differential half housing (3)

and (10).
Disassemble all the components.
Check the operating and wear conditions of the
components.
Assemble
Position a half housing (3) on a workbench and as-

semble all inner components: the discs (4), the
gears (5), the shaft (9), the gears (7), the spheric
washers (6) and the pin (8).
Assemble the two differential half housings (3) and

(10).
10
SWARNING
Carefully check that the marks of both differential
half boxes coincide.
F27310
Assemble the bevel gear crow (11) by using a ham-

mer.
11
F27314
Apply Loctite 242 on thread of the screws (1).
1
F27316
Tighten the screws (1) to the requested torque.
F27315
Press the bearing (12) or assemble after preheat-

ing.
12
F27317
Press the bearing (2).
F27318
PINION GROUP
Disassembly
Position the differential carrier in a vise.

Unscrew the ring nut (10) using special tool
380002218.
NOTE: this operation will irretrievably damage the

ring nut (10).
10
F27320
Remove the ring nut (10) and collect its washer (9).
9
10
F27321
Tap the shaft with a soft hammer to remove the bev-

el pinion (1). 8
SWARNING
Take care not to lower the bevel pinion (1). 5
1
Collect the washers (4) and (6), the spacer (5) and
the bearing (8).
6
4
F27322
Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and
a hammer. 3
8
F27326
To remove the bearing (3) of the bevel pinion (1),

use an extractor.
Collect the bearing (3) and the shim (2).
3
F27324
Check all pinion components for wear.
SWARNING
The ring nut (10) and the spacer (5) must be re- 5
placed when reassembling the unit.
10
F27325
Assembly
Place the differential support (7) on a workbench.

Fit the bearing cups (3) and (8).
3
8
F27326
Prepare the kit consisting of the special tools called

“false pinion” 380002219 and “false differential box”
380000407 + 380000440 and a depth gauge.
F27327
Insert the bearing (3) and (8) in their housings.

Assemble the “false pinion” 38002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the back-
lash is eliminated.
8
10
F27328
Install “false differential box” special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.
7
F27329
Assembly diagram of the “false differential box”

tools 380000407 + 380000440 on the bearing differ-
ential support seats. X
Use a depth gauge to measure distance “X” (dis-
tance between the axis of the differential bearings
and the point at which the pinion head is supported, X
or base of the bearing).
F27330
In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = request-
ed conical distance), from the measured value (X).
S = X-V mm
V
F27331
Select the shim (2) of thickness value (S) among the

range of available shims.
F27332
Remove the “false differential box” special tool from

the differential supports (7).
Remove the ring nut (10), the “false pinion” and the
bearing (3) and (8).
8
10
F27328
Once you have chosen and insert the suitable shim

(2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special 3 5 6
tool under 380002224 a press, making sure that it is
well set.
2 4
Insert the shims (4) and (6) and a new spacer (5).
NOTE: use always a new spacer (5). 1 1
F27334
Insert the bevel pinion (1) unit into the differential

support housing (7) and the bearing (8). 8
In order to force the bearing (8) into position, use an
hammer.
It is advisable to offer resistance, for example a
7
sledge, to the beating force.
1
F27335
Insert the washer (9) and screw a new ring nut (10)
on the bevel pinion.
9
10
F27321
Screw the ring nut (10) in, using the wrench

380002218 for ring nut and for pinion retainer.
SWARNING
The torque setting is given by the preloading mea-
surement on bearings; tighten the ring nut (10) grad-
ually.
10
NOTE: if the tightening is excessive, the collapsible

spacer must be replaced and the procedure repeat-
ed. When you check the preloading, it is advisable F27336
to beat slightly both pinion ends with a soft hammer,

so as to help setting the bearings.
Carry out the preloading measurement P of the pin-

ion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.
P = 9.2÷13.7 daN (20.7÷30.8 lbf)
SWARNING
All preloadings must be measured without the seal
ring. F27337
Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.
F27338
11
1 2 3 11
3 2 1
5 5
4 4
F27339
Toe-in

SWARNING
bars.
500 mm 500 mm
F27340


surement point.
F27341

diameter:
0 0 A
M -05
F27342

1 3
quested tolerance.
3 1
F27343

1 2
F27344

steering.
F27345

F27346

out the stop bolt (4), locking them with the locknut
5 4
F27347

the same operation.
F27348
2.3 FAULT FINDING
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tire resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while its turning
No differential action; jamming while
steering
Uneven wear of tire
Friction noise
Vibration during forward drive, intermittent
noise




5. Bent half shaft

Replace half shaft.
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.


Check the condition of ring gear, pinion gear, bearings etc. Replace when ever necessary.

10. Incorrect adjustment of bevel gear set: Parts of the transmission worn out.
(transmission gears, U joints, etc.)
Replace or adjust as required.


Ring gear tooth broken on the Excessive gear load compared to Replace bevel gear set
outer side the one foreseen Follow carefully the recommended
Incorrect gear adjustment operations for the adjustment of
(excessive backlash) bevel gear set backlash
Pinion nut loose
Ring gear tooth broken side Load bump Replace bevel gear set
Incorrect gear adjustment Follow carefully the recommended
(insufficient backlash) operations for the adjustment of
Pinion nut loose bevel gear set backlash.
Pinion or ring gear teeth worn Insufficient lubrication Replace bevel gear set.
Contaminated oil Follow carefully the recommended
Incorrect lubrication or depleted operations for the adjustment of
additives bevel gear set backlash.
Worn out pinion bearings that Use correct lubricants, fill up to the
cause an incorrect pinion axle right levels and replace according to
backlash and wrong contact the recommended program.
between pinion and ring.
Overheated ring and pinion teeth. Prolong and functioning at high Replace bevel gear set.
See if gear teeth have faded temperatures Use proper lubrication, fill up to right
Incorrect lubrication level and replace at recommended
Low oil level program.
Contaminated oil
Pinion teeth pitting Excessive use Replace bevel gear set.
Insufficient lubrication Use correct lubrication, fill up to the
right level and substitute at
recommended intervals
Axle beam body bent Vehicle over loaded Replace axle beam body
Vehicle's accident
Load bump
Excessive use right level and replace at
Normal wear out recommended intervals
Pinion nut loose
Seal lip damaged at recommended intervals.
Contaminated oil
Excessive wearing out of input Exhaustive use Replace the flange.
flange spline Pinion nut loose Check that the pinion spline is not
Pinion axle backlash excessively worn out.
Replace bevel gear set if required.
Fatigue failure of pinion teeth Exhaustive use Replace bevel gear set
See if the fracture line is well Continuous overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage Crash load of differential Check and/or replace other
components differential components.
Side gear spline worn out. Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required
(Excessive backlash)
Thrust washer surface worn out 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 0,1mm 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
3. FRONT AXLE 4WS “CARRARO”

TYPE
F27378
ASSALI POSTERIORI 4WS
POWERSHIFT SELF LOCKING RATIO

• • 18.46
Oil capacity 11.0 liters (2.9 US Gallons)

Oil specification:
use recommended oil enriched in additives.
Ambra Multi G NH 410 B
Note: do not use synthetic or vegetable oil without consent of the axle
manufacturer
1 4
3 5 5 3
5 2 5
5 5
F27379
Air breather 2
Oil drain plug 4
Greasing points 5
Before draining the oil from axle housing, use the

breather (2) to release possible internal pressure.
SWARNING
drain plug (4).
SWARNING
Drain all oil.

torque.

internal pressure.
Screw the level plug (1) to the prescribed torque.
Before draining the oil from wheel end rotate the

wheel end so that the plug (3) is at the highest posi-
tion [pos.A] and partially unscrew to release possi-
ble pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [pos.B].
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil.
Tighten the plug (3) to the requested torque.
FRONT AND REAR SUPPORT
21
18
22
17
15 16
19
23
7
6
8
5
11
1 14
3 10
4
9
12
13
2 F27380
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1).
1
3
2
F27381
Remove the ring seal (13).
13
F27382
Unscrew the screws (11) and remove the flange

(12).
12
11
F27383
Loosen the screw (4).

Take the rear support (5) out from the differential
support.
4
F27384
Remove the O-ring (7) from the rear support (5).
5
F37918
Remove the bolt (4) and the lube nibble (9).

8
5
4
9
F27386

6
F27217
Remove the washer (10) from the differential sup-

port only if necessary.
10
F27387
Loosen the screw (19).

Take the front support (20) out from the axle hous- 20
ing (15). 15
19
F27388
Remove the O-ring (22).

Remove the bolt (19) and the lube nibble (23). 21
Remove the bush (18) from the front support (20).
Remove the bushes (21) from front support (20).
20
19
18
23
22
F27389
Remove the bush (17) and the washer (16) from the
axle housing (15) only if necessary. 17
15
for the bush.
16
F27390
Assembly
Insert the washer (10) into the differential support.
10
F27387

Assemble the bushes (6) to the rear support (5) with 6
a pad and a hammer.
F27217
SWARNING

5 8
4
F27216

5
7
F27215
Insert the rear support (5) on the differential support.
SWARNING
Do not damage the O-ring when inserting the rear 5
support on the central body.

Assemble the lube nipple (9).
4
9
F27391
Insert the washer (16) into the front support seat.

Heat the bush (17) at 110÷120°C (230÷248°F) than 17
assemble it to the axle housing (20). 15
pad and a hammer.
16
F27390

Assemble the bushes (21) to the front support (20) 21
20
F27224
Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.
SWARNING 20
Align the bush hole with the bolt (19) hole. 19
18
Mount the bolt (19). 22
Assemble O-ring (22).
F27393
Insert the front support (20) on the body axle.

Tighten the bolt (19) to the requested torque. 20
Assemble the lube nibble (23).
19
23
F27394
Assemble the flange (12) and fasten by tightening

the screws (11).
12
11
F27383
Assemble the seal ring (13) use the special tool

380002225.
13
F27382
Assemble the flange (1) and lock it.

Lock with the screw (2) and the nut (3).
Tighten the nut (3) to the requested torque.
1
3
2
F27381
STEERING CYLINDER
24
23
22
10
21
9
13 20
8
19
14 18
7
6
5
4
3
17 12
16 11
15
1
F27396
Disassembly

ing (2).
SWARNING

2
F27228

13
conditions.
Unscrew the fastening screws (13) and take the 10
14
steering cylinder (7). 9
15
or replaced. 7
6
5
4
3
F27397

and 24) from the cylinder body (22), the cylinder 24
17
16 21
19
18 F27398
Assembly

and on the cylinder body (22).
24
17 22
16 21
20
19
18
F27392

body (22).
22
20
18
F27399
and (10), the nuts (4) and (9) to the ends of the rod,
then tighten with a dynamometric wrench to the re-
quested torque. 10
9
8
7
6
5
4
3
F27400

on the central body.
Assemble and tighten the screws (13) with dynamo-
metric wrench to the requested torque.
Assemble bracket (14).

serted into the swivel housing (11) arm.


11
F27402
Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). 3
ed torque.
1
F27236
Screw the locknuts (4) and (9) of the tie rods (3) and
(10) only when the toe-in adjustment has been car- 4 9 3 10
ried out.
F29526
11
9
10
8
7
6
5
1
3
2
F27404
Disassembly
F27240

the planetary carrier (1). 3
1
F27241
Remove the planetary carrier (1) from the wheel

hub.
F27405
If required replace the planetary gears as follows:

Z unscrew the screws (11) on every pin (4); 4 10
Z remove the washers (8) and (9);
Z take the planetary gears (7) out of the pins;
Z collect the roller bearings (7), checking their condi-
tions; 11
Z collect the washer (6). 9
8
NOTE: with new planetary gears is advisable to as- 7
sembly new roller bearings. 6
5
F27406
Assembly
Position the planetary carrier (1) on a workbench.

Insert in the pins of the planetary gears carrier the 1 10
washers (5) and the planetary gears (7) complete
with the rollers (6).
Assemble the washers (8) and fasten them with the
pins (10). 11
Fit the washers (9) and screw in the screws (11) by 9
tightening them at the prescribed torque. 8
7
NOTE: with new planetary gears it is advisable to 6
assembly new roller bearings. 5
F29008
Assemble the planetary carrier (1) on the wheel hub.
F27405
Assemble the screws (3) and tighten to the

requested torque. 3
F27407
Top up the oil on the wheel hub.

Fit the plug (2) on the planetary carrier (1) and tight- 2
en to the requested torque.
F27408
WHEEL HUB
19
26
18
24
27
14
22
13
12
25
11 23
10
9
8 15
7 21
4 16 20
3 17
2 5 6
F27409
Disassembly

of the wheel hub to allow the lock ring removal.
SWARNING
14
F27410
Remove the lock ring (1) from the cardan shaft.

F27250
Unscrew and remove the fastening screws (5) from

the ring gear carrier (7).
7
F27251
In order to remove the ring gear carrier group from

its housing, screw two of the just removed screws 5
(5) in the threaded extraction holes.
Extract and remove the ring gear carrier (7) together 7
with the ring gear (4).
4
F27253
Remove the steel lock ring (8) and disjoin the ring
gear carrier (7) from the ring gear (4). 8
ring gear carrier with a hammer and the special tool 6
380002667.
7
F27252

mer to facilitate the operation. 15
F27254

move the seal ring (13) with a lever. 13
12
Remove the bearing cups (9) and (12) using a ham- 10
mer and a suitable drift. 9
end using a suitable extractor.
F27412

17 19
SWARNING 16 18
ty.

F27256

and from the cardan shaft.
14
F27257
Collect the belleville washers (25) and (26).
26
25
F27413

NOTE: this is a destructive operation for the seal

ring. 22
14 23
F27259
Assembly

steering stop composed by the screw (21) and nut
(20).

20 21
F27260
Assemble the bush into the swivel housing (14) with

the special tool 380002668 and a hammer or a
23 14
press.
22
(14) with the special tool 380002669 and a hammer.
Grease carefully the seal ring (23).
F27261

moved, reassembly them on the lower (16) and up-
per king pin (18).
Grease well the king pin housings (16) and (18) with 27 15
specific grease 26
Position the Belleville washers (25) and (28) on the 18 16
king pin housings. 25
F27414

ring.
F27257
17 19
16 18
F27263
Assemble both bearing cups (9) and (12) to their

wheel hub (11) housings using the special tool
380002222 under a press or with a hammer.
Insert the seal ring (13) into the wheel hub (11) with
the special tool 380002213 and a hammer. 13 9 12
NOTE: do not lubricate the seal ring (13). 11 11
F27525

(14). 14
F27265

and force the bushes (6) to the ring gear carrier sur- 6 7
face level with the special tool 380002667.
F37835
Preassemble the ring gear carrier (7) and the epicy-

clic ring gear (4) with the lock ring (8). 8
7
4
F27267
Assemble the ring gear carrier group on the wheel

hub using the two projecting bushes as dowel pins
and screw the relative screws in order to put in con-
tact the ring bevel gear with the wheel hub.
F27268
Force all the hub dowel bushes (6) completely with

Apply sealant on fastening bolts (5) thread.
Assemble the ring gear carrier (7) fastening bolts (5) 7
F27269

of the wheel hub to make easier the lock ring inser-
tion.
14
F27410
Assemble the thrust washers (2) and (3) into the

cardan shaft.

in its seat.
3 2 1
F27416
CARDAN SHAFTS
1
2
3
4
F27417
Disassembly
1
4
F27418
Remove the seal rings (3) from the axle beam (1).
1
NOTE: destructive operation for the seal rings (3). 2
3
Remove the bush (2) from the axle beam (1) only if
the wear conditions require this.
SWARNING
3
F27419
Assembly
Assemble the bush (2) on the axle beam (1) with the
1
2
NOTE: grease carefully the seal rings. 3
F27420
F27421
SWARNING
1
6
F27273
DIFFERENTIAL SUPPORT GROUP
9 8 13
12
11
10
7
6
14
8
5
4
2 3
1
F27411
Disassembly
Drain the oil completely from the differential.

Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).
SWARNING
Support the differential support with a rope or other
appropriate means.
2
14
1
F27501
Loosen and remove the screws (9) to take out the

two ring nut retainers (8). 9
9
8
8
F27395
Before removing the bolts, mark both half-collars

(11) and the differential support with permanent ref-
erence marks to avoid inverting them during re-as-
sembly. Mark the area between the ring nuts (3) and 11
(7) and the differential support (1) as well.
3
F27422
Unscrew the adjuster ring nuts (3) and (7) using

tools 380000406 and a wrench.
F27423
Remove the 4 screws (12) and remove both half-

collars (11).
NOTE: check that the bushes (10) remains in their 12

housings.
11
10
F27424
Remove the differential group (5).

The bearings (4) and (6) are removed together with
the differential housing.
4
SWARNING 6
Do not invert the bearings if they are not replaced. 5
F27425
Assembly
Assemble the bearings (4) and (6) on the differential

group (5).
SWARNING
4
6
5
F27289
Position the differential group with bearings on the

differential carrier.
SWARNING
Check the right side of the bevel crown assembly.
F27427
Move the differential group so to place the bevel

crown gear on the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using 12
the previously traced reference marks.
Lock both half collars with the screws (12). 11
10
F27428
Assemble the ring nuts (3) and (7) to the differential

support.
Tighten both ring nuts (3) and (7) with special tools
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded.
Check that the differential bearings are well settled; 3
7
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.
F27429
Position a magnetic-base dial gauge on the differen-

tial support, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle.
F27293
Lock the pinion and move the crown gear alterna-

tively and note the pinion-ring gear backlash, mea-
sured with the comparator.
Repeat the operation on 2 or more points (teeth), ro-
tating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.18÷0.25 mm (0.007÷0.010 in)
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27430
Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the giv-
en tolerance range, unscrew the adjuster ring A A
nut (3) and screw in the adjuster ring nut (7) by
the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the B B
same measure.
F27295
Once the adjustment of the pinion-ring gear back-

lash has been carried out, check also that there is a
minimum preloading on the differential box bear-
ings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
F27431
Once the pinion-ring gear backlash has been estab-

lished, measure the total preloading (T) of the bear-
ings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion
splined end. The measured value should be within
the following range:
T = (P+3.90) ÷ (P+5.90) daN
T = (P+8.77 ÷ (P+13.3) lbf
where P is the effectively measured pinion preload-
ing.
See section “Pinion assembly”.
F27432
SWARNING
All preloadings must be measured without seal ring.
If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of A A
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
ring gear backlash value unchanged. B B
(B)- if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (3) and
ring gear backlash value unchanged. F27297
Once all the adjustment operations have been com-

pleted, fit the ring nut retainers (8) and their screws 9
(9), tightening them to the requested torque.
8
F27298
Tighten the bolts (12) of both half collars (11) to the

requested torque.
12
11
F27434
Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with ap-
propriate detergents. 13
Spread a film of adhesive on the contact surface be-
tween the axle beam (14) and the differential carrier
(1).
NOTE: check that two dowel pins (13) are in their

housing.
14
F27435
Position the differential support (1) on the axle hous-

ing (14), and tighten the retaining screws (2) to the
requested torque.
2
14
1
F27501
Bevel gear marking test
To test the marks of the bevel gear teeth, paint the

ring gear with red lead paint.
The marking test should be always carried out on
the ring bevel gear teeth and on both sides.
F27302
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
Z
OK
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in or-
der to adjust the backlash. X
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in or-
der to adjust the backlash.
F27303
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
1
F27304
DIFFERENTIAL GROUP (STANDARD)
8
1
11
10
9
13
12
7
6
8
7
6
5
4
3
2
F27437
Disassembly
10
F27438
F27307

crown (11). 11
SWARNING 1
nents.
F27308

mallet.
11
F27309

9
F27439
Remove the planetary gear (5) and the shim (4).

4
F27440
Remove the shaft (8), the gears (7) and the spheric
washers (6).
6 6
7 7
F27441
Remove the gear (12) and the shim (13).

12
13
F27442
Assemble
Apply a thin layer of Molicote G-n plus paste on the

half housing of the differential (3) and (9). 3 9
SWARNING
Remove rests of dope.
F27443

gears (5), (12), and on the gears (7). 7
12
F27444
Assemble the gears (12) with the shim (13).

12
13
F27442
Assemble the shaft (8) and the gears (7) and the
spheric washers (6).
6 6
7 7
F27441
Assemble the gear (5) with the shim (4).

4
F27440
Assemble the two half housing of differential unit (3)

and (9).
9
SWARNING
half boxes coincide.
F27439

mer.
11
F27314
Apply Loctite 242 on the thread of the screws (1).
1
F27316
F27315

ing.
10
F29010
F27318
DIFFERENTIAL GROUP (SELF-LOCKING)
14
10
13
8
12
9
5
1
4
6
11
10
8
9
7
6
5
4
3
2
F27448
Disassembly
13
F27449
F27307
Unscrew all the astening screws (1) of the bevel

gear crown (14). 14
SWARNING 1
nents.
F27446

mallet.
14
F27450

12
F27451
Remove the discs (4) and (5).

4 5
F27452
Remove the planetary gear (11).

11
F27453
Remove the shaft (10), the gears (8) and the spheric
washers (9).
9 9
8 8
10
F27454
Remove the gear (7).
F27455
4 5
F27456
Assemble

SWARNING
F27457

gears (7), (11), and on the gears (8). 8
11
F27458
Assemble the discs (4) and (5).
4 5
F27456
Assemble the gear (7).
F27455
Assemble the differential unit pin (10) and the plan-

etary gears (8) and the spheric washers (9).
9 9
8 8
10
F27454
Assemble the gear (11).

11
F37839

4 5
F27452
Assemble the two half housing of the differential unit

(3) and (12).
12
SWARNING
half housing coincide.
F27451
Fit the bevel gear crow (14) by using a hammer.
14
F29320
Apply Loctite 242 on the thread of the screws (1).
1
F27316
F27315

ing.
13
F27460
F27318
PINION GROUP
1
2
3
4
5
6
7
8
9
10
F27461
Disassembly
Position the differential carrier in a vise.

Unscrew the ring nut (10) using special tool
380002218.
NOTE: this operation will irretrievably damage the

ring nut (10).
10
F27462
Remove the ring nut (10) and collect its retaining

washer (9).
9
10
F27463
Tap the shaft with a soft hammer to remove the bev-

el pinion (1). 8
SWARNING
Take care not to lower the bevel pinion (1).
5
Collect the washers (4) and (6), the spacer (5) and 1
the bearing (8).
6
4
F28106
Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and 3
a hammer.
7
8
F28107
To remove the bearing (3) of the bevel pinion (1),

use an extractor.
Collect the bearing (3) and the shim (2).
3
F27324
Check all pinion components for wear.
SWARNING
The ring nut (10) and the spacer (5) must be re- 5
placed when reassembling the unit.
10
F27325
Assembly
Place the differential support (7) on a workbench.

Fit the bearing cups (3) and (8). 3
8
F28107
Prepare the kit consisting of the special tools called

“false pinion” 380002219 and “false differential box”
380000407 + 380000440 and a depth gauge.
F28108
Insert the bearing (3) and (8) in their housings.

Assemble the “false pinion” 380002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the back-
lash is eliminated.
3
8
10
F28109
Install “false differential box” special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.
F28110
Assembly diagram of the “false differential box”

tools on the bearing differential support seats.
Use a depth gauge to measure distance “X” (dis- X
tance between the axis of the differential bearings
and the point at which the pinion head is supported,
or base of the bearing). X
F28111
In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = request-
ed conical distance), from the measured value (X).
S = X-V mm
V
F27331
Select the shim (2) of thickness value (S) among the

range of available shims.
F27332
Remove the “false differential box” special tool from

the differential supports (7).
Remove the ring nut (10), the “false pinion” and the
bearing (3) and (8).
3
8
10
F28109
Once you have chosen and insert the suitable shim

(2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special 3 5 6
tool 380002224 under a press, making sure that it is
well set.
2 4
Insert the shims (4) and (6) and a new collapsible
spacer (5).
1 1
NOTE: use always a new spacer (5).
F27334
Insert the bevel pinion (1) unit into the differential

support housing (7) and the bearing (8). 8
In order to force the bearing (8) into position, use the
It is advisable to offer resistance, for example a
sledge, to the beating force. 5
1
6
4
F28112
Insert the washer (9) and screw a new ring nut (10)
on the bevel pinion.
9
10
F27463
Screw the ring nut (10) in, using the wrench

380003218 for ring nut and for pinion retainer.
SWARNING
surement on bearings; tighten the ring nut (10) grad-
ually.
10
NOTE: if the tightening is excessive, the collapsible

spacer must be replaced and the procedure repeat-
ed. When you check the preloading, it is advisable F27445
to beat slightly both pinion ends with a soft hammer,

so as to help setting the bearings.
Carry out the preloading measurement P of the pin-

ion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
nut torque gradually, being careful not to exceed.
P = 9.2÷13.7 daN (20.7÷30.8 lbf)
SWARNING
All preloadings must be measured without the seal
ring. F27432
Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.
F27338
1 2 3 3 2 1
5 5
4 4
F28113
Toe-in

SWARNING
bars.
500 mm 500 mm
F27340


surement point.
F27341

diameter:
0 0 A
M -05
F27342

1 3
quested tolerance.
3 1
F27343

1 2
F27344

steering.
F27345

F27346

5 4
F27347

the same operation.
F27348
3.3 FAULT FINDING
1 2 3 4 5 6 7 8 9 10 11
shaft breakage
while its turning
steering
Uneven wear of tire
Friction noise
noise




5. Bent half shaft

Replace half shaft.
components.





Pinion nut loose
Overheated ring and pinion teeth. Prolong and functioning at high Replace bevel gear set.
Contaminated oil
Vehicle's accident
Load bump
Pinion nut loose
Contaminated oil
defined
than the new ones.
intervals.
overloaded
4. SPECIAL TOOLS
P/N CNH USE 2WD 4WD 4WS

380000406 Disassembly/assembly of differential ring nuts / • •
380000407 + Calculation of pinion assembly shims / • •
380000440
380002213 Assembly of seal ring in the wheel hub / / •
380002218 Disassembly/assembly of pinion rings / • •
380002219 Calculation of pinion assembly shims / • •
380002222 Assembly of bearing cups in the wheel hub / / •
380002223 Disassembly and assembly bushings in the crown retainer hub / • /
380002224 Assembly of pinion bearing / • •
380002225 Assembly of mounting flange seal / / •
380002226 Assembly of bushing in the half beam / / •
380002227 Assembly of seal ring in the wheel hub • • /
380002432 Assembly of sliding block in the swivel housing / • /
380002660 Assembly of bushing in the swivel housing / • /
380002661 Assembly of seal ring in the swivel housing / • /
380002662 Assembly of spherical joint on lower and upper king pin / • /
380002663 Assembly of bearing cups in the wheel hub • • /
380002664 Assembly of bushing in the seat of the upper king pin / • /
380002665 Assembly of bushing in the half beam / • /
380002666 Assembly of seal ring in the half beam / • /
380002667 Disassembly/Assembly of bushings in the crown retainer hub / / •
380002668 Assembly of bushing in the swivel housing / / •
380002669 Assembly of seal ring in the swivel housing / / •
380002670 Assembly of seal ring in the half beam / / •
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 27 - REAR AXLE
1. REAR AXLE 2WS ......................................................................................................................................... 3

1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.4 FAULT FINDING.................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.3 FAULT FINDING.................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
2 SECTION 27 - REAR AXLE
SECTION 27 - REAR AXLE 3
1. REAR AXLE 2WS

The rear axle is an rigid axle and is fixed by 4 bolts

to the chassis with a torque value of 800 Nm (590
lbf·ft). It incorporates the following features:
Z mechanically differential unit;
Z hydraulically operated oil immersed foot brakes fit-
ted with four disc brakes;
Z planetary reduction carrier with 3 planetary gears.
Power from the transmission output shaft is trans-
mitted to the rear axle through the flange (1), the 1 2 3
brake pads (2) and the half shaft (3) to the rear fire.
The bevel pinion is located in preloaded roller bear-
ings.
The differential is located on two roller bearings, the
right hand bearing supported by an internal web of
the axle center housing.
The crown is fixed to the differential housing. Drive
from the housing is transmitted through a four pinion
differential to sun gear shafts which are splined into
the differential side gears. 6 5 4
The differential lock sliding coupling is located on the F29546
splines of the right hand differential side gear. The

coupling has dog teeth which engage with the dog
teeth on the differential housing lock adaptor.
If the dog teeth are not aligned, the spring engage-
ment link will be preloaded, ensuring rapid and full
tooth engagement when the dog teeth align.
The differential lock will remain engaged due to dog
tooth side loading as long as the rear wheels have
unequal traction.
The return spring disengages the lock when both
wheels have equal traction or drive is disengaged.
The brakes are mounted on the final reduction sun
gears. These brakes are wet disc type with hydraulic
piston actuator operated by foot pedals, indepen-
dently for turning assistance, or together fro trans-
port.
The planetary gears (4) are mounted in a planetary
carrier and are positioned around the sun gear and
within the planetary ring gear (5). The rear axle
shafts (3) locate into the internal splines in the carri-
ers.
As the sun gear is driven by the differential, the re-
duction planet gears revolve inside the stationary
planetary ring gear and drive the carrier and axle
shaft at reduced speed.
The rear axle shaft is supported on taper roller bear-
ings (6). Preload is adjusted by means of selective
shims held under the retaining plate and bolts.
ELECTRIC DIFFERENTIAL LOCKING

OPERATION (Powershift)
S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.
The differential lock effectively places both rear

wheels into a direct drive when selected, this action
stops one rear wheel spinning.
In conditions inducing wheel slip (differential lock not
yet engaged), press down the differential lock switch 2 3
and the lock will engage giving direct drive to both
rear wheels.
The lock will remain engaged until either of the foot
brakes are applied and the machine stops or by dis-
engaging the switch. The warning light on the instru-
ment panel will turn off when the differential lock has
disengaged.
When selecting switch (1) on gauge cluster, the dif-
ferential is activated with the oil pressure supplied by
the transmission, which acts on piston (3) for differ-
ential locking. 4 F29548
This oil under a pressure of 13-14 bar (189-203 psi),

always available when the engine is running, is con-
trolled from an electrovalve. When the switch is
released (differential locking not necessary) oil is di-
verted to the filler of the level dipstick (discharged)
and the piston spring (2) of the differential releases
the locking (4).
MECHANICAL DIFFERENTIAL LOCKING

OPERATION (Powershuttle)
SWARNING
Never use the differential lock at speeds above 8
km/h (5 mph) or when turning the machine. When
engaged the lock will prevent the machine turning
and personal injury could result.
In conditions inducing wheel slip, hold down the dif-

ferential lock pedal (1) with your heel until the lock is
felt to engage. The lock will automatically disengage
when traction at the rear wheels equalizes. If a rear
wheel spins at speed, reduce the engine speed to
idle before engaging the differential lock to minimize
shock loads on the rear axle.
When pedal (1) is pressed, a system of levers acti-
vates outer lever (2) that on its turn acts on bracket 2
(3) locking the differential. By releasing pedal (1) the
lever is also released and the differential is un-
locked. 3
F29549
F29550
POWERSHIFT POWERSHUTTLE RATIO

/ • 4.62:1
• / 4.11:1
LUBRICATION
Oil capacity: 21.2 liters (5.6 US gallons)
Oil specification: Ambra Mastertran NH 410 C
TIGHTENING TORQUES
2 11 3 4
8 9 10
F29551
1. Screw of half shaft: 554÷626 Nm (409÷462 lbf·ft) 6. Screw of block: 57÷76 Nm (42÷56 lbf·ft)
2. Screw of axle assy - rear RH or LH: 190÷231 Nm 7. Screw of baffle oil: 43÷51 Nm (32÷38 lbf·ft)
(140÷170 lbf·ft) 8. Plug: 27÷34 Nm (20÷25 lbf·ft)
3. Screw of front flange: 136÷170 Nm (100÷125 lbf·ft) 9. Screw: 32÷41 Nm (24÷30 lbf·ft)
4. Screw to fixed rear axle to the chassis: 800 Nm 10. Screw of housing rear brake: 204÷245 Nm
(590 lbf·ft) (150÷189 lbf·ft)
5. Screw: 11÷14 Nm (8÷10 lbf·ft) 11. Right nut: 406 Nm (300 lbf·ft)
REAR AXLE REMOVAL

For servicing of any rear axle component the axle
must be removed.
Prior to removal of the axle place a suitable clean
container under the axle, capable of holding 21.2
liters (5.6 US gallons) and drain the oil from the plug
at the base of the axle.
Disconnect the differential lock lever.
Accessed from the top of the rear axle disconnect
and drain the residual brake oil into a suitable clean
container. Remove the pipes from both sides of the
axle half shafts. Plug the brake pipes to prevent any
dirt or contamination entering the brake system.
Remove the 4 attaching bolts from the drive shaft
coupling and remove from the axle.
Before removal of the axle make sure the machine is
on level ground with the loader fully lowered and
backhoe resting on the ground. The stabilizers must
be lowered to the ground and the front wheels
chocked.
Support the axle and remove the retaining bolts,
gently lower the axle to the ground.
Place the axle on a suitable stand to facilitate the re-
pairs.
DIFFERENTIAL REMOVAL
Unscrew the upper screw (1). Use the hole of this

screw and holes (A) to install tool 380000990 for the 1
lifting of half-beam housing (2).
Unscrew and remove the remaining screws (1).
A
2
F29552
Remove the left housing of half-beam (2) with the

differential (3) using the tool 380000990, from the
axle central body (4).
At this point it is possible to remove from the left

housing of the half-beam the differential group assy.
The differential consists of:
Z differential lock spring (5);
Z differential housing (6);
Z crown wheel (7).
DIFFERENTIAL DISASSEMBLY
1. Snap ring 9. Bearing

2. Washer 10. Thrust washer
3. Dog gear 11. Side gear
4. Spring 12. Spider assembly
5. Dog 13. Side gear
6. Differential half housing 14. Thrust washer
7. Crown wheel 15. Differential half housing
8. Screw 16. Bearing screw
Prior to separating the differential, mark the two half

housings (6) and (15) to ensure correct reassembly.
Replace the differential lock coupling and adaptor if
worn or damaged.
The differential lock can be disassembled by com-

pressing the spring and carefully detaching the snap
ring (1).
With the snap ring removed disassemble the: wash-
er (2), outer dog (3), spring (4), inner dog (5) from
the housing (6).
Carefully inspect all moving parts for signs of scor-
ing, wear, or damage, if evident replace with new
parts.
By means of an extractor remove the bearing (16).
Unscrew and remove the screws (17). Disassemble

the half-housing of differential (15).
Now remove the thrust washer (10) and (14), the

planetary gears (11) and (13) and the spider gears
(12).
PINION REMOVAL
1. Ring nut 9. Disc

2. Lock pin 10. Seal
3. Washer 11. Bearing
4. Seal 12. Pinion
5. Coupling 13. Bearing
6. Bearing 14. Snap ring
7. Spacer 15. Screw
8. Flange
Remove the lock pin (2) to unlock the ring nut (1).
Using the special tool 380002675 hold the coupling

(5) steady while loosening the ring nut (1).
Remove the ring nut (1), the washer (3) and the gas-
ket (4).
Remove the coupling (5).
Unscrew and remove the screws (15).

Remove flange (8).
Remove the bearing (6) from the flange (8).

Remove the snap ring (14) from the axle inner cen-
tral body.
Using an rubber hammer, take out the pinion (12). 12
14
F29553
Remove from the pinion (12), the spacer (7) and by

means of extractors, the bearings (11) and (13).
BRAKE GROUP DISASSEMBLY
Powershuttle
14
17
11
10
9 16
8 2
7 3
6 4
5 5
4 6
3 15 RH
2 13
1 12
LH
F29554
Powershift
18
19 1
20 2
15 3
6 4
5 6
4 5
3 7 RH
2 12
16 13
LH
F29555
1. Housing brake outer 11. Block (Powershuttle)

2. O-ring 12. Washer
3. O-ring 13. Screw
4. Piston brake 14. Screw
5. Disc brake intermediate 15. Housing brake inner
6. Disc brake 16. Housing brake outer
7. Housing brake inner 17. Screw
8. Baffle oil (Powershuttle) 18. Baffle oil (Powershift)
9. Screw 19. Block (Powershift)
10. Shim 20. Screw
Unscrew and remove the screws (17) then disas-

semble the block (11) with the shims (10). 10 11
17
12 13
8
F29556
Untighten and remove the screws (9). Remove the

housing brake inner (7).
Remove the brake pads (6) and the intermediate

brake pads (5). 6 5
F29557
Remove the brake piston (4) and the outer housing

brake (1).
AXLE ASSY RH/LH DISASSEMBLY
1. Sun gear 9. Screw

2. Lock shaft 10. Screw bleeder
3. Bolt 11. O-ring
4. Washer 12. Axle housing assy right or left
5. Shim 13. Bearing
6. Planetary gear carrier 14. Seal
7. Bearing 15. Shaft assy
8. Manifold brake tube 16. Carrier
The brake manifold (8) can be removed by loosen-

ing and removal of the screws (9). Before reassem-
bly fit a new O-ring (11). On reassembly torque the
attaching bolts to 11 - 14 Nm (8.1-10.3 lbf·ft)
Remove the sun gear (1).
To remove the planetary gear (6) from the carrier

(16, remove the lock shaft (2), the retaining bolt (3),
the washer (4) and the shim (5).
Remove the planetary gear carrier (6).
If necessary it is possible to disassemble the plane-

tary gear carrier:
Z Remove the retaining ring (A).
Z Extract gears shaft (B) and remove planetary
gears (C).
The planetary ring gear (16) can be removed from

the axle (12) with the aid of tool 380000816. Position
the tool beneath the ring gear, expand the plates
and tighten the bolts. Invert the axle and press out
the gear form the wheel hub side.
Inspect the gear for wear scoring or damage and re-
pair or replace.
Position the axle housing (12) to allow removal of

the axle shaft (15).
Using the puller tool 380000986 and the slide ham-

mer 380000987, remove the bearing cups (13) from
the axle housing (12).
By means of extractor 380002676 remove the bear-

ing (13) from the axle shaft (15).
Applying gradual pressure to the tool the bearing will
separate from the half axle.
Inspect the bearing for wear, scoring or damage and
replace if in any doubt.
Reassembly of the bearing is the reverse proce-

dure. Using an induction heater, heat the bearing
sufficiently to expand it enough to allow it to easily
seat onto the half shaft.
After bearing removal, disassemble the seal (14)

from the axle shaft (15).
IMPORTANT: always fit a new axle seal if the axle

bearing is removed for any reason.
MEASUREMENTS AND ADJUSTMENTS

BEARING OF BEVEL PINION PRELOAD
The pinion bearing preload is set by selecting the

correct shim (spacer) which is placed between the
bearings.
Reassemble the pinion assembly, attach the fabri-
cated spanner 380002675 to the flange (1) and
torque to 406 Nm (300 lbf·ft) with spanner to the
locknut (2).
MEASURING OF PINION ROLLING TORQUE
Use a torque meter (1) to check rolling resistance

when the assembly is fitted back into the axle.
The rolling resistance should be: 1.3 Nm (0.96 lbf·ft).
Leave pinion retainer bolts loose for this check.
If under specification, fit a smaller shim. If over spec-
ification, fit a larger shim.
AXLE SHAFT BEARING PRELOAD
The preload of the axle shaft bearing is realized by X

placing the shims (1) between axle shaft (2) and wash- 1 2
er (3) as many as necessary to achieve value X.
3
F29558
The procedure to determine value X occurs in the

following manner:
Z install the largest shim (for instance: 2.16 mm (0.09
in));
Z assemble the planetary gear assy;
Z screw and tighten screw at 554÷626 Nm (409÷462
lbf.ft);
Z by means of a dial gauge find out the axle backlash
(for instance: 0.56 mm (0.02 in));
Z now determine the value: 2.16÷0.56;
Z according to this value and to the preload value to
be achieved, select the shims to be installed (see
table).
RESULTANT VALVE SHIM TO BE INSTALLED

1.24 - 1.32 mm 81803491
(0.049 - 0.052 in) 1.14 mm (0.045 in)
1.35 - 1.42 mm 81803502
(0.053 - 0.056 in) 1.24 mm (0.049 in)
1.45 - 1.54 mm 81803503
(0.057 - 0.060 in) 1.35 mm (0.053 in)
1.55 - 1.64 mm 81803504
(0.061 - 0.064 in) 1.45 mm (0.057 in)
1.65 - 1.74 mm 81803505
(0.065 - 0.068 in) 1.55 mm (0.061 in)
1.75 - 1.84 mm 81803506
(0.069 - 0.072 in) 1.65 mm (0.065 in)
1.85 - 1.94 mm 81803507
(0.073 - 0.076 in) 1.75 mm (0.069 in)
1.96 - 2.04 mm 81803508
(0.077 - 0.080 in) 1.85 mm (0.073 in)
2.06 - 2.14 mm 81803509
(0.081 - 0.084 in) 1.96 mm (0.077 in)
2.16 - 2.24 mm 81803510
(0.085 - 0.088 in) 2.06 mm (0.081 in)
2.26 - 2.34 mm 818035115
(0.089 - 0.092 in) 2.16 mm (0.085 in)
MEASURING OF AXLE SHAFT ROLLING TORQUE
After fitting the correct shim to set the preload: man-

ufacture a bridging bar to span opposing bolt holes
to the dimensions shown.
Fit bridging bar (1) across the rear axle housing

flange and use a torque meter (2) to check rolling re-
sistance which should be 2.3 - 10 Nm (1.7-7.4 lbf·ft).
NOTE: the brake housing, brake pads and sun gear

should not be installed but all bearings well lubricat-
ed.
If out of specification the shim should be adjusted

and rolling resistance rechecked.
DIFFERENTIAL BEARING PRELOAD
This adjustment is made by shimming the right hand

differential bearing.
The value of following shimming is required: dimen-
sion “T”.
VALUE “T”
SHIMS
mm in
0.034÷0.039 0.0013÷0.0015 81803515
0.040÷0.045 0.0016÷0.0018 81803516
T
F29559
0.046÷0.051 0.0018÷0.0020 81803517
0.052÷0.057 0.0020÷0.0022 81803518
0.058÷0.063 0.0023÷0.0025 81803519
0.064÷0.069 0.0025÷0.0027 81803520
0.070÷0.075 0.0028÷0.0030 81803521
0.076÷0.081 0.0030÷0.0032 81803522
Remove the differential bearing and shin from the

outer brake housing.
Place the gauge ring of tool 380000991 (1) into the
vacant bearing location.
Bolt bridge tool 380000991 (1) across the rear axle
housing flange with spacers (2) located between the
axle housing flange and the tool.
Measure the gap between the bridge tool and the
gauge ring using a feeler gauge (3).
Refer to the table to determine the correct size shim
which should be installed between the brake hous-
ing and bearing, thus preloading the bearing back to
specifications.
MEASURING OF RANGE BETWEEN THE FACE THRUST BLOCK AND THE BACK FACE OF
DIFFERENTIAL
For dimensions “S” outside normal gap range use

as required the minimum number of shims to pro-
vide design gap of 0.10 - 0.20 mm (0.0039-0.0079 S
in).
VALUE “S”
SHIMS
mm in
0.80÷0.89 0.031÷0.035 87346232 + 87346228
0.90÷0.99 0.035÷0.039 87346232 + 87346231
F29560
1.00÷1.10 0.039÷0.043 87346232 + 87346427
This procedure has the goal to get a clearance of

0.10 mm to 0.20 mm (0.0039-0.0079 in) between
the thrust face of the thrust block and the back face
of the differential bevel gear.
To get this setting we perform two measurements to
calculate the shim pack to be used.
Z On the center housing, with the differential assy in-

stalled and centered, we check the distance from
the back of the bevel gear to the trumpet mounting
face of the center housing. During this measure-
ment rotation of the differential is needed to get the Y
shortest reading. This is to take the run-out of the
back face in calculation thus to avoid interference
afterwards (dimension Y).
Y: dimension from back of differential bevel gear to
trumpet mounting face.
F29637
A: gauge clamped on housing and differential

aligned to check the dimension “Y”.
F29638
Z Assemble the thrust block to the trumpet housing

(NO SHIMS mounted in between the parts!).
Check the distance from the thrust face of the X
thrust block (1) to the center housing mounting
face of the trumpet housing (2) (dimension X).
1 2
F29639
B: gauge on trumpet housing.
F29640
S= Y-X will give you the minimum gap between the

thrust block and the back of the differential bevel
gear. Based on this calculation and the attached
shimming chart people find the shims to be used.
Shim pack thickness to be checked prior installation.
Disassemble the thrust block, fit the shim pack in
between the thrust block and the trumpet housing
and reassemble thrust block again.
Check free rotation of axle input on the completed

axle sub-group.
1.4 FAULT FINDING

Differential lock not engaging External linkage damaged or broken Replace/repair as required.
(mechanical differential lock)
Internal linkage, cross shaft rod, Remove and inspect.
fork or pivot shaft damage/broken
Damaged or broken teeth on Remove differential and inspect

differential lock adaptor or differential lock assembly.
coupling
Differential lock not disengaged Spring broken between adaptor Remove differential and replace
(mechanical differential lock) and coupling spring.
Teeth or adaptor or coupling Remove differential and replace

damaged/burred damaged parts.
Differential lock not engaging Internal linkage, cross shaft rod, Remove inspect and repair.
(electrical differential lock) fork or pivot shaft damaged/
broken

coupling
Solenoid valve sticking not Replace/repair as required.

operating
Solenoid valve electrical Replace/repair as required.

connection poor or coil not
energizing
Differential lock not disengaged Spring broken between adaptor Remove differential and replace
(electrical differential lock) and coupling spring.
Teeth of adaptor or coupling Remove differential and replace

damaged/burred damaged parts.
Internal linkage, cross shaft rod, Remove and inspect.

fork or pivot shaft damaged/
broken

coupling
Solenoid valve electrical Replace/repair as required.

connection poor or coil not
energizing
2. REAR AXLE 4WS “CARRARO”

Rear steering axle, model 26.32M
POWERSHIFT SELF LOCKING RATIO

• • 19.038
Differential oil capacity 11 liters (2.9 US gallons)

Epicyclic reduction gear oil capacity each side 1.3 liters (0.3 US gallons)
Oil specification:
use recommended oil enriched in additives.
Ambra Multi G NH 410 B
Note: do not use synthetic or vegetable oil without consent of the axle
manufacturer
Differential oil filling and level plug 1
Air breather 2
Filling / 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
Before draining the oil, loosen the oil breather (2) to

release possible internal pressure, then tighten the 2
plug to the requested torque.
F28005
To drain the oil from the central body unscrew the

plug of the draining hole (4) and level hole (1).
Then tighten them to the specified torque.
4 1
F28006
Before draining the oil, position the wheel hub so

that the filter cap is in the highest point, then loosen
the plug (3) to release possible internal pressure.
F28007
Position the wheel hub so that the filer cap is on the

center line of the horizontal axis.
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the pre-
scribed torque.
F28008
Before draining the oil, loosen the breather (6) to re-

lease possible internal pressure.
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the pre-
scribed torque.
6
F28009
FRONT FLANGE
7
6
5
4
1 2 3
F28010
Disassembly
Remove the snap ring (1).
F28011
Remove the front flange (2).
F28012
Remove the seal ring (3), the O-ring (4), the gasket
(5), the O-ring (6) and the washer (7).
5
4
3
7
6
F29009
Assembly
Assemble the washer (7) and the new O-ring (6).
7
6
F29322
Assemble the gasket (5).
F29323
Assemble the new O-ring (4) and the seal ring (3).
4
3
F29324
Assemble the front flange (2).
F28012
Assemble the snap ring (1).
F28011
STEERING CYLINDER
4
5
7
3 10
11
12
2
6
8 13
9
14
15
16
17
18
19
20
21
22
23
24
F28013
Disassembly

order to disjoint the tie rod (3) from the swivel hous-
ing (2).
SWARNING

2
F27228

conditions. 5
Unscrew the fastening screws (6) and (9) and take
7
10
the steering cylinder (7) out of its housing, if neces- 11
12
sary use a rubber hammer.
Remove only parts that need to be overhauled and/
or replaced.
3 6 8 9 13
F28014

Remove all the seals and O-rings (16, 17, 19, 21, 23 20
and 24) from the cylinder case (18), the cylinder 21
head (22), and the rod (20).
17
19
22
23
24
F28015
Assembly

18
and on the cylinder body (18).
20
21
17
19
22
23
24
F28016
and (11), the nuts (4) and (12) to the ends of the rod, 4
then tighten with a dynamometric wrench to the re- 5
quested torque.
7
10
11
12
13
F28017

on the central body.
Assemble and tighten the screws (6) and (9) to the
requested torque.

serted into the swivel housing (14) arm.


14
F28020
Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). 3
ed torque.
1
F27236
11
9
10
8
7
6
5
1
3
2
F27404
Disassembly
F27240

the planetary carrier (1).
3
F28044
Remove the planetary carrier (1) from the wheel

hub.
F27405
To replace the gears, if necessary, remove the

screw (11) and relevant washers (8) and (9). 10 11
NOTE: treat the pin (10) with care. 9
F28021
Remove the gear (7) from its seat, taking care not to
lose the rollers inside it. 7
Remove the shim (5).
5
F28022
If the pins of the pinion gears are in poor condition,

replace the entire planetary train with pre-fitted pins.
F28023
Assembly
Place the planetary carrier on a work bench and fit

the gears (7) and respective shims (5).
7
F28024
Insert all the rollers into the gears, then place the
two washers (8) and (9).
9
NOTE: the first washer must be aligned with the
dowel pin (10). 10 8
F28025
Assemble and tighten the gears bolts (11) and

tighten to the requested torque.
11
F28026
Assemble the planetary carrier (1) on the wheel hub.
F27405
Screw in screws (3) and tighten to the requested

torque.
3
F28044
To up the oil on the wheel hub.

Assemble the plug (2) on the planetary carrier (1) 2
F27408
WHEEL HUB
Disassembly

of the wheel hub to allow the snap ring removal.
SWARNING
14
F27410
Remove the snap ring (1) from the cardan shaft.

F27250
Unscrew and remove the screws (5) from the ring

gear carrier (7).
7
F27251
To extract the ring gear carrier screw two of the just

removed the screws (5) in the threaded holes. 5
Remove the ring gear carrier (7) with the ring gear
(4). 7
F27253
Remove the snap ring (8) and disjoin the ring gear
carrier (7) from the ring gear (4). 8
ring gear carrier with a hammer and the special tool 6
380002667.
7
F27252

Remove the wheel hub (11) using levers and a ham- 15
mer to facilitate the operation.
11
NOTE: collect the bearing (9).
9
F27254

move the seal ring (13) with a lever. 13
12
Remove the bearing cups (9) and (12) using a ham- 10
mer and a suitable drift. 9
end using a suitable extractor.
F27412

17 19
SWARNING 16 18
ty.

F27256

and from the cardan shaft.
14
F27257
Collect the thrust washers (23) and (28).
28
23
F28046

NOTE: this is a destructive operation for the seal

ring. 22
14 23
F27259
Assembly

steering stop composed by the screw (21) and nut
(20).

20 21
F27260
Force the bush (26) into the swivel housing (14) with
the special tool 380002668 and a hammer.
(14) with the special tool 380002669 and a hammer. 14
Grease carefully the seal ring (22). 26
22
F28047
Grease well the king pin housings with specific

grease.
Position the thrust washers (23) and (29). 28
23
F28046

moved, reassemble them on the king pins (16) and 24 27
(18).
18 16
F28027

ring.
F27257
17 19
16 18
F27263
Position the wheel hub (11) on a workbench and as-

semble the bearing cups (9) and (12) in position with 9 12 13
the special tool 380002222 under a press or with a
hammer.
Assemble the seal ring (13) into the wheel hub (11)
with the special tool 380002213 and a hammer.
11 11
F28028

(14). 14
F27265

and force the bushes (6) to the ring gear carrier (7) 6 7
surface level with the special tool 380002667.
F37835
Preassemble the ring gear carrier (7) and the ring

gear (4) with the lock ring (8). 8
7
4
F27267
Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub.
F27268
Force all the hub dowel bushes (6) completely with

Apply sealant on fastening bolts (5) thread.
Assemble the wheel carrier (7) fastening bolts (5) 7
F27269
Assemble the thrust washers (2) and (3) onto the

cardan shaft end. 3 2

1
in its seat.
F27250
CARDAN SHAFTS
4
3
2
1
F27279
Disassembly
4
1
F27280
Remove the seal rings (2) from the axle beam.
NOTE: destructive operation for the seal rings (3).

3
Remove the bush (3) from the axle beam only if the 2
wear conditions require this.
SWARNING
2
F27281
Assembly
Assemble the bush (3) on the axle beam with the

special tool 380002226 and a hammer. 2 3
F28029
F28048
SWARNING
4
1
F28049
AXLE BODY AND BRAKES
Disassembly
Put alignment marks on the axle beam body and on

the differential supporting flanges, in order to identi-
fy the right side and the left side with certainty.
F28031
Position the axle on supports fitted to hold either the

central body or the axle-beam, even after their dis-
junction, or secure the three disjointed groups to a
lifting device with ropes or belts.
Unscrew the screws (2) to disassemble the axle
beam trumpet (1).
2 1
F28033
Remove the axle beam trumpet (1).
SWARNING 4
Once the axle beam trumpet has been removed, the
brake disks are free. 1
F28034
Remove the brake disks (9) and the intermediate

disks (10). 15
Remove the gear (8), the remaining brake disk and
10
the brake counter disk (15).
9
8
F28035
Secure the brake flange (7) to a hoist with ropes or

safety belts.
Unscrew the screw (5) and the lower screw (6). Re-
move the flange (7) from the central body, together
with the bevel gear backlash-adjusting ring nut.
SDANGER 5 6
This operation frees the differential box, that acci-
dentally could fall.
7
F28036
Remove the O-ring (4) and (19) from its housing and
from oil pipe hole and check its conditions. 4
19
F28037
Collect the brake flange (7) and place it on a work-

bench or fix it in a clamp.
Unscrew the screws (11).
11
F27313
Take from the piston (14), the springs (13) and the
bushes (12) and (27) and the spacer (26). 27
26
14
13
12
F28038
Unscrew the breather (21) from the brake flange (7).

21 7
F28039
Take the piston out (14).

If necessary, blow in air through the brake bleeder 16 17 14
vent to eject the piston, using the minimum pres-
sure.
Remove the O-rings (16) and (17) from the piston
(14) and check their conditions.
F28040
Assembly
Assemble the O-rings (16) and (17) on the piston

(14) and lubricate the fraying surface piston/flange 16 17 14
with a light layer of grease.
F28040
Install the piston (14) into the brake flange (7) and
then a support flat disk on the piston and with a lever
14
anchored to an eyebolt, exert a pressure just
enough to insert the piston (14) into the brake flange
(7).
7
F28042
Collect the self-adjust kits components and insert

them in the piston (14).
14
Screw the screws (11) and tighten to the requested
torque.
11
F28116
Assemble the new O-ring (4) e (19).

4
19
F28037
Assemble and tighten the upper screw (5) and the

lower screw (6) of the brake flange (7) to the re-
quested torque.
5 6
F28043
Assembly the brake discs (9), and intermediate

disks (10), the gear (8) and the brake counter disc 15
(15).
10
9
8
F28035
Assembly the new O-ring (4).

In order to place the axle beam correctly, position
the half-beam (1) check the reference marks carried 4
out during disassembly.
1
NOTE: if new brake pads are installed, before as-
sembling, they should be dipped in the required oil.
F28034
Assemble the axle-beam (1) on the flange, being

careful to the fastening holes’ alignment.
SWARNING
Support the groups properly as already pointed out
for disassembly phase.
Screw in and tighten the screws (2) of the axle beam

to the requested torque.
2 1
F28033
DIFFERENTIAL GROUP (STANDARD)
4
5
15
10
14
6
18
9
3 17
2 16
1
5 13
4 14
15
12
11
8
7
6 F28050
Disassembly
Unscrew the screw (4) and remove the ring nut re-
tainer (5). 4 5
Unscrew the ring nut with suitable special tool
320002218.
Remove the ring nut (6).
6
F28051
Remove the bearing cups (6).

6
F28052
Support the differential group (2) with a rod and re-

move it. 2
F28053
18
F28054
F28055

crown (10). 10
SWARNING 1
nents.
F28056
Remove the bevel gear crow (10) by means of an

hammer.
10
F28057

9
F28058

17
16
F28059
Remove the shaft (13), the gears (14) and the

15 15
14 14
13
F28060

12
11
F28061
Assembly

SWARNING
F28079

gears (12) and (16) and on the gears (14). 14
12
16
14
F28063

16
17
F28064
15 15
14 14
13
F28060

11
12
F28066

(8) and (9).
9
SWARNING
F28058

mer.
10
F28067
Apply Loctite 242 on the thread of the the screws

(1).
1
F27316
F27315

ing.
18
F28068
F28069
Support the differential group (2) with a rod and as-

semble it. 2
F28070
Fit the outer cups of taper roller bearings (7) by

means of special tool 380002671 and a hammer.
F28071
Insert and tighten the ring nuts (6), using the wrench
380002218 until the clearance of bearings is re- 6
moved.
NOTE: tighten the ring nuts gradually but not exces-

sively.
Assemble the ring nut retainer (5) and fasten it by

means of screw (4).
4 5
F28072
DIFFERENTIAL GROUP (SELF-LOCKING)
4
5
6
16 15
17 10
17
18
16
9
15 11
3 12
2
13
1
5 19
4 16
15
16
15
14
13
12
6 7 8 11
F28073
Disassembly
Unscrew the screw (4) and remove the ring nut re-
tainer (5). 4 5
Unscrew the ring nut with suitable special tool
380002218.
Remove the ring nut (6).
6
F28051
Remove the bearing cups (6) with a hammer.

6
F28052
Support the differential group (2) with a rod and re-

move it. 2
F28053
18
F28054
F28055
Unscrew all screws (1) of the bevel gear crown (10).

10
SWARNING
This operation makes both differential half housing 1
nents.
F28056
Remove the bevel gear crow (10) by means of an

hammer.
10
F28057

9
F28058

11 12
F28074

19
13
F28075
Remove the shaft (17), the gears (16) and the

15 15
16 16
17
F28076
14
13
F28077
11 12
F28078
Assembly
Apply a thin layer of Molicote G-n plus paste on half

housing of differential (8) and (9). 8 9
SWARNING
F28079

gears (14) and (19) and on the gears (16). 16
14
19
16
F28080
Assembly the discs (11) and (12).
11 12
F28078
Assembly the gear (14) with the shim (13).
14
13
F28077
15 15
16 16
17
F28082

19
13
F28081

11 12
F28074

(8) and (9).
9
SWARNING
F28058

mer.
10
F28067
Apply Loctite 242 on the thread of screws (1).
1
F27316
F27315

ing.
18
F28068
F28069
Support the differential group (2), with a rod and as-

semble it. 2
F28070
Fit the outer cups of taper roller bearings (7) by

means of special tool 380002671 and a hammer.
F28071
Insert and tighten the ring nuts (6), using the wrench
380002218 until the clearance of bearings is re- 6
moved.
NOTE: tighten the ring nuts gradually but not exces-

sively.
Assemble the ring nut retainer (5) and fasten it by

means of screw (4).
4 5
F28072
BEVEL PINION GROUP
1
2
3
4
5
6
7
8
9
F28083
Disassembly
In order to avoid serious damages to the bevel

pinion thread, unscrew the ring nut (9) with the
special tool 380000406.
9
F29645
Once the ring nut washer has been removed, take

the pinion (1) out of its housing, by beating with a
hammer made of soft material on the splined end.
1
F28085
Remove the washer (6), the spacer (5) and the

shims (4) from the bevel pinion (1).
1
4
5
6
F28086
Remove the bearing (3) from the bevel pinion (1),

using an extractor. 1
Remove the shim (2) placed under the bearing and
check its wear conditions.
3 2
F28087
Remove the bearing cup (7) from the central body.
F28088
Remove the outer bearing cup (3) from the central

body.
3
F28089
Assembly
Position the central body on a workbench.

Force the cups of the bearings on their housings us-
ing the special tool 380002215 for outer bearing
race and for inner bearing race.
F28090
In order to measure the distance, the kit composed

of the special tools, respectively called “false pinion”
380002673 and “false differential box” 380002674,
is used.
Insert the false pinion, together with its bearings and
its ring nut, in the just mounted housings for the
bearings.
Tighten without exceeding, till the backlash is elimi-
nated.
F28091
Check the correct positioning of the right and left

flanges, using the reference marks on them and on
the central body.
Assemble the two brake flanges and fix them with
their screws (screw in at least two ones diametrical-
ly-opposed for each flange).
F28092
Insert the false differential box 380002674 with into

the central body to measure the distance.
Check that the false box is inserted in both brake
flanges’ housings.
F28093
Carry out the measurement with a depth gauge

through the suitable false pinion hole.
X= (conical distance to be measured)
A= (measured value)
B= (known value)= 100 mm (3.94 in)
C
X
C= (known value)= 50 mm (1.97 in)
(A+C) - B = X
A
B
F28094
In order to determine the shim (S) necessary be-

tween the pinion and the bearing, you should sub-
tract the (V) value stamped on the pinion head (V =
requested conical distance) from the (X) value.
S = X-V
V
F27331
Remove the false pinion, the bearings and the ring

nut from the central body.
Disassemble the false differential box from the
flanges and then unscrew the screws to remove the
flanges.
F28095
Insert the shim (2) on the bevel pinion (1) with cham-
fer against the gear.
Press the bearing (3) into the pinion, making sure 3
that it is well set.
1
F28096
Insert the shims (4) and (6) and the spacer (5) into
the bevel pinion (1).
1
4
5
6
F28086
Insert the bevel pinion (1) unit into the central body
housing and the bearing (7) into the pinion end.
1
F28097
Insert a new washer (8) and a new ring nut (9).

Screw the ring nut in, using the wrench 380000406
for ring nut and for pinion retainer.
8 9
SWARNING
surement on bearings.
F28084
Carry out the preloading measurement (P) of the

pinion taper roller bearings, using a dynamometer
380002672.
nut torque setting gradually, being careful not to ex-
ceed.
Once you got the requested preloading value, caulk
the ring nut.
F28098
TOE-IN/STEERING ANGLE ADJUSTMENT
1 2 3 3 2 1
5 5
4 4
F28099
Toe-in

SWARNING
bars.
500 mm 500 mm
F27340
Measure the distance in mm (M) between the bars


surement point.
F27341

diameter
nominal toe-in= A-2 → measured toe-in= M-5
A
M -05
F27342

1 3
quested tolerance.
3 1
F27343

steering rods (1) to the requested torque.
1 2
F27344
Steering angle

steering.
F27345

F27346

(5) to the requested tightening torque.
5 4
F27347

the same operations.
F27348
2.3 FAULT FINDING
1 2 3 4 5 6 7 8 9 10 11
shaft breakage
while its turning
steering
Uneven wear of tire
Friction noise
noise




5. Bent half shaft

Replace half shaft.
components.





Pinion nut loose
Overheated ring and pinion teeth. Prolonged functioning at high Replace bevel gear set.
Contaminated oil
Vehicle's accident
Load bump
Pinion nut loose
Contaminated oil
defined
than the new ones.
intervals.
overloaded
3. SPECIAL TOOLS
P/N CNH APPLICATION 2WS 4WS

380000406 Disassembly/Assembly of differential ring nuts / •
380000816 Planetary carrier disassembly • /
380000986 + Disassembly bearing cups from the axle housing • /
380000987
380000990 Axle housing lifting • /
380000991 Bearings pre-load measurement • /
380002213 Assembly of seal ring in the swivel housing / •
380002215 Assembly of pinion bearing outer cup / •
380002218 Disassembly/Assembly of pinion ring nut / •
380002222 Assembly of bearing cups in the wheel hub / •
380002226 Assembly of bushing in the half-beam / •
380002667 Assembly of bushings in the crown retaining hub / •
380002668 Assembly of bushing in the swivel housing / •
380002669 Assembly of seal ring in the swivel housing / •
380002670 Assembly of seal ring in the half-beam / •
380002671 Assembly of differential bearing cups / •
380002672 Preload measure of pinion bearing / •
380002673 Measurement of pinion shims / •
380002674 Measurement of pinion shims / •
380002675 Front coupling disassembly • /
380002676 Disassembly bearing of wheel hub shaft • /
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 33 - BRAKE SYSTEM
2. HAND BRAKE............................................................................................................................................... 6
2.1 HAND BRAKE ADJUSTMENT .............................................................................................................. 7
3. BRAKE MASTER CYLINDERS .................................................................................................................... 8
3.1 BRAKE RESERVOIR........................................................................................................................... 13
3.2 BRAKE BLEEDING PROCEDURE...................................................................................................... 13
2 SECTION 33 - BRAKE SYSTEM
SECTION 33 - BRAKE SYSTEM 3
2WS
BRAKES OPERATION HYDRAULIC

Brakes Wet disc, piston operated
Oil brake Ambra LHM - NH 610 A
Number discs (on side) 4
Brakes disc total friction area 1440 cm2 (223 in2)
4WS
BRAKES OPERATION HYDRAULIC

Brakes Wet disc, piston operated
Oil brake Ambra LHM - NH 610 A
Number discs (on side) 3
Brakes disc total friction area 1440 cm2 (223 in2)
The loader backhoe has two braking systems:

a hand operated brake, that incorporates two free
floating friction pads;
hydraulically operated inboard wet disc brakes in the
rear axle.
The hand brake, when pulled, locks the brake disc on
the rear of the transmission.
Operation of the foot brake, instead, pressurizes the
brake fluid in the master cylinders which feeds the
brake pistons in the axle housing. The brake pistons
then compress the brake friction discs and separa-
tion discs, which locks the axle shaft to the axle
housing.
BRAKE SYSTEM LAYOUT (2WS)
1. Brake piston assembly 5. Master cylinders

2. Brake discs 6. Hand brake
3. Brake reservoir 7. Trumpet housing
4. Brake pressure switch
BRAKE SYSTEM LAYOUT (4WS)
1. Brake piston assembly 5. Master cylinders

2. Brake discs 6. Hand brake
3. Brake reservoir 7. Trumpet housing
4. Brake pressure switch
2. HAND BRAKE
The transmission hand brake is fitted to all models
and incorporates two free floating friction pads.
When operated the eccentric cam (1) forces the fric-
tion pads against the disc (2), effecting a braking ac-
tion on the output shaft from the transmission,
locking the drive shaft to the rear and front axles.
19
20
3
19
2 18
1
17
21
15
16
14
12 13
11
10
9
8
7
6
5
4
F27750
1. Screw-brake mounting 12. Id seal

2. Assembly-caliper 13. Ball bearing
3. Nut-brake mounting screw 14. Plastic retainer
4. Nut-jam adjustment 15. Cam
5. Nut-adjustment 16. Torque plate-front
6. Washer-hardened 17. Carrier and lining assembly
7. Washer-stainless steel 18. Torque plate-rear
8. Washer-thrust 19. Sleeve mounting
9. Lever 20. Bolt-adjusting
10. Boot 21. Spring
11. Cam
2.1 HAND BRAKE ADJUSTMENT
The transmission hand brake is located on the trans-

mission output shaft on 4x4 transmission and rear
axle on the 4x2 transmission.
The 4x2 transmission hand brake is located on the
rear axle brake disc splined to pinion shaft (1), hy-
draulic oil filter (2), hand brake cable (3), hand brake
caliper (4).
When refitting the caliper unit (2) insert the two bolts
(1) through the caliper; it will be necessary to apply
Loctite 270 to the locknuts (3). Tighten the bolts while
holding the locknuts. Once the bolts are tightened
down back them off by 3 bolt head flat, and then
torque the locknuts to 150 Nm (110.6 lfb·ft). Ensure
that the tubes can move.
Adjust the clearance between the brake pads and

disc to 0.5 mm (0.02 inch) using the nut and locknut
(1).
Adjust the cable clevis and lock the nut (1) to get 4 to
5 clicks on the hand brake lever.
3. BRAKE MASTER CYLINDERS

Brake master cylinders are accessible from the en-
gine compartment.
The brake master 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. Reservoir adapter 9. Seals
4. Body 10. Second spool
5. Main spool 11. Spring
6. End cap 12. Balancing pipe
MASTER CYLINDER WITH BRAKES RELEASED
1 2 3 4 5 6
10
9 8 7
F29371
Trapped oil
Reservoir oil (no pressure)
1. Oil to brake piston (right hand side) 6. Master cylinder body

2. Pressure switch 7. Master cylinder body
3. Second spool 8. Main spool stop
4. Reservoir inlet 9. Balancing pipe
5. Main spool 10. Oil to brake piston (left hand side)
With the brakes released the brake lines are open to

the reservoir to allow the brakes to release. The mas-
ter cylinders are also open to reservoir through the
center of the valve.
MASTER CYLINDER WITH BRAKE PEDALS DEPRESSED
1 2 3 4 5 6
10
9 8 7
F29372
Pressurized brake fluid


As the brake pedals are depressed initial movement

of the cylinder plunger closes the center port to iso-
late the reservoir.
Further plunger movement creates brake fluid pres-
sure to apply the brakes. The equal pressure ports
are both open as the two seals on both master cylin-
ders have exposed the two ports, therefore allowing
equal pressure in both master cylinders.
MASTER CYLINDER WITH ONE BRAKE PEDAL DEPRESSED
1 2 3 4 5 6
10
9 8 7
F29373
Pressurized brake fluid


When using one brake to assist turning, the brake

master cylinder being applied operates only one
brake. This is achieved by the equal pressure port
being blocked by the two seals on the master cylin-
der not being operated.
Brake discs and piston layout

1. Steel plates
2. Outer Brake housing
3. Seals
4. Brake piston
5. Friction plates
6. Outer brake housing
Brake piston and seals

1. Brake piston
2. Brake pipe fitting
3. Outer brake housing
The brakes hydraulically operated are supplied oil

from the brake pedal reservoir and into the axle by
tubes into each half axle through the mounted brake
pipe fitting (2) which is sealed to the piston by two O-
rings.
When the brake pipe fitting (1) is removed ensure

the O-rings are replaced with new.
3.1 BRAKE RESERVOIR
1. Brake reservoir
2. Low level test switch
NOTE: depressing the low level switch test button

mounted in the middle of the brake filler reservoir
cap, the warning light system can be tested. The light
that is illuminated is the handbrake warning light
mounted on the right hand instrument console, en-
sure handbrake is in the “off” position.
3.2 BRAKE BLEEDING PROCEDURE
1. Ensure reservoir is full (1)
2. Open left hand brake bleed valve (2)
3. Pump both brakes to purge the system (3)

4. Hold pedals down
5. Lock bleed valve (2)
6. Release pedals
7. Repeat steps 3-7
8. Repeat steps 4-7 on right hand brake
9. Test brakes repeat if necessary
NOTE: when the brake pedals are operated, both to-

gether, the electrical supply to the front wheel drive
switch is cut allowing the clutch to de-energize thus
engaging the front wheel drive, providing four wheel
braking.
NOTE:
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 35 - HYDRAULIC SYSTEM
1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3

1.1 HYDRAULIC DIAGRAM - 2WS MECHANICAL MODELS CENTER PIVOT -
B90B - B95B - B95BLR - B110B ............................................................................................................ 3
1.2 HYDRAULIC DIAGRAM - 2WS PILOT MODELS CENTER PIVOT -
B90B - B95B - B95BLR - B110B ............................................................................................................ 5
1.3 HYDRAULIC DIAGRAM - 2WS MECHANICAL MODELS CENTER PIVOT - B95BTC ........................ 7
1.4 HYDRAULIC DIAGRAM - 2WS PILOT MODELS CENTER PIVOT - B95BTC ..................................... 9
1.5 HYDRAULIC DIAGRAM - 4WS MECHANICAL MODELS CENTER PIVOT - B115B ......................... 11
1.6 HYDRAULIC DIAGRAM - 4WS PILOT MODELS CENTER PIVOT - B115B ...................................... 13
1.7 HYDRAULIC DIAGRAM - QUICK COUPLER FOR B95BTC .............................................................. 15
2. HYDRAULIC PUMP.................................................................................................................................... 16
2.3 LOAD SENSING VALVE ..................................................................................................................... 19
2.4 REMOVAL ........................................................................................................................................... 21
2.5 COMPONENTS ................................................................................................................................... 22
3. CONTROL VALVES ................................................................................................................................... 27
3.1 CONTROL VALVES “HUSCO”
(B90B - B95B - B95BLR - B95BTC - B110B MECHANICAL MODELS) .............................................. 27
3.2 CONTROL VALVES “REXROTH” (B115B MECHANICAL MODELS) ................................................ 64
3.3 CONTROL VALVES “REXROTH”
(B90B - B90BLR - B95BLR - B110B - B115B PILOT MODELS) ......................................................... 80
3.4 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE
(WITH HYDRAULIC CONTROL) ......................................................................................................... 88
3.5 ACCUMULATOR “GLIDE RIDE” PARKER.......................................................................................... 91
3.6 SYSTEM RELIEF VALVES.................................................................................................................. 94
2 SECTION 35 - HYDRAULIC SYSTEM
4. HYDRAULIC SWING SYSTEM ................................................................................................................ 104

4.2 HYDRAULIC OIL FLOW .................................................................................................................... 105
4.3 PRECISION SWING CONTROL........................................................................................................ 107
5. HYDRAULIC CYLINDERS........................................................................................................................ 110
5.1 LOADER CYLINDER ......................................................................................................................... 111
5.2 LOADER BUCKET CYLINDER.......................................................................................................... 118
5.3 4X1 BUCKET CYLINDER .................................................................................................................. 127
5.4 BACKHOE BOOM CYLINDER .......................................................................................................... 130
5.5 BACKHOE DIPPER CYLINDER ........................................................................................................ 134
5.6 BACKHOE BUCKET CYLINDER....................................................................................................... 138
5.7 TELESCOPIC CYLINDER ................................................................................................................. 142
5.8 STABILIZERS CYLINDER ................................................................................................................. 146
5.9 SWING CYLINDER............................................................................................................................ 150
5.10 SPECIAL TOOLS............................................................................................................................. 154
6. PILOT HYDRAULIC CONTROL LEVERS ................................................................................................ 155
6.4 PILOT HYDRAULIC CONTROL VALVE............................................................................................ 162
7. FAULT FINDING ....................................................................................................................................... 165
7.1 PRELIMINARY CHECKS................................................................................................................... 165
7.2 FAULT FINDING (WITH “HUSCO” CONTROL VALVES) ................................................................. 166
7.3 FAULT FINDING (WITH “REXROTH” CONTROL VALVES)............................................................. 171
SECTION 35 - HYDRAULIC SYSTEM 3
1. HYDRAULIC DIAGRAMS
1.1 HYDRAULIC DIAGRAM - 2WS MECHANICAL MODELS CENTER PIVOT - B90B - B95B - B95BLR - B110B
1. Front axle
2. Steering control valve
3. 4x1 bucket cylinders
4. Crowd cylinders
5. Boom cylinders
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer (optional)
12. Backhoe hammer (optional)
13. Hydraulic pump
14. Priority valve
15. Air filter
16. Hydraulic oil cooler
17. 4x1 bucket control valve
18. Hydraulic filter manifold
19. Common return manifold
20. Backhoe control valve
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
26. Stabilizer and telescopic backhoe dipper control valve
27. Telescopic cylinder
28. Stabilizers right cylinder
29. Stabilizers left cylinder
30. Load check valve
1.2 HYDRAULIC DIAGRAM - 2WS PILOT MODELS CENTER PIVOT - B90B - B95B - B95BLR - B110B
1. Front axle
4. Crowd cylinders
5. Boom cylinders
13. Hydraulic pump
14. Priority valve
15. Air filter
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
26. Diagnostic bulkhead
31. Bi-directional auxiliary
32. Hydraulic control lever left
33. Hydraulic control lever right
34. Hydraulic control lever left - boom or dipper
35. Hydraulic control lever left - swing
36. Hydraulic control lever right - boom or dipper
37. Hydraulic control lever right - bucket
38. Solenoid valve for piloting backhoe control valve
1.3 HYDRAULIC DIAGRAM - 2WS MECHANICAL MODELS CENTER PIVOT - B95BTC

1. Front axle
4. Crowd cylinders
5. Boom cylinders
13. Hydraulic pump
14. Priority valve
15. Air filter
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
26. Stabilizer and telescopic backhoe dipper control valve
31. Quick coupler valve
32. Quick coupler
1.4 HYDRAULIC DIAGRAM - 2WS PILOT MODELS CENTER PIVOT - B95BTC

1. Front axle
4. Crowd cylinders
5. Boom cylinders
13. Hydraulic pump
14. Priority valve
15. Air filter
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
39. Quick coupler valve
40. Quick coupler
1.5 HYDRAULIC DIAGRAM - 4WS MECHANICAL MODELS CENTER PIVOT - B115B

1. Front axle
4. Crowd cylinders
5. Boom cylinders
13. Hydraulic pump
14. Priority valve
15. Air filter
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
32. Locking valve (optional)
33. Back pressure valve
34. Rear axle
35. 4WS steering control valve
36. Load locking valve (optional)
1.6 HYDRAULIC DIAGRAM - 4WS PILOT MODELS CENTER PIVOT - B115B

1. Front axle
4. Crowd cylinders
5. Boom cylinders
13. Hydraulic pump
14. Priority valve
15. Air filter
21. Dipper cylinder
22. Bucket cylinder
23. Swing cylinders
24. Swing valve
25. Boom cylinder
32. Locking valve (optional)
34. Rear axle
35. 4WS steering control valve
36. Load locking valve (optional)
1.7 HYDRAULIC DIAGRAM - QUICK COUPLER FOR B95BTC

2. HYDRAULIC PUMP
The are two types of pump:

Z for engine 97 hp;
Z for engine 110 hp.
The gear type hydraulic pump assembly is mounted
on the rear of the transmission and driven by a shaft
directly connected to the engine flywheel splined to
the torque converter housing.
The pump comprises of two pumping elements, the
front pump (1) rear pump (2) and load sensing steer-
ing flow divider control valve (3).
Oil is drawn through the common inlet port into both
pumping elements.
Front pump flow is directed to the loader and back-
hoe control valves and sideshift clamping system.
Rear pump flow passes through the flow divider
valve which maintains priority oil flow to the steering
system with remaining flow directed for operation of
stabilizers, loader and backhoe elements.
PUMP (ENGINE 97HP) Clockwise (D)

Direction of rotation (looking on drive shaft) 35.427 cm3/rev 35.427 cm3/rev
(2.162 in3/rev) (2.162 in3/rev)
Displacement 0.7 - 3 bar (10-44 psi)
Inlet pressure range for pump P1 260 bar 260 bar
(3771 psi) (3771 psi)
Maximum continuos pressure P2 280 bar 280 bar
(4061 psi) (4061 psi)
Maximum intermittent pressure P3 300 bar 300 bar
(4351 psi) (4351 psi)
Maximum peak pressure -25 to -80 °C (-13 to -112 °F)
min P1 350 min-1
Speed
max P1 3000 min-1
recommended 12 to 100 mm2/s (cSt)
Viscosity range
permitted max 750 mm2/s (cSt)
Dp > 200 bar (2900 psi) 8 - Nas 1638
bx = 75 - 10 mm 19 / 17 /14 - ISO 4406
(3.0-0.39 in)
Contamination class
Dp < 200 bar (2900 psi) 10 - Nas 1638
bx = 75 - 25 mm 21 / 19 /16 - ISO 4406
(3.0-0.98 in)
Relief valve 177 ± 3 bar (2567 ± 44 psi)
Stand by pressure load sensing valve 7 bar (102 psi)
Weight 30 kg (66 lbs)
PUMP (ENGINE 110HP) 1st PUMP 2nd PUMP

Direction of rotation (looking on drive shaft) Clockwise (D)
Displacement 40.258 cm3/rev 35.427 cm3/rev
(2.457 in3/rev) (2.162 in3/rev)
Inlet pressure range for pump 0.7 - 3 bar (10-44 psi)
Maximum continuos pressure P1 260 bar 260 bar
(3771 psi) (3771 psi)
Maximum intermittent pressure P2 280 bar 280 bar
(4061 psi) (4061 psi)
Maximum peak pressure P3 300 bar 300 bar
(4351 psi) (4351 psi)
Operating temperature -25 to -80 °C (-13 to -112 °F)
min P1 350 min-1
Speed
max P1 3000 min-1
recommended 12 to 100 mm2/s (cSt)
Viscosity range
permitted max 750 mm2/s (cSt)
Dp > 200 bar (2900 psi) 8 - Nas 1638
bx = 75 - 10 mm 19 / 17 /14 - ISO 4406
(3.0-0.39 in)
Contamination class
Dp < 200 bar (2900 psi) 10 - Nas 1638
bx = 75 - 25 mm 21 / 19 /16 - ISO 4406
(3.0-0.98 in)
Relief valve 177 ± 3 bar (2567 ± 44 psi)
Stand by pressure load sensing valve 7 bar (102 psi)
Weight 30 kg (66 lbs)
TIGHTENING TORQUES
HYDRAULIC DIAGRAM
2.3 LOAD SENSING VALVE
1. Orifice 8. Steering relief valve

2. Backhoe systems (EF) 9. Relief valve adjuster
3. Filter 10. Poppet
4. Spool 11. Return to inlet pump port
5. To steering priority flow (CF) 12. Lock plug
6. Orifice 13. Load sensing signal (LS)
7. Inlet port from rear pump (IN) 14. Orifice
When the steering is in neutral the LS port is con-

nected to the unload (through the steering) and the
steering inlet port (CF) is open.
2 7
6
F29457
Load sensing valve with pump running - Steering in neutral

Return to oil tank
Trapped oil
Pressure oil
1. Orifice 5. To steering priority flow (CF)
2. Backhoe systems (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool
The pressure on (CF) increases until the pressure value (standby pressure) is sufficient to move the spool valve
in a way to divert the flow toward (EF).
2 7
6
F29458
Load sensing valve with pump running - Steering working

Trapped oil
Return to oil tank
1. Orifice 5. To steering priority flow (CF)
2. Backhoe systems (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool
During steering two actions are performed:

1. The fluid moves to the steering through (CF).
2. The (LS) signal is in communication to the steering.
2.4 REMOVAL
1. Drain the hydraulic tank into a container capable

of holding up to 75 liters (20 US gallons).
2. Disconnect the handbrake cable and the trans-

mission to the rear axle drive shaft.
3. Disconnect and plug pump inlet and pressure

hoses.
Remove the pump flange mounting bolts and re-
move the pump.
2.5 COMPONENTS
1. Retaining bolt 19. Bushing

2. Steering control valve 20. Gasket
3. Spool 21. Bushing
4. O-ring 22. Back-up seal
5. Plug / Cap 23. Bearing block
6. Valve 24. Pump gear
7. Filter 25. Gear
8. Connector 26. Front pump using
9. Spring seat 27. Gasket
10. Spring 28. Gear
11. O-ring 29. Flange
12. Cap 30. Seal
13. Relief valve 31. Seal
14. O-ring 32. Snap ring
15. Poppet 33. Pressure seal (rubber)
16. Spring 34. Pump gear
17. Seat 35. O-ring
18. Rear pump housing 36. Bolt
DISASSEMBLY STEERING CONTROL VALVE

To aid reassembly draw an alignment line along the
total length of the pump assembly.
Remove the retaining bolts (1).
Remove the load sensing steering control valve (2).

Check and eventually replace the O-rings (35).
DISASSEMBLY STEERING CONTROL VALVE

Do not disassemble the steering system relief valve
(A) if the steering system relief valve pressure was
to specification when pressure testing the pump pri-
or to overhaul.
NOTE: if the steering system relief valve is disas-

sembled then the valve must be reset as described
in the trouble shooting pressure and flow testing
chapter before the vehicle is recommissioned.
Wash all components in an approved degreasant

and inspect for the following.
Valve bore must be free from scoring and damage to
metering edges.
The spool (3) should slide freely in the bore and be
free of scoring and damage.
Ensure all orifices are clean.
The relief valve seat should be free from pitting and
damage. A small chamfer on the mouth of the bore
is permissible.
Examine the filter (7) which fit inside the unload and
relief valves. The filter must be replaced if contami-
nated.
Pressure and flow test the pump.
DISASSEMBLE REAR PUMP

Remove the bolts (36).
Remove the rear pump assembly (18).
IMPORTANT: prior to disassembly and to ensure

correct reassembly identify the position of each
bearing block in the pump body as described below.
Scribe an identifying letter “A” and “B” “C” and “D” on

the pump housing and in the channel of each bear-
ing block.
NOTE: orientation of bearing block seals relative to

oil port.
If scribe is not available take care to keep bearing

blocks in pairs.
Disassemble the gears (24), the seals (22) and (33)
and the bearings (23).
Wash all components in approved degreasant.
Inspect the wear track cut by the gears in pump

body. The body can be reused if the track is bright
and polished and does not exceed 0.08 mm - 0.0076
mm (0.0.31 inch - 0.0030 inch) in depth.
Examine bearing block faces for scoring and flat-
ness paying particular attention to the face which
abuts the gears.
Examine bearing block bushes for scoring.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
If pump block, gears or bearing blocks are worn and

require replacement the pump assembly must be re-
placed.
Reassembly follows the disassembly procedure in
reverse whilst observing the following:
Z Ensure all parts are perfectly clean and lubricate
bushes and gears with clean hydraulic fluid.
Z Replace all seals and O-rings.
Z Install bearing blocks into the same positions from
which they were removed using identification let-
ters scribed during disassembly.
Z Ensure plastic back-up seals are correctly posi-
tioned in the rubber seal.
DISASSEMBLY FRONT PUMP

To remove from pump assembly (26) from the flange
(29) its necessary to remove the snap ring (33).
Remove and replace the flange seals (31) and (32).
Identify and note the position of each bearing block

to ensure correct reassembly.
Disassemble the gears (28) and (34), the seals (22)
and (33) and the bearings (23).
Wash all components in approved degreasant.
Inspect the wear track cut by the gears in the inlet

side of the pump body. The body can be reused if
the track is bright and polished and does not exceed
0.15 mm (0.006 in) in depth.
Examine bearing block faces for scoring.
Inspect PTFE coated bearings in body or flange for
wear. If bearings are worn the bronze backing will be
revealed.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
Examine flange seal contact area on driveshaft. If
pump block, gears, bearing blocks or drive shaft are
worn the pump assembly must be replaced.
Reassemble using disassembly procedure in re-

verse whilst observing the following:
Z Ensure all parts are perfectly clean and lubricate
bushes and gears with clean hydraulic fluid.
Z Replace all seals and O-rings.
Z Install bearing blocks into the same positions from
which they were removed.
Z Ensure back-up seals are correctly positioned in
the seal.
Assemble the inner flange seal, (31), with the spring

and lip facing into the pump. Install the outer seal,
(32), with the garter spring and lip facing outwards
and the refit circlip (33).
Coat the seals with high melting point grease.
NOTE: ensure seals are fitted back to back.
NOTE: if the seal recess has been scored during

seal removal coat outside diameter of seal with flex-
ible gasket sealant 82995770 to prevent leakage.
3. CONTROL VALVES
3.1 CONTROL VALVES “HUSCO”
(B90B - B95B - B95BLR - B95BTC - B110B MECHANICAL MODELS)
The backhoe loader is manufactured with a center

pivot backhoe.
The description and operation of the control valves
are described in this section.
Loader control valve, mounted on the right hand

side of the machine provides oil flow to the loader
boom and bucket. The valve assembly also contains
the front pump system pressure relief valve.
F29220
Stabilizer control valve, mounted to the left hand

side of the machine. The control valve for the back-
hoe telescopic dipper where fitted is also fitted into
this valve stack.
F29221
Backhoe control valve, located at the rear of the

chassis provides oil flow for operation of the boom,
dipper, bucket and swing the backhoe assembly.
F29222
Front pump oil

Rear pump oil
Suction oil
Return to oil tank
1. Hydraulic tank 8. Backhoe hammer control valve

2. Hydraulic pump 9. Backhoe hammer
3. Lower steering 10. Backhoe control valves
4. Hand hammer control valve 11. Return line distributor block
5. Hand hammer 12. Filter
6. Stabilizer and telescopic dipper (HED) control 13. Oil cooler by-pass valve
valves 14. Oil cooler
7. Loader control valves with unload
LOADER CONTROL VALVE

The loader control valve is located on the right hand
side of the loader backhoe and provides oil flow to
the loader boom and bucket.
The control valve assembly is of the mono block de-
sign with a bolt on end cover.
Located within the mono block assembly are:
Z Loader lifting
Z Loader bucket
The optional auxiliary valve section for operation of
the 4x1 loader bucket may be installed between the
inlet end cover and monoblock assembly as re-
quired.
1. Rear pump unload valve 5. 4x1 bucket relief valve

170 bar (2465 psi) 241 bar (3500 psi)
2. Loader bucket relief valve rod end 6. Bucket valve spool
227 bar (3300 psi) 7. Loader valve spool
3. Loader bucket relief valve piston end 160 bar 8. Bucket return to dig solenoid
(2300 psi) A. Loader lifting section
4. System pressure relief valve B. Loader bucket section
204 bar (2958 psi) C. 4x1 loader bucket section
Oil flow through loader and bucket control valve
D 2 3 4
E 9 8 7 6 F
6
8
7
9
5
3
E F
F29225
Front pump flow

Rear pump flow
Trapped oil
Return to oil tank
1. Combined pump flow check valve 8. Rear pump unload valve

2. Bucket system check valve 9. Auxiliary 4x1 valve section
3. Loader system check valve Port D - Flow from front pump
4. Parallel gallery Port E - Flow from rear pump
5. Staggered open center gallery Port F - Flow to backhoe control valve
6. Loader valve spool Port G - Return to tank from bucket, loader and
7. Bucket valve spool auxiliary
Hydraulic oil supply to the loader valve comes from

both the front and rear hydraulic pump assemblies.
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 center gallery before exiting at port F to flow to
the backhoe control valve at the rear of the machine.
Rear pump oil

Oil supply from the rear pump flows through port E
and when the multi-purpose valve is in neutral con-
tinues through the combined pump flow check valve
to merge with the output from the front pump.
Spool operation
When the bucket or loader control valves are oper-
ated, flow through the staggered open center 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
system check valve of its seat and oil flows through
the check valve and over the spool to operate the cyl-
inder.
Exhaust oil from the operated cylinder returns
through the control valve exhaust gallery and back to
tank through port G.
NOTE: because the parallel gallery feeds both the

bucket and loader valve spools, simultaneous oper-
ation of the bucket and loader arm elements are pos-
sible.
Check valve operation

The system check valves prevent the reverse flow of
oil if system pressure is insufficient to operate the
cylinder.
This can occur, for example, if the loader arms are
raised with the bucket at full load while the engine is
idling.
Under this condition it is possible for system pres-
sure to initially be too low to operate the cylinder and
without the check valve the loader would slightly low-
er when the valve is operated until pump pressure
rises.
Loader unload valve operation

An unload valve with sensing is installed to dump the
rear pump flow when operating the loader, to provide
more power to the transmission.
The front pump is not affected, so the loader will
have the same power, but will momentarily be slow-
er.
The operator may not notice the reduced speed, for
as soon as the pressure lowers below the preset lim-
it, the rear pump flow is directed back to the loader.
System pressure below 170 bar (2465 psi)

Oil flow from the front pump enters the loader valve
housing at port D.
Oil flow from the rear pump enters the loader valve
through the inlet end cover at port E.
When system pressure is less than 170 bar (2465
psi), the rear pump flow passes through the load
check valve and merges with the flow from the front
pump.
System pressure above 170 bar (2465 psi)

When system pressure rises to 170 bar (2465 psi),
the rear pump flow back to tank through port G.
This reduced flow through the loader and backhoe
control valves now allows a more precise control of
the loader and backhoe elements.
Disassembly
Prior to disassembly the valve should be thoroughly
cleansed using an approved degreasant.
When reassembling the end cover progressively
tighten the clamping bolts to following torques.
To remove the “auxiliary 4x1 bucket valve section” it

is necessary to unscrew and remove the nuts (1) be-
fore, then the end cover (2).
Now you can slide out from the tie rods (4) the aux-
iliary 4x1 bucket valve section (3).
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
A. Bucket valve section 9. Cover

1. Spring seat 10. Return to dig electro magnet
2. Spring 11. Seal plate
3. Spring seat 12. Seal
4. Screw retainer 13. Spool
5. Cover 14. Seal
6. Spacer 15. Wiper
7. Washer 16. Seal plate
8. Circlip
1. Relief valve assembly 7. Guide

2. Spring 8. Poppet
3. Locknut 9. Poppet sleeve
4. Valve body 10. Valve body inner
5. Adjuster 11. Spring seat
6. Spring
The piston and rod end loader bucket system relief

valves are similar in operation but the end faces of
some internal components are different.
Each relief valve can be identified by the size of hole
in the center of the plunger assembly.
The bucket rod end relief valve (1) has the small hole
and is set to a pressure of 227 bar (3300 psi).
The bucket piston end relief valve (2) has the larger
hole and can also be identified by the recess on the
face of the plunger assembly item. This valve is set
to a pressure of 160 bar (2300 psi).
For further details on the operation, overhaul and
adjustment of system relief valves used in the loader
backhoe hydraulic system, refer to system relief 64
valves principle of operation, overhaul and adjust-
ment.
A. Loader valve section 12. End cap

1. Spring seat 13. Detent collar
2. Spring 14. Seal plate
3. Spring seat 15. Seal
4. Detent 16. Spool
5. Detent balls 17. Collar
6. Spring 18. Seal
7. Ball Bearing 19. Wiper
8. Cap 20. End cover
9. Circlip 21. Seal plate
10. Cover 22. Cover
11. Spacer
Inspection
The bucket and loader valve spools are selectively
fitted to each valve bore and if damaged the mono
block assembly must be replaced.
Inspect spool and bore for scores.
Reassembly
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.
Reassembly of the spools and seals requires special

care and the use of tool 380000728 must be used to
prevent damage.
Insert oil seal into tool. Ensure lip on seals is facing

outwards.
Position tool in counterbore on spool linkage side of

valve housing and press seal into position.
Install wiper seal and seal plate.
Lubricate spool and insert into end of bore which has

not yet been installed with seals. Push spool through
bore until end of spool passes through seal.
Continue pushing spool through bore until rear face

of spool is just below the counterbore into which the
remaining seal is to be installed.
NOTE: when pushing seal through bore the feather-

ing grooves on the spool will pass through the front
seal. These will not damage the seal but do not al-
low the sharp metering lands to pass through the
seal otherwise damage and leakage will occur.
Install seal into counterbore on spool spring cen-

tered side of valve housing.
NOTE: a dust seal is not fitted on the spring cen-

tered end of the loader and bucket spool bore.
Use the metal portion of the seal installation tool to

hold the seal in position and gently center the spool
in the housing.
Assemble centering spring onto end of spool.

STABILIZER AND TELESCOPIC DIPPER (HED) CONTROL VALVE

Telescopic dipper (HED) is an optional device,
therefore if the backhoe is not equipped with this
kind of equipment, the control valve assembly is dif-
ferent. In such a case a (2 section) control valve is
installed, that controls only the stabilizers operation.
(See drawing).
The stabilizer and telescopic dipper (HED) control

valve assembly is located on the left hand side of the
chassis adjacent to the hydraulic pump (2).
The valve assembly is a stack type made up of three
valve sections together with an inlet and outlet end
cover.
The pilot operated system relief valve is located in
the inlet end cover for protection of the rear pump.
There is also a pilot operated relief valve fitted in the
telescopic dipper (HED) valve section for protection
of the piston end of the dipper cylinder from shock
loadings.
A. Stabilizer left and right 6. Return to tank from stabilizer and telescopic dip-
B. Exentible dipper (HED) per (HED) systems
1. Outlet end cover 7. Inlet port flow from rear hydraulic pump
2. Exentible dipper (HED) section control valve 8. Inlet end cover
3. Left hand stabilizer section control valve 9. Telescopic dipper (HED) (piston end) relief
4. Right hand stabilizer section control valve valve - 124 bar (1800 psi)
5. Rear pump relief valve - 196 bar (2842 psi)
Hydraulic oil flow
A 2 3 4 C
2 3 4
A C
F29244
Rear pump flow

Trapped / Static flow oil
Return to oil tank
A. Inlet from wear hydraulic pump 1. Rear pump system relief valve 196 bar (2842
B. Outlet from staggered open center gallery psi)
C. Return to tank from control valve exhaust galler- 2. Left hand stabilizer section control valve
ies 3. Right hand stabilizer section control valve
4. Telescopic dipper (HED) section control valve
5. Staggered open center gallery
Flow from the rear pump is controlled by the flow di-

vider on the rear of the pump which diverts output to
both the steering and hydraulic systems.
Hydraulic system output from the rear pump enters
the end covering port (A) and flows down the stag-
gered open center gallery running through the stabi-
lizer and telescopic dipper (HED) valve assemblies.
If the valve sections are in neutral the flow continues
out of port (B) and flows to the loader valve assem-
bly where it merges with the output from the front
pump.
When a valve section is operated, flow through the
staggered open center gallery is blocked by the
spool.
Flow through the outlet port (B) is now restricted and
the oil flow to the loader valve becomes static until
the valve is returned to neutral.
Pump pressure will now rise with a corresponding
rise of pressure in the parallel gallery which is
blocked at the outlet end cover.
Oil can now flow from the parallel gallery over the
control valve spool to operate the cylinder.
Exhaust oil from the cylinder returns to tank through
port (C).
The oil flow through the stabilizer and telescopic dip-
per (HED) valve sections are described on the fol-
lowing pages.
Stabilizer control valve 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 system 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 le-
vers are moved if the stabilizers are extended and
the engine is turned off.
Control valve in neutral

When the stabilizer control valve is in neutral output
from the rear pump can flow uninterrupted through
the staggered open center gallery and the lands on
the spool prevent flow to the cylinder ports.
In neutral the lands on the spool trap the oil between
the outlet port of the valve and the lock valves.
With no pressure in these lines the lock valves (2)
assume the closed position and oil in the stabilizers
is trapped, preventing leak down of the stabilizer cyl-
inders.
Control valve operating

When the stabilizer system is operated the spool is
moved to either the extend or retract position.
Oil flow through the staggered open center gallery is
blocked and system pressure rises in the parallel
gallery.
Pressure oil flows past the spool through the cylinder
port to the check valve.
The load sense lines in the lock valves are now pres-
surized which opens the valve to allow oil flow to the
stabilizer cylinder.
Return oil from the opposite end of the cylinder also
flows through a lock valve and back to tank across
the spool.
1 2 3 4 5
9 8 7 6
F29248
Stabilizer control valve section - Neutral position
1 2 3 4 5
9 8 7 6
F29249
Stabilizer control valve section - Operating position

Pump pressure oil
Trapped oil
Return to oil tank
1. Stabilizer lock valve 6. Centering spring
2. To stabilizer cylinder 7. Exhaust gallery
3. Parallel gallery 8. Staggered open center gallery
4. To stabilizer cylinder 9. Spool
5. Stabilizer lock valve
Telescopic dipper (HED) valve section

The telescopic dipper (HED) valve section is differ-
ent from that of the stabilizer valves and contains a
built in check valve to prevent the back flow of oil into
the parallel gallery.
These valves are not required in the stabilizer valve
sections due to the external pilot operated “Fail Safe”
lock valves used in the stabilizer system.

When a control valve is in neutral the oil in a cylinder
is trapped by the spool and pump oil is allowed to
flow 29 through the staggered open center gallery.
The pressure in the parallel galley is at pump pres-
sure, however the oil is static as the gallery termi-
nates at the outlet end cover.
The return to tank oil in the control valve exhaust gal-
lery is static.
Oil to either end of the cylinder is trapped by the
spool. Oil is also trapped in the “D” shaped gallery
behind the check valve.

When the valve spool is moved either left or right to
extend or retract a cylinder, flow through the stag-
gered open center gallery is blocked.
Pump pressure in the staggered an parallel galleries
will rise.
Moving the spool joins one cylinder port to tank and
the other to the “D” shaped gallery behind the check
valve. As pump pressure rises in the parallel gallery
the check valve will open and oil will flow through the
“D” shaped gallery to the cylinder port.
Exhaust oil from the cylinder flows from the exhaust-
ing port into the cylinder exhaust port and returns to
tank.
1 2 3 4 5
9 8 7 6
F29250
Telescopic dipper (HED) control valve section - Neutral position
1 2 3 4 5
9 8 7 6
F29251
Telescopic dipper (HED) control valve section - Operating position

Pump pressure oil
Trapped oil
Return to oil tank
1. Cylinder port 6. Centering spring
2. Check valve 7. Exhaust gallery
4. Cylinder port 9. Spool
5. System relief valve
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 systems by moving the load-
er 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 re-
quired to catch oil draining from inside the hoses.
Remove valve from loader backhoe.
Disassembly
1. Nut 8. O-ring
2. Longer tie bar 9. Left stabilizer section control valve
3. Shorter tie bar 10. Right stabilizer section control valve
4. Outlet end cover 11. Rear pump relief valve
5. O-ring 12. O-ring
6. Telescopic dipper (HED) section control valve 13. Inlet end cover
7. Telescopic dipper (HED) relief valve 14. Nut

Scribe a diagonal line across the valve sections to
aid reassembly.
Untighten and remove the nuts (1).
Remove the outlet end the cover (4).
Disassemble the section control valve (6), (9) and

(10).
NOTE: the check valve (A) is only installed in the

telescopic dipper (HED) valve section.
When reassembling the valve stack progressively

tighten the two smaller tie (3) bar retaining nuts to (1)
a torque of 19 Nm (14 lbf.ft).
Tighten the longer tie bar (2) nut (1) to a torque of 45
Nm (33 lbf.ft).
Disassembly the telescopic dipper (HED) valve

section.
The stabilizer valve sections are not fitted with a
check valve between each section.
The rear pump relief valve and telescopic dipper
(HED) system relief valve can be serviced if required
but must be readjusted prior to use.
Refer to system relief valve overhaul and pressure
testing sections for further details.
1. Spool cap 10. System relief valve

2. Cap plate 11. Valve section body
4. Wiper seal 13. Spring
5. Screw 14. Check valve
6. Spring seat 15. Wiper seal
7. Spring 16. O-ring
8. Spring seat 17. Plate
9. Spool 18. Screw
Disassembly stabilizer valve sections
1. Spool cap 9. Spool

2. Cap plate 10. Valve section body
4. Wiper seal 12. Wiper seal
5. Screw 13. O-ring
6. Spring seat 14. Plate
7. Spring 15. Screw
8. Spring seat
Disassembly inlet end cover

1. Rear pump relief valve
2. Outlet from exhaust port
3. Inlet port
4. Parallel gallery
5. Open center gallery
6. Exhaust gallery
7. O-ring
Inspection
Wash components in an approved degreasant.
Inspect spool and bore for scoring and damage.
If spool is baldly scored or worn the valve assembly
must be replaced.
Reassembly
reverse.
Lubricate spool before reassembly.
To avoid damage to O-ring seals on either end of
spools insert spool into valve housing before install-
ing O-ring (1) and wiper (2).
BACKHOE CONTROL VALVES

The backhoe control valve assembly located at the
rear of the loader backhoe is a stack type assembly
containing four valve sections, together with an inlet
and outlet end cover.
The valve assembly allows operation of the following
functions:
Z Boom
Z Swing
Z Bucket
Z Dipper
A. Dipper 5. Boom relief valve (cylinder rod) 317 bar (4600

B. Bucket psi)
C. Swing 6. Inlet end cover
D. Boom 7. Boom relief valve (cylinder piston) 271 bar
1. Outlet end cover (3500 psi)
2. Dipper relief valve 241 bar (3500 psi) 8. Swing relief valve (cylinder piston) 207 bar
3. Bucket relief valve 207 bar (3000 psi) (3000 psi)
4. Swing relief valve (cylinder rod) 207 bar (3000
psi)
Hydraulic oil flow
2 3 4 5
2 3 4 5
8
7
F29262
Pump pressure oil

Return to oil tank
Port H - Pump flow from loader valve 5. Dipper section control valve
Port J - Return to tank 6. Regenerative check valve
1. Valve section check valve 7. Back pressure valve
2. Boom cylinder section control valve 8. Inlet end cover
3. Swing cylinder section control valve 9. Outlet end cover
4. Bucket cylinder section control valve
Flow from the loader control valve assembly enters

the backhoe control valve at port (H).
Neutral
When all control valve sections are in neutral pump
oil flows through the staggered open center gallery
and returns to tank through port (J).
Spool operation
When a control valve spool is operated flow through
the staggered open center 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 op-
erated the oil behind the system 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.
Check valve operation

The check valve prevents the back flow of oil if pump
pressure is insufficient to operate the cylinder. This
could occur for example if the boom is raised when
at full reach and full load while the engine is idling
and pump pressure is initially to low to operate the
cylinder. Under these conditions and without the
presence of the check valve the boom would initially
lower when the spool is operated.
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.
Backhoe control valve section

When a control valve is in neutral the oil in a cylinder
is trapped by the spool and pump oil flows through
the staggered open center gallery.
Oil in the parallel gallery is at pump pressure.
The trapped oil in the “D” shaped gallery holds the
check valve on its seat.
There is no exhaust from the cylinder and the oil in
the control valve exhaust gallery is static.

When the valve spool is moved either left or right to
extend or retract a cylinder flow through the stag-
gered open center gallery is blocked.
Pump pressure in the staggered and parallel galler-
ies will rise.
Moving the spool joins one cylinder port to tank and
the other to the “D” shaped gallery behind the check
valve. As pump pressure rises in the parallel gallery
the check valve will open and oil will flow through the
“D” shaped gallery to the cylinder port.
Exhaust oil from the cylinder flows into the control
valve exhaust gallery and returns to tank.
1 2 3 4 5 6
10 9 8 7
F29264
Backhoe control valve section - Neutral position
1 2 3 4 5 6
10 9 8 7
F29265
Backhoe control valve section - Operating position

Pump pressure oil
Trapped oil
Return to oil tank
1. System relief valve 6. System relief valve

2. Cylinder port 7. Centering spring
3. Check valve 8. Exhaust gallery
5. Cylinder port 10. Spool
Light load conditions

If the backhoe is operated under light load condi-
tions, e.g. slowly lowering the backhoe to the ground
or into a trench, control of the elements can become
less precise if a back pressure in the cylinder ex-
haust system was not present.
To ensure precise control during this type of opera-
tion the back pressure valve maintains a cylinder ex-
haust back pressure of 9.5 bar (140 psi).
When pump (system) pressure is less than 69 bar
(1000 psi) the valve remains closed and cylinder ex-
haust oil returns to tank through the small drilling
connecting control valve exhaust and return to tank
galleries. The restriction created by the drilling gen-
erates the back pressure in the control valve exhaust
gallery required under light load conditions.
Heavy load conditions

When the backhoe is operated under heavy load
conditions, e.g. digging the spoil from a trench, a
high exhaust back pressure will reduce hydraulic
power.
To improve efficiency it is now necessary to reduce
the back pressure in the system to a more accept-
able level.
As pump pressure increases in the parallel gallery
the back pressure valve pins gradually forced down-
wards opening the back pressure valve. This allows
cylinder exhaust oil to flow freely through gallery (J).
Regenerative check valve operation

When a digging element is rapidly operated, for ex-
ample the boom is quickly lowered into a trench, the
situation can arise where, if engine speed is too low,
pump output is insufficient to meet demand of the
cylinder and the cylinder will cavitate.
This will result in a hydraulic void occurring in the pis-
ton (extending) side of the cylinder.
To overcome this situation the regenerative check
valve is installed.
When cylinder exhaust pressure is higher than pump
pressure, the flow of oil from the exhausting cylinder
lifts the check valve of its seat allowing exhaust oil to
flow past the check valve into the parallel gallery and
supplement the insufficient flow from the pump to op-
erate the cylinder and prevent the void from occur-
ring.
The back pressure valve will remain closed in this
operation.
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 systems by moving the load-
er 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 re-
quired to catch oil draining from inside the hoses.
Disconnect control lever linkages (1).
Remove the bolts (2) securing the valve assembly to

the chassis.
Remove the backhoe control valve.

Disassembly
1. Nut 11. Relief valve

2. Shorter tie bar 12. Bucket section control valve
3. Longer tie bar 13. Plug
4. Inlet end cover 14. Dipper section control valve
6. Relief valve 16. Outlet end cover
7. Boom section control valve 17. Plug
8. O-ring 18. Check valve
9. Relief valve 19. Back pressure valve
10. Swing section control valve

Scribe a diagonal line across the valve sections to
aid reassembly.
Untighten and remove the nuts (1).
Remove the outlet end cover (16).
Disassemble the section control valve (7), (10), (12),

(14) and the inlet end cover (4).
NOTE: retrieve check valves positioned between

each valve section.
Disassembly control valve sections
NOTE: the components within the bucket, swing and

dipper control valves are similar to the boom valve
shown above.
The differences between each section are minimal

and relate to the shape of the spool and type of relief
valves installed.
The system relief valves can be serviced if required
but must be re-adjusted prior to use.
1. Screw 11. Valve section body

2. Spool cap 12. Check valve
3. Cap plate 13. Spring
4. Wiper seal 14. Seal
5. Seal 15. Wiper seal
6. Screw 16. Plate
7. Spring seat 17. Screw
8. Spring 18. Direct acting system relief valve
9. Spring seat 19. System relief valve with anti-caution
10. Spool
Disassembly outlet end cover

2. Body end cover
3. Plug assy
4. Check valve
A. Plug
B. O-ring
C. Spring
D. Valve
E. Plunger
F. O-ring
G. Plug
H. Valve
I. Spring
J. O-ring
K. Plug
Inspection
Wash components in an approved degreasant.
Inspect spool and bore for scoring and damage.
If spool is baldly 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 pre-
vent damage.
Insert oil seal into tool. Ensure lip on seals is facing

outwards.
Position tool into counter bore on spool linkage end

of valve housing and press seals into position.
Install the wiper (1) and the seal plate (2).
Lubricate spool and insert into end of bore which has

not yet been installed with seals. Push spool com-
pletely through bore until it emerges through seal.
Continue pushing spool through bore until face of

spool is just below the counterbore into which the re-
maining seal is to be installed.
NOTE: when pushing seal through bore the feather-

ing grooves on the spool will pass through the seal.
These will not damage the seal but do not allow the
sharp metering lands to pass through the seal other-
wise damage and leakage will occur.
Install the remaining seal into counterbore on the

spring centered end of the valve.
Using central portion of seal installation tool, hold

seal in position gently center the spool in the hous-
ing.
Install the wiper seal.
Install the seal plate and the centering spring as-

sembly.
Reassemble the valves into stack using alignment

line to ensure correct reassembly.
Progressively torque rod nuts to the specified

torque. Do not over tighten.
Short tie bar nuts 65 Nm (48 lbf·ft)
Long tie bar nuts 100 Nm (74 lbf·ft)
3.2 CONTROL VALVES “REXROTH” (B115B MECHANICAL MODELS)
The hydraulic system is a load sensing flow sharing

system working in conjunction with a fixed displace-
ment gear type hydraulic pump.
This system has the advantage that at any time the
distribution of flow to the services being operated is
in proportion to the openings of the control valve
spools.
The flow distribution to the backhoe and loader con-
trol valves is independent of the load and it is there-
fore possible to operate two or more spools
satisfactorily at the same time.
The principal components of the load sensing flow
sharing system are the pressure compensator
valves in each control valve section, together with
the load sense line which connects all the spool sec-
tions in both the loader and backhoe control 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 center galler-
ies of the loader and backhoe control valves assem-
blies.
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
system with remaining flow directed to supplement
the flow from the front pump for the loader and back-
hoe systems.
The center gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply system is controlled by the
pump flow balancer valve in accordance with the
pressure in the load 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 systems.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure
in the load sense line when it reaches 210 bar (3046
psi).
Because the pump flow balancer valve is influenced
by load sense pressure the valve diverts sufficient
flow back to tank to maintain the maximum system
pressure of 210 bar (3046 psi).
Loader control valve

The loader control valve is mounted on the right
hand side of the machine adjacent to the pump.
The valve assembly consists of a maximum of three
spool operated sections and provides oil flow to the
loader boom, bucket and auxiliary services where
fitted.
Backhoe control valve

The backhoe control valve is located at the rear of
the chassis.
The control valve consists of a maximum of seven
sections of spool control valves and provides the oil
flow for operating the boom, the toothed scoop, the
bucket, the superstructure, the stabilizer and the lat-
eral sliding clamping components of the backhoe
assembly.
Hydraulic system oil

Steering system oil
Loader sense oil
Suction oil
Return to oil tank
1. Hydraulic tank 8. Backhoe hammer control valve

2. Hydraulic pump 9. Backhoe hammer
3. Power steering 10. Oil cooler
4. Hand hammer control valve 11. Return line distributor block
5. Hand hammer 12. Filter
6. Backhoe control valve 13. Oil cooler by-pass valve
OIL FLOW OPERATION
All loader/backhoe systems in neutral

Each control valve section within the backhoe or
loader control valve assemblies contains a spool,
two check valves and a load sensing pressure com-
pensator.
A load sense gallery connects the compensators in
each control valve section.
When all control valves are in neutral the spools pre-
vent the flow of oil in each system and pressure in
the load sense line can bleed to tank through the 1
liter/min (0.26 US gals/min) load sense return to tank
orifice in the backhoe control valve inlet cover.
Because there is no load sense pressure being ap-
plied to the rear face of the flow balancer valve, the
valve will move against the spring and off its seat
when pump pressure reaches 15 bar (218 psi).
Pump flow is now diverted back to tank and the bal-
ancer valve maintains a standby pressure of 15 bar
(218 psi) while the systems are in neutral.
1
2
5
7
6
F29287
Flow balancer valve operation - All spools in neutral

Pump standby pressure 15 bar (218 psi)
Return to oil tank
1. Load sense bleed orifice 1 l/min (0.26 US gals/ 4. Load sense line
min) 5. Pump flow balancer (unload) valve
2. Load sense limiter (system relief valve) 6. Pump flow IN
3. Return to oil tank 7. To backhoe control valves
1 2 3
4 4 4
F29288
Load sensing flow sharing - All spools in neutral

Pump pressure
Trapped oil
Return to oil tank
1. Load non-return check valve
2. Load sense line
3. Pressure compensating valve
4. Spool
One hydraulic system operating

When a single hydraulic system is operated the When pump pressure overcomes the pressure be-
spool in the control valve section is moved allowing hind the load check valve, the valve opens allowing
oil to flow past the lands of the spool and apply pres- oil to flow into the cylinder port.
sure to the metering element of the pressure com- Exhaust oil from the cylinder returns to tank through
pensating valve. the other port in the control valve section.
The metering element moves upwards to allow oil to If the load sense pressure in a system reaches 195
flow to the load check valve and at the same time bar (2828 psi), the load sense relief valve in the
uncovers the drilling in the spool portion of the pres- backhoe control valve end cover will operate. Pump
sure compensator valve enabling operating pres- pressure is now limited to 210 bar (3046 psi). This is
sure to be sensed in the load sense gallery. the pressure required to overcome the pressure of
As pressure increases to open the load check valve, the flow balancing valve spring 15 bar (218 psi) plus
load sense pressure is applied to the spring side of the load sensing pressure controlled at 195 bar
the flow balancer valve in the backhoe control valve (2828 psi).
end cover. A higher pressure is now required to op-
erate the flow balancer valve and pump pressure in-
crease accordingly.
1
2
5
7
6
F29289
Flow balancer valve operation - Hydraulic systems operating

Pump pressure
Load sense pressure
Return to oil tank
1. Load sense bleed orifice 1 l/min (0.26 US Gals/ 4. Load sense line
min) 5. Pump flow balancer (unload) valve
1 2 3
4 4 4
F29290
Load sensing flow sharing - One spool operating

Pump pressure
Trapped oil
Return to oil tank
1. Load non-return check valve 3. Pressure compensating valve
2. Load sense line 4. Spool
Two or more hydraulic systems operating

When two or more hydraulic systems are operated operating pressure to be sensed in the load sensing
each system will operate at a different pressure. gallery.
If pump flow to a specific system is not controlled the Pump pressure will rise until it overcomes the pres-
system requiring a lower operating pressure will sure behind the load check valve of the heaviest
work faster than that requiring the higher pressure loaded system and the pressure in the load sense
because flow will take the path of least resistance. line is similarly at this high pressure.
To overcome this situation the pressure compensat- The pressure required to operate the lower loaded
ing valve regulates the flow of oil to the system op- system is now too high and if not restricted will result
erating at a lower load. in the lower loaded system operating in preference
When two spools are operated simultaneously to and faster than the higher loaded system.
pump pressure is applied to the metering element of To compensate for this condition the load sense
the pressure compensating valve in both valve sec- pressure moves the metering element of the pres-
tions. sure compensating valve in the lower loaded system
Both metering elements therefore move upwards al- downwards and restricts the flow to the system.
lowing oil to flow to the load check valves. At the This balancing of flow and pressure according to
same time the aperture in the spool portion of the load ensures that both systems operate simulta-
pressure compensating valve is uncovered to allow neously and at a balanced flow rate.
1
2
5
7
6
F29291
Load sense relief valve operating

Pump pressure at 210 bar (3046 psi)
Load sense pressure at 195 bar (2828 psi)
Return to oil tank
1. Load sense bleed orifice 1 l/min (0.26 US Gals/ 4. Load sense line
min 5. Pump flow balancer (unload) valve
1 2 3
4 4 4
F29292
Load sensing flow sharing - Two spools operating

st
1 spool operating pressure
2nd spool operating pressure
Trapped oil
Return to oil tank
1. Load non-return check valve 3. Pressure compensating valve
2. Load sense line 4. Spool

The loader control valve is mounted on the right side
of the machine adjacent to the pump. The valve as-
sembly consists of two or three spool operated sec-
tions:
Z Loader lifting
Z Loader bucket
Z 4x1 loader lifting
Usually the loader control valve has three valve sec-
tions when is installed on the loader backhoe the 4x1
bucket.
A. 4x1 loader bucket section control valve

B. Loader bucket section control valve
C. Loader lifting section control valve
1. End cover
2. Bucket 4x1 relief valve
3. Bucket relief valve (rod end) 240 bar (3481 psi)
4. Hydraulic speed relief valve 165 bar (2393 psi)
5. Hydraulic speed solenoid
6. Inlet section
7. Bucket relief valve (piston end) 165 bar
(2393 psi)
Removal
Z Lower the loader to the ground, with the bucket in a
vertical position firmly placed on the ground.
Z Stop the engine and eliminate any residual
pressure in the backhoe and loader systems by
moving the loader and backhoe control levers
through all operating positions.
Z Disconnect the battery.
Z Clean the area around the control valve.
Z Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Z Unscrew and remove clamping screw to chassis.
Z Remove the control valve assembly from the
machine.
Z Installation is the reverse of the removal procedure.
Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 ± 2 Nm (20±1.5 lbf.ft). Slide out the three
tie bars (2).
Disassemble the end cover (4), the section control

valves (4), (5) and (6), and the inlet section (7).
Check and possibly replace the O-rings (8) located
between the section control valves.
BACKHOE CONTROL VALVE (WITH MECHANICAL CONTROL)

The backhoe control valve assembly is located at the
rear of the loader backhoe. It consists of six or seven
cover.
Valve sections are:
Z Stabilizer right
Z Stabilizer left
Z Boom
Z Dipper
Z Slew
Z Bucket
Z Telescopic (optional)
A. Right stabilizer section control valve 5. Swing system relief valve (piston end) - 205 bar
B. Left stabilizer section control valve (2973 psi)
C. Dipper section control valve 6. Boom system relief valve (piston end) - 315 bar
D. Bucket section control valve (4569 psi)
E. Swing section control valve 7. Pump flow balancer valve - 15 bar (217 psi)
F. Boom section control valve 8. Load sensing return to tank
G. Telescopic dipper (HED) section control valve 9. Swing system relief valve (rod end) - 205 bar
1. End cover (2973 psi)
2. Inlet section 10. Boom system relief valve (rod end) - 240 bar
3. Dipper system relief valve (piston end) - 240 bar (3481 psi)
(3481 psi) 11. Telescopic system relief valve (rod end) - 205
4. Bucket system relief valve (piston end) - 220 bar bar (2973 psi)
(3191 psi) 12. Load sensing relief valve - 210 bar (3046 psi)
Removal
Z Position the loader backhoe on a hard level sur-
face.
Z Lower the loader to the ground.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Z Stop the engine and eliminate any residual pres-
sure in the backhoe and loader systems by moving
the loader and backhoe control levers through all
operating positions.
Z Clean the area around the control valve.
Z Tag and identify the position of all hydraulic hoses.
Z Disconnect and plug all the hydraulic hoses.
Z Disconnect the linkages of the manual control le-
vers.
Z Unscrew and remove clamping screw to chassis.
Z Remove the control valve assembly from the loader
backhoe.
Z Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm (20±1.5 lbf.ft).
Slide out the three tie bars (2).

valve (4), (5), (6), (7), (8), (9) and (10), the inlet sec-
tion (11).
between the section control valve.
Disassembly the inlet section.

Remove the pump flow balancer valve (13), the load
sensing relief valve (14) and the check valve (15)
from the inlet section (11).
Disassembly of control valve sections (with

mechanical control)
There are indicated all possible solutions relevant to
backhoe control sections with mechanical control.
1. Secondary relief valve 6. Spool with mechanical detent system (loader

2. Pressure compensator boom element)
3. Check valves 7. Spool with electrical detent system (loader
4. Plug bucket element)
5. Spool with spring return system
Removal and reassembly mechanical control spool
Removal
Z Remove the screws (A), the boot along with its
plate (B) and the plate (C).
Z Remove the mounting screws (D) and the cover
(E).
Z Remove the spool (F) from the valve section.
Z Remove the lip seal (L).
Z Use a spool clamp (G) and a vice to secure the

spool.
Z Heat the spool to 200 °C (392°F) in an oven or with
a heat gun.
Z Remove the adapter (H), the retainers (I), the
spring (J), the plate (K) and the lip seal (L).
Z Remove the tongue (M) if necessary.
Reassembly
Z Reassemble parts in reverse order after greasing
the spring.
Z Position the metal part of the lip seal (L) on the out-
side of the spool.
Z The lip seal must be fitted on the end of the spool
so that it is not damaged by the spool grooves (N)
and its tightness is not damaged.
Z slide the lip seal perpendicularly onto the spool.
Z Tighten the screws (A and D), the adapter (H) and
the tongue (M) from 9 to 11 Nm (6.6-8.1 lbf.ft).
Precautions to be taken for replacing the spool lip

seal.
Z Place the spool in the working section.
Z Slide the lip seal perpendicularly onto the spool,
positioning the metal part of the lip seal on the out-
side of the spool.
S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.
Mechanical detent system spool
Removal
Z Remove the tongue and the cover sides.
Z Use a spool clamp (G) and a vice to secure the
spool.
Z Using a metal rod (minimum length = 80 mm (3.15
in), diameter 6) push the central ball (H) while ex-
tracting the detent bush (I).
Z Mark the orientation of the detent bush for the reas-
sembly.
Z Remove the balls (J) and the spring (K) from the
adapter (M).
Reassembly
Z Introduce the spring (K) into the adapter (M).
Z Place the 3 balls (J) into the radial holes of the
adapter (M) and use grease to prevent them from
falling.
Z Position the central ball (H) against the spring (K).
Z Slip the detent bush (I) onto a metal rod.
Z Using the metal rod, press the central ball (H) into
the adapter (M), then slide the detent bush (I) onto
the adapter, making sure that the 3 balls are still in
place.
NOTE: make sure that the orientation of the detent

bush is respected.
3.3 CONTROL VALVES “REXROTH”

(B90B - B90BLR - B95BLR - B110B - B115B PILOT MODELS)
The backhoe loader with hydraulic control (pilot mod-

els) differs basically from the backhoe loader with
mechanical models for the reason that the controls
driving the backhoe loader and stabilizers are hy-
draulic instead of being mechanic. By means of the
control levers located in the cab a control valve is
driven, that on its turn drives hydraulically the back-
hoe control valve, monitoring the backhoe loader
and the stabilizers.
The backhoe loader with hydraulic control is
equipped with two control valves:
Z Loader control valve: mounted on the right hand
side of the backhoe loader and provides oil flow to
the loader boom and bucket.
Z Backhoe control valve: located at the rear of the
chassis and provides oil flow to the backhoe,
stabilizers and bucket.
Hydraulic system oil Suction oil

Steering system oil Return to oil tank
Load sensing oil Pilot control system oil
1. Hydraulic tank 10. Oil cooler

2. Hydraulic pump 11. Return line distributor block
3. Steering motor 12. Filter
4. Hand hammer control valve 13. Oil cooler by-pass valve
5. Hand hammer 14. Solenoid valve for piloting hydraulic backhoe
6. Backhoe control valve control valve
7. Loader control valve 15. Hydraulic control lever
8. Backhoe hammer control valve 16. Accumulator
9. Backhoe hammer

The loader control valve is mounted on the right side
of the machine adjacent to the pump. The valve as-
sembly consists of two or three spool operated sec-
tions:
Z Boom
Z Bucket
Z 4x1 bucket
Usually the loader control valve has three valve sec-
tions when is installed on the loader backhoe the 4x1
bucket.
A. 4x1 bucket section control valve

B. Bucket section control valve
C. Boom section control valve
1. End cover
2. Bucket 4x1 relief valve
3. Loader bucket relief valve (rod end) 240 bar (3481 psi)
5. Hydraulic speed solenoid
6. Inlet section
7. Loader bucket relief valve (piston end) 165 bar (2393 psi)
Removal
Lower the loader to the ground, with the bucket in a
vertical position firmly placed on the ground.
Stop the engine and eliminate any residual pressure
in the backhoe and loader systems by moving the
loader and backhoe control levers through all operat-
ing positions.
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 screw 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 (20±1.5 lbf.ft). Slide out the three
tie bars (2).

valve (4), (5) and (6), and the inlet section (7).
between the section control valve.
BACKHOE CONTROL VALVE (WITH HYDRAULIC CONTROL)

The backhoe control valve assembly is located at the
rear of the loader backhoe. It consists of six or seven
cover.
Valve sections are:
Z Stabilizer right
Z Stabilizer left
Z Boom
Z Dipper
Z Swing
Z Bucket
Z Telescopic (optional)
A. Right stabilizer valve section 6. Boom system relief valve (piston end) - 315 bar
B. Left stabilizer valve section (4569 psi)
C. Dipper valve section 7. Pump flow balancer valve - 15 bar (217 psi)
D. Bucket valve section 8. Load sensing return to tank
E. Swing valve section 9. Swing system relief valve (rod end) - 205 bar
F. Boom valve section (2973 psi)
G. Telescopic dipper (HED) valve section 10. Boom system relief valve (rod end) - 240 bar
1. End cover (3481 psi)
2. Inlet section 11. Telescopic system relief valve (rod end) - 205
3. Dipper system relief valve (piston end) - 240 bar bar (2973 psi)
(3481 psi) 12. Load sensing relief valve - 210 bar (3046 psi)
4. Bucket system relief valve (piston end) - 220 bar
(3191 psi)
5. Swing system relief valve (piston end) - 205 bar
(2973 psi)
Removal
Position the loader backhoe on a hard level surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
Stop the engine and eliminate any residual pressure
in the backhoe and loader systems by moving the
loader and backhoe control levers through all oper-
ating positions.
Clean the area around the control valve.
Tag and identify the position of all hydraulic hoses
and hydraulic tubes.
Disconnect and plug all the hydraulic hoses and all
the hydraulic tubes.
Unscrew and remove clamping screw to chassis.
Remove the control valve assembly from the loader
backhoe.
Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm (20±1.5 lbf.ft).
Slide out the three tie bars (2).
Disassemble the end cover (3), the sections control

valves (4), (5), (6), (7), (8), (9) and (10), the inlet sec-
tion (11).
between the sections.
Disassembly the inlet section.

Remove the pump flow balancer valve (13), load
sensing relief valve (14) and check valve (15) from
the inlet section (11).
Disassembly of control valve sections (with

hydraulic control)
In this section are indicated all possible solutions rel-
evant to backhoe control valve sections with hydrau-
lic control.
1. Secondary relief valve 3. Non return check valve

2. Pressure compensator 4. Plug
2A. Pressure compensator with shock absorber 5. Spring return system with guide
2B. Fixed pressure compensator 6. Spool
Removal and reassembly hydraulic control spool
Removal
Z Remove the screws (A), and the plate (B).
Z Extract the spring guides (C) and the springs (D).
Z Discard the seals (E).
Z Remove the spool (F) from the valve section.
Reassembly
Z Grease and install the spool (F) in the valve sec-
tion.
Z Install the springs (D) in the caps (B).
Z Install the spring guides (C) in the springs (D).
Z Install new seals (E).
Z Install the cap assemblies on the valve section, in-
stall and tighten the screws (A) to a torque of 9 to
11 Nm (6.8-8.1 lbf.ft).
Electrical detent system spool
Solenoid replacement (with spool pulled out)

Z Remove the 2 mounting screws (A) and the detent
system.
Z Unscrew the rear housing (B).
Z Remove the circlip (C), the spring and the coil.
Z Install a new solenoid (D).
Z Reassemble parts in reverse order.
Z Tightening torque:
screws (A) - 9 to 11 Nm (6.8-8.1 lbf.ft)
rear housing (B) -1.8 to 2.2 Nm (1.3-1.6 lbf.ft)
Solenoid replacement (with spool pushed in)

Z Remove the solenoid (A).
Z Install a new solenoid.
Z Tightening torque -18 to 22 Nm (13-16 lbf.ft).
3.4 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE (WITH
HYDRAULIC CONTROL)
Solenoid valve is located under the cab floor and is

installed directly in the lower part of the chassis that
supports the operating levers. The solenoid valve is
installed with the pilot models and has the task to
transform the electrical controls, received from the
operating levers, in hydraulic controls and to send
those to the rear control valve assy. The module (A)
is installed only on the machines versions with tele-
scopic dipper (HED). If the machine is not equipped
with telescopic dipper (HED), the solenoid valve in-
stalled is of type (B); while if the telescopic dipper
(HED) is installed the solenoid valve can be of type
(A) + (B).
REMOVAL
Z Position the loader backhoe on a hard level sur-
face.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
Z Stop the engine and eliminate any residual pres-
sure in the backhoe and loader systems by moving
the loader and backhoe control levers through all
operating positions.
Z Clean the area around the solenoid valve.
Z Tag and identify the position of all hydraulic hoses
and hydraulic tubes.
Z Disconnect and plug all the hydraulic hoses and all
the hydraulic tubes.
Z Unscrew and remove clamping screw to chassis
supporting the operating levers.
Z Remove the solenoid from the loader backhoe.
Z Installation is removal procedure in reverse.
DISASSEMBLY
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).
Untighten and remove the three screws (3) and dis-

assemble valve (4).
Check and possibly replace the O-rings (5).
In case of necessity it is possible to disassemble the

various solenoid valves from the manifold blocks.
Z Untighten and remove the screws (6).
Z Disassemble solenoid valves (7).
Z Check and possibly replace the O-rings (8).
Z Untighten and remove the valve (9).
Z Remove the check valve (11) and the orifice (12).
Z Untighten and remove the solenoid valves (13).
Z Untighten and remove the solenoid valves (15).
3.5 ACCUMULATOR “GLIDE RIDE” PARKER
Technical specifications
Capacity (gas)............................................................................................................. 2 liters (0.53 US Gallons)
Capacity (oil) .......................................................................................................... 1.84 liters (0.49 US Gallons)
Precharge ................................................................................................................. 30 ± 1 bar (435 ± 14.5 psi)
Maintenance
Z Check the gas pre-charge pressure regularly during the first few weeks of operation, and then at suitable in-
tervals afterwards based on this initial experience.
Z Carry out a visual examination of the accumulator periodically in order to detect any early signs of deteriora-
tion such as corrosion, deformation etc.
Z Comply with the regulatory provisions concerning the monitoring of operational equipment.
Z Before removal, it is vital to ensure that there is no residual hydraulic pressure in the accumulator. Discharge
the gas side of the accumulator using a Parker UCA charging and gauging assembly before carrying out any
maintenance operations
Safety
Charging must be carried out by qualified personnel.
Before taking any readings or pressurizing with nitrogen, the accumulator must be isolated from the hydraulic
system and the fluid side discharged in order to depressurize it.
Use only nitrogen (N2) to pressurize the accumulator.
Danger of Explosion - Never Charge with Oxygen

The types of nitrogen permitted are: type S (99.8% pure); type R (99.99% pure); type U (99.993% pure).
If the pressure of the gas contained in the nitrogen bottle is greater than the maximum permissible operating
pressure of the accumulator, a pressure regulator must be fitted to the nitrogen bottle.
Parker recommends that the precharge should be checked during the first week following commissioning of
the system.
Thereafter, it should be checked every three months, or at intervals determined by the system builder.
The Effect of Temperature on Precharge Pressure

In order to compensate for the difference in pressure at ambient and operating temperatures, it is recommend-
ed that the precharge pressure po should be adjusted to reflect the operating temperature of the system, using
the correction factor equations and relevant table.
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.
Checking and Adjusting Precharge Pressure

The precharge pressure of an ACP Series accumulator may be checked, and nitrogen filled or vented, using
the UCA Universal Charging & Gauging kit tool 380002714.
The kit assembly is screwed onto the accumulator’s gas valve, allowing the precharge pressure to be checked
or reduced. If the precharge pressure is to be increased, the UCA can be connected to the nitrogen source with
the hose supplied. The kit is supplied with two pressure gauges, reading 0-25 bar (0-363 psi) and 0-250 bar
(0-3626 psi); where a different pressure range is required, a commercially-available pressure gauge may be
used.
UCA kit 380002714 see drawing
A. Inflation valve
B. Bleed valve
1. UCA
2. Adapter (long)
3. Adapter (short)
4. Adapter (insert) with fibre washer
5. Pressure gauge
6. Knurled protective cap - gauge port
7. Knurled collar - gas port
8. Knurled protective cap - filling port
9. Filling hose (G1/4 fitting, 60° cone) with O-ring
10. Filling port valve
Z Remove the protective cover and cap (11) from the

accumulator, to gain access to the gas valve (12).
Z Select the appropriate pressure gauge (5) for the
pressure to be checked, remove the protective cap
(6) and attach the gauge to the UCA (1).
Z Make sure that the bleed valve (B) is fully closed
and that 12 the inflation valve (A) is in the fully
raised position by turning the handwheel in an anti-
clockwise direction.
Z Assemble the short adapter and adapter insert (3
and 4), screw onto the gas valve (13) and hand
tighten.
Z Screw the UCA onto the adapter. Position the as-
sembly to permit easy reading of the gauge, then
hand tighten the knurled collar (7).
Z Open the inflation valve (A) by screwing the hand-
wheel clockwise until the inflation pressure regis-
ters on the gauge.
Readings and Results

One of three conditions will apply - the precharge
pressure in the accumulator will be correct, or it will
be too high or too low.
Nitrogen Pressure po is Correct

Z Screw the handwheel (A) anti-clockwise to close the accumulator gas valve.
Z Slacken the bleed valve (B) to release pressure in the UCA.
Z Unscrew the UCA from the adapter.
Z Unscrew the adapters from the accumulator gas valve.
Nitrogen Pressure po is Too High

Z Slacken the bleed valve (B) to vent nitrogen from the accumulator until, after stabilization, the desired pres-
sure po is registered. Nitrogen vents into the air.
Z Tighten the bleed valve (B) once the desired filling pressure is reached.
Z Unscrew the UCA from the adapter.
Z Unscrew the adapters from the accumulator gas valve.
Nitrogen Pressure po is Too Low

Z Close the inflation valve (A) by screwing the handwheel anti-clockwise.
Z Remove the knurled cap on the filling port (8).
Z Connect the end of the filling hose (9) to the filling port valve (10).
Z Connect the other end of the hose to the nitrogen source.
Z Progressively open the valve on the nitrogen source.
Z Screw the handwheel (A) clockwise to admit the pressurized gas, taking particular care if the accumulator has
a small capacity.
Z When pressure po is reached, close the valve on the nitrogen source. To allow for the effects of temperature
transfer, the accumulator should be allowed to stand for a minimum of 15 minutes to allow the temperature to
stabilize before a final reading of the precharge pressure is taken.
Z Remove the hose carefully, to release internal pressure.
Z Refit the knurled cap (8) to the filling port valve (10).
Z Unscrew the UCA from the adapter(s).
Unscrew the adapters from the accumulator gas valve. After removing the UCA and adapter(s), make sure that
the accumulator gas valve (13) is sealing effectively. Refit the gas valve dust cap (12) and replace the
protective cover (11).
3.6 SYSTEM RELIEF VALVES
The relief valves may be either pilot operated with

anti-cavitation feature (1) or direct acting (2) and
protect individual systems from excessive pressure
created by external cylinder overload.
Relief valves (on “HUSCO” control valves)

The backhoes, having this kind of control valves in-
stalled, are equipped with different relief valves.
Some of them are installed on the loader control
valve:
1. Rear pump unload valve 170 bar (2465 psi)
2. Loader bucket relief valve rod end 227 bar (3300
psi)
3. Loader bucket relief valve piston end 160 bar
(2300 psi)
4. System pressure relief valve 204 bar (2958 psi)
Some of them are installed on the stabilizer and tele-

scopic dipper (HED) control valve:
1. Rear pump relief valve - pilot operated 196 bar
(2842 psi)
2. Telescopic dipper (HED) (piston end) relief valve
- pilot operated 124 bar (1800 psi)
Some of them are installed on the backhoe control

valve:
1. Dipper relief valve 241 bar (3500 psi)
2. Bucket relief valve 207 bar (3000 psi)
3. Swing relief valve (cylinder rod) 207 bar (3000
psi)
4. Boom relief valve (cylinder rod) 317 bar (4600
psi)
5. Boom relief valve (cylinder piston) 241 bar (3500
psi)
6. Swing relief valve (cylinder piston) 207 bar (3600
psi)
Relief valves (on “REXROTH” control valve)

The backhoes, having this kind of control valves in-
stalled, are equipped with different relief valves.
Some of them are installed on the loader control
valve:
1. 4x1 bucket relief valve
2. Loader bucket relief valve (rod end) 240 bar
(3481 psi)
4. Loader bucket relief valve (piston end) 165 bar
(2393 psi)
Some of them are installed on the backhoe control

valve:
1. Dipper relief valve (piston end) - 240 bar (3481 psi)
2. Bucket relief valve (piston end) - 220 bar (3191 psi)
3. Swing relief valve (piston end) - 205 bar (2973 psi)
4. Boom relief valve (piston end) - 315 bar (4569 psi)
5. Swing relief valve (rod end) - 205 bar (2973 psi)
6. Boom relief valve (rod end) - 240 bar (3481 psi)
7. Telescopic relief valve (rod end) - 205 bar (2973
psi)
8. Load sensing relief valve - 210 bar (3046 psi)
SYSTEM RELIEF VALVES OPERATING
Relief valve inoperative

When the system is not subject to overload condi- 1 2 3
tions pressure in the system is insufficient to over-
come pilot valve spring pressure and move the valve
of its seat.
System pressure sensed on the larger rear face of
the poppet valve maintains the poppet and sleeve
firmly on their seats.
1. Sleeve poppet
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston 7 6 5 4 F29539
6. Control valve (cylinder) exhaust gallery Exhaust oil

7. Cylinder supply gallery High pressure oil
Pilot valve operation

When the cylinder is subjected to shock forces the 1 2 3
pressure increase in the cylinder supply gallery
overcomes pilot valve spring pressure lifting the pilot
valve off its seat.
System pressure on the rear face of the poppet
valve escapes to tank between the sleeve poppet
and valve body causing a pressure differential be-
tween the front and rear face of the poppet valve.
The higher pressure in the cylinder supply gallery
unseats the poppet valve and moves the piston to
seat against the pilot valve.
1. Sleeve poppet 7 6 5 4 F29540
2. Poppet valve Exhaust oil

3. Pilot valve High pressure oil
4. Pilot valve body Reduced pressure oil
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery
Pilot and poppet valve operation

The excessive system pressure in the cylinder sup- 1 2 3
ply gallery now flows past the poppet valve to the
cylinder exhaust gallery and back to tank.
NOTE: during this operation the sleeve poppet is

held in the fully seated position by pressure oil.
1. Sleeve poppet
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston 7 6 5 4 F29541

High pressure oil
Exhaust oil
Reduced pressure oil
Anti-cavitation operation
System relief valves with an anti-cavitation feature
are fitted in systems where rapid extension of the
cylinder could create a void condition and permit the
transfer of oil from the high pressure side of a cylin-
der to the lower pressure (void) end of the cylinder.
When for example the boom is rapidly lowered and
the cylinder rod end system relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is auto-
matically replenished by the anti-cavitation device in
the opposite system relief valve as follows:
The void creates a pressure lower in the cylinder
supply gallery and back pressure in the control valve
exhaust gallery acts on the outer face of the sleeve
poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.
2
1
5 4 F29542
High pressure oil

Anti-cavitation oil supply to cylinder
Relief valve exhaust oil
1. Anti-cavitation system relief valve 4. Control valve exhaust gallery
2. Cylinder rod 5. Spool
3. System relief valve
Pilot operated with anti-cavitation feature system

relief valve subjected to overload and fully relieving 1 2 3
high pressure oil
1. Sleeve poppet
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
7 6 5 4 F29543
Anti-cavitation cylinder resupply oil

Exhaust oil
Direct acting system relief valve operation

High pressure system oil is sensed in the cylinder 1 2 3 A
supply gallery and acts on the face of the relief valve
poppet.
When pressure in the system exceeds relief valve
setting the oil pressure lifts the poppet allowing ex-
cess pressure in the overloaded cylinder to escape
to the exhaust gallery.
6 5 2 F29544
A. Direct acting system relief valve

Valve not subjected to overload conditions 1 2 3 B
B. Direct acting system relief valve
Valve subjected to overload conditions
1. Relief valve seat
2. Relief valve poppet
3. Valve pressure adjusting screw
4. Spring
5. Control valve exhaust gallery
6. Cylinder supply oil
6 5 2 F29545
Exhaust oil
High pressure system oil
Overhaul
IMPORTANT: before removing relief valves from

the machine lower the loader and backhoe to the
ground, switch of engine and relieve all pressure in
systems by moving the backhoe, loader, and tele-
scopic dipper (HED) controls through all operating
positions. The system relief valves if suspected of
contamination may be disassembled and inspected
for wear but must be reset to the correct pressure.
The relief valves contain no serviceable components

with the exception of the external O-rings and
square section seals.
During disassembly examine the poppet and seat in
the plunger assembly for a complete seating sur-
face.
Pilot operated relief valve
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
Direct acting relief valve
1. Body 6. Cap
2. Poppet 7. O-ring
3. Spring 8. Locknut
4. Spring 9. O-ring
5. Shim 10. Adjuster screw
Loader bucket relief valve
1. Relief valve assembly

2. Spring 7. Guide
3. Locknut 8. Poppet
4. Valve body 9. Poppet sleeve
5. Adjuster 10. Valve body inner
6. Spring 11. Spring seat
System relief valve adjustment

After overhaul the system relief valves must be test-
ed and adjusted using a suitable hand pump (1), 275
bar (4000 psi) pressure gauge and V. L. Churchill
test kit (2).
The hand pump must be attached to inlet port I and

the drain hose to the outlet port T of test block using
suitable 1/2 inch BSP (British Standard Pipe) adap-
tors.
The pressure gauge may be connected to either the
hand pump as shown or to the 3/8 UNF threaded
port G in the test block.
Remove plug and insert valve to be tested into the
appropriate port in the test block as follows:
A. Stabilizer and backhoe relief valves
B. Loader bucket relief valves
C. Unload valve
NOTE: a special removable insert which, is part of

the test block, is installed in the bottom of the port
used for testing the loader valve. If difficulty is expe-
rienced in screwing the loader valve into the test
block, check that the insert is fully seated and cor-
rectly installed. When correctly installed the O-ring
(3) on the face of the insert should be visible.
Operate hand pump and record maximum pressure

reading on gauge. Compare pressure values with
previous specifications.
IMPORTANT: before removing valve from test block

release pressure in system using the vent valve on
the hand pump.
To adjust all relief valves with the exception of the

loader bucket relief valve remove the valve cap,
loosen locknut and turn adjuster to obtain correct
pressure.
NOTE: relief valves must not be set outside off the

specified range.
Loader bucket relief valve adjustment
NOTE: if the loader bucket system relief valve re-

quires adjustment, the special adjusting tool sup-
plied with the test kit is required as described below.
Hold relief valve in vice and using wrench supplied

with tool, unscrew the internal valve assembly from
the valve body.
Screw the internal valve assembly (2) into the body

of the adjusting tool (1).
Install valve into test block and operate hand pump

until valve is pressurized to 170 bar (2500 psi).
Using the special spanner supplied, loosen the lock-
nut on the end of the valve and adjust pressure set-
ting using Allen wrench.
Operate hand pump and recheck pressure.
When pressure setting is correct tighten locknut and
release pressure in system using the vent valve on
the hand pump.
Remove valve and using 3/8 inch 16 UNC bolt re-
move insert, then reassemble valve and install into
test block.
Operate hand pump and recheck pressure.
If pressure is now lower than that recorded with the
insert installed it is an indication that the anti-cavita-
tion feature of the valve is leaking and the valve re-
quires overhaul or replacement.
NOTE: the insert isolates the anti-cavitation feature

of the valve. When reassembling the insert into the
test block ensure it is installed correctly. When cor-
rectly installed the O-ring (3) on the face of the insert
should be visible.
4. HYDRAULIC SWING SYSTEM

The backhoe boom and digging elements can be

moved in an arc about the main chassis of 180 de-
grees.
This movement is obtained by the use of two hydrau-
lic cylinders (1) coupled between the main chassis
and swing post.
The cylinders act directly on the swing post, without
the use of any connecting links or bell cranks.
Each cylinder incorporates a head stock consisting

of two large trunnions (3) positioned near the gland
carrier (2).
As each cylinder extends or retracts and the swing
post rotates, the cylinders turn in a horizontal plate,
pivoting on the headstocks within the carriage.
Each cylinder is double acting and as hydraulic oil is
fed to a cylinder to turn the swing post, one cylinder
pushes and the other cylinder pulls to perform the
swing cycle.
4.2 HYDRAULIC OIL FLOW
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 sup-
contains pilot operated relief valves with anti cavita- ply and exhaust ports in the main control valve are
tion feature to protect the system and cylinders totally blocked.
should an overload condition occur. The momentum of the swinging backhoe assembly
The diagram illustrates operation of the swing sys- if not controlled will make the machine extremely un-
tem when retracting the right hand cylinder (4) and stable.
extending the left hand cylinder (5) in order to swing To prevent this from occurring the system 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 oper- operates the cylinder rod will move and a void will be
ation 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 cylin- the excess pressure side of the system to the low
der. pressure side.
The flow of oil at pump pressure lifts the one way re-
strictor (2) of its seat allowing the flow to continue
unrestricted to the inlet port of the piston end of the
left hand cylinder.
System pressure increases causing the right hand
cylinder to retract and the left hand cylinder to ex-
tend.
As the cylinders move, displaced oil on the piston
side of the left hand cylinder flows towards the one
way restrictor (7) in the inlet port on the rod end of
the right hand cylinder.
The oil flow moves the restrictor to the restrict posi-
tion which limits the flow of oil and creates a back
pressure (1st stage restricted return oil) in the right
hand cylinder.
The restricted flow of oil passes through restrictor
(7) into the rod end of the left hand cylinder before
returning to the control valve and back to tank.
The spool in the swing control valve assembly (1) is
designed such that during operation oil can flow
freely through the port directing oil flow to the swing
cylinders but restricts the flow returning oil back to
tank.
This restriction is achieved using metering lands
machined into the lands of the spool and creates a
secondary back pressure (2nd stage restricted re-
turn oil) in the rod end of the cylinder.
By allowing oil to flow unrestricted to the power side
of the cylinder and be restricted on the exhaust side
a smooth controlled swing of the backhoe at opti-
mum speed is achieved.
When the swing system reaches the last 20-25° of
travel the sliding restrictor in the end of the piston
rod touches the outlet port in the cylinder barrel.
This further restricts the flow of oil exhausted from
the cylinder and as the piston moves towards the
end of its stroke the sliding restrictor is gently
pushed down the center of the cylinder rod allowing
a progressive and controlled halt to the swing cycle.
7 2
6 3
5 4
F29480
Pump pressure oil

1st stage restricted return oil
2nd stage restricted return oil
Return to oil tank
1. Control valve swing section

2. One way restrictor
3. Cushioning rod
4. Right hand cylinder
5. Left hand cylinder
6. Cushioning rod
7. One way restrictor
4.3 PRECISION SWING CONTROL
Each of this assy consists of a valve (2) fitted on a

bracket (3) that is on its turn installed on rear axle (4)
and of some hydraulic pipings (6) connecting the
valves with the swing cylinders (7) and the backhoe
control valve (5).
OPERATION
Backhoe swing system without precision swing

control
When the backhoe is being swung from side to side
and the control valve spool is returned to the neutral
position, the pressure generated by the inertia of the
backhoe structure will cause the cylinders to contin-
ue to stroke as oil is forced over the system relief
valve. The high pressure induced by this inertia in the
return system and corresponding low pressure in the
supply side of the system, provides the force differ-
ence which causes the backhoe to move in the op-
posite direction (rebound). This condition can occur
multiple times and give the appearance of loose or
worn pins.
Backhoe swing system with precision swing

control
The anti-rebound valve monitors conditions in the
swing system as it speeds up, slows down, moves at
a steady speed or is stopped. When stopped, speed-
ing up or moving at a steady speed, the system is in-
active. Neither swing speed, power or internal
leakage is affected.
When the swinging boom is brought to a stop the
anti-rebound valve is designed to meter oil from one
side of the swing cylinder system to the other. The
system is activated only when the control valve spool
is in the neutral position and the cylinder return oil
passes over the port relief. At that point, the return
side of the system becomes the high-pressure side
with the oil passing through the 100 psi check (A).
This 100 psi pressure differential across the check
shifts a throttling spool (B) that allows a restricted
“cross over” flow between the two swing cylinders.
This restricted flow allows the swing cylinders to de-
accelerate to a smooth stop. When the swing has
stopped the pressure differential decreases and the
throttling spool closes.
If the oil temperature in the swing system is not
above approximately 80 degrees F, a thermal com-
pensating feature prevents the spool from overcom-
ing the spring force holding it closed. Below this
actuation temperature the system performs as if the
feature were not installed.
PRECISION SWING SYSTEM
1. Port to cylinder 4. Port from valve

2. Screen 5. Shuttle valve
3. Throttling spool (B) 6. Restrictor (A)
PRECISION SWING VALVE COMPONENTS
1. Port to cylinder 7. Thermal actuator

2. Check valve 5 psi 8. Thermal spring
3. Screen 9. Thermal compensating spool
4. Orifice spool 10. Spool return spring
5. Orifice plug 11. Port from valve
6. Check valve 100 psi 12. Shuttle check valve
PRECISION SWING VALVE FAULT FINDING
Measurement of swing drift Symptom:

On horizontal ground, tilt unit approximately 10° with The backhoe linkage would likely drift slowly to one
stabilizers. Extend the boom, dipper, and bucket so side after the swinging motion is stopped and the
they are horizontal. Warm unit up to approximately unit is tilted slightly.
120 °F (valve will be warm to the touch).
Center boom, lower to the ground, and make a mark Verification method:
with the bucket (or line up an object with a bucket Repeat the motion, so that the drift occurs again,
tooth). Raise bucket to approximately 6’. and then add tilt to the unit. Repeat the motion sev-
Turn unit off and wait 5 minutes. Lower boom (no eral times to verify that drift is not reproducible at
swing!) to the ground. higher angles.
Measure the difference between mark (or reference
object) and bucket tooth. Delay orifice or delay screen contaminated
This distance should be approximately 5” for a B95. Symptom:
The backhoe boom takes longer than normal to stop
Delay check leaks from a swinging motion in both directions.
Symptom:
The backhoe linkage would likely swing slowly to Verification method:
one side during roading / loading of the backhoe. Perform the swing drift test with a cross-over orifice
plugged. If the symptom stops, this would indicate
Verification method: that the delay orifice is contaminated.
Switch swing port relief valves. If the drifting switch-
es to the opposite side, the problem is with the relief Thermal bypass fails
valve. Symptom:
Perform swing drift test measurement. If the check The backhoe boom takes longer than normal to stop
is leaking, the measured distance will increase sig- from a swinging motion in both directions when
nificantly. starting in cold weather or the system may not actu-
Performing the swing drift test with a cross-over ori- ate after oil is warmed up.
fice plugged would eliminate the cross-over spool as
a cause of the leakage. Verification:
In cold weather, remove the cross-over spool as-
Shuttle valve leaks sembly, and with snap ring pliers, remove all internal
Symptom: components. Reinstall the crossover spool in the
The backhoe linkage would likely swing slowly to valve and verify that the backhoe boom stops quick-
one or both sides during roading / loading of the ly and with some oscillations.
backhoe. If the system is not activating after the oil is warmed
up, remove the cross-over spool assembly. Push
Verification method: the back of the thermal actuator and verify that it
See “Delay Check Leaks” above. easily strokes approximately ¼”. With snap ring pli-
ers, remove all internal components. Visually in-
Cross-over spool leaks spect the thermal actuator for evidence of damage.
Symptom:
The backhoe linkage would likely swing slowly to 100 or 5 psi main flow check fails
both sides during roading / loading of the backhoe. Symptom:
The swing may drift slowly after almost stopping Anti-rebound valve works well in one direction, but
when the unit is tilted. doesn't work in the other direction.
Verification method: Verification method:

Perform the swing drift test and then repeat the test Remove the swing anti-rebound valve. Switch the
with a cross-over orifice plugged. check valves from one side to the other side. Make
This would determine if the cross-over spool is the sure that the black (100 psi) check valves are insert-
cause of the leakage. ed closest to the mounting surface, and that the di-
rection of good performance is noted before the
Bypass orifice contaminated swap.
5. HYDRAULIC CYLINDERS
1. Loader cylinder
2. Loader bucket cylinder
3. 4x1 bucket cylinder
4. Backhoe boom cylinder
5. Backhoe crowd cylinder
6. Backhoe bucket cylinder
8. Swing backhoe cylinder
9. Stabilizer cylinder
5.1 LOADER CYLINDER
2WS
1. Stroke
2. Closed
2WS - B95BTC
1. Stroke
2. Closed
4WS
1. Stroke
2. Closed
REMOVE LOADER CYLINDER (B90B - B90BLR - B95B - B95BLR - B110B)

Park machine on a firm level surface and position
the bucket as for bucket dump.
Raise the loader sufficiently to allow the lift cylinder
pivot pin to be removed and using axle stands se-
curely support the front and rear of bucket to prevent
the loader arms lowering when the cylinder is dis-
connected.
F28757
If the bucket cannot be safely supported it must be

removed and the loader arms supported using a
suitable stand or hoist.
SWARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal
injury may occur.
Relieve the residual pressure in the system by mov-

ing the loader control lever through all operating po-
sitions.
F28758
Support the cylinder using sling and suitable hoist.

Disconnect the hydraulic hoses. Cap or plug all ex-
posed openings.
F28759
Disconnect the hydraulic hoses.

Remove the snap ring (1) and the spacer (2).
Remove the ring (3) and the pin (4).

To use hammer to slide out the rod pin (5).
Remove the loader cylinder.
REMOVE LOADER CYLINDER

(B95BTC - B115B)
Park machine on a flat surface. Raise the loader suf-
ficiently to allow the loader cylinder pin to be re-
moved.
Remove the loader bucket and support the arm us-
ing a suitable stand or hoist.
SWARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal
injury may occur.
F30317

sitions.
Stop the engine.

Disconnect the hydraulic hoses. Cap or plug all ex-
posed openings.
F30318


Use a hammer to slide out the rod pin (5).
3 4
F30320
Remove the loader cylinder.

DISASSEMBLY LOADER CYLINDER
1. Cylinder rod 9. Back-up ring

2. Bushing 10. O-ring
3. Wiper seal 11. Piston
4. Seal ring 12. Piston seal
5. Seal ring 13. Piston ring guide
6. Bearing sleeve 14. Screw
7. Cylinder head 15. Cylinder tube
8. Safety screw 16. Bushing
The disassembly procedure below starts on the

premise that the hydraulic lines already removed.
SWARNING
Cylinder weight: 36 kg.
Lift and securely place the cylinder on a workbench.

Be sure that the cylinder is placed horizontally. Drain
hydraulic oil from cylinder.
Support the cylinder rod (1). Remove the safety

screw (8).
To using the wrench 380000725 for to loose the cyl-
inder head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
Remove the cylinder head (7) from the cylinder tube

(15) by using a rubber hammer. Remove the cylin-
der rod (1) and the cylinder head (7).
IMPORTANT: be sure to pull out cylinder rod (1)

straight so as not to damage the sliding surfaces.
Untighten and remove the screw (14). Remove from

the cylinder rod (1), the piston assy (11) and the cyl-
inder head assy (7).
Only if necessary:
Z Remove from the cylinder head (7), the wiper seal
(3), the seal rings (4) and (5), the bearing sleeve (6)
and the back-up ring (9) with O-ring (10).
Z Remove from the piston (11) the piston seal (12)
and the piston ring guide (13).
5.2 LOADER BUCKET CYLINDER
2WS
1. Stroke
2. Closed
2WS - B95BTC
1. Stroke
2. Closed
4WS
1. Stroke
2. Closed
REMOVE LOADER BUCKET CYLINDER (B90B - B90BLR - B95B - B95BLR - B110B)

the bucket firmly on the ground.
Position a suitable support below the bucket cylinder
tie rod (1).
Use a suitable block to support the cylinder.
Remove the ring (2) and the pin (3). With an hammer
remove the pin (4) to release the idler (5).

Remove the tipping link (6), the idler (5) and disas-
sembly the cylinder rod from the tie rod (1).

With an hammer remove the pin (13).
Remove the loader bucket cylinder.

REMOVE LOADER BUCKET CYLINDER (B95BTC - B115B)

sitions.
Support the link rods and the idlers.


Remove the loader bucket cylinder.

DISASSEMBLY LOADER BUCKET CYLINDER
2. Cylinder rod 10. Piston
3. Wiper seal 11. Piston seal
5. Seal ring 13. Screw
7. Safety ring 15. Bushing
8. Back-up ring
The disassembly procedure that follows takes into

consideration the hydraulic piping already disas-
sembled.
SWARNING
Cylinder weight (2WS) = 26.5 kg (58.4 lbs)
Cylinder weight (4WS) = 32.5 kg (71.7 lbs)
Lift and place the cylinder on a workbench and se-

cure it. Be sure that the cylinder is placed horizontal-
ly. Drain hydraulic oil from cylinder.
Support the rod (2) and use the wrench 380000722

to loose the cylinder head (6).
Remove the safety ring (7).

Pull out the cylinder head (6) from the cylinder tube
(14) by tapping with a plastic hammer. Remove the
cylinder rod (2) and the cylinder head (6).
IMPORTANT: be sure to pull the cylinder rod (2)

Untighten and remove the screw (13).

Remove from the cylinder rod (2), the piston assy
(10) and the cylinder head assy (6).
Only if necessary:
Z remove from the cylinder head (6), the wiper seal
(3), the seal rings (4), and (5), the back up ring (8)
with the O-ring (9);
Z remove from the piston (10) the piston seal (11)
and the piston ring guide (12).
DISASSEMBLY LOADER BUCKET CYLINDER (B95BTC)
1. Wiper seal 11. O-ring

2. Bushing 12. Piston seal
3. Cylinder rod 13. Piston ring guide
5. Seal ring 15. Washer
7. Bearing sleeve 17. Cylinder tube
9. Cylinder head 19. Wiper ring
10. Back-up ring

sembled.
SWARNING
Cylinder weight: 26 kg (57 lbs)

Suppot the cylinder rod (3).

Remove the safety screw (8). To using the wrench
380000724 for to loose the cylinder head (9).
(17) by tapping with a rubber hammer. Remove the
IMPORTANT: be sure to pull cylinder rod (3) straight

so as not to damage the sliding surfaces.
Untighten and remove the screw (16) with the rela-

tive washer (15). Remove from the cylinder rod (3),
the piston assy (14) and the cylinder head assy (9).
Only if necessary:
(4), the seal rings (5) and (6), the bearing sleeve
(7), and the back-up ring (10) with O-ring (11);
Z remove from the piston (14), the piston ring guide
(13) and the piston seal (12).
5.3 4X1 BUCKET CYLINDER
1. Cylinder rod pin 5. Stud

2. Dowel 6. Nut
3. Bucket 7. Cylinder bottom pin
4. Cylinder
CYLINDER REMOVAL
sitions.
Unscrew and remove the clamping screws of the

cover (C). Remove the cover (C).
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 pin (7) with an hammer.
Remove the 4x1 bucket cylinder.

DISASSEMBLY CYLINDER
1. Cylinder tube 7. Cylinder head

2. Piston 8. Gasket
3. Pin 9. Wiper seal
4. O-ring 10. Cylinder rod
5. Piston ring guide 11. Bushing
6. O-ring
5.4 BACKHOE BOOM CYLINDER
(1) Stroke
(2) Closed
with long dipper
with short dipper
CYLINDER REMOVAL
Park the machine on a level, firm surface and posi-
tion the bucket on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.
SWARNING
Always support the structural members so that they
will be stable and safe to work around.
Stop the engine and move the backhoe control le-

vers through all operating positions to relieve possi-
ble residual pressures in the system.
Position a sling or other suitable lifting equipment
around the cylinder.
Untighten and remove the screw (1) and the nut (2).
Slide out the pin (3) with an hammer.
NOTE: the cylinder line end of the dipper cylinder

and the rod end of the boom cylinder use a common
pin (3).
If the boom cylinder has to be disassembled, slide

out the pin (3) only partially, then remove the cylin-
der rod and finally reinsert the pin.
If necessary use hydraulic power to very slowly re-
tract the cylinder so that the rod comes clear of the
attaching point.
Disconnect the hydraulic hoses. Remove the stop

ring (4) and slide out the head pin (5).
NOTE: accurate positioning of the cylinder prior to

hose disconnection will aid pin removal.
Remove the backhoe boom cylinder.

BOOM CYLINDER DISASSEMBLY

10. Back-up ring

sembled.
SWARNING
Cylinder weight (with short dipper): 80.3 kg (177 lbs)
Cylinder weight (with long dipper): 93.4 kg (206 lbs)

Suppot the cylinder rod (3).


Untighten and remove the screw (16) with the rela-

tive washer (15). Remove from the cylinder rod (3),
the piston assy (14) and the cylinder head assy (9).
Only if necessary:
Z remove from the piston (14), the piston ring guide
(13) and the piston seals (12).
5.5 BACKHOE DIPPER CYLINDER
(1) Stroke
(2) Closed
with long dipper
with short dipper
CYLINDER REMOVAL
tion the backhoe on the ground. Support the back-
hoe elements for cylinder removal using a suitable
stand.
SWARNING

vers through all operating positions to relieve possi-
ble residual pressures in the system.
Untighten and remove the nut (1) and the screw (2).
Slide out the rod pin (3) with an hammer.
attaching point.
Disconnecting the hydraulic hoses. Untighten and

remove the screw (4) and the nut (5). Slide out the
pin (6) with an hammer.
The tube end of the crowd cylinder and rod end of
the boom cylinder use a common pin (6).
Therefore before shifting the dipper cylinder, support
the boom cylinder with a rope or an hoist.
Remove the backhoe dipper cylinder.

DISASSEMBLY BACKHOE DIPPER CYLINDER

10. Back-up ring

sembled.
SWARNING
Cylinder weight (with short dipper): 71.7 kg (158 lbs)
Cylinder weight (with long dipper): 72.3 kg (159 lbs)

ly. Drain hydraulic oil from the cylinder.
Support the cylinder rod (3).


Untighten and remove the screw (16) with the wash-

er (15). Remove from the cylinder rod (3), the piston
assy (14) and the cylinder head assy (9).
Only if necessary:
Z remove from the piston (14) the piston ring guides
5.6 BACKHOE BUCKET CYLINDER
(1) Stroke
(2) Closed
BUCKET CYLINDER REMOVAL

Park the machine on a flat and firm surface. Lay the
backhoe bucket firmly on the ground.
SWARNING

vers through all operating positions to relieve all re-
sidual pressures in the system.

Remove the stop ring (1) with the shim (2). Slide out
the pin (3) with an hammer and pay attention to le-
vers.
attaching point.
Disconnect the hydraulic hoses. Unscrew and re-

move the nut (4). Slide out the screw (5). With an
hammer remove the pin (6).
Remove the backhoe bucket cylinder.

DISASSEMBLY BACKHOE BUCKET CYLINDER
1. Wiper seal 10. Back-up ring

3. Cylinder rod 12. Piston seal
4. Wiper seal 13. Piston ring guide
5. Seal ring 14. Piston

sembled.
SWARNING




Only if necessary:
(7), and the back-up ring (10) with the O-ring (11);
Z remove from the piston (14) the piston ring guide
5.7 TELESCOPIC CYLINDER
with short telescopic

with long telescopic
(1) Stroke
(2) Closed
CYLINDER REMOVAL
stand.
SWARNING

Remove the snap ring (1). Hammer to slide out the

pin (2) from the other side.
Disconnect the hydraulic hoses (3), at dipper cylin-

der and support cylinder using suitable hoist.
Remove the snap ring (5). Hammer to slide out the
pin (4) from the other side.
Remove the telescopic cylinder.

DISASSEMBLY TELESCOPIC CYLINDER

5. Bearing sleeve 12. Piston
6. Safety screw 13. Screw

sembled.
SWARNING
Cylinder weight (with short telescopic): 41.5 kg (91.5
lbs)
Cylinder weight (with long telescopic): 45 kg (99 lbs)

Support extend the cylinder rod (1).

Unscrew and remove the safety screw (6). To using
the wrench 380000721 for to loose cylinder head
(7).
(14) by tapping with a plastic hammer. Remove the


Only if necessary:
and the back-up ring (8) with O-ring (9);
5.8 STABILIZERS CYLINDER
(1) Stroke
(2) Closed
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.
Support the cylinder safely with suitable belt and

hoist.
Remove the snap ring (1) and the shim (2).
Hammer out the pin (3) and by means of hydraulic
power, retract the cylinder very slowly.
With engine stopped, release any residual pressure

by moving the control levers of stabilizers.
Disconnect all hydraulic pipings. Remove the snap
ring (4) and the shim (5). Hammer to slide out the pin
(6).
Remove the stabilizer cylinder.

DISASSEMBLY STABILIZER CYLINDER

5. Bearing sleeve 12. Piston
6. Safety screw 13. Screw

sembled.
SWARNING
Cylinder weight: 43.5 kg (96 lbs)


380000726 for to loose cylinder head (7).


Only if necessary:
and the back-up ring (8) with O-ring (9);
5.9 SWING CYLINDER
(1) Stroke
(2) Closed
CYLINDER REMOVAL
stand or a hoist.
SWARNING

Untighten and remove the nut (1). Slide out the

screw (2) from the opposite side. Now the pin (3) can
come out and release the rod cylinder. If necessary
hammer to help the pin (3) to come out.
Disconnect the feed and return hose to the cylinders

and cap all exposed openings.
Untighten and remove the nuts (4) and the screws
(5) (from both sides).
Now it is possible to remove the support (6).
Carefully lift and remove the swing cylinder from the

swing bracket.
DISASSEMBLY SWING CYLINDER
1. Bushing 10. Trunnion

4. Wiper seal 13. Piston seal
5. Seal ring 14. Piston guide ring
6. Seal ring 15. Piston
7. Bearing sleeve 16. Lock retaining piston
8. Bushing 17. Cylinder tube
9. Seal ring

consideration the hydraulic pipings already disas-
sembled.
SWARNING

cure it to a vice. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from the cylinder.
Use the wrench 380000725 to loose the trunnion

(10).
Remove the rod assy with the trunnion and the pis-
ton assy.
Unscrew and remove the piston lock (16). Disas-

sembly the cylinder rod (3), the piston assy (15) and
the trunnion (10) complete with gaskets.
Check the bushings (8).
Only if necessary:
Z remove from the trunnion (10), the wiper seal (4),
the road seal (5), the buffer seal (6), the bearing
sleeve (7) and the back-up ring (12) with O-ring
(11).
Z remove from the piston (15) the piston seal (13)
and the ring piston guide (14).
REASSEMBLY AND INSTALLATION

reverse whilst observing the following:
1. Tighten the piston lock retaining to a torque of
1400 - 1540 Nm (1032 - 1136 lbf·ft)
2. Apply 6 lowers of thread sealant New Holland
Part No 82975721 to the gland threads.
3. Tighten swing cylinder plate retaining bolts to a
torque of 607 Nm (448 lbf·ft).
5.10 SPECIAL TOOLS
P/N CNH DESCRIPTION APPLICATION

380000721 Wrench Telescopic dipper (HED) cylinder head
380000722 Wrench Loader bucket cylinder head
380000724 Wrench Backhoe boom cylinder head
Backhoe crowd cylinder head
380000725 Wrench Backhoe bucket cylinder head
Swing cylinder head
Loader cylinder head
380000726 Wrench Stabilizer cylinder head
6. PILOT HYDRAULIC CONTROL LEVERS

Weight 5.1 ÷ 5.3 kg (11.2 ÷ 11.7 lbf)
Spool stroke 7.55 mm (0.2 in)
SPECIAL TORQUE SETTINGS
Maximum permissible on the control lever 80 Nm (59 lbf·ft)
Control block retaining screw 30 Nm (22 lbf·ft)
Control block universal joint 50 Nm (37 lbf·ft)
Control block nut 40 Nm (30 lbf·ft)
Lower body screw 50 Nm (37 lbf·ft)

1. CONTROL CANCELLATION SWITCH: With 6. TELESCOPIC DIPPER (HED) CONTROLS:

the switch in “ON” (alight) position all the back- (proportional controls) (if fitted).
hoe attachment controls are functional. Press the right-hand button to extend the dipper.
2. LEFT-HAND HYDRAULIC CONTROL LEVER: Press the left-hand button to retract the dipper.
The left-hand lever controls attachment swing 7. WRIST RESTS: The wrist rests may be adjust-
and the boom or the dipper (depending on the ed to the required height.
control pattern adopted). 8. HYDRAULIC CONTROL ARM TILT ADJUST-
3. RIGHT-HAND HYDRAULIC CONTROL LE- MENT: These controls are used to make control
VER: The right-hand lever controls the bucket arm fore/aft and left-right adjustments.
and the boom or the dipper (depending on the 9. WARNING HORN BUTTON: Press the tip of the
control pattern adopted). left-hand control lever to sound the audible
warning device (momentary action).
NOTE: Speed of movement depends on the angle 10. AUXILIARY BI-DIRECTIONAL CONTROL (if fit-
to which the control levers are tilted. In intermediate ted).
position two movements may be obtained simulta- 11. ONE TOUCH DECEL:
neously. By pressing this button the engine rpm sets to
idle run. During this phase the accelerator han-
4. STABILIZER CONTROLS: The right-hand con- dle and pedal are disabled.
trol is for the right-hand stabilizer and the left- By pressing again the button the engine rpm are
hand control is for the left-hand stabilizer. restored and the accelerator handle and accel-
5. CONTROL PATTERN CHANGE SWITCH: This erator pedal as well.
switch is used for changing the standard control
pattern to the ISO pattern.
RIGHT HAND CONTROL LEVER
1. Pilot hydraulic control valve 10. Half handle

2. Plate 11. Cap
3. Screw 12. Switches
4. Nut M12 13. Grommet
5. Boot 14. Spacer
6. Connector 15. Clip
7. Wedge 16. Clip
8. Half handle 17. Plugs [if the switches (12) are not fitted]
9. Screw
LEFT HAND CONTROL LEVER
1. Pilot hydraulic control valve 11. Cap

2. Plate 12. Switch push button (horn)
3. Screw 13. Grommet
4. Nut M12 14. Spacer
5. Boot 15. Clip
6. Connector 16. Clip
7. Wedge 17. Plugs [if the switches (13) are not fitted]
8. Half handle 18. Switch push buttons (aux bi-dir)
9. Screw 19. Connector
10. Half handle 20. Wedge
Disassembly
Release pressure in the hydraulic systems 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. Move both stabilizer control levers in both
directions. Turn key switch “OFF”. Disconnect the
negative battery cable(s).
Z Mark the position of the lever parts (see the
exploded view on previous pages).
Z Remove the knob (P) and the support (S).
Z Remove the bracket (O) with the relevant screws
(with left control lever).
Z Remove the decal (D), the mounting plate (D1) and

the detach connectors (Q) (with left control lever).
Z Pull out both switches (I) and the detach relevant

connectors (Q1) (with right control lever).
Z Remove the knob (P1) in the rear section of control

lever.
Z Remove the screws (V) and the plate (N).
Z Lift the rubber boot (RL) for the left control lever
and the rubber boot (RR) for the right control lever.
Z Tag all hydraulic hoses before disconnecting them.

Disconnect all hoses (H).
Z Disconnect all connectors (Q2).
Z Remove the screws (V1) and take out control lever

from the column.
Z Remove the screws (9). Remove the half handles

(8) and (10). Remove the cap (11). Remove the
wedge (7) from the connector (6). Remove the
wedge (20) from the connector (19). Remove the
connectors (6) and (19). Remove the grommet
(13), the clips (15) and the tie hose (16).
Extract the switches (12) and (18). Remove the
spacers (14). Remove the boots (5).
Unscrews the nut (4) and remove the screw (3).
Remove the plate (2).
Reassembly
To reassemble the lever, proceed in the reverse or-
der to that of removal.
Follow the marks made during disassembly, and
tighten the nut (9) to a torque of 36 to 44 Nm (27 to
32 lbf.ft).
6.4 PILOT HYDRAULIC CONTROL VALVE
P. Supply
T. Tank return
Right control valve (dipper/bucket) Left control valve (backhoe/swing)

1. Retracting the dipper 1. Lifting
2. Opening the backhoe bucket 2. Right swinging
3. Extending the dipper 3. Lowering
4. Closing the backhoe bucket 4. Left swinging
1. Universal joint cam 12. Cup

2. Thrust plate 13. Lock washer
3. Shim 14. Spring
4. Upper body 15. Spool
5. Push rod guide 16. Shims
6. Seal 17. Screw
7. Seal 18. Seal
8. Push rod 19. Lower body
9. Thrust bearing 20. Seal
10. Spring 21. Seal
11. Shim
OVERHAUL OF THE CONTROL BLOCK
Disassembly
1. Mark the direction of installation of all disassem- 14. Loosen and remove the screw (17) using a male
bled parts. 10 mm Allen key and discard the seal (18).
2. Remove the U/J cam (1) using a male 8 mm 15. Separate the upper (4) and lower (19) bodies
Allen key. and discard the seals (20) and (21).
3. Remove the thrust plate (2).
4. Remove the adjustment shim (3) from the upper Reassembly
body (4). 1. To reassemble, proceed in the reverse order to
5. Extract the push-rod guide (5) and discard the that of removal.
seals (6) and (7). 2. In the case of reassembly without changing the
6. Drift the push-rod (8) out. U/J cam (1), put the same value of shims (3) as
7. Remove the thrust bearing (9), the spring (10) those in place.
and the shims (11). 3. After changing the U/J cam (1) adjust the pres-
8. Extract the spool assembly. sure of the cam on the push-rods.
9. Drive the cup (12) and remove the lock washer 4. Install a 2 mm (0.08 in) shim (3), check that the
(13). recessing of the push-rods is less than 0.2 mm
10. Remove the spring (14) and the spool (15). (0.008 in), modify the shimming to more or less
11. Remove and note the thickness of the shims if required.
(16). 5. Install new seals (6), (7), (18), (20) and (21).
12. Proceed in the same manner for the other push- 6. Lubricate the moving parts.
rods. 7. Apply brake thread fluid on the threads of the U/
13. Secure the upper body (4) in a vice. J cam (1) and the screw (17).
8. Tighten the U/J cam (1) to 50 Nm (37 lbf.ft) and
the screw (17) to 50 Nm (37 lbf.ft).
7. FAULT FINDING
7.1 PRELIMINARY CHECKS
If fault finding, pressure and flow testing is carried out

in a systematic manner and the results analyzed, the
malfunction can be readily and accurately identified.
If short cuts, assumptions and guesses are made,
unnecessary strip-down or component replacement
could result. Follow the step-by-step procedures out-
lined below.
As a first step in the fault finding procedure, several
preliminary checks should be made. These checks
are important in that once performed, they need no
longer be considered as a possible cause of the im-
mediate or reported malfunction.
Z Check that the hydraulic oil is at the correct level
and of the correct specification.
Z Check the loader, backhoe or any additional
accessory such as hydraulic bucket, hammers etc.,
for correct assembly or installation and additionally
for signs of external damage that might cause gross
misalignment of structural members.
Z Check in more detail for other mechanical damage
such as kinked, twisted, worn or decayed hoses,
damaged cylinders and bent elements.
Z Do not forget to check underneath the unit for
damaged steel tubes, particularly if the unit has
been known to have operated in arduous
conditions, been grounded, or bogged down.
Z Ensure optimum operating temperature of the
hydraulic oil is achieved.
Z Perform the system pressure and rear pump relief
valve pressure tests.
The preceding preliminary checks assume that the
engine performance is not in question. Having per-
formed these checks and failed to locate the cause
of the malfunction, the following procedures should
be adopted:
Z If possible, operate the backhoe and make notes of
the operating characteristics. Cycle each control
lever to operate each of the cylinders to the fully
extended and retracted positions.
Z Compare the operating characteristics in the
preceding stage with the malfunctions listed
hereunder.
7.2 FAULT FINDING (WITH “HUSCO” CONTROL VALVES)
GENERAL
PROBLEM CAUSES ACTION

All systems fail to operate Pump drive inoperative Investigate and repair as necessary
Low oil level Check and add oil
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 systems replace/reseal as necessary
as necessary
Backhoe and loader systems fail Main system relief valve leaking Perform main system relief valve
to operate or operate slowly while or incorrectly adjusted pressure test
telescopic dipper (HED) and sta-
bilizers operate correctly Front pump worn Perform pump performance and
pressure test and overhaul as neces-
sary
Refer to loader and backhoe fault

finding charts
STABILIZERS AND TELESCOPIC DIPPER (HED)

Stabilizer and telescopic dipper Rear pump system relief valve Perform rear pump system relief
(HED) systems fail to operate, leaking or incorrectly adjusted valve pressure test and overhaul as
are slow or has loss of power necessary
Rear pump worn Perform pump performance

pressure and flow test and replace/
reseal as necessary
Telescopic dipper (HED) fails to Telescopic dipper (HED) system Pressure test telescopic dipper
operate or is slow to operate on relief valve leaking or incorrectly (HED) system relief valve
extend cycle adjusted
Telescopic dipper (HED) slow to Valve spool leakage Examine telescopic dipper (HED)
operate in extend and retract valve section for wear or scoring
cycle
Piston seal leaking or cylinder Examine/reseal piston and gland
barrel damaged
Stabilizer leg leaks down Stabilizer lock valve leaking Examine/overhaul stabilizer lock
valve

barrel damaged
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 system is performing normally, thereby confirming that the pump and
hydraulic supply systems are functioning to specification. See also “Fault finding hydraulic pump”.

Lift fails to operate, is slow, has Lift system relief valve stuck Pressure test lift system relief valve
loss of power or is not holding open, set too low or seat is
leaking
Examine lift section of backhoe
Valve spool leakage control valve assembly for wear and
scoring
Examine/reseal piston and gland

Piston seal leaking or cylinder
barrel damaged
Crowd fails to operate, is slow, Crowd system relief valve (piston Pressure test crowd system relief
has loss of power end) stuck open, set too low or valve
seat is leaking
Valve spool leakage Examine crowd section of backhoe

control valve assembly for wear and
scoring

barrel damaged
Bucket fails to operate, is slow, Bucket system relief valve (rod Pressure test bucket system relief
has loss of power end) stuck open, set too low, or valve
seat is leaking
Valve spool leakage Examine bucket section of backhoe

scoring

barrel damaged
Telescopic dipper (HED) fails to Refer to telescopic dipper (HED)
operate, is slow, has loss of fault finding chart
power or is not holding
All backhoe systems fail to Regenerative check valve in Examine regenerative check valve
operate, are slow or have loss of control valve outlet end cover
power stuck open or seat is leaking
SWING

Right or left direction swing fails Swing system relief valves not Swing system relief valve test
to operate, is slow, or has loss of seating, set too low or seat is
power leaking
Valve spool leakage Examine swing section of backhoe

control valve assembly for wear or
scoring

barrel damaged
Swing fails to slow (cushion Integral sliding restrictor Disassemble and inspect
arrest) at end of travel damaged

barrel damage
Swing continues to move when System relief valve (return side) Swing system relief valve test
control lever returned to neutral stuck open, set too low or seat
(one direction only) leaking

scoring
Swing drifts, slow to respond, System relief valve anti-cavitation Disassemble and inspect
hesitates function stuck/seized
Restrictors seized/incorrectly Disassemble and inspect

positioned
Cylinders leak down (spools in Internal valve leakage Examine appropriate valve section
neutral) of backhoe control valve assembly
for wear or scoring

barrel damaged
Any one system lowers Load check valve between Disassemble and inspect
momentarily when signalled to control valve sections damaged
raise
LOADER

Lift fails to operate, is slow or has Valve spool leakage Examine lift section of loader control
loss of power valve assembly for wear or scoring

barrel damaged
Bucket fails to operate, is slow or System relief valves stuck open, Bucket system relief valve test
has loss of power set too low or seat leaking
Valve spool leakage Examine bucket section of loader

scoring

barrel damage
Cylinder leak down (spools in Piston barrel damaged Examine/reseal piston and gland
neutral)
Internal valve leakage Examine appropriate valve section
of loader control valve assembly for
wear or scoring
Hesitation in loader lift or bucket Load check valve between Disassemble and inspect
cylinders when control initially control valve sections damaged
moved
HYDRAULIC PUMP

System noisy Worn or damaged pump gears or Hydraulic pump performance test
pressure plates
Aeration: air entering the systems Hydraulic pump performance test

at: suction tube, pump shaft,
fittings, or cylinder glands
Cavitation: restrictions in the Visual and/or hydraulic pump

system at the suction line or at performance test
the suction screen in the tank
Water in the system

Visual
System relief valve chatter
Check system relief valve, adjust/
overhaul as necessary
Tubing vibration
Visual
Cold hydraulic oil
Check hydraulic oil operating
temperature
Wrong type oil being used
Investigate/drain and refill
Hydraulic oil exhausts from Tank overfilled Check hydraulic oil level
breather at the tank
Aeration: air entering the system Hydraulic pump performance test
Cavitation: Restriction in the Visual and/or hydraulic pump

system at the suction screen in performance test
the tank
Oil heating Oil supply low Fill tank
Contaminated oil Drain tank and refill with clean oil
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
Oil cooler fins blocked Clean oil cooler

Shaft seal oil leakage Worn shaft seal Replace shaft seal and inspect
pump
Foaming oil Low oil level Fill tank
Air drawn into suction line Check/tighten suction line
Wrong oil grade Drain and refill with correct oil

7.3 FAULT FINDING (WITH “REXROTH” CONTROL VALVES)
GENERAL

All systems fail to operate Pump drive inoperative Investigate and repair as necessary
Low oil level Check and add oil
as necessary
Slow operation or loss of power in Pump worn Perform pump performance test and
all systems replace/reseal as necessary
as necessary
Load sense pressure relief valve Pressure test system

incorrectly adjusted
Hydraulic speed solenoid valve Pressure test system

inoperative
LOADER

Lift fails to operate, is slow or has Valve spool leakage Examine lift section of loader control
loss of power valve assembly for wear or scoring
Piston seals leaking or cylinder Examine/reseal piston and gland

barrel damaged
Bucket fails to operate, is slow or System relief valves stuck open, Bucket system relief valve test
has loss of power set too low or seat leaking
Valve spool leakage Examine bucket section of loader

scoring

barrel damage
Cylinder leak down (spools in Piston barrel damaged Examine/reseal piston and gland
neutral)
Internal valve leakage Examine appropriate valve section
of loader control valve assembly for
wear or scoring
Hesitation in loader lift or bucket Load check valve between Disassemble and inspect
cylinders when control initially control valve sections damaged
moved
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 system is performing normally, thereby confirming that the pump and
hydraulic supply systems are functioning to specification. See also “Fault finding hydraulic pump”.

Lift fails to operate, is slow, has Lift system relief valve stuck Pressure test lift system relief valve
loss of power or is not holding open, set too low or seat is
leaking
Examine lift section of backhoe
Valve spool leakage control valve assembly for wear and
scoring
Examine/reseal piston and gland

Piston seals leaking or cylinder
barrel damaged
Crowd fails to operate, is slow, Crowd system relief valve (piston Pressure test crowd system relief
has loss of power end) stuck open, set too low or valve
seat is leaking
Valve spool leakage Examine crowd section of backhoe

scoring

barrel damaged
Bucket fails to operate, is slow, Bucket system relief valve (rod Pressure test bucket system relief
has loss of power end) stuck open, set too low, or valve
seat is leaking
Valve spool leakage Examine bucket section of backhoe

scoring

barrel damaged
Telescopic dipper (HED) fails to Telescopic dipper (HED) relief Pressure test telescopic dipper
operate, is slow, has loss of valve (piston end) stuck open, set (HED) system relief valve
power too low, or seat is leaking
Valve spool leakage Examine telescopic dipper (HED)

section of backhoe control valve
assembly for wear and scoring

barrel damaged
Stabilizer leg leaks down Stabilizer lock valve leaking Examine/overhaul stabilizer lock
valve

barrel damaged
SWING

Right or left direction swing fails Swing system relief valves not Swing system relief valve test
to operate, is slow, or has loss of seating, set too low or seat is
power leaking

scoring

barrel damaged
Swing fails to slow (cushion Integral sliding restrictor Disassemble and inspect
arrest) at end of travel damaged

barrel damage
Swing continues to move when System relief valve (return side) Swing system relief valve test
control lever returned to neutral stuck open, set too low or seat
(one direction only) leaking

scoring
Cylinders leak down (spools in Internal valve leakage Examine appropriate valve section
neutral) of backhoe control valve assembly
for wear or scoring

barrel damaged
Any one system lowers Load check valve between Disassemble and inspect
momentarily when signalled to control valve sections damaged
raise
HYDRAULIC PUMP

System noisy Worn or damaged pump gears or Hydraulic pump performance test
pressure plates
Aeration: air entering the systems Hydraulic pump performance test

Cavitation: restrictions in the Visual and/or hydraulic pump

system at the suction line or at performance test
the suction screen in the tank
Water in the system

Visual
System relief valve chatter
Check system relief valve, adjust/
overhaul as necessary
Tubing vibration
Visual
Cold hydraulic oil
Check hydraulic oil operating
temperature
Wrong type oil being used
Investigate/drain and refill
Hydraulic oil exhausts from Tank overfilled Check hydraulic oil level
breather at the tank
Aeration: air entering the system Hydraulic pump performance test
Cavitation: Restriction in the Visual and/or hydraulic pump

system at the suction screen in performance test
the tank
Oil heating Oil supply low Fill tank
Contaminated oil Drain tank and refill with clean oil
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
Oil cooler fins blocked Clean oil cooler

Shaft seal oil leakage Worn shaft seal Replace shaft seal and inspect
pump
Foaming oil Low oil level Fill tank
Air drawn into suction line Check/tighten suction line
Wrong oil grade Drain and refill with correct oil

B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 39 - CHASSIS

2. REMOVAL AND INSTALLATION COMPONENTS ...................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS .............................................................................................. 5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS....................................................................... 8
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS .......................................................................... 9
2.5 TIGHTENING TORQUES .................................................................................................................... 11
2 SECTION 39 - CHASSIS
SECTION 39 - CHASSIS 3
1. DESCRIPTION AND OPERATION

This section can be used as a quick reference for
general disassembly of the machine and its compo-
nents.
The chassis of the Backhoe Loader is manufactured

as a one piece unit on which the major assemblies
are attached or supported from.
All the machines are featured as center pivot mod-
els, which means that the backhoe is connected di-
rectly to the chassis and can be removed from the
machine at that point.
The chassis change according to the machine steer-
ing (2WS or 4WS) because of the different wheel
shape; or because the machine can be equipped ei-
ther with loader arm (standard machines) or with
loader bent arm (4WS machines).
2WS CENTER PIVOT CHASSIS (LOADER ARM)
2WS CENTER PIVOT CHASSIS (LOADER BENT ARM)

4WS CENTER PIVOT CHASSIS (LOADER BENT ARM)

2. REMOVAL AND INSTALLATION COMPONENTS

2.1 COMPONENTS WITHIN THE CHASSIS
ENGINE
Supported by 2 rubber bushes and held in position Remove:
by 2 support brackets. The brackets, which are Air filter bowl
welded to the frame one either side of the engine Engine guard
are positioned just ahead of the loader posts. Radiator’s and related hoses (Or pivot forward
where possible)
SWARNING Front support cowling (if required)
The engine and transmission bolted together act as
a one piece unit. If separated in the machine they Disconnect:
are not self supporting and will collapse causing in- Fuel pump accelerator cable and electric shut off
jury or damage to the machine. Engine harness
Fuel tank connection and leak off return pipes
Hydraulic Pump and related pipework (plug all ports
TORQUE CONVERTOR as required)
Transmission Lever
Fitted between the engine and transmission can
Transmission harness connectors
only be removed when the engine/transmission as-
Engine supports (with engine supported by hoist)
sembly are separated.
Transmission supports
TRANSMISSION
Attached to the rear of the engine and supported in
rubber bushes 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:
2.2 COMPONENTS BELOW THE CHASSIS
FRONT AXLE REAR AXLE

The from axle is attached to the underside of the The rear axle is attached to the frame at the rear of
chassis by 8 trough bolts. To remove front axle from the machine by 4 through bolts.
the machine: To remove rear axle from the machine:
Z Park the machine on a flat hard ground. Stop the Z Park the machine on a flat hard ground.
engine, remove the key and relieve any residual Stop the engine, remove the key and relieve any
pressure in the backhoe and loader systems by residual pressure in the backhoe and loader sys-
moving the loader and backhoe control levers tems by moving the loader and backhoe control le-
through all operating position. vers through all operating position.
Z Lower the stabilizers on the ground. Z Lower the stabilizers on the ground.
Z Lower the loader bucket on the ground. Z Lower the loader bucket on the ground.
Z Using the loader bucket raise the front of the loader Z Using the stabilizers, raise the rear of the loader
backhoe, high enough to remove the front wheels. backhoe, high enough to remove the rear wheels.
Z Place stands under the chassis, supporting appro- Z Place stands under the chassis, supporting appro-
priately the machine. priately the machine.
Place under the axle the appropriate supporting/ Z Remove the nuts from the wheels and then remove
removing tool. them.
Z Remove the nuts on the wheels and then remove Z Disconnect the steering cylinder hoses (4WS).
them. Z Disconnect the brake system hoses.
Z Disconnect the steering cylinder hoses. Z Disconnect the connector of harness of the differ-
Z Remove the axle swivel pin attaching bolts (4WD). ential lock (electrically controlled version).
Z Disconnect the spider coupling (4WD). Z Remove the precision swing assy if installed (see
Z Remove the axle attaching bolts. section 35).
Z Remove axle swivel pin attaching bolts.
Z Disconnect spider coupling.
Z Remove the axle attaching bolts.
COUNTERWEIGHT
Counterweight: is installed under the chassis in the

front section of the machine with two bolts.
The are different types of counterweights:
2WS (A)
1. Standard counterweight ...........125 kg (276 lbs)
2. medium counterweight.............362 kg (798 lbs)
3. big counterweight...................475 kg (1047 lbs)
4. extra counterweight (optional) .125 kg (276 lbs)
4WS (B)
5. Zavorra media..........................125 kg (276 lbs)
6. Zavorra grande ........................333 kg (734 lbs)
7. Extra zavorra (optional) ...........125 kg (276 lbs)
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS
TANKS
Attached to the chassis below the cab are the tanks
for the hydraulic system (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.
IMPORTANT: ensure all ports and pipes are

plugged or blanked off to prevent dirt ingress.
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS
CAB
A. Front fixing 7. Screw

B. Rear fixing 8. Washer
S. Cab skirts 9. Cab floor
1. Main frame 10. Support
2. Dampener assy 11. Support
3. Dampener 12. Boss
4. Washer 13. Cab anchor support
5. Washer
6. Nut
The cab frame is a one piece unit mounted on top of

the chassis. The mains operations that have to be
done in order to remove the cab are:
Z Remove the cab skirts (S) all around the cab.
Z Disconnect the two electrical connectors from the
main harness and engine harness.
Z Remove the two front fixing bolts between the cab
floor and the cab anchor support (detail A).
Z Remove the two rear fixing bolts between the cab
floor and the rear supports on the main frame (de-
tail B).
Z Disconnect the two steering cylinder hoses (left
side).
Z Disconnect the pump - power steering valve hose.
Z Disconnect the power steering valve - oil tank
hose.
Z Disconnect the load sensing valve hose.
Z Disconnect the stabilizers cables (mechanical ver-
sion).
Z Disconnect the hand brake cable.
Z Disconnect the water - heater hoses (after water
discharge).
Z Disconnect the air conditioning hoses (after refrig-
erant drain).
Z Disconnect the transport lock cable (mechanical
version).
Z Disconnect the telescopic dipper control pedal
(mechanical version).
Z Remove the knobs and the boots of the various le-
vers (front and rear)
Z Lift the cab with the crane after its anchorage to lift-
ing hook.
IMPORTANT: when lifting the cab ensure the hy-

draulic brake reservoirs are not caught and dam-
aged on the loader support frame.
2.5 TIGHTENING TORQUES
In the following table are the torques for the various assemblies that should be removed to affect repair.
IMPORTANT: always ensure prior to carrying out repairs on the machine that the vehicle parking brake is on
and the wheels are chocked.
ENGINE/TRANSMISSION
ù
COMPONENTS TORQUES
Engine/Transmission retaining screws and nuts 95 Nm (70 lbf·ft)
Engine/Transmission mounting screws 95 Nm (70 lbf·ft)
Air filter retaining screws to frame 25 Nm (18 lbf·ft)
Coolant radiator screws to frame 95 Nm (70 lbf·ft)
Radiator retaining screws to frame 95 Nm (70 lbf·ft)
Front cardan joint to axle 38 Nm (28 lbf·ft)
Front cardan joint to transmission 38 Nm (28 lbf·ft)
Rear cardan joint to axle 38 Nm (28 lbf·ft)
Rear cardan joint to transmission (PS) 38 Nm (28 lbf·ft)
Rear cardan joint to transmission (PT) 70 Nm (52 lbf·ft)
FRONT/REAR AXLE
COMPONENTS TORQUES
Front axle retaining screws to frame (2WS) 500 Nm (369 lbf·ft)
Front axle retaining screws to frame (4WS) 500 Nm (369 lbf·ft)
Rear axle to frame retaining screws (2WS) 800 Nm (590 lbf·ft)
Rear axle to frame retaining screws (4WS) 900 Nm (664 lbf·ft)
HYDRAULIC SYSTEMS
COMPONENTS TORQUES
Power steering hoses to support frame 55 Nm (41 lbf·ft)
Backhoe control valve to frame screws 90 Nm (90 lbf·ft)
Loader control pipes clamp to frame 25 Nm (18 lbf·ft)
OIL TANK/FUEL TANK
COMPONENTS TORQUES
Oil tank screws 85 Nm (63 lbf·ft)
Fuel tank screws 85 Nm (63 lbf·ft)
LOADER
COMPONENTS TORQUES
Loader control pipe bracket to frame 25 Nm (18 lbf·ft)
BACKHOE
COMPONENTS TORQUES
Backhoe to frame hose retaining clamps 52 Nm (38 lbf·ft)
Fastening pin of boom to swing bracket 320 Nm (236 lbf·ft)
Stabilizers upper pins retaining screws 80 Nm (59 lbf·ft)
CAB
COMPONENTS TORQUES
Cab support 450 Nm (332 lbf·ft)
Front cab retaining screws 210 Nm (155 lbf·ft)
Rear cab retaining screws 180 Nm (133 lbf·ft)
WHEELS
COMPONENTS TORQUES
Front/rear wheels (4WS) 700 Nm (369 lbf·ft)
Front wheel (2WS) 330 Nm (243 lbf·ft)
Rear wheel (2WS) 540 Nm (398 lbf·ft)
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 41 - STEERING SYSTEM

3. POWER STEERING ................................................................................................................................... 12
3.2 COMPONENTS ................................................................................................................................... 15
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING.................................................................................................................................. 33
2 SECTION 41 - STEERING SYSTEM
SECTION 41 - STEERING SYSTEM 3
The hydrostatic steering system shows these fea-

tures:
Z double acting, balanced type steering cylinder on
both 2 and 4WD axles;
Z common hydraulic tank with the main hydraulic
system;
Z a tandem gear pump located on the rear of the
transmission; both pumps are driven by a shaft run-
ning directly off the flywheel. Oil is drawn through
the common inlet port into both pumping elements.
The front pump flow is directed to the loader and
backhoe control valves and sideshift clamping sys-
tem. Rear pump flow passes through the flow divid-
er valve which maintains priority oil flow to the
steering system with remaining flow directed for
stabilizers, loader and backhoe elements. The flow
divider, located on the rear of the pump, comprises
a load sensing valve and steering system pressure
relief valve. The valve ensures a priority oil flow to
the steering system while the steering is operated,
with the remaining flow directed to the stabilizer,
loader and backhoe systems;
Z an hydrostatic load sensing steering motor;
Z oil cooler and filter is an integral part of the hydrau-
lic system (for 4WS models).
1. STEERING SYSTEM 2WS

LAYOUT
1. Flow divider
2. Steering motor
3. Hydraulic system tank
4. Front axle
STEERING MOTOR - NEUTRAL
F29379
Pump pressure Trapped oil

Stand-by pressure Return to oil tank
When the steering wheel is held still, the leaf springs

return and hold the spool and sleeve in the neutral
position.
This ensures no more oil is supplied to the steering
cylinder. The sleeve also traps the oil in the steering
cylinder and allows oil in the sensing lines to return
to tank therefore allowing the priority flow divider to
move to the left. to tank therefore allowing the priority
flow divider to move to the left.
STEERING MOTOR - TURNING RIGHT
F29384
Pump pressure Trapped oil

Metered pressure Return to oil tank
When the steering wheel is turned, the movement of

the control valve spool in its sleeve forms a series of
passages. During right turn, oil flows through the
sleeve along a groove in the valve spool and into a
passage in the steering motor housing which leads
to the metering unit. A gallery is also lined up to al-
low pressure oil to flow down the sensing line to the
priority flow divider.
As the metering unit is turned by the drive shaft, it di-

rects a measured quantity of oil along another set of
passages in the spool and sleeve then from these to
the steering cylinder.
Return oil from the other side of the cylinder is di-

rected through the valve spool and sleeve to a re-
turn passage in the housing.
2. STEERING SYSTEM 4WS

LAYOUT
1. Flow divider 6. Oil cooler by-pass valve

2. Steering motor 7. Hydraulic oil cooler
3. Hydraulic system tank 8. Front axle
4. Common return manifold 9. Steering control valve
5. Hydraulic system filter 10. Rear axle
STEERING CONTROL VALVE

The steering control valve is located just above the
rear axle attached to the main chassis.
Remove the four pipes and then the 2 chassis fixing
bolts, then withdraw the valve for overhaul.
Draw a diagonal line across the complete valve
block this will assist in the correct reassembly later.
The valve consists of a central manifold block which

all input and output pipes are attached to. On each
side of this block is a solenoid valve. The solenoid
valves have two positions, both of these positions
are working positions and there is no neutral point.
Each spool is detented and therefore the solenoids
are only energized momentarily to move the spool.
On the end of each solenoid is an emergency hand
operating pin which moves the control spool without
energizing the solenoid. The switching of the steer-
ing valve is normally controlled by a microprocessor
located underneath the right hand side console.
1. Solenoid fixing screw 6. Fixing screws

2. Solenoid 7. Plunger
3. Control spool 8. O-rings
4. Spool block 9. O-ring
5. Central manifold block
STEERING VALVE SCHEMATIC
In the position shown both spools have been moved

by solenoids (2b) and (3b); the detents on the (a)
side of the solenoid hold the spool in this position
until another solenoid is pulsed
T3
P3
A3 B3
A2 B2
P2
T2
F29529
The spool in valve (3) was last moved by solenoid

(3b): oil flowing in from P3 flows through the internal
galleries of the spool and exits at port A3. From
here, oil enters valve (2), whose spool was last
moved by solenoid (2b). Oil flows through port P2
and exits through port T2, cutting off flow to the rear
steering cylinder. Now the oil returns in valve (3),
entering through port B3 and flowing out through
port T3. From here, oil enters the front steering cyl-
inder.
The three modes of steering are as follows:
Front wheel only steering
Front and rear wheel steer
Front and rear wheel crab
The solenoids energized are shown in the table op-

posite.
These are also the pins which need to be pressed
when changing steering mode manually in an emer-
gency.
X = Energized
O = Not Energized
3a 3b 2a 2b
2WS O X O X
2WS X O O X
4WS O X X O
CRAB X O X O
3. POWER STEERING
The steering unit consists of a metering and emer- wheel, through column, that can be of two types:
gency hand pump that includes a gear wheel as- fixed or adjustable.
sembly with fixed stator (with inner teeth) and a rotor Z A cardan shaft, mechanically tied to gear wheel as-
(with outer teeth). sembly and to outer sleeve, allows the movement
Z A 4 ways rotary distributor consisting of an outer transmission.
sleeve and an inner selection rotor. Z Set of centering springs between outer sleeve and
The selection rotor is connected to the steering inner rotor.
L. Left control port (steering cylinder)

R. Right control port (steering cylinder)
P. Inlet to steering pump
T. Outlet to hydraulic tank
LS. Outlet to steering pump
Displacement (2WS) 125 cm3/rev (7.63 in3/rev)

Displacement (4WS) 160 cm3/rev (9.76 in3/rev)
Adjustment shock valves (4WS) 240 ÷ 260 bar (3481 - 3771 psi)
TIGHTENING TORQUES
3/4 - 16 UNF Nm (lbf·ft) 60 (44)
7/16 - 20 UNF Nm (lbf·ft) 20 (15)
Steering wheel nut Nm (lbf·ft) 55 (41)
Steering motor to steering column bracket Nm (lbf·ft) 23 (17)
Steering motor end cover Nm (lbf·ft) 30 (22)
Steering motor pipe connection Nm (lbf·ft) 45 (32)
Steering motor pipe adaptors Nm (lbf·ft) 55 (41)
Check valve bolt Nm (lbf·ft) 30 (22)
Shock valve (4WS) Nm (lbf·ft) 30 (22)
HYDRAULIC DIAGRAM (2WS)
1. Power-steering assy 3. Anticavitation valve

2. Check valve 4. Power steering control valve
HYDRAULIC DIAGRAM (4WS)
1. Power-steering assy 4. Anti-shock valve set at 240 ÷ 260 bar

2. Power steering control valve (3481÷3771 psi)
3. Check valve 5. Anticavitation valve
3.2 COMPONENTS
* Only with 4WS models
1. Sleeve 14. O-ring

2. Spool 15. End cover
3. Ball 16. Washer
4. Thread bushing 17. Special screw
5. O-ring 18. Screw
6. Bearing 19. Body
7. Ring 20. Ball
8. Cross pin 21. Pin
9. Cardan shaft 22. Check valve
10. Set of springs 23. Shock valve
11. O-ring 24. Seal ring
12. Distribution plate 25. Seat
13. Rotor/stator geart
DISASSEMBLY
To gain access to the steering motor the bonnet and
air filter should be removed.
Removing steering motor

Disconnect the four connectors and collect the O-
ring seals, noting the connector positions.
Remove the four Allen screws from within the cab.

The motor can be removed from the front of the cab
through the engine compartment. Place the steering
unit in the holding tool.
Screw out the screws (18), the special screw (17)

and the washers (16) from the end cover (15).
Remove the end cover (15).
Lift the rotor/stator gear (13) (with spacer if fitted) off

the unit. Take out the two O-rings (14).
Remove the cardan shaft (9).
Remove the distribution plate (12).

Screw out the threaded bush (4) over the check

valve.
Shake out the check valve ball (3) and the pins (21)
and the balls (20). Replace the pins (21) prior to the
reassembly.
Take care to keep the cross pin in the sleeve and

spool horizontal. The pin cab be seen through the
open end of the spool. Press the spool (2) inwards
and the sleeve, ring, bearing races and needle bear-
ing will be pushed out of the housing together.
Take the ring (7), the bearing races and the bearing
(6) from sleeve and spool. The outer (thin) bearing
race can sometimes “stick” in the housing, therefore
check that is has come out.
Press out the cross pin (8). Use the special screw
(17). A small mark has been made with a pumice
stone on both spool and sleeve close to one of the
slots for the neutral position springs (see drawing). If
the mark is not visible, remember to leave a mark of
your own on sleeve and spool before the neutral po-
sition springs are dismantled.
Carefully press the spool (2) out of the sleeve (1).
Press the springs (10) out of their slots in the spool.

Remove the seal ring (24) and the O-ring (5).
Remove plugs from shock valves using a 6 mm

(0.23 in) hexagon socket spanner.
NOTE: carry out step 18 - 22 only with 4WS models.
Remove the seal washers (2-off).
Unscrew the setting screws using a 6 mm (0.23 in)

hexagon socket spanner.
Shake out the two springs and two valve balls into
your hand. The valve seats are bonded into the
housing and cannot be removed.
The shock valves (23) are now dismantled.
CLEANING
Clean all parts carefully.
INSPECTION AND REPLACEMENT

Check for signs of wear in the following areas:
Z Rotor and stator of metering unit move freely.
Z Check the drive pin is not cracked or bent.
Z Check the rollers in thrust bearing are free to ro-
tate.
Z Ensure thrust washers are not warped or cracked.
Z Ensure check valve ball is free to move.
Z Check control valve, spool and sleeve for wear or
scoring.
Z Replace all seals and O-ring.
LUBRICATION
Before assembly, lubricate all parts with hydraulic
oil.
ASSEMBLY
NOTE: great care should be taken during re-assem-

bly.
Place the two flat neutral position springs in the slot.

Place the curved springs between the flat ones and
press them into place.
Line up the spring set (10).
Guide the spool (2) into the sleeve (1). Make sure
that spool and sleeve are placed correctly in relation
to each other.
Assemble spool and sleeve.

When assembling spool and sleeve only one of two
possible ways of positioning the spring slots is cor-
rect. There are three slots in the spool and three
holes in the sleeve in the end of the spool/sleeve op-
posite to the end with spring slots. Place the slots
and holes opposite each other so that parts of the
holes in the sleeve are visible through the slots in the
spool.
Press the springs together and push the springs into

place in the sleeve.
Line up the springs and centre them.
Guide the ring (7) down over the sleeve.
NOTE: the ring should be able to move - free of

springs.
Fit the cross pin (8) into the spool/sleeve.
Fit bearing races and needle bearings (6) as shown

on the next drawing.
1. Spool
2. Sleeve
6. Needle bearings
6A. Outer bearing race
6B. Needle bearing
6C. Inner bearing race
The inside chamfer on the inner bearing race must

face the inner spool.
Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool into the
bore for the spool/sleeve.
Grease the O-ring (5) with hydraulic oil and place

them on the tool.
Hold the outer part of the assembly tool in the bottom

of the steering unit housing and guide the inner part
of the tool right to the bottom.
Press and turn the O-ring into position in the hous-

ing.
Draw the inner and outer parts of the assembly tool

out of the steering unit bore, leaving the guide from
the inner part in the bore.
Lubricate the seal ring (24) with hydraulic oil and

place it on the assembly tool.
Guide the assembly tool right to the bottom.
Press and turn the seal ring into place in the hous-
ing.
With a light turning movement, guide the spool and

sleeve into the bore.
Fit the spool / sleeve the cross pin horizontal.
The spool set will push out the assembly tool guide.
The O-ring is are now in position.
Turn the steering unit until the bore is vertical again.

Put the check valve ball (3) into the hole indicated in
the picture.
Screw the thread bushing (4) lightly into the check

valve bore. The top of the bush must lie just below
the surface of the housing.
Place a ball (20) in the two holes indicated in the pic-

ture.
Place a new pin (21) in the same two holes.
Grease the O-ring (11) with mineral oil.
Place the distribution plate (12) so that the channel

holes match the holes in the housing.
Guide the cardan shaft (9) down into the bore so that
the slot is parallel with the connection flange.
Place the cardan shaft (9) as shown - so that it is

held in position by the mounting fork.
Grease the two O-rings and place them in the two

grooves in the gear rim. Fit the rotor/stator gear (13)
and rim on the cardan shaft.
Fit the rotor/stator gear (rotor) and cardan shaft so

that a tooth base in the rotor is positioned in relation
to the shaft slot. Turn the gear rim so that the seven
trough holes match the holes in the housing.
For precise keying and alignment of steering control

valve, pay attention to the parallelism of (A), (B), (C)
and (D) reference marks.
A. Rotor/stator surface
B. Plate distribution surface
C. Pin axis
D. Housing surface
E. Rotor/stator gear
F. Cardan shaft
Place the end cover (15) in position.
Fit the special screw (17) with the washer (16).

Fit the six screws (18) with the washers (16) and in-
sert them. Cross-tighten all the screws and the rolled
pin with a torque of 30 ± 6 Nm (22 ± 4.4 lbf·ft) in the
sequence shown, initial torque of 10.8 Nm (7.9
lbf·ft).
Put a ball in the two holes.
Place springs and valve cones over the two balls.
Screw in the two setting screws.

Screw plug with seal ring into the two shock valves
and tighten them with a torque of 30 ± 10 Nm (22 ±
7.3 lbf·ft).
Place the seal ring (24) in the body.
Fit the seal ring in the housing using the special tool
and a plastic hammer.
3.4 SPECIAL TOOLS
P/N CNH DESCRIPTION

380000281 Assembly tool for seal ring.
380002677 Assembly tool for ring.
380002679 Assembly tool for cardan shaft.
380002680 Assembly tool for O-ring.
3.5 FAULT FINDING

No steering or excessive effort Incorrect oil level in tank Fill with the correct grade and
required to steer quantity of oil.
Air in system Check for loose connections or
damaged tubing. Purge system of
air.
Pump relief valve faulty Check system pressure.
Worn pump Inspect and repair.
Leaking power cylinder Inspect and repair.
Damaged valve spool Inspect and replace.
Broken or damaged steering Inspect and replace.
column
Damaged or worn metering Inspect and replace.
element
Steering wanders Excessive play in steering Inspect and replace.
linkage ball joints
Leaking power cylinder Inspect and repair.
Control valve spool sticking or Inspect and replace.
worn
element
Front wheels surge when Leaking power cylinder Inspect and repair.
steering Control valve spool sticking Inspect and repair.
element
Noisy pump Incorrect oil level in tank Fill with the correct grade and
quantity of oil.
Air in system Check for loose connections or
damaged tubing. Purge system of
oil.
Water in oil Drain and replace the oil.
Worn pump Replace pump.
NOTE:
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 50 - CAB HEATING AND AIR

CONDITIONING
2. CAB HEATING.............................................................................................................................................. 5
3. AIR CONDITIONING .................................................................................................................................. 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 27
3.5 FLUSHING THE SYSTEM................................................................................................................... 45
3.6 EVACUATING THE SYSTEM.............................................................................................................. 47
3.7 CHARGING THE SYSTEM.................................................................................................................. 48
3.8 COMPONENTS OVERHAUL .............................................................................................................. 49
3.9 COMPRESSOR ................................................................................................................................... 54
3.10 SPECIAL TOOLS............................................................................................................................... 68
2 SECTION 50 - CAB HEATING AND AIR CONDITIONING
SECTION 50 - CAB HEATING AND AIR CONDITIONING 3
HEATING
ENGINE RADIATOR COOLANT
Antifreeze - Ambra Agriflu 12 liters (3.2 US gals)
Water 12 liters (3.2 US gals)
System type Pressurized FULL FLOW by-pass with
expansion chamber
FAN BELT DEFLECTION
Naturally aspired 13 - 19 mm (0.51 in - 0.75 in)
Turbocharged 10 - 16 mm (0.39 in - 0.63 in)
THERMOSTAT
Start to open at 82 °C (179.6°F)
Fully open at 95 °C (203°F)
Radiator cap 0.90 bar (13 psi)
TORQUE VALUES
Coolant/hot water hose connections 5 Nm (3.7 lbf·ft)
Air hose ducting connections 5 Nm (3.7 lbf·ft)
Heater housing to floor mounting bolts 6.2 Nm (4.6 lbf·ft)
Refrigerant HFC 134a

Refrigerant charge 1.2 kg (2.65 lbs)
Compressor oil SP20 (PAG Type, Viscosity index 100)
Oil change amount 135 cc (8.24 in3)
CHECK CONDITIONS
Air inlet temperature 37.8 °C (100°F)
Rated air inlet moisture 40%
Evaporation temperature 0°C (32°F)
Overheating 5°C (41°F)
Inlet air speed 1.0 - 2.0 - 3.0 m/s (3.3 - 6.6 - 9.9 ft/s)
Condensation temperature 58°C (absolute 16 bar(232 psi)) (136.4°F)
Undercooling 2°C (35.6°F)
PERFORMANCE CALCULATED AT m/s (191.72 m3/h)

Exchanged warmth 5.48 kW (4059 ft.lb/s) 4718.28 kcal/h
Air outlet temperature 5.64 °C (42.152 °F)
Air side load loss 2.97 daPa 0.30 mmH20
(0.00431 psi) (0.012 in H20)
Coolant side load loss 13.1 kPa 0.13 bar (1.9 psi)
PERFORMANCE CALCULATED AT 2.0 m/s (383.4 m3/h)
Exchanged warmth 9.29 kW (6882 ft.lb/s) 7998.69 kcal/h
(0.0135 psi) (0.037 in H20)
PERFORMANCE CALCULATED AT 3.0 m/s (575.1 m3/h)
Exchanged warmth 12.00 kW 10332.00 kcal/h
(8889 ft.lb/s)
(0.0265 psi) (0.074 in H20)
2. CAB HEATING
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.
Heater blower control

The three speed blower is controlled by switch (1)
mounted in the instrument console to the right of the
cab seat. Turn the switch clockwise to the first position
for slow speed. Further rotation of the switch in a clock-
wise direction selects medium and fast speeds. The
blower draws outside air from beneath the cab floor
and through a filter medium into the cab.
Heater temperature control

The temperature of the air from the radiator is adjust-
ed by rotation of the control knob (2) which opens or
closes the radiator valve increasing or decreasing
the water flow as required. Turn the control clock-
wise to increase the temperature of air from the
heater and counter clockwise to reduce the temper-
ature.
S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.
Cab air filter

Before servicing the air filter situated under the driv-
ers seat, switch off the blower and close all windows
and one door. Forcibly close the other door. The re- 3
sulting back pressure will dislodge loose dirt from
the underside of the filters. To remove the filter (3)
release the retaining straps (4) and remove the filter
element. Ensure the element, and sealing faces are
not damaged on removal.
IMPORTANT: in humid conditions, such as occur on

most early mornings, do not switch on the blower pri- 4
or to servicing the filters. Damp particles drawn into F29325
the filter may solidify and prove difficult to remove

without washing.
The filter element is made of specially treated paper

with a sealing strip bonded to the outer face.
Clean this element by blowing with compressed air
from the clean side through to the dirty side. The
compressed air should not exceed 2 bar and the air
line nozzle should be at least 300 mm from the ele-
ment.
Heater radiator
The heater radiator (1) is fitted in a housing under
the cab seat for central displacement of warm or cold
air flow.
IMPORTANT: too ensure a good flow of air through

the heater radiator the filter should be cleaned more
frequently when operating in extremely dusty condi-
tions.
Air flow vents

Air flow vents are connected to the heater housing
and receive air from the blower motor, to direct warm
or cold air onto the windscreen and side windows or
to the cab interior as required.
Each vent may be swivelled and adjusted to control
the flow of air.
To open a vent, press one side of the disc and turn
it, as required, to direct the air flow.
The vents are located as follows:
Z two on the top of the main console (A);
Z two on the front edge of the main console (E);
Z two to the rear of the operator seat (C);
Z two under the seat, one in front, the other on the
rear (D);
Z two on the cab posts, right and left (B);
Z two on the ceiling, in front and back of operator’s
head (F).
NOTE: the vents (B) and (F) are mounted only when
air conditioned (optional) is fitted.
3 4
2
6
5
F30058
Schematic - Heater system

1. Heater valve mounted to the right of the heater
housing
2. Air ducting to the front windscreen
3. Heater control panel cooler pipes
4. Air ducting to the rear windscreen below the cab
floor
5. Air intake to the heater housing from below the
cab floor
6. Heater pipes to and from heater taken from the
engine oil
Electrical heater valve

The electrical valve is equipped with a software that,
each time the supply of the cock is delayed (there-
fore also at backhoe loader start), carries out the mo-
mentary positioning of the cock to “completely
closed” and returns to the position set by the temper-
ature regulation handle located on the control con-
sole. This enables the software to carry out a self-
control on the cock drive so as to always obtain an
optimal regulation of the ball for the water flow.
This is part of the cock normal operation and is not to
be considered as a fault.
Release of the electrical heater valve
IMPORTANT: The release of the valve has to be

performed if this valve remains idle for long periods.
Carry out this operation observing the following pro-

cedure:
Z Disconnect the electrical connectors (1).
Z Loosen the screws (2) and take out the electrical
valve (3) from the evaporator.
Z Unscrew and remove screws (4). 3
4
1 2
F30059
Z Separate the driving unit (5) from the cock (6).

Z By means of a wrench turn pin (A) of the cock so as
to unlock it.
SWARNING
5
Once this operation is complete, reset pin (A) in the
correct start position.
6
Reinstall the heater valve, repeating the previous
operation in the reverse order.
A
F30060
FAULT FINDING -GENERAL

Items that may cause a concern are suggested in Hoses are unrestricted and not leaking.
the fault finding chart but as a general rule apply the Check the electrical connections are good and the
following steps: blower motor is operational.
Ensure water flow to the heater radiator is steady The operating cable to the heater valve and valve is
and all air has been removed from the system. operational.
FAULT FINDING

Dust enters the cab Improper seal around filter element Check seal condition
Blocked filter Clean or replace filter
Defective filter Replace filter
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 radiator core blocked Clean radiator core thoroughly

Blower motor not working Fuse blown Replace fuse
Cab does not heat up Engine not reaching operating Replace thermostat
temperature. Thermostat stuck open
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
Heater control valve stuck in open Free up valve or change as required

position
Temperature not stable Low engine coolant Top up coolant recovery tank
OVERHAUL
IMPORTANT: when overhauling the heating system

remember that, with the engine running or shortly af-
ter it is turned off, the system will be at engine tem-
perature and therefore the water will be hot and
under pressure.
To effect repairs to the heater core or blower motor,

it will be necessary to remove the attaching bolts (1)
from the seat and remove seat from the heater hous-
ing.
Draining the system

Too drain the cooling system down disconnect either
hose at the T junction (2) found at the rear of the en-
gine oil filter mounted to the left hand side of the en-
gine.
F28674
Heater radiator
With the system drained remove the heater radiator
hose connections, attaching bolts and remove from
the vehicle.
Inspect the heater radiator (3):
Check water flow through the heater pipe which
should be free running; if not, clear any blockage.
Fins should be free of all debris and not damaged;
clean and or repair.
Clean the heater radiator using compressed air not
exceeding 7 bar taking care not to damage the radi-
ator fins.
Ensure the radiator is not leaking under pressure;
repair or replace as required.
Clean the chamber with a damp, cloth and re-as-
semble the housing filter element with the seal fac-
ing the inside of the cover.
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.
Heater control valve

To service the control valve (2) disconnect the hoses
and the control cable and remove. Check the opera-
tion of the valve and if tight or worn replace.
Heater control panel

The blower motor is operated by a 3 position switch
(3) which through a variable potentiometer increas-
es or decreases voltage to the blower motor.
The heater valve is operated by a control cable
which will push or pull the valve into an open or
closed position.
Both of the above are mounted to the right of the

driver’s seat and can be accessed by removal of the
control panel for repair or replacement.
F32411
3. AIR CONDITIONING
3.1 PRINCIPALS OF AIR CONDITIONING
The function of the air conditioning system is to im-

prove the operator’s comfort by cooling the air tem-
perature inside the cab and reducing the humidity
level. In order to achieve this heat transfer the follow-
ing principals of heat generation and transfer are ap-
plied within the air conditioning system.
1. When two bodies of different temperature come
together heat is transferred from one to another.
On air conditioning systems an evaporator is
used to hold the low temperature refrigerant
which absorbs the heat from the air within the
cab.
F28680
2. When a gas is pressurized the temperature of

the gas will rise. In air conditioning systems the
increase in pressure is achieved using a com-
pressor.
F28681
3. When a gas is cooled it will condense into a liq-

uid. In the air conditioning system a condenser is
used to cool the gas and the resulting liquid is
stored in a receiver dryer.
F28682
4. When a liquid is atomized through an orifice, the

temperature of the resultant vapor will lower.
The low temperature of the atomized liquid will
then absorb heat from its surrounding. On air
conditioning systems the refrigerant is atomized
using an expansion valve.
C?
F28683
Air conditioning principle of operation

1. Expansion valve-atomizes liquid refrigerant be-
fore passing to evaporator
2. Evaporator-absorbs heat from air in cab
3. Compressor-compresses and raises tempera-
ture of refrigerant gas
4. Condenser and receiver dryer-converts refriger-
ant from gas to a liquid
LOW PRESSURE SIDE HIGH PRESSURE SIDE
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
HEAT FROM INSIDE HEAT MOVES TO

CAB MOVES TO OUTSIDE AIR FROM
REFRIGERANT REFRIGERANT
Air conditioning flow diagram
It can now be seen that the principal components of The figure in the this page shows in schematic form
an air conditioning system are: the flow of refrigerant through the five major compo-
Z Refrigerant nents of an air conditioning system.
Z Compressor Refrigerant is drawn into the compressor as a cool,
Z Condenser low pressure vapour which is compressed and then
Z Receiver dryer pumped out as a hot, high pressure vapour to the
Z Expansion valve condenser.
Z Evaporator As the hot, high pressure vapour passes through the
The figure in the previous page uses the examples condenser core it gives off heat to the cooler outside
above to illustrate the air conditioning cycle. air, being drawn past the fins by the engine cooling
fan.
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.
3.2 SAFETY PRECAUTIONS Make sure to comply with the following indications
and simple precautions to avoid any risk of injury:
Z Never discharge refrigerant into the atmosphere.
SWARNING When servicing air conditioning units a certified re-
frigerant recovery unit operated by a certified tech-
Before overhauling an air conditioning system read
nician must be used.
and observe the following safety precautions. If a re-
Z When discharging the refrigerant in the system
pair or replacement becomes necessary, ensure
make sure you are operating in well-ventilated pre-
that only certified air conditioning technicians are
mises with good air circulation and far away from
employed, using approved equipment to effect re-
open flames.
pairs.
Z When charging and discharging the system always
Do not attempt to disassemble the air conditioning
wear goggles and take suitable precautions to pro-
system. It is possible to be severely frostbitten or in-
tect the face in general and the eyes in particular,
jured by escaping refrigerant.
from accidental spillage of the refrigerant fluid.
Z The oil and refrigerant mixture inside the air condi-
IMPORTANT: do not allow refrigerant to escape tioning system is pressurized. Consequently, nev-
into the atmosphere. er loosen fittings or tamper with lines unless the
system has been properly discharged.
Refrigerant must be handled with care in order to Z Before loosening any connection, cover the fitting
AVOID HAZARDS. in question with a cloth and wear gloves and gog-
Undue direct contact with liquid refrigerant can pro- gles in order to prevent refrigerant from reaching
duce freezing of skin and eyes. the skin or eyes.
Keep the refrigerant container and air conditioning Z In the event of an accident, proceed as follows:
system away from flame or heat sources; the result- If the refrigerant has reached the eyes, wash them
ing pressure increase can cause the container or immediately with copious amounts of sterilized wa-
system to explode. ter or mains pressure tap water and transfer to
If in direct contact with open flames or heated metal hospital for immediate medical help.
surfaces, the refrigerant will decompose and pro- If the refrigerant has touched the skin, wash with
duce products that are toxic and acidic. cold water and transfer to hospital for immediate
medical help.
CONTROLS (B90B)
The air conditioning control can be adjusted to obtain
the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the warning lamp (3) turns on. The
selector (1) allows choosing the ideal temperature
according to your requirements. Positioning selector
(1) to “0” and turning selector (2) you will obtain more
or less cold according to the selector (2) position. By
positioning selector (1) to any other position different
from “0”, you will obtain instead a mixture of warm
and cold air and the desired climate inside the cab.
NOTE: the air conditioning can be operated only if

the ventilation selector (4) is not set to the stop posi-
tion.
Turn the selector (4) for air capacity according to

your requirements.
CONTROLS (B95B - B110B - B115B)

The air conditioning control can be adjusted to obtain
the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the warning lamp (4) on the side in-
strument cluster turns on. The selector (1) allows
choosing the ideal temperature according to your re-
quirements. Positioning selector (1) to “0” and turn-
ing selector (2) you will obtain more or less cold
according to the selector (2) position. By positioning
selector (1) to any other position different from “0”,
you will obtain instead a mixture of warm and cold air
and the desired climate inside the cab.
NOTE: the air conditioning can be operated only if

the ventilation selector (3) is not set to the stop posi-
tion.
Turn the selector (3) for air capacity according to

your requirements.
IMPORTANT: when using the air conditioning, it is

essential that all the windows of the operator's com-
partment are completely closed.
NOTE: to ensure correct operation and full efficiency

of the air conditioning system, it must be used at
least once a week, even for a short time.
The air-conditioner filter is located on the left hand

side of the seat pod.
S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.
If the machine has been parked in the sun, quicken

the cooling by operating the air-conditioning for 2-3
minutes at its coldest setting. Set maximum blower
speed with a window left partially open to force most
of the warm air from the cab.
With the air cooled sufficiently, close the window
and adjust the controls to the desired temperature.
To ensure proper operation of the system be sure
the cab filter is regularly serviced. Refer to filter
maintenance.
It is the normal function of the air-conditioner to ex-
tract water from the air. As such it is possible pools
of water will collect beneath the drain hose outlets
under the cab when the machine is stationary.
REFRIGERANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air condition- S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 32
bility features. °C (89.6 °F), cover the area loosely with a bandage
The refrigerant used in the air conditioning system is to protect affected area against infection and con-
refrigerant HFC 134a. sult a doctor immediately.
If refrigerant should contact the eyes wash immedi-
NOTE: to help protect the environment legislation ately in cold clean water for at least 5 minutes and
has been introduced in most territories banning the consult a doctor immediately.
release into the atmosphere of refrigerants, includ-
ing HFC 134a. All service procedures contained in
this manual can be carried out without the need to
release refrigerant into the atmosphere.
In order to prevent the incorrect type of refrigerant

being charged to the system the service valves fitted
to the Backhoe Loader and necessary to connect up
refrigerant recovery, evacuation and recycling/re-
charging equipment will be of two different sizes as
recognized and specified by the air conditioning in-
dustry.
S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.
HFC 134a refrigerant is stable at all operating tem-

peratures and able to absorb great quantities of
heat.
The boiling point of HFC 134a is -22 °C (-7.6 °F) at
atmospheric pressure.
If the pressure is increased, HFC 134a will readily
vaporize to absorb heat at temperatures between -
11.7 °C (53°F) at 1.9 bar (28 psi) and 0 °C (32°F) at
2.9 bar (42 psi) in the evaporator.
At higher pressures, HFC 134a will condense and
give off heat at temperatures between 48 °C (118.4
°F) at 12.4 bar (180 psi) and 58 °C (136.4 °F) at
15.85 bar (230 psi) in the condenser.
SWARNING
HFC 134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
explosion, and the production of phosgene gas.
Never disconnect or disassemble any part of the air-
conditioning system as escaping refrigerant can
cause frostbite.
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 system.
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 sys-
tem.
The compressor is activated by an electro-magnetic
clutch which functions to engage or disengage the
compressor as required in the operation of the air
conditioning system.
The clutch is primarily activated by the:
Z ·Temperature control
Z ·Low pressure cut-out switch
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.
Low pressure cut-out switch

The low pressure switch (1) is mounted in the top of
the filter (2) mounted in front of the radiator behind
the battery.
The purpose of the switch is to shut off the compres-
sor pump in the event of low pressure in the refriger-
ant system.
Low refrigerant pressure may occur due to a faulty
expansion valve, icing up of the expansion valve or-
ifice or refrigerant loss. Low refrigerant pressure
may result in damage to the compressor pump.
The low pressure switch is factory set and cannot be
adjusted.
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.
NOTE: the condenser after removal of the attaching

bolts can be slid out for cleaning.
The condenser receives the hot, high pressure re-

frigerant vapour from the compressor. The hot va-
pour passes through the condenser coils and
outside air is drawn through the condenser by the
engine cooling fan.
Heat moves from the hot refrigerant vapour into the
cooler outside air flowing across the condenser coils
and fins.
When the refrigerant vapour reaches the pressure
and temperature that will induce a change of state, a
large quantity of heat is transferred to the outside air
and the refrigerant changes to a high pressure warm
liquid.
The warm liquid refrigerant continues onto the re-
ceiver/drier where it is filtered and desiccated, to re-
move any moisture, before passing through an
outlet line to the thermostatic expansion valve.
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.
NOTE: any moisture in the air conditioning system is

extremely harmful. Moisture not absorbed by the de-
hydrator will circulate with the refrigerant and drop-
lets may collect and freeze in the thermostatic
expansion valve orifice. This action will block the re-
frigerant flow and stop the cooling action. Moisture
will also react with refrigerant HFC 134a and the lu-
bricant to form a corrosive acid.
The desiccant can only absorb a limited amount of

moisture before reaching saturation point. Because
of this, after any system component replacement or
repairs requiring entry into the system, the receiver/
dryer should be replaced.
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 would
dam-17 age 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.
Expansion valve - operation

All of the needed temperature sensing and pressure
sensing functions are consolidated into this basic
unit and no external tubes are required for these pur-
poses.
The refrigerant from the condenser and receiver dry-
er enters the thermostatic expansion valve as a high
pressure warm liquid. Upon passing through the ball
and spring controlled metering orifice, the pressure
and temperature of the refrigerant is reduced and
the refrigerant leaves the thermostatic expansion
valve as a low pressure, lower temperature atom-
ized liquid. F28691
The atomized liquid now passes through the evapo-

rator where it absorbs heat before returning via the
expansion valve to the compressor as a warm low
pressure vapour. There are two refrigerant passag-
es in the valve. One passage is in the refrigerant line
from the condenser to the evaporator and contains
the ball and spring type orifice valve.
The other passage is in the refrigerant line from the
evaporator to the compressor and contains the
valve’s temperature sensing element.
Liquid refrigerant flow from the condenser and re-
ceiver dryer is controlled by a push-rod forcing the
orifice valve ball off its seat and the spring exerting
pressure on the ball to keep it on its seat.
During stabilized (vehicle shutdown) conditions, the
pressure on the bottom of the expansion valve dia-
phragm rises above the pressure on the top of the di-
aphragm allowing the valve spring to close the
orifice.
When the system is started, the pressure on the bot-

tom of the diaphragm lowers rapidly, allowing the or-
ifice to open and meter atomized liquid refrigerant to
the evaporator where it begins to vaporize.
Suction from the compressor draws the vaporized
refrigerant out of the evaporator and back through a
gallery in the top of the valve which asses the tem-
perature sensor.
The temperature sensor reacts to variations in refrig-
erant gas pressure returning from the evaporator.
When heat from the passenger compartment is ab-
sorbed by the refrigerant the pressure of the gas in-
creases causing a differential pressure above and
below the temperature sensor diaphragm. The dia-
phragm reacts to this pressure differential and a
push rod forces the ball in the expansion valve orifice
further off its seat. This reaction allows an increase
in the atomized refrigerant to flow through the valve,
to the evaporator, so that more heat can be absorbed
by the air conditioning system.
Similarly when the temperature of the gas returning
from the evaporator decreases the pressure of the
gas decreases. This causes the diaphragm to react
accordingly and allow the ball in the orifice to move
closer towards its seat thus reducing the flow of re-
frigerant through the valve to the evaporator.
EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature refrigerant in the evaporator ab-
sorbs heat from the hotter air in the operator’s com-
partment, thereby cooling the air.
Air Recirculation
An intake grille is located on the left side of the seat
base. A portion of the air flow will recirculate through
the evaporator.
Filter General
The blower fan, draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recircula- 2
tion grille (1). The air passes over the evaporator
then into the cab through the six louvered vents.
Two vents are located on the front instrument panel
to direct air onto the windshield. Two are located at
the base of the rear posts to direct air onto the rear
window. Two additional vents are located at the front
and rear of the seat base to direct air at the opera- 1
tor’s feet.
F29327
Blower Fan
The blower motor is controlled by a three-speed
switch (2) 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.
3.4 FAULT FINDING AND TESTING Preliminary fault finding

Always conduct the preliminary fault finding checks
Overhaul of the air conditioning system should only before performance testing the system.
be undertaken by a certified specialist refrigeration 1. Run the engine at 1000-1200 rpm for 10 min-
engineer using a comprehensive air conditioning utes with the air conditioner set at maximum
test kit, including a gas leak detector, suitable for cooling and the blower on high speed.
HFC 134a refrigerant gas. 2. Check that the heater temperature control is
switched OFF.
SWARNING 3. Check that the blower fan is operating at all
speeds.
Before dismantling an air conditioning system for re-
4. Check that the compressor clutch engages
pair the gas within the system must be discharged
when the temperature control switch is turned
and recovered using a certified recovery unit de-
from “OFF” to “ON” position. A clicking sound in-
signed for the type of refrigerant gas used in the sys-
dicates the clutch is engaging. If the clutch fails
tem.
to operate it may indicate an electrical problem
NEVER release refrigerant gas into the atmo-
in the high low pressure cut out switches or mal-
sphere.
function of the electrical drive clutch on the com-
ALWAYS wear safety goggles and gloves when ser-
pressor.
vicing any part of the air conditioning system.
5. Check the engine cooling fan is drawing cool air
To prevent the entry of any foreign material, observe through the condenser.
the following points: 6. Check the compressor drive belt tension.
Z Ensure all tools, gauges, hoses and replacement 7. Check the condenser core and grid is clean and
parts are kept clean and dry and are suitable for free of obstruction.
the type of refrigerant gas used in the system. 8. Check the cab air filter is clean and free of ob-
Z Clean all hoses and fittings before disconnecting. struction.
Z Cap or plug all openings when disconnected. 9. Check the evaporator fins are not plugged or ex-
Z When adding lubricating oil to the system always cessively dirty.
uncap and re-cap the oil container immediately be-
fore and after use. Always ensure the oil remains
free of moisture.
Attaching Manifold Gauge Set to the Loader Backhoe

1. Low Side Gauge 6. Test Hose to Low Side Service Connector
2. High Side Gauge 7. Shut-off Valve
3. Shut-off Valve 8. Low Pressure (Suction) Side Service Valve
4. Test Hose to High Side Service Connector 9. High Pressure (Discharge) Side Service Valve
5. Center Hose (Not Used)
Performance Testing The Air Conditioning Sys- Operating Precautions

tem
The manifold gauge set is the most important tool IMPORTANT: always ensure the shut-off valves are
used in testing and servicing the air conditioning closed (turn clockwise until seated) during all test
system. operations.
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.
Z 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 Z 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.
Attaching The Gauge Set To The Loader Back- 1. Apply the parking brake, check the gearshift le-
hoe vers are in neutral and close the cab windows
and doors.
SWARNING 2. Re-check that both the high and low side shut
To avoid personal injury, stop the loader backhoe off valves on the manifold gauge set are fully
engine during connection of the manifold gauge set. closed.
3. Run the engine at 1000-1200 rpm.
1. Check that the gauge set shut off valves are 4. Turn the heater temperature control ‘off’.
closed (turned fully clockwise). 5. Operate the system at maximum cooling, with
2. Connect the high side gauge hose (normally the blower fan at high speed for 10 minutes to
red) to the high pressure (discharge) side ser- stabilize all components.
vice valve and the low side gauge hose (normal- 6. Check the manifold low pressure gauge reading
ly blue) to the low pressure (suction) side is within the specified range of approximately
service valve on the loader backhoe. Ensure the 0.28-2.48 bar (4-36 psi).
hose connections are fully tightened. 7. Check the manifold high pressure gauge read-
ing and compare the reading to the pressure in-
IMPORTANT: prior to connection of the manifold dicated on the pressure temperature chart
gauge set, identify the suction (low pressure) and below.
discharge (high pressure) service gauge ports. The 8. Measure and compare the temperature of con-
high pressure service valve is always in the line from ditioned air entering the cab through the lou-
the compressor to the condenser. vered air vents with the ambient air at the air
intake filters on the outside of the cab.
The high and low pressure service valves on the If the system is operating correctly the condi-
loader backhoe are spring loaded valve and will be tioned air entering the cab should be 6-9 °C
automatically opened when the test hose is con- (42.8-48.2 °F) cooler than the ambient tempera-
nected. ture of the outside air.
9. If it is confirmed that the system is not operating
NOTE: the test hose must incorporate a valve de- correctly refer to the fault diagnostic charts and
pressor to actuate this type of valve. performance test gauge reading examples on
the following pages for possible corrective ac-
The service valves have a protective cap. This cap tion.
must be removed for test gauge connections and re-
placed when service operations are completed. SWARNING
A significant amount of refrigerant vapour may have
Test Procedure
condensed to a liquid at the service fitting at the high
After the manifold gauge set has been connected
side of the compressor. Use a cloth or other protec-
and before pressure tests can be made, the system
tive material when disconnecting the manifold hose
must be stabilized as follows:
from this fitting to prevent personal injury to hands
and face.
APPROXIMATE HIGH PRESSURE GAUGE READINGS
Ambient air temperature High pressure gauge reading

Degrees F Degrees C bar kgf/cm2 lb/in2
80.6 27 10.0/11.6 10.3/11.8 145/168
84.2 29 11.2/12.7 11.4/12.9 162/184
89.6 32 12.3/13.8 12.5/14.0 178/200
95 35 13.3/15.2 13.6/15.5 193/220
100.4 38 14.5/16.7 14.8/17.0 210/242
105.8 41 16.0/18.3 16.3/18.6 232/265
109.4 43 17.3/20.0 17.7/20.3 251/290
PERFORMANCE TEST DIAGNOSIS
Gauge Readings: Low Pressure - Low

High Pressure - Low
PROBLEM POSSIBLE CAUSE CORRECTION

Evaporator air not cold Low refrigerant charge Perform leak tests and repair
Evacuate system
Charge system, re-test system

Evaporator air warm Extremely low refrigerant charge Perform leak tests and repair
Evacuate system
Charge system, re-test system

Evaporator air cool but not Expansion valve not permitting Check expansion valve as follows:
sufficiently cold sufficient flow
Low pressure switch cutting Stuck valve Set a for maximum cooling
out Low pressure gauge should lower
Expansion valve to evaporator slowly
tube shows considerable If expansion valve is defective:
condensation or frost Discharge system
Too cold to touch Replace expansion valve
Evacuate system
Charge system
Re-test
PERFORMANCE TEST DIAGNOSIS CHART
Gauge Readings: Low Pressure - High

High Pressure - High

Evaporator air warm Improper operation of condenser Inspect for dirty condenser
Liquid line hot (condenser restricting air flow and cooling
outlet to expansion valve
tube) Check operation of condenser
cooling fans. Repair or replace as
needed
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
Gauge Readings: Low Pressure - Low

High Pressure - High

Insufficient cooling Restriction in liquid line Discharge the system
Replace the receiver/drier
Inspect all lines and tubing from
compressor outlet to expansion
valve
Replace if needed
Evacuate the system
Charge the system
Re-test

High Pressure - Low

Evaporator air not cold Internal leak in compressor (reed Discharge the system
valves, gasket, worn or scored Replace the compressor
piston rings or cylinder) Evacuate the system
Charge the system
Re-test
Gauge Readings: Low Pressure - Normal

High Pressure - Normal

Insufficient cooling Low System low on charge. Air or Perform leak test
pressure reading does not moisture present in system Discharge system
fluctuate with changes in Repair leaks
temperature control switch Replace receiver/drier
(pressure should lower until Check oil level
compressor cycles) Evacuate system
Evaporator air not cold Charge the system
Re-test

High Pressure - Normal

Compressor cycles “on” and Defective temperature control Stop engine and shut off A/C
“off” too frequently (thermostatic) switch Replace temperature control switch
Re-test system and check
compressor cycling
EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS

The following examples show typical low and high pressure gauge readings obtained when performance test-
ing the air conditioning system with an ambient temperature of 35 °C (95 °F).
The recommended corrective action is based on a similar fault as identified in the performance test diagnosis
charts.
PERFORMANCE TEST EXAMPLE 1
7 1
6 2
5 4 3
F28697
Performance Test Example 1

1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side low
4. Not used
PROBLEM 3. Check compressor oil to ensure no loss.

Little or no cooling. 4. Evacuate the system.
5. Charge the system.
CAUSE 6. Performance test the system.
Refrigerant slightly low.
DIAGNOSIS
CONDITIONS* System refrigerant is low. May be caused by a small
Low side pressure too low. leak.
Gauge should read 1-2 bar (14.5-29 psi).
NOTE: * test procedure based upon ambient tem-
High side pressure too low. perature of 35 °C (95 °F). For proper high side
Gauge should read 13.3-14.8 bar (193-215 psi). gauge reading for other ambient temperatures, refer
Evaporator air not cold. to the pressure temperature chart.
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Repair leaks. (Discharge and recover the refrig-
erant from the system; replace lines or compo-
nents).
7 1
6 2
5 4 3
F28698

connector 7. Low side normal
4. Not used
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 95 °F. For proper high side gauge read-
CONDITIONS* ing for other ambient temperatures, refer to the
Low side pressure very low. pressure temperature chart.
Gauge should read 1-2 bar (14.5-29 psi).
High side pressure too low.

Gauge should read 13.3-14.8 bar (193-215 psi).
Evaporator air warm.

Low pressure switch cutting out.
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.
7. Performance test the system.
7 1
6 2
5 4 3
F28699

1. High side normal 5. Low side hose connected to low side service
4. Not used
PROBLEM 2. Discharge and recover the refrigerant from the

Insufficient cooling. system.
3. Repair leaks.
CAUSE 4. Replace the receiver/dryer.
Air in system. 5. Check compressor oil to ensure no loss.
6. Evacuate the system.
CONDITIONS* 7. Charge the system.
Low side pressure reading does not change when 8. Performance test the system.
compressor cycles “ON” and “OFF”.
DIAGNOSIS
High side pressure slightly high or slightly low. Air or moisture in system. System not fully charged.
Gauge should read 13.3-14.8 bar (193-215 psi).
Evaporator air not cold. perature of 35 °C (95 °F). For proper high side
gauge reading for other ambient temperatures, refer
CORRECTIVE PROCEDURES to the pressure temperature chart.
1. Leak test the system. Give special attention to
the compressor seal area.
7 1
6 2
5 4 3
F28700

connector 7. Low side high
4. Not used
PROBLEM CORRECTIVE PROCEDURES

Insufficient cooling. 1. Replace the compressor.
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 (14.5-29 psi). perature of 35 °C (95 °F). For proper high side
High side pressure too low. Gauge should read to the pressure temperature chart.
13.3-14.8 bar (193-215 psi).
Evaporator air not cold.

7 1
6 2
5 4 3
F28701

1. High side high 5. Low side hose connected to low side service
connector 7. Low side high
4. Not used
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 (14.5-29 psi). 7. Evacuate the system, and recharge it with the
High side pressure too high. Gauge should read correct quantity of refrigerant.
13.3-14.8 bar (193-215 psi). 8. Performance test the system.
Liquid line hot.
Evaporator air warm. DIAGNOSIS
High pressure switch cutting out. Lack of cooling caused by pressure that is too high
on the high side, resulting from improper operation
CORRECTIVE PROCEDURES of condenser. (Refrigerant charge may be normal or
1. Check belt. Loose or worn drive belts could excessive).
cause excessive pressures in the compressor
head. NOTE: * test procedure based upon ambient tem-
2. Look for clogged passages between the con- perature of 35 °C (95 °F). For proper high side
denser fins and coil, or other obstructions that gauge reading for other ambient temperatures, refer
could reduce condenser airflow. to the pressure temperature chart.
3. If engine is overheating replace engine thermo-
stat and radiator pressure cap.
7 1
6 2
5 4 3
F28701

connector 7. Low side normal
4. Not used

Insufficient or no cooling. 1. Discharge and recover the refrigerant from the
system.
CAUSE 2. Replace the receiver/dryer.
Large amount of air in system. 3. Evacuate the system.
CONDITIONS* 5. Performance test the system.
Low side pressure too high. Gauge should read 1-2
bar (14.5-29 psi). DIAGNOSIS
Air in system. This, and the moisture in the air, is
High side pressure too low. Gauge should read contaminating the refrigerant, causing the system to
13.3-14.8 bar (193-215 psi). operate improperly.
Evaporator air not cold. NOTE: * test procedure based upon ambient tem-
perature of 35 °C (95 °F). For proper high side
to the pressure temperature chart.
7 1
6 2
5 4 3
F28704

1. High side high 5. Low side hose connected to low side service
connector 7. Low side hide
4. Not used
PROBLEM 2. If the test indicates that the expansion valve is

Insufficient or no cooling. defective, proceed as follows:
Discharge and recover the refrigerant from the
CAUSE system.
Improper operation of thermostatic expansion valve Replace the expansion valve.
(stuck open). Evacuate the system.
Charge the system.
CONDITIONS* Performance test the system.
Low side pressure too high. gauge should read 1-2
bar (14.5-29 psi). DIAGNOSIS
Thermostatic expansion valve is allowing too much
High side pressure too high. Gauge should read refrigerant to flow through the evaporator coils.
13.3-14.8 bar (193-215 psi). Valve may be stuck open.
Evaporator air warm. NOTE: * test procedure based upon ambient tem-
perature of 35 °C (95 °F). For proper high side
Evaporator and suction hose (to compressor) sur- gauge reading for other ambient temperatures, refer
faces show considerable moisture. to the pressure temperature chart.
1. Check for sticking expansion valve as follows:
Operate the system at maximum cooling.
Check the low side gauge. The pressure should
lower slowly.
7 1
6 2
5 4 3
F28705

4. Not used
PROBLEM Check the low side gauge. The pressure should

Insufficient cooling. lower slowly.
2. If the procedure outlined in Step 1 shows that
CAUSE the expansion valve is defective, proceed as fol-
Improper operation of thermostatic expansion valve lows:
(stuck open). Discharge system.
Replace the expansion valve.
CONDITIONS* Evacuate the system.
Low side pressure too low (zero or vacuum). Gauge Charge the system.
should read 1-2 bar (14.5-29 psi). Performance test the system.
High side pressure low. Gauge should read 13.3- DIAGNOSIS
14.8 bar (193-215 psi). Expansion valve is not permitting a sufficient flow of
refrigerant. May be caused by valve stuck in restrict-
Evaporator air cool, but not sufficiently cold. ed or closed position.
Evaporator inlet pipe surface shows considerable NOTE: * test procedure based upon ambient tem-
moisture or frost. perature of 35 °C (95 °F). For proper high side
Low pressure switch cutting out.
1. Place finger on expansion valve to evaporator
tube. If too cold to touch, proceed as follows:
7 1
6 2
5 4 3
F28706

4. Not used

Insufficient or no cooling. 1. Check for sticking expansion valve as follows:
CAUSE Check the low side gauge. The pressure should
Restriction in high side of system. lower slowly.
2. If the test indicates that the expansion valve is
CONDITIONS* defective, proceed as follows:
Low side pressure too low. gauge should read 1-2 Discharge and recover the refrigerant from the
bar (14.5-29 psi). system.
Replace the expansion valve.
High side pressure too low. Gauge should read
Evacuate the system.
13.3-14.8 bar (193-215 psi).
Charge the system.
Performance test the system.
NOTE: a normal or high reading of the high side
pressure gauge under these conditions indicates DIAGNOSIS
the system is overcharged or the condenser or re- Thermostatic expansion valve is allowing too much
ceiver/dryer is too small. refrigerant to flow through the evaporator coils.
Valve may be stuck open.
Evaporator only slightly cool.
Liquid line and receiver/dryer are cool to touch and perature of 35 °C (95 °F). For proper high side
show frost or considerable moisture. gauge reading for other ambient temperatures, refer
7 B A 1
6 2
5 4 3
F28707

connector 7. Low side gauge
4. Not used Compressor cycles on at 2.3 bar (33 psi)
Compressor cycles off at 1.9 bar (28 psi)
PROBLEM 3. Make sure the switch’s temperature sensor is in-

Compressor cycles (cuts in and out) too rapidly. stalled in the same position and depth (in evap-
orator core) as previous.
CAUSE 4. Performance test the system.
Thermostatic switch defective.
DIAGNOSIS
CONDITIONS* Defective thermostatic switch.
Low side pressure readings too high during both
“ON” and “OFF” compressor cycles and between NOTE: * test procedure based upon ambient tem-
cycles. perature of 35 °C (95 °F). For proper high side
Readings should be: gauge reading for other ambient temperatures, refer
0.8-1.0 bar (11.6-14.5 psi) - cycle “OFF” to the pressure temperature chart.
2.5-2.7 bar (36-39 psi) - cycle “ON”
1.7-1.9 bar (25-28 psi) - between cycles
High side pressure normal. Gauge should read

13.3-14.8 bar (193-215 psi).
1. Stop the engine and shut off A/C system.
2. Replace thermostatic switch with switch of same
type.
LEAK TESTING, DISCHARGING AND CHARGING THE AIR CONDITIONING SYSTEM
Leak Testing
To perform a leak test if refrigerant leakage is sus-
pected, use a leak detector following the manufac-
turer’s instructions.
Leak detectors use light or sound dependent upon
the type used to alert the operator of a leak. If the
leak detector’s sensitivity is adjustable, be sure you
calibrate the detector according to the manufactur-
er’s instructions before use.
When using a leak detector, keep in mind that a very
slight amount of leakage in the compressor pulley
area is normal and does not necessarily indicate a
repair is required. F28708
When a leak is located, follow these steps.

Z Discharge the system using a certified refrigerant
recovery system.
Z Repair the leak.
Z Evacuate the system.
Z Partially charge system with 400 gr (14 ozs) of re-
frigerant.
Z Check system for leaks.
Z Fully charge the system.
Always check the system for leaks as a final test af-
ter evacuating and before recharging. Refer to
“Evacuating the system”.
Discharging the system

Legislation has been introduced banning the release
of refrigerant into the atmosphere.
Whenever overhauling the air conditioning system
or performing other tasks which require the air con-
ditioning system to be dismantled it is necessary to
discharge the refrigerant gas before commencing
repair.
Before you can dismantle an air conditioning system
for repairs, you must discharge and recover the re-
frigerant using a certified recovery unit in accor-
dance with the manufacturers instructions.
Shown is a combined refrigerant recovery, evacua-
tion and recycling/charging station. This equipment
removes HFC 134a refrigerant from the air condi-
tioning system, recycles and recharges all in one
hook up.
The unit is designed to be used with the manifold
gauge set built into the control panel.
F28709
Connecting recovery evacuation and recycling/charging station to the loader backhoe

1. Built in manifold gauge set 3. Low side (suction) service valve (blue hose)
2. Recovery/recharging unit 4. High side (discharge) service valve (red hose)
Other recovery systems are available where the

manifold gauges are not an integral part of the ma- NOTE: if a unit requiring the manifold gauge set is
chine. When this type of equipment is used a sepa- being used, the low and high sides of the manifold
rate manifold gauge set must be used. set are connected to the low and high sides of the
The following is a summary of the steps for dis- loader backhoe air conditioning system. The hose
charging the system using a recovery/recycling unit. from the recovery unit is then connected to the man-
ifold center port.
SWARNING
Never discharge refrigerant gas into the atmo- 3. To recover refrigerant, open both high and low
sphere. Always wear safety goggles and gloves side valves on the control panel or the valves on
when working with refrigerant. Only use authorized the manifold gauge set if being used.
refrigerant tanks. 4. Open the valves labelled “gas” and “liquid” on
the recovery unit refrigerant tank.
5. Plug in the unit’s power cord.
IMPORTANT: always follow the manufactures in- 6. Operate the recovery system in accordance with
structions when operating recovery equipment. the manufacturers instructions.
The compressor will shut off automatically when the
1. Run the vehicle’s air conditioning system for a recovery is complete.
few minutes.
2. Set up the recovery unit following manufactur-
er’s instructions. Ensure that the units red (high
side) low side (suction) service valve (blue
hose) high side (discharge) service valve (red
hose) hose is connected to the high side (dis-
charge) fitting and the blue (low side) hose to
the low side (suction) fitting.
3.5 FLUSHING THE SYSTEM
7 1
6 2
5 4 3
F28711
Manifold side gauge

1. High side gauge 5. Low side hose
2. High side shut-off valve 6. Low side shut-off valve
3. High side hose 7. Low side gauge
4. Center service hose
Air conditioning systems may occasionally become

contaminated with solid particles. This contamina-
tion may be the result of allowing dirt to enter the
system while it was open, from aluminium corrosion
or sludge, or from disintegrated compressor reed
plates. Contamination of this nature can result in
plugged evaporators, condensers and expansion
valves.
Flush System with dry nitrogen
Each individual component must be flushed after

disconnecting every hose fitting.
The compressor and expansion valve can not be

flushed, therefore, the compressor should be disas-
sembled and cleaned or replaced and the expan-
sion valve should be replaced. When flushing the
system always replace the receiver/drier.
NOTE: Never use any solvent for flushing an air con-

ditioning system other than a special flush solvent
made specifically for air conditioning systems. Al-
ways follow the manufacturer’s recommendations
and directions for using the flushing equipment and
solvent.
Re-assemble and evacuate the system to remove

air and moisture as described in “Evacuating the
System”.
F28712
3.6 EVACUATING THE SYSTEM
Fully open both the low and high side gauge

IMPORTANT: a system in which the refrigerant has shut off valves.
been recovered to facilitate repairs, must be evacu- 2. If a combined recovery/evacuation unit is to be
ated before new refrigerant is installed. used attach the unit to the air conditioning sys-
tem in accordance with the manufacturers in-
Air and moisture are removed by evacuating the structions. Be sure to read all installation and
system using a vacuum pump. operating instructions carefully before starting
The automatic recycling, recharge and evacuation the unit.
stations or evacuating and charging stations avail- 3. After starting the evacuation cycle, note the low
able throughout the air conditioning industry incor- side gauge to be sure the system pulls down
porate a vacuum pump within the assembly. If this into a vacuum.
type of equipment is not available a separate vacu- 4. Time the evacuation for a minimum of 30 min-
um pump and manifold gauge set must be used. utes from the point when lowest vacuum is at-
As the system is evacuated the boiling point of any tained.
moisture within the system is similarly lowered. As 5. Thirty minutes later when the low side gauge at-
the vacuum increases the boiling reduces to below tains the lowest steady vacuum, stop the evac-
that of the ambient temperate and the moisture is uation process.
subsequently boiled away.
The relationship of system vacuum to the boiling NOTE: the vacuum pump achieves ultimate vacu-
temperature at which the water vapour is removed um with the vented exhaust valve closed. Do not
from the system is as follows: evacuate too quickly as oil may be drawn from the
system.
System System 6. Check the system by closing the gauge shut-off
Temperature
Vacuum Vacuum valves, turning the vacuum pump off and noting
In In Cm. of the low side gauge reading. A loss of more than
°F °C 2² (5 cm) of vacuum in 5 minutes indicates either
Mercury Mercury
a leak or moisture in the system.
28.0 71.0 100 38 7. If the gauge needle remains stationary and the
28.9 73.4 80 27 vacuum is maintained for 3-5 minutes, close
both the high and low side manifold hand
29.4 74.6 60 16 valves, turn off and disconnect the center hose
29.7 75.4 40 5 from the pump. The system is now ready for
charging.
29.8 75.7 20 -7 8. If a leak is detected, charge the system with ap-
29.9 75.9 0 -18 proximately 14 ozs (400 g) of refrigerant, see
charging the system and locate the leak using a
leak detector.
9. Once the leak is located discharge and recover
NOTE: for every 1000 feet (305 m) above sea level,
the refrigerant in the system, repair the leak,
the vacuum gauge reading must be corrected by
then repeat the evacuation procedure.
adding 1² (2.54 cm) of mercury to compensate for
the change in atmospheric pressure.
IMPORTANT: be sure the system is completely dis-

charged as refrigerant will damage the vacuum
pump.
1. If the manifold gauge set is being used connect

the low and high sides of the manifold to the low
and high sides of the vehicle air conditioning
system as described for discharging the system.
Connect the manifold center hose to the vacu-
um pump suction port as per the manufacturers
instructions.
3.7 CHARGING THE SYSTEM 5. If the refrigerant charge will not completely
transfer to the air conditioning system, recover
and recharge the system.
IMPORTANT: be sure there are no leaks in the sys- 6. Close the high and low side valves on the units
tem and the system has been fully evacuated. Ob- control panel, or manifold gauge set if being
serve all safety recommendations when handling used and test the air conditioning as detailed in
refrigerant HFC 134a, see “Precautions when Han- Performance testing the air conditioning system
dling Refrigerant HFC 134a” in this Section. on Page 15.
1. Ensure the charging unit is correctly connected NOTE: after charging a system use the following
to the loader backhoe air conditioning system in start up procedure to ensure the lubricating oil is
accordance with the manufacturers instructions. properly dispersed around the system:
2. If a charging unit, in conjunction with the mani-
fold gauge set is used, open the high and low Z Ensure air conditioning is switched OFF.
side hand valves on the manifold. Z Start the engine and bring speed down to idle.
3. Charge the system with 0.75 kg (1.65 lbs) of re- Z Turn the air conditioning ON and allow system to
frigerant as per the manufacturers instructions. operate for at least one minute before increasing
4. If the charging rate becomes very slow close engine speed.
the high side valve carefully, start the loader
backhoe and set engine speed to idle. Turn ‘ON’
the air conditioning so that the compressor can
pull the remainder of the refrigerant into the sys-
tem.
Connecting recovery evacuation and recycling/charging station to the loader backhoe

1. Built in manifold gauge set 3. Low side (suction) service valve (blue hose)
2. Recovery/recharging unit 4. High side (discharge) service valve (red hose)
3.8 COMPONENTS OVERHAUL
GENERAL
S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.
If an air conditioning component is to be replaced

during a system overhaul it is necessary to drain any
refrigerant oil that has collected in the component
being replaced into a clean calibrated container.
A volume of clean refrigerant oil equivalent to that re-
moved from the replaced component must then be
added to the new item before being installed onto the
loader backhoe.
Upon completion of the repair evacuate, recharge,
leak test and performance test the system to ensure
correct operation.
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 Allen screw securing the inlet and
outlet connections to the valve and pull valve
from tubing.
5. Replace the ‘O’ ring seals and lubricate with re-
frigerant oil prior to installing the valve using dis- F28714
assembly procedure in reverse.

6. Evacuate, leak test and recharge the system.
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.
AIR CONDITIONER TEMPERATURE CYCLING

CONTROL
1. Remove the seat mounting plate.
2. The temperature cycling switch (2) is mounted to
the side of the blower motor assembly.
3. Carefully pull and disconnect the switch wiring at
the connector.
4. Remove temperature control switch and replace
as required.
LOW PRESSURE CUT-OUT SWITCH

1. With the engine “OFF” check continuity across
the switch contacts. If the switch (1) shows open
circuit replace as detailed below.
IMPORTANT: the pressure switch can not be re-

placed without discharging the system.
2. Remove switch by unscrewing from self sealing

Schrader valve.
3. Replace with new switch and connect to har-
ness.
BLOWER MOTOR ASSEMBLY

The blower motor (2) can if required be removed
without discharging the system as follows:
1. Remove the cab seat mounting plate.
NOTE: take care not to damage hoses during this

operation. If the cab heater hoses restrict movement
of the housing drain the heater assembly and dis-
connect the hoses.
2. Disconnect the motor wiring connector block.

3. Remove the remaining motor securing screws
and withdraw motor.
4. Re-assembly follows the disassembly procedure
in reverse.
RECEIVER DRYER
The receiver/dryer (3) cannot be overhauled and
must be replaced as an assembly. The receiver/dry-
er assembly should be replaced if it is suspected that
moisture is in the system.
The receiver dryer must also be replaced if the sys-
tem has been discharged and the air conditioning
joints disconnected.
1. Discharge and reclaim refrigerant gas using cer-
tified recovery systems.
2. Disconnect the hoses and switch and remove
the dryer from the loader backhoe.
3. Drain the refrigerant oil from the receiver dryer
into a clean calibrated container. Measure the
quantity of oil obtained and add the same quan-
tity of new refrigerant oil directly into the ne-
witem.
4. Cap and plug all fittings to prevent any dirt enter-
ing the system.
5. Install a new receiver dryer.
CONDENSER
1. Unscrew and remove the fixing screw (2). Re-
move the front grill (1).
2. Unscrew and remove the nut (3). Remove the

horn (4). Unscrew and remove the nut (5). Re-
move the fuel cooler (6).
3. Unscrew and remove the fixing upper nut (7) and

loosen the fixing lower nut. Move the dryer filter
(8) to the right side.
4. Unscrew and remove the nuts (9).

5. Move the condenser (10) forward.

Clean the condenser (10) by compressor air.
CAB AIR FILTER

1. Before servicing the filter (1), switch off the blow-
er and close all windows and one door. Slam the
final door closed and the resulting back pressure
will dislodge most of the loose dirt from the un-
derside of the filters.
2. Remove the filter (1) element and clean by blow-
ing with compressed air not exceeding 2 bar (30
lbf/in2).
IMPORTANT: make sure you protect your face be-

fore using compressed air.
Blow the dust from the upper surface through the

element to the underside. Hold the nozzle at
least 12 in (300 mm) from the element to prevent
damage to the paper pleats.
3. Clean both filter chambers with a damp, lint free
cloth.
4. Replace the filter element with the rubber seal
uppermost and re-install the covers.
3.9 COMPRESSOR
TECHNICAL SPECIFICATIONS
Basic compressor specifications

Displacement ............................................................................................................................ 155 cc (9.46 in3)
Weight .......................................................................................................................................... 9.9 kg (22 lbs)
Oil type ....................................................................................................................................................... SP20
Rotation.............................................................................................................................. CW (Clockwise only)
Compressor clutch and pulley air gap.....................................................................0.9-0.8 mm (0.035-0.031 in)
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
Assembly torques
ITEM Nm lbf·ft
Armature retaining nut, M8 17.7±2.9 13±2.1
Cylinder head bolts, M6 13.7±2.9 10±2.1
Cylinder head bolts, M8 34.3±4.9 25.3±3.6
Clutch dust cover screw, M5 9±2 6.6±1.5
Oil filler plug 19.6±4.9 14.5±3.6
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.

Unusually high suction Valve plate test Replace or repair:
pressure with unusually low Broken head or block gasket
discharge pressure Broken or deformed reed valve
Foreign substance under reed valve
or gasket
Unusually low suction and Check for low refrigerant charge Replace or repair:
discharge pressure Shaft seal leak
Leak check compressor Cylinder head leak
Gasket leak
Leak check and diagnose system Oil filler plug leak
Cracked cylinder block
Front housing O-ring leak
Intermittent or inoperative Check belt tension Replace
Check clutch air gap Adjust air gap
Check clutch volts, amps, coil lead Replace or repair:

wire Broken lead wire
Clutch coil defect - Internal
System ground (see system manual)
Rough running Shaft turning smoothness test Compressor failure - Internal

Clutch engaged Check compressor mounting Replace or repair
components
Check engine components Replace or repair
Check for intermittent or slipping Adjust air gap - defective coil

clutch
Check for proper refrigerant charge Recharge and recheck
Check clutch bearing Replace rotor / Armature assembly
Oil level procedure Restore to proper level
Shaft turning smoothness test Compressor failure (Internal)
Remove valve plate and inspect Replace or repair:

Broken discharge valve reed or
retainer
Broken suction valve reed
Broken gasket
Clutch disengaged Check air gap Replace or repair:
“chattering” Adjust air gap
Defective clutch pulley or front plate
REMOVAL AND INSTALLATION
13
10
7
12
11 1
7 2
5
8
14
9
1 3 6 5
F28721
Removal
Discharge the air conditioning system. Disconnect
the electrical harness of the compressor (12) from
the electrical harness of the engine. Disconnect tub-
ing to compressor. Remove the washer (7) and the
screw (1). Remove the protective guard (13). Re-
move the bolt (11). Remove the nut (14) and the
screw (9).
Remove the washers (5), the nut (6), the screw (2)
and the block (8). Remove the screw (1), the wash-
ers (3) and the belt tensioner (4). Remove the screw
(10), the washers (2) and the compressor (12).
Installation
Installation is the reversal of the removal but the fol-
lowing points should be noted:
Z Torque the mounting bolts to 40-51 Nm (29 - 38
lbf·ft).
NOTE: it is recommended that a new receiver/drier

assembly is installed after any system component
replacement or any repair that requires entry into
the system.
Z Drain the oil from the new compressor to be fitted

into a clean container, or if the old compressor is to
be refitted, obtain a new can of refrigerant oil. F28723
Z Calculate the amount of oil to be installed and refill

the compressor.
Z Reconnect the hoses to the compressor and tight-
en all bolts and hoses.
After charging a system use the following start up

procedure to ensure the lubricating oil is properly
dispersed around the system:
Z Ensure air conditioning is switched “OFF”.
Z Start the engine and bring speed down to idle.
Z Turn the air conditioning “ON” and allow system to
operate for at least five minutes before increasing
engine speed.
A correctly tensioned belt can be deflected 13-19

mm (0.50-0.75 in) when hand pressure is applied
midway between the alternator and crankshaft pul-
ley.
Once adjusted re-torque the tension arm bolt to 33.9
Nm (25 lbf·ft).
F28725
The compressor drive belt (1) can be tensioned by

rotation of the idler arm (2). Slacken the idler arm
bolt and adjust the arm to a belt deflection of 16 mm
(0.63 in).
Once adjusted re-torque the tension arm bolt to 33.9
Nm (25 lbf·ft).
F28726
OVERHAUL COMPRESSOR
Before any internal repair is done, drain the oil from
the compressor:
Z Remove the oil plug and drain as much oil as pos-
sible into a suitable container.
Z Remove the caps (if present) from suction and dis-
charge ports.
Z Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retain-
CC
ing nut.
F28727
Z Measure and record the amount of oil discharged.

Z Inspect the oil for signs of contamination such as
discoloration of foreign material.
F28728
CLUTCH
1 2 3 4 5 6 7 8 9 10
F28729
1. Armature dust cover screw 6. Rotor bearing snap cover

2. Armature dust cover 7. Rotor snap ring
3. Shaft nut 8. Rotor assembly
4. Armature plate 9. Field coil snap ring
5. Clutch shims 10. Field coil assembly
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 armature dust cover (2) is present, re-
move the 3 or 6 bolts (1) holding it in place and re-
move cover. If auxiliary sheet metal pulley is
present, remove the screws holding it in place. The 4
remove pulley.
Attach tool to the cover on the front of the clutch
plate and placing a socket and ratchet through the
tool remove the cover attaching nut (3).
F28730
Using the front plate tool and a tommy bar hold the
clutch plate stationary.
Place the bolt into the tool and by tightening the bolt
onto the end of the shaft the front plate will be ex-
tracted from the shaft.
If shims (5) are above shaft key, remove them now.
If shims (5) are below shaft key, the key and bearing
dust cover (if present) must be removed before
shims can be removed.
Remove bearing dust cover (6) (if present). Use
caution to prevent distorting cover when removing it.
Remove shaft key by tapping loose with a flat blade
screwdriver and hammer. Remove shims (5). Use a F28731
pointed tool and a small screwdriver to prevent the

shims from binding on the shaft.
Remove the rotor snap ring (7), remove the shaft

key and lift the pulley assembly from the compres-
sor.
F28732
Inspect the rotor assembly (8) for wear and replace

the assembly as necessary.
8
F28733
Remove the field coil wire retaining clip.
F28734
Remove the coil snap ring (9).
F28735
Lift the coil (10) from the housing and replace as re-
quired. 10
F28736
Assembly
Install the coil (10), ensuring that the wire is located
back at cable clip on the outside of the body and
snap ring (9) is placed in the groove. 10
F28737
Position the rotor (8) on the housing hub and care-

fully slide the rotor (8) down the shaft.
F28738
Install the snap ring (7).
F28732
Replace the armature plate (4) and retaining nut and

tighten to a torque of 18 Nm (13 lbf·ft).
F28730
Check the clearance between the armature plate (4)

and rotor (8). This should be consistent around the
circumference and be between 0.4-0.8 mm (0.015- 4
0.030 in.)
NOTE: if the air gap is not consistent, lightly pry up

on the counter weighted front plate at the low spots
or lightly tap down at the high spots.
8
F28741
If the clearance is not within specification the shims

(5) under the front plate should be added to or sub-
5
tracted from, until the correct clearance is obtained.
NOTE: new shims are available in sizes 1.00, 0.50

and 0.13 mm, (0.040, 0.020 and 0.005 in.).
Replace armature dust cover (2) if present and

torque 3 on 6 bolts (1).
F28742
COMPRESSOR
5 6 7 8 9 10
1 3
2 4
F28743
Air conditioning refrigerant compressor

1. Shaft key 6. Gasket
2. Ring 7. Plate
3. Snap ring 8. Head gasket
4. Gasket 9. Cylinder head
5. Plug 10. Screw
Removal
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior
to replacing the shaft seal.
Z Remove the armature plate, as detailed in the
steps of clutch disassembly.
Z Remove the shaft key (1), shims and felt lubrica-
tion ring (2) to expose the snap ring (3). 3
Z Remove the shaft seal retaining snap ring (3).
F28744
Insert the gasket remover/installer tool (A).

Twist the tool to engage the slots in the gasket. Pull
up to remove and discard the gasket (4). A
F37893
Installation
Thoroughly clean the seal cavity in the hub. Use “lint
free” cloth only.
Ensure the new shaft seal O-ring is installed onto
the seal assembly. Dip the new seal assembly in
clean refrigerant oil and attach to the seal remover/
installer tool.
F28746
Insert the new gasket (4) fully into the hub.
NOTE: if remover/installer tool (A) is not available, A

position the seal squarely in the hub and tap gently
until fully seated. 4
F37894
Install the snap ring (3). If the snap ring has a bev-
elled edge this should face outwards.
F28744
Install a new ring (2) and push into position.
F28713
Position the shims over the shaft and refit the shaft
key.
Reinstall the armature plate as described in clutch
reassembly.
F28911
CYLINDER HEAD
Disassembly
Drain the refrigerant oil from the compressor into a
clean calibrated container.Measure and record the 10 9
quantity of oil obtained. This information is required
during installation of the new or overhauled unit.
Remove the six cylinder head screws (10) and using
a hide mallet, gently tap the cylinder head (9)
free.The use of a gasket scraper may also be re-
quired to free the cylinder head from the compressor
body.
F28747
If the plate (7) and/or cylinder head are to be reused,

carefully remove the gasket (8) using a suitable 7
scraper.
F28748
Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage. 7
F28749
Reassembly
Coat the top of the valve plate with clean refrigerant
oil and reassemble the cylinder head using the re-
verse of the disassembly procedure.
When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins
in the cylinder block.
Install the cylinder head bolts and tighten using the
sequence shown. Torque initially to 20 Nm (14 lbf·ft)
then finally to 34 Nm (24 lbf·ft).
When the overhaul is complete add to the compres-
sor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.
F28750
OIL RETAINED IN SYSTEM COMPONENTS

After replacement of individual system components it
will be necessary to add some oil to the system to
make up the amount lost in the removed component.
The table below shows some typical volumes for the
components. It is, however, still recommended that
the oil level measurement, described previously is
carried out after a new component has been installed
to establish correct oil quantity.
Typical oil amount

Component
fl.oz. cc
Accumulator 2.0 60
Evaporator 2.0 60
Condenser 1.0 30
Receiver/drier 0.5 15
Hoses 0.3 10
Preliminary Inspection
1. Rotate the compressor shaft. Use a suitable
socket on the hub center bolt or by hand using
the rubber dampers.
If severe roughness is felt while rotating the hub,
the compressor should be disassembled.
2. Using a 12 V battery check current drawn by the
field coil which should be between 3.6-4.2 Amps.
Very high current readings indicate a short sys-
tem 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
should be 51 approximately 3.0 Ω at 20 °C F28751
(68°F).
A poor ground connection of the field coil will re-
sult in a low voltage.
3. Ensure clutch is disengaged and rotate pulley by
hand. If roughness in the bearing is felt, it will be
necessary to replace the pulley and bearing as
an assembly.
F28752
3.10 SPECIAL TOOLS
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.
PIN DESCRIPTION USE

380000315 Recovery / recharge portable system Discharging and recovering of the
refrigerant
380000312 Evaporator and condenser cleaner Evaporator and condenser cleaning
380000314 Electronic gas leak detector Leak testing
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 55 - ELECTRICAL SYSTEM
1. GENERALITIES............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B90B) ............................................................ 5
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B90B)............................................................. 22
2.3 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B95B - B110B) ............................................ 42
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B95B - B110B)............................................... 56
2.5 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (B110B)................................................................. 73
2.6 ELECTRICAL DIAGRAMS - POWERSHIFT 4WS CAB (B115B) ........................................................ 89
3. CONTROLS AND INSTRUMENTS .......................................................................................................... 106
3.1 FRONT INSTRUMENT PANEL ......................................................................................................... 106
3.2 CALIBRATION OF SPEEDOMETER ................................................................................................ 108
3.3 SIDE INSTRUMENT PANEL (B90B) ................................................................................................. 109
3.4 SIDE INSTRUMENT PANEL (B95B - B110B - B115B) ..................................................................... 111
3.5 SIDE INSTRUMENT CLUSTER (B90B) ............................................................................................ 113
3.6 SIDE INSTRUMENT (B95B - B110B - B115B).................................................................................. 115
3.7 IMMOBILISER SYSTEM.................................................................................................................... 117
4. DIAGNOSTICS DISPLAY (B95B - B110B - B115B)................................................................................. 118
4.1 SYMBOLS.......................................................................................................................................... 120
4.2 SETUP MENU ................................................................................................................................... 121
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 122
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 123
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 124
4.6 WORK HOURS.................................................................................................................................. 125
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 126
4.8 MAINTENANCE................................................................................................................................. 132
4.9 WARNING MESSAGES .................................................................................................................... 133
2 SECTION 55 - ELECTRICAL SYSTEM
5. STARTING SYSTEM ................................................................................................................................ 139

5.2 FAULT FINDING ................................................................................................................................ 140
5.3 STARTER MOTOR ............................................................................................................................ 143
6. ALTERNATOR .......................................................................................................................................... 149
6.3 COMPONENTS ................................................................................................................................. 151
6.4 REMOVAL.......................................................................................................................................... 152
6.5 PRELIMINARY CHECK AND TESTS ................................................................................................ 153
6.6 FAULT FINDING ................................................................................................................................ 162
7. BATTERY.................................................................................................................................................. 163
7.3 REMOVAL AND INSTALLATION ...................................................................................................... 164
7.4 MAINTENANCE ................................................................................................................................. 166
7.5 TESTS................................................................................................................................................ 168
7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 170
7.7 BATTERY MASTER SWITCH ........................................................................................................... 170
8. COMPONENT TESTING .......................................................................................................................... 171
8.1 GENERAL INTRODUCTION ............................................................................................................. 171
8.2 COMPONENT TESTING ................................................................................................................... 172
8.3 GROUND POINTS............................................................................................................................. 172
8.4 KEY-START AND STOP SWITCH .................................................................................................... 174
8.5 ALTERNATOR ................................................................................................................................... 175
8.6 TRANSMISSIONS ............................................................................................................................. 175
8.7 PARKING BRAKE SWITCH............................................................................................................... 179
8.8 CAB.................................................................................................................................................... 180
8.9 4WD SWITCH .................................................................................................................................... 185
8.10 BRAKE PEDAL SWITCHES ............................................................................................................ 185
8.11 BRAKE OIL LEVEL LAMP ............................................................................................................... 186
8.12 FRONT WORK LAMP SWITCH - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH ......... 186
8.13 HAZARD SWITCH ........................................................................................................................... 187
8.14 FLASHER RELÈ .............................................................................................................................. 187
8.15 MULTI FUNCTION SWITCH............................................................................................................ 188
8.16 FRONT WIPER MOTOR (1) - REAR WIPER MOTOR (2) .............................................................. 188
8.17 4WS -STEERING SELECTOR SWITCH ......................................................................................... 189
8.18 STEERING CONTROL UNIT........................................................................................................... 190
8.19 4WS REAR AXLE STEERING SENSOR......................................................................................... 192
8.20 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 192
8.21 STEERING SOLENOID VALVE....................................................................................................... 193
8.22 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 194
8.23 LOADER .......................................................................................................................................... 195
8.24 BACKHOE........................................................................................................................................ 197
8.25 REVERSING BUZZER..................................................................................................................... 200
8.26 FUEL LEVEL INDICATOR ............................................................................................................... 201
SECTION 55 - ELECTRICAL SYSTEM 3
1. GENERALITIES
1.1 TEMPORARY WIRING HARNESS REPAIR
The following method to repair wiring is a temporary

expedient only. Wiring should be replaced as soon
as possible. Replacement of temporary repaired ca-
bles with new is particularly important if the loader
backhoe is to be used for spraying as chemicals can
enter the repaired area, travel up the cable and dam-
age electrical components. Do not attempt to repair
the wire on any system sensors as these are sealed
and should only be replaced with a new component.
NOTE: when conducting a cable repair it is impor-

tant that only RESIN CORED SOLDER is used. Use
of other types of solder ma result in further cable
damage.
To carry out a temporary repair, proceed as follows:

Z Locate damaged portion of cable then cut away
outer protective cover on both sides of the dam-
aged area.
Z Peel back the cable from both ends of the dam-
aged area and carefully cut away the inner cable
cover at the damaged area and strip about 13 mm
(1/2 inch) of insulation from the wires. Do not cut
away any wire strands.
Z Using a suitable solvent, clean about 2 inches
(50 mm) from each cover end. Clean the grey ca-
ble cover and the individual leads.
Z Twist two bare leads together for each damaged

lead, being careful to match wire colors, then sol-
der the leads using resin cored solder. Tape each
repaired lead with vinyl insulation tape.
Z Wind a layer of vinyl insulation tape up to the grey
cable cover at each end of the repair section. Make
a paper trough, Figure 3, then apply silicon rubber
compound (non hardening sealant) over the re-
paired section up to the cover ends. Sufficient seal-
ant must be used to fill the ends of the cut away
area.
Z Allow the compound to cure then cover the area

with insulating tape taking the tape well over each
end of the repair. An overlap of at least 2 inches
(50 mm) of tape at each end is necessary.
Z Check to ensure the repair is satisfactory and se-
cure the repaired cable so that repeat damage is
avoided.
NOTE: this is a temporary repair only. Ensure the

damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.
1.2 FAULT FINDING

Check battery open circuit voltage
Loose or corroded battery
for 12.6 V minimum.
connections
Check electrolyte level and specific
Clean and tighten connections
gravity.
Sulphated batteries
Electrical system is inoperative
Re-instate isolator switch.
Battery Isolator switch turned
“off”
Establish reason of failure and
Main machine fuse link blown
replace fuse link.
Clean and tighten loose
Loose or corroded connections
connections.

Low battery output
Starter speed low and engine for 12.6 V minimum.
cranks slowly Check electrolyte level and specific
gravity.
Use correct viscosity oil for

Incorrect viscosity engine oil
temperature conditions.
Transmission shift lever in gear Place shift lever in neutral.
Loose or corroded connections Clean and tighten loose

Starter inoperative
connections.
Dead batteries Charge or replace batteries.

Low engine idle speed Increase idle speed.
Loose belt Check belt tension.
Charge indicator lamp stays on Malfunctioning battery Check battery open circuit voltage
with engine running for 12.6 V minimum.
gravity.
Malfunctioning alternator Check alternator.

Clean and tighten connections.
Loose or corroded terminal
connections
Sulphated batteries
for 12.6 V minimum.
Batteries will not charge
gravity.
Check automatic belt tensioner.

Loose or worn belt
Replace belt if required.
Charge indicator flashing
indicating excessive charging Malfunctioning alternator Check alternator.
voltage
2. ELECTRICAL DIAGRAMS
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B90B)
FUSES AND RELAYS DESCRIPTION K1 Forward-reverse travel gearshift relay

Fuse K2 Parking brake engaged relay
Rating Function
No. K3 Starting relay
F1A K4 Bucket level solenoid valve relay
Engine stop, (+15) anti-theft device, K6 Inner front work light relay
F1B 7.5 A
“grid heater”
K7 Inner rear work light relay
F1C 10 A Stop light switch, 4-wheel braking
K8 Outer front work light relay
Instrument power supply, switch
F2A 15 A lamps, brake fluid level sensor, K9 Outer rear work light relay
pneumo-electric seat, buzzer K10 Reverse travel relay
F2B K11 Forward travel relay
F2C 15 A Pilot control K12 Hazard warning lights
Rear right/front left side light,
F3A 3A
instrument backlighting
Rear left/front right side lights,
F3B 3A
number plate light
Front work light switch, ride control,
F3C 10 A
double delivery, 4x1 bucket
F4A 5A Reverse travel buzzer, gearshift
Rear hammer button, bucket level
F4B 10 A solenoid valve + sensor, clutch
disconnect buttons
Backhoe attachment lock, rear work
F4C 10 A
light
F5A 15 A Inner front work lights
F5B
F5C
F6A 7.5 A Rotating beacon
(+15) hazard warning light power
F6B 7.5 A
supply
F6C 7.5 A Hand hammer, 4WD
(+30) hazard warning lights, warning
F7A 10 A
horn
F7B 15 A
F7C 6A
F8A 15 A Outer rear work lights
F8B 15 A Outer front work lights
F8C 15 A Inner rear work lights
COMPONENTS AND CONNECTORS
NAME DESCRIPTION NAME DESCRIPTION

BZ1 Alarm buzzer Backhoe attachment lock switch
S8
EV0 Fuel shut off solenoid valve (optional)
EV1 Double delivery solenoid valve (optional) S9 Light switch
EV2 Hand hammer solenoid valve (optional) S10 Hazard
EV3 Rear hammer solenoid valve (optional) S11 Front work light switch
Backhoe attachment lock solenoid valve S12 Rear work light switch
EV5 S15 Rotating beacon switch
(optional)
EV6 Bucket level solenoid valve S17 Starting switch
EV8 4WD solenoid valve (optional) S18 Parking brake switch
EV9 Reverse speed solenoid valve S20 Engine oil low pressure switch
EV10 Forward speed solenoid valve S21 Air filter blocked switch
EV11 Ride control solenoid valve (optional) S24 Transmission oil pressure switch
EV12 4x1 bucket solenoid valves (optional) S25 Transmission oil high temperature switch
FG1 General fuse 80 A S26 Clutch shut off button
FG2 Alternator fuse 70 A S27 Clutch shut off button
G1 Battery S28 Bucket sender
G2 Alternator S29 Horn button
Backhoe attachment lock warning light S30 Rear hammer pedal button (optional)
H1
(optional) S31 Brake oil level sender
H7 Front left indicator S32 Stop light switch
H8 Rear left light S33 Stop light switch
H9 Front right indicator S40 Gearshift
H10 Rear right light S41 Indicators switch
H11 External front left work light S42 Speedometer sender (optional)
H12 External front right work light S44 Seat (optional)
H13 External rear left work light S47 Main switch
H14 External rear right work light S48 Engine water high temperature switch
H15 Rotating beacon S50 Safety seat switch
H19 Internal front left work light (optional) ST1 Side panel
H20 Internal front right work light (optional) ST2 Front panel
H21 Internal rear left work light (optional) ST3 Bucket 4x1
H22 Internal rear right work light (optional) General cable-engine cable - 18-way
X1
HA1 Reverse speed buzzer connector
HA2 Horn X2 Cold start cable - 6-way connector
K01 Starter relay X3 Fuel pump - 3-way connector
K02 A/C relay X4 Air filter - 2-way connector
K13 Antitheft unit X5 Fuel level sender - 2-way connector
KC Fuses-relays control unit X6 Forward speed - 2-way connector
KF Flasher unit X7 Reverse speed - 2-way connector
M1 Starter motor X8 4WD - 2-way connector
R1 Heating start General harness-front panel - 1-way
X9
R2 Engine water temperature sender connector
R3 Fuel level sender Solenoid valves harness - general cable -
X10
24-way connector
S2 4WD switch (optional)
X11 1-way connector
S3 Hand hammer switch (optional)
General cable-cab cable - 5-way
S4 Double delivery switch (optional) X12
connector
S5 Ride control switch (optional)
General cable-side panel - 9-way
X14
connector

General harness-side panel - 7-way X64 1-way connector
X15
connector X65 Cold start switch - 1-way connector
General harness-side panel - 21-way X70 Front panel - 12-way connector
X16
connector X71 Starting switch - 10-way connector
X17 Antitheft - 11-way connector X80 Rotating beacon - 2-way connector
General harness-rear lamps harness - X101 Front right lights - 6-way connector
X18
12-way connector
X102 Controller - 10-way connector
X19 Reverse buzzer - 2-way connector
X103 Relay - 2-way connector
X21 Seat - 4-way connector
XC1 Control unit - 11-way connector
X22 Side panel - 32-way connector
X23 Clutch shut off button - 2-way connector
Backhoe attachment lock solenoid valve -
X24 XC4 Control unit - 21-way connector
2-way connector
X25 XC6 Control unit - 13-way connector
2-way connector
X26 Bucket sender - 3-way connector XD Fuel shut off diode - 2-way connector
X27 Horn button - 2-way connector XX Diodes - 5-way connector
X28 Clutch shut off button - 2-way connector XY Safety seat switch - 2-way connector
X29 Grab level - 2-way connector
Double delivery solenoid valve - 2-way
X30
connector
Quick coupler connection solenoid valve
X31
- 2-way connector
Rear hammer solenoid valve - 2-way
X32
connector
X33 Speedometer sender - 2-way connector
Ride control solenoid valve - 2-way
X34a
connector
Ride control solenoid valve - 2-way
X34b
connector
Hand hammer solenoid valve - 2-way
X35
connector
X36 Rear hammer button - 2-way connector
X37 Rear right light - 2-way connector
X38 Rear right work light - 4-way connector
Rear right work light (optional) - 4-way
X40
connector
X42 Front right indicator - 4-way connector
X44 Front right work light - 4-way connector
Front right work light (optional) - 4-way
X45
connector
Rear left work light (optional) - 4-way
X46
connector
X47 Rear left work light - 4-way connector
X48 Rear left light - 4-way connector
Front left work light (optional) - 4-way
X50
connector
X51 Front left work light - 4-way connector
X52 Front left indicator - 4-way connector
X60 Horn/left light - 7-way connector
X62 Gearshift - 6-way connector
ENGINE LINE DIAGRAM

SOLENOID VALVE LINE DIAGRAM


LIGHT LINE DIAGRAM

REAR LIGHT LINE DIAGRAM

WORK LIGHT LINE DIAGRAM

BEACON LAMP LINE DIAGRAM

OPTIONAL SEAT LINE DIAGRAM

COLD START DIAGRAM
CONTROLLER
1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82
G1
R1
N1
M1
N1
S1
B-N1
V-B1
L-N1
1 2
X83 X83
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER
RELAY
TO ENGINE LINE
F27176
SIDE INSTRUMENT CLUSTER
Calibrations
Pointer Calibration
Gage type Input Reading Input tolerance
tolerance direction
0 HZ 0 rpm ±3° N/A Descending
Speedometer 307 HZ 1000 rpm N/A ± 60 rpm Ascending
736 HZ 2400 rpm N/A ± 60 rpm Ascending
230-240 OHMS
240 OHMS Empty +0/-6° Descending
(REF)
Level fuel
102 OHMS 1/2 Tank ±3° (REF) 98-108 OHMS Descending
33 OHMS Full +4/-2° 33-42 OHMS Ascending
900 OHMS Point B +0/-6° N/A Descending
Transmission
temperature 114 OHMS 106 °C (223°F)
±5° 111-117 OHMS (REF) Ascending
(Red/green line)
700 OHMS Point A +0/-5° N/A Descending
Coolant
temperature 106 °C (223°F)
95 HMS ±3° 93-97 OHMS (REF) Ascending
(Red/green line)
11V Red/green left line ±3° 10.7-11.3 V (REF) Descending
VOLT Red/green right
15.9V ±5° 15.0-15.6 V (REF) Ascending
line
Connections
WARNING
PIN # NAME FUNCTION
LAMP No.
1 Ignition 10V-16V INPUT
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Parking brake Low side switch input LP3
5 Alternator Alternator D+ input LP4
6 Not used
7 Crab steer Low side switch input LP6
8 Neutral High side switch input
9 Seat switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
12 Driving lights High side switch input LP9
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
20 Fuel level sender Speed sensor input LP27
21 Water temperature sender Speed sensor input
22 Transmission temperature sender Speed sensor input
23 Not used
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Transmission oil temperature Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Horn Open collector output
36 Ground Ground
Other calibrations
Indicator Reading Resistance

Low fuel (lamp) 1/10 Tank (Ref) 180-200
Brake temperature (warning lamp) 152 °C (305.6°F) (Ref) 30-45
Coolant temperature (buzzer) 152 °C (305.6°F) (Ref) 70-83
FRONT INSTRUMENT
Pos. Pin Function Signal

+12 1 Positive (+12 V)
GND 2 Negative
S1 3 Speedometer Sensor
L4 4 Main beam lamp (blue) Positive
L3 5 Side light lamp (green) Positive
+ILL 6 Backlighting (+) + Light
L8 7 NC
L7 8 NC
L6 9 NC
L5 10 NC
L1 11 Direction lamp (green) Positive
L2 12 Brake level oil lamp (red) Positive
QUICK COUPLER LINE DIAGRAM

T
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B90B)

Fuse K2 Parking brake engaged relay
Rating Function
F1A 15 A Rear windshield wiper and washer K4 Bucket level solenoid valve relay
F1B 7.5 A
“grid heater” K7 Inner rear work light relay
F1C 10 A Stop light switch, 4-wheel braking K8 Outer front work light relay
Instrument power supply, switch K9 Outer rear work light relay
F2A 15 A lamps, brake fluid level sensor, K10 Reverse travel relay
pneumo-electric seat, buzzer
K11 Forward travel relay
F2B 15 A Air conditioning
K12 Hazard warning lights
F2C 15 A Pilot control
F3A 3A
Rear left/front right side lights,
F3B 3A
number plate light
F3C 10 A
F4A 5A Reverse travel buzzer, gearshift
disconnect buttons
F4C 10 A
light
F5B 10 A
F5C 15 A
F6B 7.5 A
supply
F7A 10 A (+30) hazard warning lights, horn
F7B 10 A Electrical socket, radio, roof lamp
F7C 6A Front windshield wiper

BS1 Right speaker (optional) M7 Front windshield washer
BS2 Left speaker (optional) M9 Optional blower motor
BZ1 Alarm buzzer M10 A/C compressor
EV1 Double delivery solenoid valve (optional) R1 Heating start
EV2 Hand hammer solenoid valve (optional) R2 Engine water temperature sender
EV3 Rear hammer solenoid valve (optional) R3 Fuel level sender
Backhoe attachment lock solenoid valve S1 Cold start switch (optional)
EV5
(optional) S2 4WD switch (optional)
EV6 Bucket level solenoid valve S3 Hand hammer switch (optional)
EV7 Fuel shut off solenoid valve S4 Double delivery switch (optional)
EV8 4WD solenoid valve (optional) S5 Ride control switch (optional)
EV9 Reverse speed solenoid valve Backhoe attachment lock switch
S8
EV10 Forward speed solenoid valve (optional)
EV11 Ride control solenoid valve (optional) S9 Light switch
EV12 4x1 bucket solenoid valves (optional) S10 Hazard
FG1 General fuse 80 A S11 Front work light switch
FG2 A/C fuse 10 A S12 Rear work light switch
G1 Battery S14 Windshield wiper switch
G2 Alternator S15 Rotating beacon switch
Backhoe attachment lock warning light S17 Starting switch
H1
(optional) S18 Parking brake switch
H7 Front left indicator S20 Engine oil low pressure switch
H8 Rear left light S21 Air filter blocked switch
H9 Front right indicator S24 Transmission oil pressure switch
H10 Rear right light S25 Transmission oil high temperature switch
H11 External front left work light S26 Clutch shut off button
H12 External front right work light S27 Clutch shut off button
H13 External rear left work light S28 Bucket sender
H14 External rear right work light S30 Rear hammer pedal button (optional)
H15 Rotating beacon S31 Brake oil level sender
H16 Rotating beacon S32 Stop light switch
H17 Current intake illumination S33 Stop light switch
H18 Cab light S34 Left cab light switch
H19 Internal front left work light (optional) S35 Right cab light switch
H20 Internal front right work light (optional) S40 Gearshift
H21 Internal rear left work light (optional) S41 Windshield wiper - Indicators switch
H22 Internal rear right work light (optional) S42 Speedometer sender (optional)
HA1 Reverse speed buzzer S43 Radio (optional)
HA2 Horn S44 Seat (optional)
K01 Starter relay S45 Conditioner and blower motor switch
K02 A/C relay S46 Current intake
K13 Antitheft unit S47 Main switch
KC Fuses-relays control unit S48 Engine water high temperature switch
KF Indicator flasher unit S49 Air conditioned pressure switch
M1 Starter motor S50 Safety seat switch
M4 Rear windshield wiper motor ST1 Side panel with optional diagnostics
M5 Front windshield wiper motor ST2 Front panel
M6 Rear windshield washer ST3 Bucket 4x1

General harness-engine harness - 18- X39 Rear windshield wiper - 4-way connector
X1
way connector Rear right work light (optional) - 4-way
X40
X2 Cold start - 6-way connector connector
X3 Fuel shut off - 1-way connector X41 Optional blower motor - 2-way connector
X4 Air filter - 2-way connector X42 Front right indicator - 4-way connector
X5 Fuel level sender - 2-way connector X43 Rotating beacon - 4-way connector
X6 Forward speed - 2-way connector X44 Front right work light - 4-way connector
X7 Reverse speed - 2-way connector Front right work light (optional) - 4-way
X45
X8 4WD - 2-way connector connector
General harness-front panel - 5-way Rear left work light (optional) - 4-way
X9 X46
connector connector
Solenoid valves harness - general cable X47 Rear left work light - 4-way connector
X10
29-way connector X48 Rear left light - 4-way connector
X11 1-way connector X49 Front windshield wiper - 6-way connector
General harness-cab harness - 5-way Front left work light (optional) - 4-way
X12 X50
connector connector
General harness-side panel - 9-way X51 Front left work light - 4-way connector
X14
connector X52 Front left indicator - 4-way connector
General harness-side panel - 7-way X53 Radio (brown color) - 8-way connector
X15
connector X54 Radio (black color) - 8-way connector
General harness-side panel - 21-way X55 Current intake - 2-way connector
X16
connector
Front windshield washer - 2-way
X17 Antitheft - 11-way connector X56
connector
General cable-rear lamps cable - 12-way Rear windshield washer - 2-way
X18 X57
connector connector
X19 Reverse buzzer - 2-way connector X58 Flasher unit - 13-way connector
X21 Seat - 4-way connector X59 Right light - 5-way connector
X22 Side panel - 32-way connector X60 Horn/left light - 7-way connector
X23 Clutch shut off button - 2-way connector X61 Wiper and light switch - 12-way connector
Backhoe attachment travel lock solenoid X62 Gearshift - 6-way connector
X24
valve - 2-way connector
X64 A/C compressor - 1-way connector
X25 X65 Cold start switch - 1-way connector
2-way connector
X67 Alternator - 3-way connector
X26 Bucket sender - 3-way connector
Engine water temperature sender - 3-way
X27 Horn button - 2-way connector X68
connector
X28 Clutch shut off button - 2-way connector
X69 A/C pressure switch - 2-way connector
X29 Grab level - 2-way connector
X70 Front panel - 12-way connector
Double delivery solenoid valve - 2-way
X30 X71 Starting switch - 10-way connector
connector
X72 Pilot control line - 1-way connector
Quick coupler connection solenoid valve -
X31 Engine oil pressure switch - 1-way
2-way connector X73
connector
X32 X75 Diagnostics - 5-way connector
connector
X33 Speedometer sender - 2-way connector X76 Diagnostics - 13-way connector
Ride control solenoid valve - 2-way X80 Rotating beacon - 2-way connector
X34 X81 Rotating beacon - 2-way connector
connector
Hand hammer solenoid valve - 2-way X82 Controller - 10-way connector
X35
connector X83 Relay - 2-way connector
X36 Rear hammer button - 2-way connector X110 Conditioner - 2-way connector
X37 Rear right light - 4-way connector X111 Conditioner - 9-way connector
X38 Rear right work light - 4-way connector XC1 Control unit - 11-way connector
NAME DESCRIPTION
XD Fuel shut off diode - 2-way connector
XX Diodes - 5-way connector
XY Safety seat switch - 2-way connector
ENGINE LINE DIAGRAM

R/N1 4.1
R/N1
M-V1
2 6 1 5 9 1 9 I II F N R NO
1 1 0 I
2 0 II F
0
R
S2
4 8 3 7 10
S3
5 10
+ + NI
S40
M/B1
1 2 3 4 5 6
X62
N1
N1
C1
M-N1
M-V1
M-B1
R-N1
L/G1
C1 4.4
N1 4.1
R-N1 5.1
3
X9
C1
M-N1
M-V1
M-B1
M/B1
H-N1
L/G1
7 2 6 11 5 9 3 1
XC4 XC2 XC2 XC4 XC1 XC1 XC1 XC1
1.4
3
F6C
7,5A
+15 +15
+15
F4B F4A
10A 5A
1.4
1
K10 K11
K1 86 87a 87
K4 86 87a 87 86 87a 87 86 87a 87
K2 86 87a 87
85 30 85 30 85 30 85 30 85 30
KC
1 6 9 19 16 8 5 8 1 11
XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC6 XC6 XC3
M-N1
1.2
M-B1 1.2
R-V1 R-V1 3.5
M-N1
M-V1
M-B1
H-N1
A-G1
H-R1
C-N1
B-R1
A-R1
B-R1
A-R1
R-V1
18 6 7 8 24 9 11 29 14 10 4 17 20
X1 X1 X10 X10 X10 X10 X10 X10 X10 X10 X1 X1 X10
M-B1
M-B1
H-N1
A-G1
H-R1
B-R1
A-R1
B-R1
A-R1
R-V1
M-N1
M-V1
C-N1
M-B1
M-B1
A-G1
H-R1
B-R1
A-R1
B-R1
A-R1
R-V1
2 1 1 2 1 2 1 2 C A B 1 2 1 2 2 1 2 2 1
X8 X8 X35 X35 X28 X28 X23 X23 X26 X26 X26 X29 X29 X7 X7 X19 X6 X6 X27 X27
EV2
EV8 S27 S26 S28 EV6 EV9 HA1 EV10
1
2
1
N2.5
N2.5
X19
N1
N1
N1
N1
N1
N1
N1
N1
1.5
31 31 3.1
F27169
R-N1 R-N1 6.1

C/N1 C/N1 6.1
C/B1 C/B1 6.2
V1
1 0
1 9
1 0
1 9
1 0
1 9
1 0
1 7 9
H1
S4 5 10
S5 5 10
S7 5 10
S8 5 10
A-N1
B-N1
L-G1
N1
N1 6.1
L/G1
C-B1
6 9 5 15 16 8
X15 X14 X15 X16 X16 X14
V1
A-N1
B-N1
C-B1
L-G1
L/G1
1.2
L-G1
2.5
R-V1
R-V1
18
23 16 27 X10 24 15
X10 X10 X10 X10 X10
V1
R-V1
2 1
X31 X31
2
X36
S30
B-N1
A-N1
C-B1
L-G1
1
X36
ST3
R-V1
EV12 1 2
1 2 1 2 X24 X24 1 2 1 2
X30 X30 X34 X34 X25 X25 X32 X32
EV4 EV5 EV3
EV1
EV11
1
1
N1
C
2
2
N1
N1
N1
N1
N1
31 31
2.5 4.1
F27464
LIGHT LINE DIAGRAM

REAR WORK LIGHT LINE DIAGRAM

3.5
R-N1 R-N1 R-N1 7.1
3.5
C/N1 C/N1 C/N1 7.1
3.5
C/B1
1 6 8 9 1 6 8 9
0 1 2 0 1 2
S11 3 2 10
S12 3 2 10
3.5
N1 N1 N1 7.1
G-V1
S-G1
A-V1
Z-N1
C/B1
3 1 3 5 14
X15 X15 X16 X16 X16
G-V1
S-G1
A-V1
Z-N1
C/B1
3 14 4 12 14 13 15 11 18
XC3 XC5 XC3 XC5 XC3 XC5 XC3 XC5 XC3
F4C
10A
H1
V1
H-N1
V-N1
+30 +30 +30 +30
+15
F5A F8B F8C F8A

15A 15A 15A 15A
K6 86 87a 87
K8 86 87a 87
K7 86 87a 87
K9 86 87a 87
85 30 85 30 85 30 85 30
KC
N1
H1
N1
H1
N1
N1
V1
H-N1
H-N1
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3V-N1 4
X51 X50 X44 X45 X47 X46 X38 X40
H11 H19 H12 H20 H13 H21 H14 H22

N1
5.5
31 31 7.1
F27173
WINDSHIELD WASHER/WIPER LINE DIAGRAM
6.5
R-N1 R-N1 R-N1 8.1 4.5
R/N1
6.5
C/N1
57/58 56b 56a 54S 54D 53 31b 49

H15 H16
0 1 2 R
2 6 7 9 0 1 9
II I 0 1 0 M M
L
S41 56 30 L 15 31
S14 3 5 10
S15 5 10
A-V1.5
1 2 3 4 5 6 7 8 9 10 11 12 - l - l
X61 X80 X80 X81 X81
V-N1.5
G/R1
A/N1
A/R1
L-G1
A-V1
A/B1
L-N1
N1
M1
6.5
L1
4.5
A-V1
4.5
L-N1
1 2 3 4
L-G1
A-G1.5
4.5 X43
4.5
G/R1
4.5
V-N1.5
C/N1
A/N1
A/R1
A/B1
L-B1
L/B1
13 2 1 12 1 4
X16 X16 X16 X16 X9 X16
A-G1.5
A-G1.5
A-V1.5
Z1
Z1
R/N1
C/N1
A/N1
A/R1
A/N1
A/B1
A/B1
4 1 3 14 15 12 1 1 16 5 7 4 7
XC5 XC5 XC5 XC4 XC4 XC4 XC4 XC2 XC5 XC2 XC2 XC2 XC3
F7C
6A A.R. F6A F3C
7,5A 10A
+15 +15 +15
+15
F1A
15A
4.4
50
KC
17
XC3
A/N1
A/N1
A/R1
A/B1
L-B1
L/B1
5 6 5 4 1 2 3
X10 X10 X12 X12 X12 X12 X12
R/N1
A/N1
A/N1
A/R1
A/N1
A/B1
A/B1
L-B1
L/B1
- l 4 1 2 3 - l - l 6 3 4 1
X41 X41 X39 X57 X57 X56 X56 X49
M4 M6 M7 M5
M9 53a 53a
53 M 53b M M 53 M53b
31b 31b
31 31
N1.5
N1.5
N1.5
N1
N1
N1
N1
N1
N1
6.5
31 31 8.1
F27467
HEATER AND RADIO LINE DIAGRAM

COLD START LINE DIAGRAM
CONTROLLER
1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82
G1
R1
N1
M1
N1
S1
B-N1
V-B1
L-N1
1 2
X83 X83
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER
RELAY
TO ENGINE LINE
F27176
Calibrations
Pointer Calibration
Gage type Input Reading Input tolerance
tolerance direction
0 HZ 0 rpm ±3° N/A Descending
Speedometer 307 HZ 1000 rpm N/A ± 60 rpm Ascending
736 HZ 2400 rpm N/A ± 60 rpm Ascending
230-240 OHMS
240 OHMS Empty +0/-6° Descending
(REF)
Level fuel
102 OHMS 1/2 Tank ±3° (REF) 98-108 OHMS Descending
33 OHMS Full +4/-2° 33-42 OHMS Ascending
900 OHMS Point B +0/-6° N/A Descending
Transmission
temperature 114 OHMS 106 °C (223°F)
±5° 111-117 OHMS (REF) Ascending
(Red/green line)
700 OHMS Point A +0/-5° N/A Descending
Coolant
temperature 106 °C (223°F)
95 HMS ±3° 93-97 OHMS (Ref) Ascending
(Red/green line)
11V Red/green left line ±3° 10.7-11.3 V (Ref) Descending
VOLT Red/green right
15.9V ±5° 15.0-15.6 V (Ref) Ascending
line
Connectors
WARNING
PIN # NAME FUNCTION
LAMP No.
1 Ignition 10V-16V INPUT
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Parking brake Low side switch input LP3
5 Alternator Alternator D+ input LP4
6 Not used
7 Crab steer Low side switch input LP6
8 Neutral High side switch input
9 Seat switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
20 Fuel level sender Speed sensor input LP27
21 Water temperature sender Speed sensor input
22 Transmission temperature sender Speed sensor input
23 Not used
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Transmission oil temperature Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Horn Open collector output
36 Ground Ground
Other calibrations
Indicator Reading Resistance

Low fuel (lamp) 1/10 Tank (Ref) 180-200
Coolant temperature (buzzer) 152 °C (305.6°F) (Ref) 70-83
FRONT INSTRUMENT

+12 J1 Positive (+12 V)
GND J2 Negative
S1 J3 Speedometer Sensor
L4 J4 Main beam lamp (blue) Positive
L3 J5 Side light lamp (green) Positive
+ILL J6 Backlighting (+) + Light
L8 J7 NC
L7 J8 NC
L6 J9 NC
L5 J10 NC
L1 J11 Direction lamp (green) Positive
Brake level oil lamp
L2 J12 Positive
(red)
AIR CONDITIONER SCHEMATIC
S Evaporator box S45 11-way connector

1 3RD speed relay 9 Potentiometer
2 Fuse 25 A 10 Speed switch
3 Ventilated electrical motor 11 Thermostat
4 1 and 2 speed resistor 12 12 V light
5 Electrical cock A Waterproof - 2-way connection
X111 9-way connector B Waterproof - 5-way connection
X110 2-way power connector
PILOT CONTROL DIAGRAM
TO SOLENOID
VALVES LINE
SAFETY
SWITCH
LVC RIGHT
JOYSTICK
LEFT
JOYSTICK
1 A B
X72 X23 X23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 1 2
X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X14 X14 X14 X14 X14 X14 X4 X4
N1
M-N1
G-R1
G-N1
M-B1
G-V1
B-G1
C-N1
A-R1
A-N1
B-R1
L-G1
V-N1
L-R1
Z-B1
V-B1
H1.5
N1.5
L-B1
H-G1.5
A1
L1
H-N1.5
K1 86 87a 87
85 30
N1
H-N1
H-R1.5
1 2 3 4 5 1 2 1 2 1 2 1 2 1 2 1 2 1 2 A B C A B C 1 2 1 2 A B A B 1 2
X13 X13 X13 X13 X13 X17 X17 YP4 YP4 YP3 YP3 YP6 YP6 YP5 YP5 YP7 YP7 YP8 YP8 XL XL XL XR XR XR X11 X11 X12 X12 X1 X1 X2 X2 X27 X27
CONNECTION
PRESS. SW
PRESS. SW
RETRACT
EXTEND
RH DOWN
JOYSTICK
PATTERN
JOYSTICK
PATTERN
LH DOWN
HORN JUMPER
RH STAB.
RH STAB.
LH STAB.
LH STAB.
VALVE 1
VALVE 2
PLUG 4
PLUG 3
PLUG 6
PLUG 5
PLUG 7
PLUG 8
MAINFOLD
RH UP
LH UP
POWER
P4
P3
P6
P5
P7
P8
R
L
2
B-R1
B-R1
H1.5
H-G1.5
H-N1.5
H-R1.5
N1
N1
N1
N1
1 2 3 4 5 6 1 2 1 2
X24 X24 X24 X24 X24 X24 YP9 YP9 YP10 YP10
AUX FORWARD
P10 PLUG 10
AUX REVERSE
LEFT
PLUG 9
N1
JOYSTICK
P9
2 5 3 6 7 8 2 3 7
S1 S1 S1 S1 S1 S1 S2 S2 S2
PILOT ON/OFF PATTERN

SWITCH SWITCH
31 31
F27182
NAME DESCRIPTION
K1 Safety relay
S1 Pilot ON/OFF switch - 8-way connector
S2 Pattern change switch - 8-way connector
X1 Valve configuration “1” - 2-way connector
X2 Valve configuration “2” - 2-way connector
X4 Left hydraulic control lever - 2-way con-
nector
X11 Left stabilizer pressure switch - 2-way
connector
X12 Right stabilizer pressure switch - 2-way
connector
X13 Right line - 5-way connector
X14 Right hydraulic control lever - 6-way con-
nector
X17 Manifold power - 2-way connector
X20 LVC control unit - 23-way connector
X23 Safety switch - 2-way connector
X24 Left stabilizer control lever - 6-way con-
nector
X27 Horn jumper connection - 2-way connec-
tor
X72 Pilot control cable - 1-way connector
XL Left stabilizer control lever - 3-way con-
nector
XR Right stabilizer control lever - 3-way con-
nector
YP3 Left bottom plug 3 - 2-way connector
YP4 Left bottom plug 4 - 2-way connector
YP5 Right bottom plug 5 - 2-way connector
YP6 Right bottom plug 6 - 2-way connector
YP7 Extension plug 7 - 2-way connector
YP8 Retraction plug 8 - 2-way connector
YP9 Reverse travel auxiliary speed plug 9 - 2-
way connector
YP10 Auxiliary forward travel plug 10 - 2-way
connector
2.3 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (B95B - B110B)

Fuse K3 Starting relay
Rating Function
No. K4 Bucket level solenoid valve relay
F1A K6 Inner front work light relay
Engine stop, (+15) anti-theft device, K7 Inner rear work light relay
F1B 7.5 A
(+15) ECU power supply K8 Outer front work light relay
F1C 10 A Stop light switch K9 Outer rear work light relay
Instrument power supply, switch K10 Reverse travel relay
F2A 15 A lamps, brake fluid level sensor, K11 Forward travel relay
pneumo-electric seat
K12 Hazard warning lights
F2B
F3A 3A
F3B 3A Rear left/front right side lights
F3C 10 A
4x1 bucket
Forward travel, reverse travel,
F4A 5A
reverse travel buzzer, gearshift
disconnect buttons
F4C 10 A
light
F5B
F5C
F6B 7.5 A
supply
F7A 10 A
horn
F7B
F7C

A106 Engine control unit S23 Transmissione disconnect button
A131 Flasher control unit S27 Rear horn button
B4 Air filter pressure switch S27 Transmissione disconnect button
B5 Fuel level sensor S36 Rear hammer button (optional)
B24 Accelerator knob S120 Hazard switch
B25 Foot accelerator S122 4WD switch
B26 Bucket sensor S123 Hand tool switch
B29 Bucket level sensor S126 Light switch
B30 Parking brake S127 Rotary beacon switch
B33 Speed sensor (optional) S130 Indicator switch
B66 Oil temperature switch S132 Gear shift switch
B74 Trasmission oil pressure switch S135 Rear traslation lock switch (europe only)
B107 Water in fuel sensor S136 Up and down switch
B129 Brake oil level sensor S137 Rear work light switch
E15 Rotary beacon S139 Display enter switch
E26 Backhoe attachment lock warning light S140 Transport lock switch (optional)
E37 Rear right light S141 Front work light switch
E38 Rear right work light S142 “Glide ride” switch
E40 Rear right work light (optional) S143 Unloading valve switch (europe only)
E42 Front right indicator light S134.1 Stop light switch
E44 Front right work light S134.2 Stop light switch
E45 Front right work light (optional) SB1 Battery stopper
E46 Rear left work light (optional) ST1 Side panel
E47 Rear left work light ST2 Front panel
E48 Rear left light ST3 Bucket 4x1
E50 Front left work light (optional) X14 Antitheft
E51 Front left work light X17 Seat option
E52 Front left indicator light X21 Diagnostic
E144 Lock valve switch lamp (optional) X25 Foot throttle
F1 General fuse X31 Front loader quick coupler
F2 ECU control unit fuse X55 Auxiliary 12 V socket
F5 Water in fuel fuse X72 From pilot control cable
Fuse for anti-theft device, diagnostic X107 Water in fuel
F31 socket, menu scroll switch, display enter X124 Fast connection
switch, side instrument cluster X128 Optional
G1 Battery XX From pilot control cable
G67 Alternator Y6 Forward speed solenoid valve
H7 Reverse buzzer Y7 Reverse speed solenoid valve
H32 Horn Y8 4WD solenoid valve
HA2 Horn Y12 4x1 bucket solenoid valves (optional)
K102 Relay for start signal from the control unit Backhoe attachment travel lock solenoid
Y24
K103 Starting relay valve
K104 Starter motor relay Backhoe attachment travel lock solenoid
Y25
M1 Starter motor valve (optional)
S15 Start switch Y30 Speed control solenoid valve (optional)

Y32 Rear hammer solenoid valve (optional) Optional front right indicartor light - 4-
X59
Y34 Ride control solenoid valve (optional) way connector
Y35 Hand hammer solenoid valve X47 Left rear light - 4-way connector
X1 Engine line interface - 18-way connector X48 4-way connector
X10 General line interface - 31-way connector X5 Fuel level sender - 2-way connector
X106 Engine control unit - 89-way connector X50 Right front light - 4-way connector
X107 Water in fuel sensor - 3-way connector X51 Left front light - 4-way connector
General cab line interface - 5-way X52 Left front indicator light - 4-way connector
X12
connector X55 Plug - 2-way connector
X14 Antitheft - 11-way connector Front right indicator light - 4-way
X58
X121 7-way connector connector
X125 12-way connector Forward speed solenoid valve - 2-way
X6
connector
X131 13-way connector
X64 Air conditioning switch - 1-way connector
X15.1 Start - connector
X7 Reverse speed buzzer - 2-way connector
X72 3-way connector
X17 Seat option - 4-way connector
X8 4WD solenoid valve - 2-way connector
Preheating relay (option) - 2-way
X2 X80 2-way connector
connector
X21 Diagnostic - 10-way connector X81 2-way connector
X23 2-way connector X82 10-way connector
X24 Accelerator knob - 6-way connector X83 EGS connector
X25 Accelerator pedal - 6-way connector General-left side panel interface wirings -
X87
13-way connector
X26 Bucket sensor - 3-way connector
General-right side panel interface wirings
X27 Number plate - 2-way connector X88
- 17-way connector
X28 Rear left lamp - 4-way connector
X9 Front harness - 5-way connector
X29 Rear right lamp - 4-way connector
Fuse and relay control unit line interface -
Speed control solenoid valve - 2-way XC1
X30 - 11-way connector
connector
Fronr loader quick coupler - 2-way XC2
X208 - 17-way connector
connector
X32 Horn - 2-way connector XC3
- 21-way connector
X33 Speedometer sensor - 2-way connector Fuse and relay control unit line interface -
XC4
X34 Ride control - 2-way connector - 21-way connector
X35 Hand hammer button - 2-way connector Fuse and relay control unit line interface -
XC5
X36 Rear hammer button - 2-way connector - 17-way connector
X37 Rear right light - 4-way connector Fuse and relay control unit line interface -
XC6
- 13-way connector
XST1 Panel instrument - 20-way connector
X4 Air filter - 2-way connector
1-way super seal connector form pilot
Right front indicartor light - 4-way X201.p
X42 control cable
connector
X43 Rotating beacon - 4-way connector X201.s
control cable
X44 Front right light - 4-way connector
Rear traslation solenoid valve - 2-way
X45 Air conditioning - 11-way connector X202
connector
X46 Left front light - 4-way connector
NAME DESCRIPTION
Backhoe transport lock solenoid valve -
X203
2-way connector
X204 Horn switch - 2-way connector
X206 Return to dig - 2-way connector
Speed control solenoid valve (optional) -
X207
2-way connector
X209
connector
Transmissione disconnect button - 2-way
X210
connector
ENGINE LINE DIAGRAM



LIGHT LINE DIAGRAM

REAR LIGHT LINE DIAGRAM



Calibrations
GAGE TYPE INPUT READING TOLERANCE

320 OHMS Empty - minimum reading +0/-2°
FUEL LEVEL 185 OHMS Right - edge of red band ± 3° (Ref)
6.5 OHMS Full - maximum reading +4/-0°
193 OHMS ON ± 5 OHMS
LOW FUEL LAMP
185 OHMS OFF ± 5 OHMS
TACHOMETER Can message 0-3000 RPM ± 50 RPM
Can message Minimum reading 65°C (149°F) ± 3°C (± 37.4°F)
COOLANT Can message Left edge of red band 106°C (223°F) ± 2°C (± 35.6°F)
Can message Maximum reading 112°C (234°F) ± 3°C (± 37.4°F)
11 V Right edge of lower red band ± 3°C (± 37.4°F)
VOLT
16 V Edge of upper red band ± 3°C (± 37.4°F)
385 OHMS Minimum reading 75°C (167°F) ± 3°C (± 37.4°F)
TRANSMISSION 149 OHMS Left edge of red band 105°C (221°F) ± 2°C (± 35.6°F)
112 OHMS Maximum reading 115°C (239°F) ± 3°C (± 37.4°F)
Connectors
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used 1 Keep alive power Need to fuse at 1
2 Key on power Wake up ampere without dis-
3 In gear input Digital input connect
4 Driving lights Digital input 2 Not used
5 Front work lights Digital input 3 Can bus input Twisted pair with
120 OHM terminal
6 Rear work lights Digital input
4 Can bus input Twisted pair with
7 Not used
120 OHM terminal
8 Not used
5 Not used
9 Not used
6 Audible alarm Floyd bell under
10 Air conditioning Digital input buzzer 80 mA
system pressure
7 Starter motor inter- 40 OHM relay =
11 Display input Digital input lock 300 mA
switch
8 Not used
12 Enter input switch Digital input
9 Not used
13 Up input switch Digital input
10 Not used
14 Down input switch Digital input
11 Not used
15 Cranking Digital input
12 Not used
16 Air filter restriction Digital input
13 Fuel level gauge Variable resistance
17 Not used
14 Transmission tem- Thermistor
18 Parking brake Digital input perature
19 Not used 15 Not used
20 Idle validation Digital input 16 Foot accelerator 0.5-4.5 V
switch
17 Accelerator knob 0.5-4.5 V
21 Decelerator button Digital input
18 Foot accelerator Output monitored
22 Not used for diagnostics
23 Not used 19 Accelerator knob Output monitored
25 Transmission oil Digital input 20 Foot accelerator
pressure 21 Accelerator knob
23 Not used
24 Alternator excita- Low alternator out-
tion put signals fault
25 Not used
26 Ground Digital input
FRONT INSTRUMENT

GND J2 Negative
Main beam lamp
L4 J4 Positive
(blue)
L3 J5 Side light lamp (green) Positive
L8 J7 NC
L7 J8 NC Negative
L6 J9 NC Negative
L5 J10 NC Negative
Direction indicator
L1 J11 Positive
lamp (green)
Brake level oil lamp
L2 J12 Positive
(red)
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (B95B - B110B)

Rating Function
F1A 15 A Rear windshield wiper and washer K6 Inner front work light relay
F1B 7.5 A “grid heater”, (+15) ECU power K8 Outer front work light relay
supply K9 Outer rear work light relay
F1C 10 A Stop light switch K10 Reverse travel relay
Instrument power supply, switch K11 Forward travel relay
F2A 15 A lamps, brake fluid level sensor,
K12 Direction indicator flashing
F3A 3A
Work light switch, ride control, double
F3C 10 A
delivery, 4x1 bucket
Forward travel, reverse travel,
F4A 5A
reverse travel buzzer, gearshift
disconnect buttons
F4C 10 A Backhoe attachment lock
F5B
F5C
F6B 7.5 A
supply
F7A 10 A
horn

A1 Right speaker (optional) Fuse for anti-theft device, diagnostic
A2 Left speaker (optional) F31 socket, menu scroll switch, display enter
switch, side instrument cluster
A53 Radio (optional)
FG4 Fuse A/C
A106 Engine control unit
G1 Battery
A131 Flasher control unit
G67 Alternator
B107 Water in fuel sensor
H7 Reverse buzzer
B4 Air filter pressure switch
H32 Horn
B5 Fuel level sensor
HA2 Horn
B24 Accelerator knob
K102 Relay for start signal from the control unit
B25 Foot accelerator
K103 Starting relay
B26 Bucket sensor
K104 Starter motor relay
B29 Bucket level sensor
K105 A/C relay
B30 Parking brake
M1 Starter motor
B33 Speed sensor (optional)
M39 Rear windshield wiper
B66 Oil temperature switch
M41 Blower motor (optional)
B69 A/C pressure switch
M49 Front windshield wiper
B74 Trasmission oil pressure switch
M56 Front windshield washer
B129 Brake oil level sensor
M57 Rear windshield washer
E15 Rotary beacon
M64 A/C compressor
E16 Rotary beacon
S15 Starting switch
E17 Lamp for socket
S23 Transmission disconnect button
E18 Cab light
S27 Rear horn button
E26 Backhoe attachment lock warning light
S28 Transmissione disconnect button
E27 Number plate light
S34 Left door switch
E28 Rear left light
S35 Right door switch
E29 Rear right light
S36 Rear hammer button (optional)
S120 Hazard switch
E38 Rear right work light
S122 4WD switch
E40 Rear right work light (optional)
S123 Hand tool switch
E42 Front right indicator light
S126 Light switch
E44 Front right work light
S127 Rotary beacon switch
E45 Front right work light (optional)
S130 Windshield wiper-light switch
E46 Rear left work light (optional)
S132 Gearshift switch
E47 Rear left work light
S135 Rear traslation lock switch
E48 Rear left light
S136 Up and down switch
E50 Front left work light (optional)
S137 Rear work light switch
E51 Front left work light
S138 Rear wiper switch
E52 Front left indicator
S139 Display enter switch
E121 Front left light/horn
S140 Transport lock switch (optional)
E133 Front right light
S141 Front work light switch
E114 Valve block lamp switch (optional)
S142 Ride control switch
F1 General fuse
S143 Hydraulic speed control switch
F2 ECU control unit fuse
S134.1 Stop light switch
F4 Third speed blower fuse

SB1 Battery stopper X25 Foot accelerator - 6-way connector
ST1 Side panel X26 Grab sensor - 3-way connector
ST2 Front panel X27 Number plate - 2-way connector
ST3 Bucket 4x1 X28 Rear left lamp - 4-way connector
X31 Front loader quick coupler X29 Rear right lamp - 4-way connector
X55 Auxiliary 12 V socket Speed control solenoid valve - 2-way
X30
X72 From pilot control cable connector
X107 Water in fuel (WIF) Front loader quick coupler - 2-way
X208
connector
X124 Fast connection
X32 Horn - 2-way connector
X128 Optional
X33 Speedometer sensor - 2-way connector
XX From pilot control cable
X34 Ride control - 2-way connector
Y6 Forward speed solenoid valve
X35 Hand hammer button - 2-way connector
Y7 Reverse speed solenoid valve
Y8 4WD solenoid valve
Y12 4x1 bucket solenoid valves (optional)
Y24 Backhoe attachment travel lock solenoid
Rear windshield wiper motor - 4-way
Backhoe attachment travel lock solenoid X39
Y25 connector
(optional)
Y30 Speed control solenoid valve (optional)
Y32 Rear hammer solenoid valve (optional)
X41 Blower motor - 2-way connector
Y34 Ride control solenoid valve (optional)
Y35 Hand hammer solenoid valve
Right front indicartor light - 4-way
X1 Engine line interface - 18-way connector X42
connector
X10 General line interface - 31-way connector
X43 Rotating beacon - 4-way connector
X106 Engine control unit - 89-way connector
X107 Water in fuel sensor - 3-way connector
X45 Air conditioning - 11-way connector
Front right indicator light - 4-way
connector
General cab line interface - 5-way X47 Left rear light - 4-way connector
X12
connector
X48 4-way connector
X14 Antitheft - 11-way connector
X49 6-way connector
X5 Fuel level sender - 2-way connector
X50 Right front light - 4-way connector
X52 Left front indicator light - 4-way connector
X53 8-way connector
X54 Radio - 8-way connector
X55 Plug - 2-way connector
Windshield washer pump - 2-way
X15.2 Start - connector X56
connector
X17 Seat option - 4-way connector Windshield washer pump - 2-way
X57
Preheating relay (option) - 2-way connector
X2
connector Right front light - 5-way connector
X58
X21 Diagnostic - 10-way connector (optional)
X23 EGS - 9-way connector Forward speed solenoid valve - 2-way
X6
X24 Accelerator knob - 6-way connector connector
X64 Air conditioning switch - 1-way connector
NAME DESCRIPTION
X72 3-way connector
X80 2-way connector
X81 2-way connector
General-left side panel interface wirings -
X87
13-way connector
X88
- 17-way connector
XC1
11-way connector
XC2
7-way connector
XC3
21-way connector
XC4
21-way connector
XC5
17-way connector
XC6
13-way connector
X201.p
control cable
X201.s
control cable
X202
connector
X203
2-way connector
X207
2-way connector
X209
connector
X210
connector
ENGINE LINE DIAGRAM



LIGHT LINE DIAGRAM





QUICK COUPLER LINE DIAGRAM - B95BTC
S3
1
X2.p
M/B1
1 7
X1 X1
1 0 2
S1
3
X1
M/B1
A-N1
M1
A-N1
M1
M1
1 1
1 1 X6
X3 X4 X5
V3 V4 Y5 Y6
2 2
X3 X4 2 2
X5 X6
N1
N1
N1
F29321
AIR CONDITIONING LINE DIAGRAM
1
3
87a
30
86
87
85
M
- +
10 11
9
Off
Off
Off
4
L M H
4
I H ML C
A S
12
5
X111 X110 S45

2 1 10 11
X111 X110 S45 X1

pos 8
+15 +30 +15
F27181

FRONT INSTRUMENT

GND J2 Negative
L4 J4 Lamp driving beams (blue) Positive
L3 J5 Lamp position lights (green) Positive
L8 J7 NC
L7 J8 NC
L6 J9 NC
L5 J10 NC
L1 J11 Lamp direction (green) Positive
L2 J12 Lamp brake oil level (red) Positive
SIDE INSTRUMENT
Calibrations

LOW FUEL LAMP
Can message Minimum reading 65 °C (149 °F) ± 3 °C (37.4 °F)
COOLANT Can message Left edge of red band 106 °C (222.8 °F) ± 2 °C (35.6 °F)
Can message Maximum reading 112 °C (233.6 °F) ± 3 °C (37.4 °F)
11 V Right edge of lower red band ± 3 °C (37.4 °F)
VOLT
16 V Edge of upper red band ± 3 °C (37.4 °F)
385 OHMS Minimum reading 75 °C (167 °F) ± 3 °C (37.4 °F)
TRANSMISSION 149 OHMS Left edge of red band 105 °C (221 °F) ± 2 °C (35.6 °F)
112 OHMS Maximum reading 115 °C (239 °F) ± 3 °C (37.4 °F)
Connectors
CN1 CN2
1 Not used Need to fuse at 1 A
1 Keep alive power
2 Key on power Wake up without disconnect
3 In gear input Digital input 2 Not used
4 Driving lights Digital input Twisted pair, with

3 Can bus input
120 OHM terminator
5 Front work lights Digital input
Twisted pair, with
6 Rear work lights Digital input 4 Can bus input
120 OHM terminator
8 Not used Audible alarm Floyd bell under
6
9 Not used buzzer 80 mA
Air conditioning 40 OHM relay =
10 Digital input 7 Starter interlock
system pressure 300 mA
11 Display input switch Digital input 8 Not used
12 Enter input switch Digital input 9 Not used
13 Up input switch Digital input 10 Not used
14 Down input switch Digital input 11 Not used
15 Cranking Digital input 12 Not used
16 Air filter restriction Digital input 13 Fuel level gauge Variable resistance
17 Not used Transmission
14 Thermistor
18 Park brake Digital input temperature
Idle validation 16 Foot accelerator 0.5-4.5 V

20 Digital input
switch 17 Hand accelerator 0.5-4.5 V
One touch Output monitored
21 Digital input 18 Foot accelerator
deceleration for diagnostics
22 Not used Output monitored
19 Hand accelerator
24 Not used 20 Foot accelerator
Transmission oil 21 Hand accelerator

25 Digital input
pressure 22 Not used
Low alternator
24 Alternator excitation
output signals fault
25 Not used
2.5 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (B110B)
FUSES AND RELAYS DESCRIPTION K1A Flasher

Rating System
F1A 15 A Rear windshield wiper and washer K6 Inner front work light relay
F1B 7.5 A
ECU power supply K8 Outer front work light relay
F1C 10 A Stop light switch K9 Outer rear work light relay
Instrument power supply, switch K10 Differential lock relay
F3A 3A
F3C 10 A
4WD switch, transmission disconnect
F4A 7.5 A
button, EGS power supply
disconnect buttons
F5B
F5C
F6A 15 A Rotating beacon
F6B 7.5 A
supply
F6C 7.5 A Hand hammer, differential lock
F7A 10 A
horn

A1 Right speaker (optional) Fuse for anti-theft device, diagnostic
A2 Left speaker (optional) F31 socket, menu scroll switch, display enter
FG4 Fuse A/C
G1 Battery
G67 Alternator
A23 EGS
H7 Reverse buzzer
H32 Horn
HA2 Horn
K103 Starting relay
B26 Bucket sensor
B30 Parking brake
K105 A/C relay
K14 Trasmission cut relay
M1 Starter motor
E15 Rotary beacon
E16 Rotary beacon
E17 Lamp for socket
M64 A/C compressor
E18 Cab light
S15 Starting switch
E28 Rear left light
S120 Hazard switch
S122 4WD switch
S124 EGS auto-switch
S126 Light switch
S128 Differential lock switch
E48 Rear left light
E114 Valve block lamp switch (optional)
F1 General fuse
S142 Ride control switch
F5 Water in fuel fuse

SB1 Battery stopper X21 Diagnostic - 10-way connector
ST1 Side panel X23 EGS - 9-way connector
ST2 Front panel X24 Accelerator knob - 6-way connector
ST3 Bucket 4x1 X25 Accelerator pedal - 6-way connector
X205a Front horn button X26 Grab sensor - 3-way connector
X205b Transmission disconnect button X27 Number plate - 2-way connector
X14 Antitheft-block control lamp X28 Rear left lamp - 4-way connector
X17 Seat option X29 Rear right lamp - 4-way connector
X21 Diagnostic Speed control solenoid valve - 2-way
X30
X55 Auxiliary 12 V socket connector
X72 From pilot control cable Front loader quick coupler - 2-way
X208
connector
X107 Water in fuel (WIF)
X32 Horn - 2-way connector
X128 Optional
X34 Ride control - 2-way connector
XX From pilot control cable
X35 Hand hammer button - 2-way connector
Y12 4x1 bucket solenoid valves (optional)
Y8 Differential lock solenoid valve
Y24 Backhoe attachment travel lock solenoid
Backhoe attachment travel lock solenoid
Y25 Rear windshield wiper motor - 4-way
(optional) X39
connector
Y206 Bucket level solenoid valve
Y30 Speed control solenoid valve (optional)
Y32 Rear hammer solenoid valve (optional)
X41 Blower motor - 2-way connector
Y34 Ride control solenoid valve (optional)
Y35 Hand hammer solenoid valve
Right front indicartor light - 4-way
X1 Engine line interface - 18-way connector X42
connector
X10 General line interface 31-way connector
X107 Water in fuel sensor - 3-way connector
Front right indicator light - 5-way
connector (optional)
General cab line interface - 5-way X47 Left rear light - 4-way connector
X12
connector
X48 4-way connector
X49 6-way connector
X53 8-way connector
X17 Seat option - 4-way connector X56
connector
Preheating relay (option) - 2-way Windshield washer pump - 2-way
X2 X57
connector connector
X205 Decluch switch and horn X208 4X1 - 2-way connector
X206 Bucket level solenoid valve connector X64 Air conditioning switch - 1-way connector
NAME DESCRIPTION
X72 3-way connector
X80 2-way connector
X81 2-way connector
X83 EGS connector
X84 EGS connector
X85 EGS connector
General-left side panel interface wirings -
X87
13-way connector
X88
- 17-way connector
XC1
11-way connector
XC2
7-way connector
XC3
21-way connector
XC4
21-way connector
XC5
17-way connector
XC6
13-way connector
X201.p
control cable
X201.s
control cable
X202
connector
X203
2-way connector
X207
2-way connector
X209
connector
X210
connector
ENGINE LINE DIAGRAM



LIGHT LINE DIAGRAM





1
3
87a
30
86
87
85
M
- +
10 11
9
Off
Off
Off
4
L M H
4
I H ML C
A S
12
5
X111 X110 S45

2 1 10 11
X111 X110 S45 X1

pos 8
+15 +30 +15
F27181

FRONT INSTRUMENT

GND J2 Negative
L4 J4 Lamp driving beams (blue) Positive
L3 J5 Lamp position lights (green) Positive
L8 J7 NC
L7 J8 NC
L6 J9 NC
L5 J10 NC
L1 J11 Lamp direction (green) Positive
L2 J12 Lamp brake oil level (red) Positive
SIDE INSTRUMENT
Calibrations

LOW FUEL LAMP
VOLT
Connectors
CN1 CN2
1 Keep alive power

3 Can bus input
120 OHM terminator
Twisted pair, with
120 OHM terminator
6
14 Thermistor

20 Digital input
19 Hand accelerator

25 Digital input
Low alternator
25 Not used
2.6 ELECTRICAL DIAGRAMS - POWERSHIFT 4WS CAB (B115B)
FUSES AND RELAYS DESCRIPTION K1A Hazard warning lights

Fuse K2A Buzzer
Rating Function
F1A 15 A Rear windshield wiper and washer K4 Bucket level solenoid valve relay
F1B 7.5 A
(+15) ECU power supply K7 Inner rear work light relay
Steering switch, steering unit power K8 Outer front work light relay
F1C 10 A
supply, stop light switch K9 Outer rear work light relay
Instrument power supply, switch K10 Optional relay
pneumo-electric seat, buzzer
Pilot control, loader attachment lamp
F2C 15 A
(optional)
F3A 3A
F3C 10 A
4WD switch, transmission
F4A 7.5 A disconnect button, EGS power
supply
F4B 10 A
solenoid valve + sensor
F5B
F5C
F6A 15 A Rotating beacon
F6B 7.5 A
supply
F6C 7.5 A Hand hammer
F7A 10 A
horn

A1 Right speaker (optional) F5 Water in fuel fuse
A2 Left speaker (optional) Fuse for anti-theft device, diagnostic
F31 socket, menu scroll switch, display enter
FG4 Fuse A/C
G1 Battery
A23 EGS
G67 Alternator
H7 Reverse buzzer
H32 Horn
HA2 Horn
B26 Bucket sensor
K103 Starting relay
B30 Parking brake
K105 A/C compressor relay
K14 Trasmission cut relay
KS Steering unit
B97 Rear axle sensor
M1 Starter motor
B98 Front axle sensor
E15 Rotary beacon
E16 Rotary beacon
E17 Lamp for socket
M64 A/C compressor
E18 Cab light
S15 Starting switch
E28 Rear left light
S120 Hazard switch
S122 4WD switch
S124 EGS auto-switch
S126 Light switch
S132 Steering switch
E48 Rear left light
E144 Lock valve switch lamp (optional)
F1 General fuse
S142 “Glide ride” switch

S134.1 Stop light switch X21 Diagnostic - 10-way connector
S134.2 Stop light switch X23 EGS - 9-way connector
S205a Front horn button X24 Accelerator knob - 6-way connector
S205b Transmissione disconnect button X25 Foot accelerator - 6-way connector
SB1 Battery stopper X26 Grab sensor - 3-way connector
ST1 Side panel X27 Number plate - 2-way connector
ST2 Front panel X28 Rear left lamp - 4-way connector
ST3 Bucket 4x1 X29 Rear right lamp - 4-way connector
X208 Front loader quick coupler Speed control solenoid valve - 2-way
X30
X55 Auxiliary 12 V socket connector
X72 From pilot control cable X32 Horn - 2-way connector
X107 Water in fuel (WIF) X33 2-way JUMPER connector
XX From pilot control cable X34 Ride control - 2-way connector
Y24 Backhoe attachment travel lock solenoid X35 Hand hammer button - 2-way connector
Backhoe attachment travel lock solenoid X36 Rear hammer button - 2-way connector
Y25
(optional) X37 Rear right light - 4-way connector
Y206 Bucket level solenoid valve X38 Rear right light - 4-way connector
Y12 4x1 bucket solenoid valves (optional) Rear windshield wiper motor - 4-way
X39
Y30 Speed control solenoid valve (optional) connector
Y32 Rear hammer solenoid valve (optional) X4 Air filter - 2-way connector
Y34 Ride control solenoid valve (optional) X40 Rear right light - 4-way connector
Y35 Hand hammer solenoid valve X41 Blower motor - 2-way connector
Y91 Steering solenoid valve Right front indicartor light - 4-way
X42
connector
Y92 4WS Steering solenoid valve
Y93 Round steering solenoid valve
Y94 2WS steering solenoid valve
Engine-general wirings interface - 18-way
X1 X46 Left front light - 4-way connector
connector
X10 General line interface - 31-way connector Right front light - 5-way connector
X58
(optional)
Optional front right indicartor light - 4-
X107 Water in fuel sensor - 3-way connector X59
way connector
X47 Left rear light - 4-way connector
X48 4-way connector
General cab line interface - 5-way
X12 X49 6-way connector
connector
X53 8-way connector
X15.1 Start - connector X56
connector
X17 Seat option - 4-way connector X57
connector
Preheating relay (option) - 2-way X64 Air conditioning switch - 1-way connector
X2
connector

X67 Alternator - 3-way connector 1-way super seal connector form pilot
X201.s
X69 A/C pressure switch - 2-way connector control cable
X7 Reverse speed buzzer - 2-way connector Speed control solenoid valve (optional) -
X207
2-way connector
X72 3-way connector
X81 2-way connector X202
connector
X209 Back hammer solenoid valve connector
X83 EGS connector
X205 Decluch switch and horn
X84 EGS connector
X206 Bucket level solenoid valve connector
X85 EGS connector
Front loader quick coupler - 2-way
General-left side panel interface wirings - X208
X87 connector
13-way connector
X88
- 17-way connector
X91 Steering solenoid valve - 2-way connector
4WS steering solenoid valve - 2-way
X92
connector
Round steering solenoid valve - 2-way
X93
connector
2WS steering solenoid valve - 2-way
X94
connector
X95 Steering unit - 12-way connector
X96 Steering unit - 8-way connector
X98 Front axle sensor - 3-way connector
X97 Rear axle sensor - 3-way connector
XC1
11-way connector
XC2
7-way connector
XC3
21-way connector
XC4
21-way connector
XC5
17-way connector
XC6
13-way connector
Backhoe transport lock solenoid valve - 2-
X203
way connector
X210
connector
X206 Level grab - 2-way connector
X209
connector
X201.p
control cable
ENGINE LINE DIAGRAM



LIGHT LINE DIAGRAM




STEERING LINE DIAGRAM


1
3
87a
30
86
87
85
M
- +
10 11
9
Off
Off
Off
4
L M H
4
I H ML C
A S
12
5
X111 X110 S45

2 1 10 11
X111 X110 S45 X1

pos 8
+15 +30 +15
F27181

FRONT INSTRUMENT

GND J2 Negative
L4 J4 W/L driving beams (blue) Positive
L3 J5 W/L position lights (green) Positive
L8 J7 NC
L7 J8 NC Negative
L6 J9 NC Negative
L5 J10 NC Negative
L1 J11 W/L direction (green) Positive
L2 J12 W/L brake oil level (red) Positive
SIDE INSTRUMENT
Calibrations

LOW FUEL LAMP
VOLT
Connectors
CN1 CN2
1 Keep alive power

3 Can bus input
120 OHM terminator
Twisted pair, with
120 OHM terminator
6
14 Thermistor

20 Digital input
19 Hand accelerator

25 Digital input
Low alternator
25 Not used
3. CONTROLS AND INSTRUMENTS

3.1 FRONT INSTRUMENT PANEL
1. DIRECTION INDICATOR LAMP 4. MAIN BEAM INDICATOR LAMP

This lamp turns on when the direction indicators This indicator lamp turns on when the main
are working. beams are on.
2. BRAKE LIQUID LEVEL WARNING LAMP 5. “FOUR WHEEL STEER” (4WS) STEER INDI-
This lamp turns on and the audible warning de- CATOR LAMP
vice sounds when the brake liquid is at minimum This lamp turns on when 4 wheel steer mode is
level. selected and phased.
3. SIDE LIGHT AND LOW BEAM INDICATOR 6. “ROAD” (4WS) STEER INDICATOR LAMP
LAMP This lamp turns on when 2 wheel steer mode is
This indicator lamp turns on when the side lights selected and phased.
or the low beams are on.
7. “CRAB” (4WS) STEER INDICATOR LAMP 14. 2WD/4WD SWITCH

This lamp turns on when crab steer mode is se- This switch is used to engage or disengage the
lected and phased. four wheel drive.
This switch has three positions:
NOTE: if the three lamps turn on at once, this - First position (by pushing button on the right
means there is a problem with the electrical system. ):
Consult your Dealer. rear wheel drive with braking only on rear
wheels (lamp off).
8. TACHOMETER - Second position (by pushing button on the left
The tachometer shows travel speed in kilome- ):
tres per hour (km/h) and miles per hour (mph). four wheel drive with braking on four wheels
9. DIFFERENTIAL LOCK SWITCH (Powershift (lamp on).
transmission) - Third position (by pushing a second time but-
This switch is used to lock or unlock the differen- ton on the left ):
tial. rear wheel drive and braking on four wheels.
10. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon NOTE: when the 4WD switch is in OFF position and
on or off. the two brake pedals are pressed at the same time,
11. LIGHT SWITCH the 4 wheel drive is engaged automatically (at
This switch has three positions: speeds higher than 3 km/h (1.86 mph)) to ensure
- The first position is OFF. braking on the 4 wheels; it disengages when the
- The second position powers the instrument brake pedals are released.
cluster panel, the side lights and the low beam
indicator lamp (3). 15. MANUAL MODE SELECTION SWITCH
- The third position enables the main beams, (Powershift transmission)
turns on the low beams and the indicator lamp In situations where manual gearshift (up or
of the main beams (4). downshift) is required, the automatic gearshift of
12. HAZARD LIGHT SWITCH the powershift transmission can be overridden
Press the control down to locked position. The by means of this switch.
direction indicators and the control will flash si-
multaneously. Press the control down again to NOTE: changing gears up or down must always be
turn off the direction indicators and the indicator done using the powershift transmission lever.
lamp.
13. HAND-HELD AUXILIARY HYDRAULIC AT- When the manual mode is no longer required,
TACHMENT SWITCH (Optional) place the switch back to the OFF position to
This switch has two positions: return to automatic gearshifting.
- The first position is OFF. 15. HYDRAULIC QUICK COUPLER SWITCH
- The second position is ON and enables the (B95BTC)
auxiliary hydraulic attachments. The switch has a central neutral position. By
pressing the switch to the left, the bucket is re-
leased. By pressing the switch to the right, the
bucket is locked.
3.2 CALIBRATION OF SPEEDOMETER
Dependent upon the model and tires fitted it may be

a requirement to set the calibration of the front con-
sole.
This setting is required if fitting a new instrument or
a change of tires takes place, and can be performed
by adjusting the settings of the switch block, mount-
ed at the rear of the console.
Each switch numbered 1 to 8 mounted in the block

should be turned ON = or OFF as shown
in the opposite example, to suit the requirement and
8
as shown in the following tables.
7
Switch positions: 6
1 = ON 5
0 = OFF 4
3
2
on 1
F28666
POWERSHUTTLE
TIRE - ROLLING FREQUENCY AT SWITCH POSITIONS

AXLE RATIO
CIRCUMFERENCE 50 Km/hr 1-2-3-4-5-6-7-8
18.5 4065 - 4335 2055 1-1-1-1-0-1-0-0
18.5 3810 - 3911 2245 1-1-1-0-1-0-1-0
20.8 4065 - 4335 2310 1-1-1-0-1-1-1-0
20.8 3810 - 3911 2522 1-1-0-0-0-0-0-1
POWERSHIFT
TIRE - ROLLING FREQUENCY AT SWITCH POSITIONS

EGS FREQUENCY
CIRCUMFERENCE 50 Km/hr 1-2-3-4-5-6-7-8
6.53 - 6.12 4065 - 4335 315 Hz 0-0-0-0-0-0-0-0
6.97 - 6.79 3810 - 3911 345 Hz 0-1-0-0-0-1-0-0
3.3 SIDE INSTRUMENT PANEL (B90B)
1. FRONT WORK LIGHT SWITCH 4. “GLIDE RIDE” SWITCH (Optional)

This switch has three positions: The “glide ride” system control improves the ma-
- The first position is OFF. chine comfort during travel, regardless of the
- Second position, the two front external work type of terrain and with the loader bucket full or
lights turn on. empty. It reduces forward and rearward pitching
- Third position, the two front internal work lights when moving to the rear or forwards and when
turn on. carrying loads, at the same time increasing pro-
The light switch turns on only in the second ductivity and operator comfort. It also reduces
and third position. impact forces to the machine during operation.
2. LOADER ATTACHMENT SWITCH (Available) Do not use this system while operating the load-
3. ROLL-OVER PROTECTION SWITCH er attachment.
(Optional)
This switch is used to engage or disengage the SWARNING
roll-over protection device. When the operator is Never operate the “glide ride” system control when
about to start working with the backhoe attach- the loader arm and loader bucket are maintaining
ment in conditions which could cause the ma- the front of the machine raised off the ground. The
chine to roll over, he/she must activate the roll- machine could fall and cause serious or fatal injury.
over protection device by pressing the switch
(ON position and lamp turned on).
In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cyl-
inder, detects a pressure exceeding the follow-
ing values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
5. LOADER ATTACHMENT LOCKING SWITCH

(Optional)
When operated, this switch is for preventing any
movement of the loader attachment during trav-
el.
6. SIDE INSTRUMENT CLUSTER
7. BACKHOE ATTACHMENT SWITCH (Avail-
able)
8. AUXILIARY BACKHOE ATTACHMENT
SWITCH (Optional)
9. REAR WINDSHIELD WIPER AND WASHER
SWITCH
When this switch is pressed, the windshield wip-
er is activated and will continue operating until
the switch is returned to the OFF position.
The windshield washer is operated by further
pressing and holding the switch.
When the switch is released, the washer stops
and the wiper starts operating again.
10. BACKHOE ATTACHMENT LOCKING SWITCH
(Optional)
The switch is used to lock or unlock the backhoe
attachment locking plate in preparation for road
travel.
able)
12. REAR WORK LIGHT SWITCH
- The first position is OFF, the rear lights are off.
- Second position, the two rear external work
lights turn on.
- Third position, the two rear internal work lights
turn on.
The light switch turns on only in the second and
third position.
NOTE: never use the work lights during road travel.

3.4 SIDE INSTRUMENT PANEL (B95B - B110B - B115B)
1. FRONT WORK LIGHT SWITCH 4. “GLIDE RIDE” SWITCH (Optional)

This switch has three positions: The “glide ride” system control improves the ma-
- The first position is OFF. chine comfort during travel, regardless of the
- Second position, the two front external work type of terrain and with the loader bucket full or
lights turn on. empty. It reduces forward and rearward pitching
when moving to the rear or forwards and when
- Third position, the two front internal work
carrying loads, at the same time increasing pro-
lights turn on.
ductivity and operator comfort. It also reduces
The light switch turns on only in the second
impact forces to the machine during operation.
and third position.
Do not use this system while operating the load-
2. LOADER ATTACHMENT SWITCH (Available) er attachment.
3. ROLL-OVER PROTECTION SWITCH
(Optional) SWARNING
This switch is used to engage or disengage the Never operate the “glide ride” system control when
roll-over protection device. When the operator is the loader arm and loader bucket are maintaining
about to start working with the backhoe attach- the front of the machine raised off the ground. The
ment in conditions which could cause the ma- machine could fall and cause serious or fatal injury.
chine to roll over, he/she must activate the roll-
over protection device by pressing the switch 5. LOADER ATTACHMENT LOCKING SWITCH
(ON position and lamp turned on). (Optional)
In this condition, the audible alarm will sound by When operated, this switch is for preventing any
means of the buzzer when the pressure switch, movement of the loader attachment during trav-
installed on the backhoe attachment boom cyl- el.
inder, detects a pressure exceeding the follow- 6. SIDE INSTRUMENT CLUSTER
ing values: 7. UP/DOWN SWITCH
2WS = 116 bar (17 psi) By means of this control, it is possible to scroll
4WS = 126.5 bar (18 psi)
through the menu or data options shown on the

diagnostic display.
8. MENU ENTER SWITCH
By means of this control it is possible to display
and confirm the menu options shown on the dis-
play.
9. REAR WINDSHIELD WIPER AND WASHER
SWITCH
When this switch is pressed, the windshield wip-
er is activated and will continue operating until
the switch is returned to the OFF position.
The windshield washer is operated by further
pressing and holding the switch.
When the switch is released, the washer stops
and the wiper starts operating again.
10. BACKHOE ATTACHMENT LOCKING SWITCH
(Optional)
The switch is used to lock or unlock the backhoe
attachment locking plate in preparation for road
travel.
able)
12. REAR WORK LIGHT SWITCH
- The first position is OFF, the rear lights are off.
- Second position, the two rear external work
lights turn on.
- Third position, the two rear internal work lights
turn on.
The light switch turns on only in the second and
third position.
NOTE: never use the work lights during road travel.

3.5 SIDE INSTRUMENT CLUSTER (B90B)
1. ENGINE OIL PRESSURE WARNING LAMP 4. PARKING BRAKE INDICATOR LAMP

This warning lamp turns on and the audible This indicator lamp turns on when the parking
warning device sounds when the engine oil brake lever is in the raised position (wheels
pressure is too low. braked).
If the lamp turns on while the machine is work- 5. AIR FILTER RESTRICTION WARNING LAMP
ing, move the machine to a safe place, immedi- This warning lamp turns on when the air filter el-
ately stop the engine, remove the starter switch ement needs to be cleaned or replaced.
key and find the cause of the problem. 6. TRANSMISSION OIL PRESSURE WARNING
2. “GRID HEATER” INDICATOR LAMP (If fitted) LAMP
If the machine is equipped with a “grid heater”, This lamp turns on and the audible alarm
wait for the indicator lamp to turn off before start- sounds when the transmission oil pressure is
ing the engine. too low. If the lamp turns on while the machine
3. BATTERY CHARGE WARNING LAMP is working, move the machine to a safe place,
This warning lamp turns on when the alternator/ immediately stop the engine, remove the starter
fan belt is broken or when the alternator is not switch key and find the cause of the problem.
charging the battery. 7. LOW FUEL LEVEL WARNING LAMP
If the lamp turns on while the machine is work- This warning lamp turns on when the fuel level
ing, move the machine to a safe place, immedi- is low. You have approximately an hour to fill the
ately stop the engine, remove the starter switch fuel tank.
key and find the cause of the problem.
NOTE: when the starter switch key is in the ON po-
sition, all lamps turn on and the instrument buzzer
sounds for 5 seconds. Afterwards, the lamps turn off
and only lamp (2) remains on. The gauges (9) and
(10) set to position.
8. FUEL LEVEL GAUGE

This gauge shows the quantity of fuel in the fuel
tank.
9. BATTERY CHARGE GAUGE
This indicator shows the state of charge of the
battery. At normal charge the needle should be
in the grey area. If the needle is in the left red ar-
ea, this shows that the battery charge is insuffi-
cient or that the alternator is not charging the
battery. If the needle is in the right red area, this
indicates excessive battery charge which may
cause damage to the battery.
10. HOURMETER
The hourmeter shows the number of hours and
tenths of hours the engine has been functioning.
It also makes it possible to determine when ser-
vicing operations are due.
11. TACHOMETER
The tachometer shows the engine speed in rev-
olutions per minute.
The figures indicated must be multiplied by 100.
Each intermediate mark shows a value of
100 rpm.
We recommend not to reach the red line.
12. TRANSMISSION OIL TEMPERATURE
GAUGE
This gauge shows the transmission oil tempera-
ture. When the temperature is normal, the nee-
dle is in the grey area. If the needle is in the red
area, change down to a lower gear. If the needle
still remains in the red area, stop the machine
travel, place the gearshift lever and the direc-
tion-of-travel control lever in the neutral position
and leave the engine running at 1000 rpm. If this
operation does not enable the oil temperature to
be reduced, check the gearbox oil level and
make sure that the radiator and oil cooler are
perfectly clean.
13. ENGINE COOLANT TEMPERATURE GAUGE
This gauge shows the temperature of the engine
coolant solution. When the temperature is nor-
mal, the needle is in the grey area. If the needle
is in the red area, the audible warning sounds.
Move the machine to a safe place, immediately
stop the engine, remove the starter switch key
and check the coolant level. Make sure that the
radiator and oil cooler are perfectly clean and
that all the thermostats function correctly.
3.6 SIDE INSTRUMENT (B95B - B110B - B115B)
1. CAUTION MASTER LAMP 5. PARKING BRAKE INDICATOR LAMP

This lamp signals a not critical caution. This indicator lamp turns on when the parking
When this caution is active, it is necessary to brake lever is in the raised position (wheels
change the operating mode, plan a down time to braked).
carry out maintenance or, if the fault continues, 6. AIR FILTER RESTRICTION WARNING LAMP
consult your dealer. This warning lamp turns on when the air filter el-
This lamp turns on at the same time of lamps ement needs to be cleaned or replaced.
(2), (4), (6), (7) and (9). 7. TRANSMISSION OIL PRESSURE WARNING
2. ENGINE OIL PRESSURE WARNING LAMP LAMP
This warning lamp turns on and the audible This lamp turns on and the audible alarm
warning device sounds when the engine oil sounds when the transmission oil pressure is
pressure is too low. too low.
3. STOP MASTER LAMP 8. AIR CONDITIONER INDICATOR LAMP (Op-
The stop master lamp signals a critical caution. tional)
When this lamp turns on, stop the machine im- This lamp turns on when the air conditioner is
mediately and shut off the engine. working.
If this is not the case, the machine can get dam- 9. “GRID HEATER” INDICATOR LAMP (If fitted)
aged or accidents may occur. This lamp turns on while the engine is being pre-
4. BATTERY CHARGE WARNING LAMP heated.
This warning lamp turns on when the alternator/
fan belt is broken or when the alternator is not
charging the battery.
10. LOW FUEL LEVEL WARNING LAMP

This warning lamp turns on when the fuel level
is low. You have approximately an hour to fill the
fuel tank.
NOTE: when the starter switch key is in the ON po-

sition, all lamps turn on and the instrument buzzer
sounds for 5 seconds. Afterwards, the lamps turn off
and only lamp (2) remains on. The gauges (11) and
(12) set to position.
11. FUEL LEVEL GAUGE

This gauge shows the quantity of fuel in the fuel
tank.
12. BATTERY CHARGE GAUGE
This indicator shows the state of charge of the
battery. At normal charge the needle should be
in the grey area. If the needle is in the left red ar-
ea, this shows that the battery charge is insuffi-
cient or that the alternator is not charging the
battery. If the needle is in the right red area, this
indicates excessive battery charge which may
cause damage to the battery.
13. DIAGNOSTIC DISPLAY
By means of this display it is possible to visual-
ize the various data of diagnostics. The service
hours are also indicated.
14. TACHOMETER
The tachometer shows the engine speed in rev-
olutions per minute.
The figures indicated must be multiplied by 100.
Each intermediate mark shows a value of
100 rpm.
We recommend not to reach the red line.
15. TRANSMISSION OIL TEMPERATURE
GAUGE
This gauge shows the transmission oil tempera-
ture. When the temperature is normal, the nee-
dle is in the grey area. If the needle is in the red
area, change down to a lower gear. If the needle
still remains in the red area, stop the machine
travel, place the gearshift lever and the direc-
tion-of-travel control lever in the neutral position
and leave the engine running at 1000 rpm. If this
operation does not enable the oil temperature to
be reduced, check the gearbox oil level and
make sure that the radiator and oil cooler are
perfectly clean.
16. ENGINE COOLANT TEMPERATURE GAUGE
This gauge shows the temperature of the engine
coolant solution. When the temperature is nor-
mal, the needle is in the grey area. If the needle
is in the red area, the audible warning sounds.
3.7 IMMOBILISER SYSTEM
F28667
A. M38 Immobiliser E. Starter motor

B. Electronic key socket with LED F. + 15 key positive
C. 2 piece electronic key G. Electronic key
D. + 50 to ignition
Wire
Function Connection
No.
1 (+15) Key positive Connected to the + 12 V full ignition supply
2 (+30) Permanent + 12 V power supply Connected to the wire from the battery positive
Connected to the vehicle negative at two independent
3 (-31) Negative power supply
points
Connected in line with the wire controlling the starter
5-6 Immobilization relay No. 2 motor relay/solenoid - Minimum 500 mA maximum 10 A
capacity
Connect in line with the wire controlling the ignition or
7 - 8 - 9 Immobilization relay No. 1
fuel system - Minimum 500 mA maximum 10 A capacity
4. DIAGNOSTICS DISPLAY (B95B - B110B - B115B)

The diagnostics display (1) is located in the middle
of the side instrument (4) on the side instrument pan-
el.
The switchs used to enter diagnostics are following:
Z UP/DOWN SWITCH (2)

Use this UP/DOWN switch to scroll through the
menus.
NOTE: push the arrow at start up to display engine

rpms on the display.
Z DISPLAY ENTER SWITCH (3)

Use this switch to select and confirm a service
menu.
The Diamond icon, or top portion of the switch, is
used to select displays.
The 90° arrow icon or bottom portion of the switch,
is used to enter selected choices.
Using the display switches, you will be able to scroll

through the following:
- battery voltage;
- backhoe loader hours;
- setup.
Features adjustable during setup:
- backlighting dimming control;
- maintenance/service interval customization;
- storage of error codes;
- “Grid heather”presence:
it possible to select or deselect the “grid heather”
options;
- low temperature idle speed setting:
when the engine coolant temperature is below
10 °C, the unit will change from normal low idle to
a low temperature idle which can be adjusted
between 975 and 1500 rpm. The default setting is
1000 rpm.
4.1 SYMBOLS
Work hours Hydraulic oil filter blocked
Maintenance Transmission oil pressure too high
HEAVY Maintenance heavy (hours) Battery charging failure

1000
LIGHT Maintenance light (hours) Fuel contaminated

500
Stored error code Malfunction
Grid heater Back-light dimming
Engine speed Battery voltage too high

n/min
Engine area of fault Battery voltage too low
Engine intake air filter blocked
Charge air temperature too high
Engine coolant level too low
Engine coolant temperature too high
Engine oil pressure too low
Brake fluid level too low
Handbrake not released
Put the shuttle lever into neutral

position
4.2 SETUP MENU
Dimmer
Increase O
Decrease P
Increase
Decrease
Service
interval
Increase
Decrease
Stored error
code
3-second scroll unless the switch is

pressed
“grid heater”
presence Select / Deselect
Low and high Increase O

idle speed
Decrease P
HARDWARE
P/N Increase O
Hardware code
ID Decrease P
VER
SOFTWARE
Software code P/N O Press Enter to make the value flash and then set up
ID
VER P Press Enter to make the value stop flashing
4.3 PROCEDURE ABOUT SELF TEST
Z Power up LCD and show work

Any of the above at with ignition low hours for 10 seconds
Foot max: X.X.
Foot min: X.X. 113/111
range

Go to menu
Hand max: X.X. 125/120
Normal “Key ON” Z Hand min: X.X. range

Z
Initiate Self test
Foot %: XXX 113/122
Any of the above at “Key ON” Hand %: XXX range
Check:
100 mA < Current draw < 1amp

Step 1: Lamps switch on at full intensity.
Requested
98/88
engine rpm:
Step 2: Lamps switch off after 2 seconds. range
XXX
10 mA < Current draw < 1 mA

Step 3: Wait 2 seconds.
Check: Fuel lvl: XX.X 117/120
Step 4: Instrument backlighting turns on at full intensity. 100 mA < Current draw < 1 A Fuel tank: XX range

Step 5: Lamps switch off after 2 seconds.
10 mA < Current draw < 100 mA
Voltage: XX.X
116/124
Trans oil temp:
Step 6: Wait 2 seconds. range
XX

Step 7: Sweep all 5 gauges to maximum angle.
Makes sure that needles can
move freely and have proper Brakes: XXX
102/92
Step 8: 2 seconds after maximum angle sweep to red position Engine rpm:
range
border. XXXX
Step 9: 2 seconds after red-green border is reached move Makes sure that needles are
to second red border for voltage. properly calibrated to applique
Coolant temp:
107/123
XXX
Step 10: Park all gauges and start LCD test. range
Air temp: XXX

Step 11: When LCD test is complete sound alarm for 2
seconds.
Engine oil temp:
122/126
XXX
range
Fuel temp: XXX
Step 12: Display following on LCD until key-off or the self test ends. All gauges and
lamps should work as normal and engine will be able to be started.

4.4 ON BOARD ERROR CODE RETRIEVAL
MAIN SCREEN
↵
Z
Stored error code
Z Page 1/6
CODE 3059 3 second scroll unless
↵ OCCURRENCE 3
up/down pressed
HOUR 1004.5
Page 2/6
CODE 3009
OCCURRENCE 2
HOUR 1010.6
Page 3/6
Occurrence counter will be incremented on transition from CODE 1018
inactive to active status. Status has to be stored in EEPROM and
checked at key on. Only the hour count of the last occurrence will OCCURRENCE 1
be stored per SAE convention. HOUR 1024.5
Page 4/6
CODE 3022
OCCURRENCE 1
HOUR 969 .4
Page 5/6
CODE 3113
OCCURRENCE 2
HOUR 1050.6
Page 6/6
CODE 1003
OCCURRENCE 3
HOUR 1076.4
4.5 BACKLIGHTING AND DIMMING
A proper and uniform backlighting for matrix, gauge

pointer and symbols shall be provided.
Separate backlighting electronics shall be provided

for matrix and symbols-gauge pointers. The back-
lighting will be achieved by LEDs and dimming shall
be provided through the setup menu selections.
The backlighting shall go at its maximum level when

the front, rear and driving lights are off.
The gauges backlighting dimming is switched on
when the cluster sees a HIGH level on front work
lights, rear work lights or driving lights for more then
100 ms.
The TELL TALE lamps intensity is decreased when
side lights are activated. The 2 different luminance
levels are defined as 100% during daytime use and
50% when backlighting is active.
The display intensity of luminance will be 6 cd/m2

(not dimmed). The maximum available luminance
spread will be 30%. To avoid dark zones the maxi-
mum difference of intensity of luminance between
closed points is 15%. Note that the matrix backlight-
ing may go to 0 by customer selection. Telltales and
the audible alarm will still be present to alert the cus-
tomer a warning condition exists.
DIMMING LAW
The dimming adjustment is done through the setup
menu, it can be used in single. In single step mode,
the luminance level go from min to max value in 10
steps.
The luminance levels of display and gauges always

varies in parallel.
The cluster switches between day and night lumi-
nance levels using the work and driving light status,
and is able to manage the display and gauges inde-
pendently using the same law and customer setting.
Only the night settings can be adjusted since the
day setting of the display is 100% intensity.
During dimming setup the matrix shows the dim-

ming symbol together with the percentage of lumi-
nance: its value varies using a step of 10%. The
dimming symbol appears when the proper menu is
selected and stays on the matrix for at least 2 s.
The dot matrix visualization will be as follows:
The default value is 80% and the may go to zero if

set by the customer.
4.6 WORK HOURS
In order to allow service or the customer to view ve- Z once in the adjustment mode the meaning of the
hicle hours of operation, it will not be necessary to arrow UP switch is “increase hour meter value”,
have the key. By pressing the enter/display/up/ and the meaning of arrow DOWN switch is “de-
down switch, with the key-off, the cluster must wake crease hour meter value”. Single switch pressure
up and display hours for 10 seconds. will increase or decrease the value of one unit
The hour meter increments when the engine is run- (6 min). Continuous switch pressure will increase
ning (rpm > 600). The hours are visualized starting or decrease the value continuously (1 every 300
from 0.0 until 210,554,060.7 using a step of 6 min- milliseconds): when the value reaches a multiple of
utes. In case of battery disconnection, the cluster 10, the increment/decrement rate is 10 units every
can lose 0.1 hour or 6 minutes max. 300 ms; when the value reaches a multiple of 100,
the rate is 100 units every 300 ms; when the value
WORK HOURS SETTING reaches a multiple of 1000, the rate is 1000 units
In order to allow service to install a new Vehicle every 300 ms.
Control Module (VCM) on an old vehicle, it is possi-
ble to increase (no decrease will be allowed) the During continuous setting the value stops flashing.
hour to the same setting as the original. Once the operator has reached the desired value
To modify the hour meter value, execute the follow- press and hold down the arrow UP and display
ing procedure: switches for 15 seconds to end setting procedure. It
Z select the hour meter function on the display; is not possible to set a value lower than the current
Z press and hold depressed for 15 seconds “arrow one, and the procedure can be repeated three times
UP” and “display” until the value shown on display in the cluster life.
starts to blink (1 Hz, duty 50%);
Service hours
Power up LCD and show work hours

for 10 seconds
Any of the above at with ignition low
To save the new value

Hourmeter setting
0.1, 1, 10, 100 or 1000 hours

step depending on
With key to ON press for 15 seconds continuous time pressed
Blinking to indicate To exit without saving

ability to edit values
Value may only increase for the hourmeter. While setting the value it can be decreased due to
operator overshoot, but the value can not be stored if it is below the current stored value.
Pressing DISPLAY will exit without saving. ENTER must be pressed to store the modified value
in protected memory.
4.7 FUNCTIONAL DESCRIPTION
Auto wake up at every 600 ms for sensing a change At key off all the needles have to be put into parking
in ENTER, DISPLAY, UP or DOWN switch status position. parking position will be hard against inter-
will be provided. Upon sensing of one of those in- nal stepper motor stops. At key on the following flow
puts transition, the cluster has to wake up. must be followed.
As a general rule, during cranking, all warnings ac-
tivation and all gauges movements have to be fro-
zen unless we detect an error on the cranking line.
Needle collision
control at key-on
At key-on drive all

needles CCW for 1
second
Vibration, service,
transport or battery If RTZ is observed TRUE
loss can generate a on all 5 gauges
FALSE
FALSE
Remove power from gauges:

- engine coolant
- fuel level
Drive gauges until they reach:

- tachometer
- transmission temp
- battery voltage
Drive gauges:
- engine coolant
- fuel level
Start all normal

display functions
TACHOMETER - ENGINE SPEED GAUGE Audible alarm output needs to be activated when
The tachometer accuracy should be less than or the engine temperature exceeds 106 °C (222 °F).
equal ±50 rpm. The above specified tolerances In case the sender is disconnected, the gauge has
must be respected in all operating ranges (tempera- to go to 65 °C (149 °F) position. Reconnecting the
ture, voltage, etc.). A stepper motor will drive the ta- sensor the gauge has to return to the correct posi-
chometer. Needle calibration has never to be lost for tion. Both the movements have to be uniform.
any external condition. The behavior of the gauge in case of faulty sensor
The message to be used is EEC1. will be to return to the parked position. Since this
signal is a function of the engine controller the ap-
EEC1 message Gauge position propriate warning lamp and telltale will be illuminat-
0000 0 rpm ed. During cranking, the needle movement shall be
frozen in order to inhibit any spurious movement of
0001 => FFFD According to the value it.
Green field 0 - 2500 rpm
VOLTMETER GAUGE
Red field 2500 - 3000 rpm
The voltmeter will indicate the voltage of the vehicle
FFFF 0 rpm electrical system. This gauge will have three operat-
ing ranges: two reds and one green. One red range
will indicate low voltage. The other red will indicate
The behavior of the gauge in case of faulty sensor
high voltage. The green range will indicate normal
will be to return to the parked position. Since this
operating voltage.
signal is a function of the engine controller the ap-
Z Bottom of the scale will be 9 V.
propriate warning lamp and telltale will be illuminat-
Z Low voltage range is 11 V or less. The CL of the
ed. During cranking, the needle movement shall be
pointer will be ±3° of the centerline of the tick mark
frozen in order to inhibit any spurious movement of
that indicates 11 V.
it.
Z The normal operating range will be 11 V to 16 V.
ENGINE COOLANT TEMPERATURE GAUGE Z High voltage range is 16 V or higher. The CL of the
pointer will be ±3° of the centerline of the tick mark
A stepper motor will drive water temperature gauge. that indicates 16 V.
The gauge accuracy should be less than or equal Z Top of the scale will be 18 V.
3%. Needle calibration has never to be lost for any A stepper motor will drive the voltmeter gauge. The
external condition. gauge accuracy should be less than or equal 3%.
Gauge Temperature Needle calibration has never to be lost for any exter-
nal condition. Loss of voltmeter sensor will be the
+65 to +112 °C loss of the internal VCM A/D converter. During
Gauge indication range
(+149 to +233 °F) cranking, the needle movement shall be frozen in
+65 to +106 °C order to inhibit any spurious movement of it.
Green field A/D accuracy is specified as ±180 mV during self
(+149 to +222 °F)
test operation.
+106 to +112 °C
Red field
(+222 to +233 °F)
The message to be used is engine temperature.

Engine temperature
Gauge position
message
According to the logic
00 => FD
above
FE Minimum value
FF Minimum value
TRANSMISSION OIL TEMPERATURE GAUGE

The oil temp gauge indicates transmission oil tem-
perature from 75 °C to 115 °C (167 °F to 239 °F).
This gauge is broken up into two ranges, green and
red. The green zone is 75 °C to 106 °C (167 °F to
222 °F). The red zone is from 105 °C to 115.5 °C
(221 °F to 240 °F)). This gauge will be connected to
a sensor that will provide a specific resistance to
correlate to a specific oil temperature.
Gauge Temperature
+75 to +115 °C
Gauge indication range
(167 °F to 239 °F)
+75 to +105 °C
Green field
(221 °F to 239 °F)
+105 to +115 °C
Red field
(221 °F to 239 °F)
Z 5 V = 75 °C (221 °F). The CL of the pointer will be

±2 angular degrees of the centerline of the tick
mark that indicates this temperature.
Z 2.6 V = 93.3 °C (200 °F). The CL of the pointer will
be ±3 angular degrees of the centerline of the tick
mark that indicates this temperature.
Z 2.05 V = 115.5 °C (240 °F). The CL of the pointer
will be ±2 angular degrees of the centerline of the
tick mark that indicates this temperature.
The same range of temperature is used for power-

shift and powershuttle transmissions. The gauge
will move 9 angular degrees at key-on in the clock-
wise position to replicate the current production
cluster behavior. This is necessary due to the cool
temperatures present when the unit is working in
backhoe position. In case the sender is disconnect-
ed, the gauge has to go down to home position. Re-
connecting the sensor will make the error code
inactive and the gauge has to return to the correct
position. Both the movements have to be uniform.
A stepper motor will drive the transmission oil tem-
perature gauge. The gauge accuracy should be less
than or equal ±2%. Needle calibration has never to
be lost for any external condition. During cranking,
the needle movement shall be frozen in order to in-
hibit any spurious movement of it.
FUEL LEVEL GAUGE

When a certain low fuel level is reached, the relevant
“low fuel” lamp will be lit according to the following
logic. The filtering of the data read is obtained with a
hysteresis on the resistance value joined to a delay
time of 2 seconds.
Ohmic parameter threshold and delay time value
must be kept in NVM. Lamp activation depends on
values used for needle movement; this means that
at key-on the low fuel level warning is active if the
cluster sees a resistance value greater the table be-
low.
Resistance values used are as follows:

The fuel level gauge will indicate the fuel level of the
vehicle tank. The gauge dial will be divided in to two
ranges: red and green. The red range will indicate a
low fuel zone. The green range will indicate a non-
low fuel zone. This gauge will be connected to a sen-
sor that will provide specific a resistance to correlate
to a specific fuel tank level.
Red-green border Fuel level
Tank size Empty value (X) Full (Z) value
(Y) indicated
30% with 18
133 l/35 gal 320 ohms 186 ohms 6.5 ohms angular degrees of
gauge motion
Z X = empty. The centerline (CL) of the pointer will be

+0/-2 angular degrees of the centerline of this emp-
ty mark.
Z Y = Red - Green threshold. The CL of the pointer
will be +/-3 angular degrees of the centerline of this
1/2 mark.
Z Z = full. The CL of the pointer will be +4/-0 angular
degrees of the centerline of this full mark.
In case the sender is disconnected, the gauge has to

go down in empty position. Reconnecting the sensor
the gauge has to return to the correct position. Both
the movements have to be uniform.
A stepper motor will drive fuel level gauge. The
gauge accuracy should be less than or equal ±2%.
Needle calibration has never to be lost for any exter-
nal condition. During cranking, the needle movement
shall be frozen in order to inhibit any spurious move-
ment of it.
4.8 WARNING SYSTEM
The diagnostic has to inform the operator regarding

all the operating conditions of the loader backhoe
which are out of range. These conditions are differ-
ent from each other:
Z Warnings
Z Error codes
Z Faults on the system
Z Action Required
1. We can define warnings as all those situations

that could be dangerous for the TLB or for the op-
erator. The diagnostic will turn the display Red or
as well as activate the buzzer; the display will
show an icon symbol that identifies the occurring
problem.
2. There are conditions in which the diagnostic de-
tects one of its sensors out of order: in this case
it will generate an error code. Depending on the
severity it will control the appropriate lamp and
audible alarm: the display will display the appro-
priate Icon together with the error code number.
3. When there is the need to inform the operator
that he/she has done an incorrect maneuver or,
that he/she has to do a particular action in order
to proceed (Action required), the diagnostic
again, will display an icon and/or activate the
proper audible alarm.
ALARM ACTIVATION
A failure is present but the operator can continue his work: the purpose is to warn him
Non Critical
regarding the presence of the fault. This will be a 1 second beep every 30 seconds.
A serious fault that can affect either the safety of the operator or the damage of the
Critical loader backhoe is present: the operator shall stop the loader backhoe. This will be a
continuous alarm.
The system is asking for a certain maneuver from the operator in order to return to the
Action Required
normal functionality. This will be a continuous alarm.
The system purpose is to warn the operator regarding the presence of a dangerous
Safety
situation for his safety. This will be a continuous alarm.
There are some condition in which there is the need of an activation of the audible
General Sound
alarm. This is a one second beep to draw the operators attention to the cluster.
Whenever a audible alarm activation is related to an

icon visualization, this icon should remain displayed
at least for 4 seconds in order to give the possibility
to the operator to understand the cause of the sound
activation.
When many warnings with different priority occur,
the audible alarm is related to the higher priority
warning.
When a new warning having a audible alarm activa-
tion type different from the current one occurs, the
corresponding icon visualization must start simulta-
neously.
If a dedicated function lamp is associated to the
cause of the audible alarm activation, if appropriate,
the lamp will be lit together with the audible alarm ac-
tivation.
4.9 MAINTENANCE
Two different kinds of maintenance will be available: HEAVY MAINTENANCE

Z light maintenance; From 10 hours before the set value, display on the
Z heavy maintenance. display the “heavy maintenance symbol” at every
key on and should last for 1 second after cranking.
LIGHT MAINTENANCE
After cranking after this, the last selected icon will be
From 2 hours before the set value, display on the visualized on the display. The hours shown will be
display the “light maintenance symbol” at every key the hours when light maintenance is required, not
on for 1 second after cranking; after this, the last se- the standard hourmeter.
lected icon will be visualized on the display. The
hours shown will be the hours when light mainte- HEAVY
nance is required, not the standard hourmeter. 1000
In Amber backlighting
LIGHT
500
The interval can be set between 50 and 500 hours
In Amber backlighting in steps of 100 (0.0, 500, 600, 700, 800, 900, 1000).
The 0.0 setting turns the heavy maintenance feature
The interval can be set between 50 and 500 hours off.
in steps of 50 (0.0, 50, 100, 150, 200, 250, 300, 350,
400, 450, 500). The 0.0 setting turns the light main-
tenance feature off.
DISPLAY FUNCTIONALITY
When the hourmeter reaches the light service interval
3 seconds
MAIN SCREEN
LIGHT
3 seconds
500
GREEN AMBER
Audible alarm for 1 second when displaying either service interval the first time
When the hourmeter reaches the heavy service interval
3 seconds
MAIN SCREEN
HEAVY
3 seconds
1000
GREEN AMBER
Audible alarm for 1 second when displaying either service interval the first time
Since heavy maintenance contains light maintenance the following will be shown:
500 - Light
1000 - Heavy
1500 - Light
2000 - Heavy
The service indicator message will be cleared with a single key cycle
4.10 WARNING MESSAGES
Fault Display
Function Alarm Lamp Condition DTC SA Description Priority Color
lamp lamp
Coolant
Coolant
Engine STOP above
temperature
coolant too Continuous 112 °C 1002 VCM 1 Red
signal - Above
high (233.6 °F) for
normal
5 seconds
Pressure Oil pressure
Engine oil STOP < 26 bar sensor -
pressure too Continuous 3028 ECU 1 Red
(37.7 psi) pressure too
low
rpm>500 low
The engine
Switch
Transmission STOP must be
closed to
oil pressure Continuous 1008 VCM running with 1 Red
ground for 25
too low switch closed
seconds
for 25 seconds
5 seconds
Timeout of
Malfunction STOP Continuous without 1051 ECU 1 Red
message
message
25 seconds
Timeout of
Malfunction STOP Continuous without 1053 ECU 1 Red
message
message
Timeout of
5 seconds
STOP message
Malfunction Continuous without 1054 VCM 1 Red
engine
message
temperature
5 seconds Timeout of
Malfunction STOP Continuous without 1055 VCM message inlet/ 1 Red
message exhaust
Malfunction STOP Continuous without 1056 VCM message 1 Red
message engine fluid
Timeout of
5 seconds
STOP message
Malfunction Continuous without 1057 VCM 1 Red
vehicle
message
electrical
Malfunction STOP Continuous without 1059 VCM message 1 Red
message display
Transmission
Transmission Transmission
STOP oil above
oil oil
Continuous 115 °C 1009 VCM 1 Red
temperature temperature
(239 °F) for 5
too high limit reached
seconds
Fault Display
lamp lamp
General Only display
DTC’s 3000 -
display STOP Continuous STOP with display 1 Red
3366
message request
One touch AUTO N/A VCM 1 Red

idle active
n/min
Continuous, Switch This prevents

Park brake
if vehicle is closed to N/A VCM park brake 2 Red
engaged
in gear ground damage
Sender
Warns
Brake temperature
customer
temperature Continuous over 152 °C 1006 VCM 2 Red
before brake
too high (305.6 °F)
fade
for 5 seconds
Switch
Brake fluid STOP closed to
Continuous 1007 VCM 2 Red
level low Vbat for 5
seconds
Engine oil Pressure
pressure too STOP Continuous depends on 3032 ECU 2 Red
high speed
Battery
Battery
charge
Continuous 3051 ECU voltage too 2 Red
voltage too
high
high
Battery Supply
Supply battery
charge source
Continuous 1014 VCM voltage above 2 Red
voltage too above 16 V
16 V
high for 5 seconds
Battery
Battery
charge
Continuous 3052 ECU voltage too 2 Red
voltage too
low
low
Battery Supply
Supply battery
charge source below
Continuous 1015 VCM voltage below 2 Red
voltage too 11 V for 5
11 V
low seconds
Alternator L+
Alternator not Alternator
terminal
able to Continuous 1050 VCM unable to 2 Red
under 1.5 V
charge charge
for 5 seconds
Foot IVS not Foot
One second
accelerator changing accelerator
alarm every 1010 VCM 2 Amber
signal out of state in sensor - not
30 seconds
range 300 ms plausible
Fault Display
lamp lamp
Foot Foot
One second Accelerator
accelerator accelerator
alarm every above 4.75 V 1011 VCM 2 Amber
signal out of sensor -signal
30 seconds for 5 seconds
range above range
Foot Foot
alarm every below 0.25 V 1012 VCM 2 Amber
range below range
Foot Foot
One second
signal out of sensor -no
30 seconds
range signal
Foot
Foot
One second Voltage over accelerator
accelerator
alarm every 9 V for 5 1029 VCM sensor - 2 Amber
signal out of
30 seconds seconds shorted high to
range
Vbat
Foot
Foot
One second Voltage accelerator
accelerator
alarm every under 0.5 V 1030 VCM sensor - 2 Amber
signal out of
30 seconds for 5 seconds shorted low to
range
Vbat
Foot
Foot One second Voltage over
accelerator
accelerator alarm every 5.1 V for 5 1023 VCM 2 Amber
supply voltage
5 V supply 30 seconds seconds
too high
Foot
Foot One second Voltage
accelerator
accelerator alarm every under 4.9 V 1024 VCM 2 Amber
supply voltage
5 V supply 30 seconds for 5 seconds
too low
Foot
Foot One second Voltage over
accelerator
accelerator alarm every 9 V for 5 1025 VCM 2 Amber
supply shorted
high to Vbat
Foot
Foot One second Voltage accelerator
accelerator alarm every under 0.5 V 1026 VCM supply shorted 2 Amber
5 V supply 30 seconds for 5 seconds low
to ground
Fault Display
lamp lamp
Hand Hand
alarm every above 4.75 V 1035 VCM 2 Amber
range above range
Hand Hand
alarm every below 0.25 V 1036 VCM 2 Amber
range above range
Hand Hand
One second
signal out of sensor - no
30 seconds
range signal
Hand
Hand
One second Voltage over accelerator
accelerator
alarm every 9 V for 5 1038 VCM sensor - 2 Amber
signal out of
30 seconds seconds shorted high to
range
Vbat
Hand
Hand
One second Voltage accelerator
accelerator
alarm every under 0.5 V 1039 VCM sensor - 2 Amber
signal out of
30 seconds for 5 seconds shorted low to
range
ground
Hand
Hand One second Voltage over
accelerator
accelerator alarm every 5.1 V for 5 1031 VCM 2 Amber
supply voltage
too high
Hand
Hand One second Voltage
accelerator
supply voltage
too low
Hand
Hand One second Voltage over
accelerator
accelerator alarm every 9 V for 5 1033 VCM 2 Amber
supply shorted
high
Hand
Hand One second Voltage
accelerator
supply shorted
low
Switch
This must
closed to
Seat not in have a
ground with
driving Continuous N/A VCM debounce time 2 Amber
vehicle in
position of less then
gear and no
500 ms
park brake
Fault Display
lamp lamp
Boost
temperature Engine over
Boost air One second
over operating
temperature alarm every 1018 VCM 3 Amber
88 °C boost air
too high 30 seconds
(190 °F) for 5 temperature
seconds
Coolant
Engine over
Engine One second above
operating
coolant too alarm every 106 °C 1019 VCM Amber
coolant
high 30 seconds (222.8 °F) for
temperature
5 seconds
Coolant
Engine One second
temperature
coolant too alarm every 3007 ECU 3 Amber
signal source
high 30 seconds
high
Coolant
Transmission
One second above Transmission
oil above
alarm every 105 °C 1020 VCM over operating 3 Amber
105 °C
30 seconds (221 °F) for 5 temperature
(221 °F)
seconds
Fuel over
Fuel One second Fuel over
82 °C
temperature alarm every 1021 VCM operating 3 Amber
(179.6 °F) for
too high 30 seconds temperature
5 seconds
Fuel
Fuel One second
temperature
temperature alarm every 3015 ECU 3 Amber
signal source
too high 30 seconds
high
Fuel
Fuel One second
temperature
temperature alarm every 3016 ECU 3 Amber
signal no
too high 30 seconds
signal
Switch
One second
Air filter closed to Air filter
alarm every 1001 VCM 4 Red
restriction ground for 5 threshold
30 seconds
seconds
Switch
Air One second Air
closed to
conditioning alarm every 1003 VCM conditioning 4 Amber
Vbat for 5
not functional 30 seconds high pressure
seconds
Switch
Hydraulic One second
closed to Hydraulic filter
filter alarm every 1004 VCM 4 Red
ground for 5 threshold
restriction 30 seconds
seconds
Fuel One second
Display
contaminated alarm every 1022 VCM 4 Amber
message
with water 30 seconds
Fault Display
lamp lamp
One second Fuel sender Fuel sender
Fuel level
alarm every above 9 V for 1043 VCM shorted high - 4 Amber
sensor
30 seconds 5 seconds park gauge
One second Fuel sender Fuel sender
Fuel level
alarm every below 0.5 V 1044 VCM shorted low - 4 Amber
sensor
30 seconds for 5 seconds park gauge
Input is
One second Fuel sender
Fuel level switched
alarm every 1045 VCM open circuit - 4 Amber
sensor battery for 5
30 seconds park gauge
seconds
Transmission
Transmission
Transmission One second temperature
temperature
temperature alarm every sender 1046 VCM 4 Amber
sender
sensor 30 seconds above 9 V for
shorted high
5 seconds
Transmission
Transmission
Transmission One second temperature
temperature
temperature alarm every sender below 1047 VCM 4 Amber
sender
sensor 30 seconds 0.5 V for 5
shorted low
seconds
Input is
Transmission One second Transmission
switched
temperature alarm every 1048 VCM temperature 4 Amber
battery for 5
sensor 30 seconds open circuit
seconds
Brake
Brake One second Sender over
temperature
temperature alarm every 1000 ohms 1049 VCM 4 Amber
sender out of
sensor 30 seconds for 5 seconds
range
General Only display
One second DTC’s 3000 -
display VCM with display 4 Amber
alarm 3366
message request
Low fuel -
Low fuel One second must stay on
VCM 5 Amber
warning alarm for remaining
key cycle
5. STARTING SYSTEM
The system includes a key switch, reinforced ca-

bling, a motor and a relay and solenoid assembly.
This is a starter motor with built-in solenoid and pos-
itive engagement drive system.
When the key switch is operated with the forward
and reverse travel lever in the neutral position, the
solenoid windings are energized and cause the mo-
bile core to be drawn inside the solenoid.
This movement causes the drive pinion to mesh with
the ring gear on the engine flywheel. When the ring
gear and the drive pinion are engaged, the mobile
core of the solenoid closes a series of contacts en-
abling the battery to power the field coils directly and
provide the entire power to the starter motor.
The starter motor contains only a single set of con-
tacts and a mobile core, which closes the contacts
completely, even if the teeth of the drive pinion and
the gear are not aligned. In this case, a spring is
compressed and forces the complete engagement of
the pinion as soon as the starter motor starts rotat-
ing.
Once the ignition is turned off, the solenoid and the
starter motor are de-energized. The solenoid’s recoil
spring causes the drive pinion to be uncoupled and
the contacts of the solenoid to reopen.
5.2 FAULT FINDING
The motor does not start if the ignition key is operated and the transmission is in the neutral position.
Is the battery properly charged? NO Charge or replace the battery

YES
Check the starter motor cabling. Are there bad Repair or replace the cables
connections, cut or stripped cables? YES
NO
Is the starter motor seized? YES Repair or replace the starter motor
NO
Operate the key switch. Is there a Does the solenoid Windings, brush or starter
voltage of +12 V on the (white) wire at make a “clicking” YES motor mechanism possibly
the input of the starter motor solenoid YES
sound? defective.
(terminal 30)?
NO
NO
Check the starter motor relay (K01). Solenoid possibly

Can one hear the relay operate after defective. Remove the
operating the key switch? starter motor and inspect
NO
Remove the connector from the relay (K01). Is there a voltage of

+12 V at terminal 86 (white/black) after the key switch is YES Replace the relay
operated?
NO
Check the starter motor safety relay (K3). Can one hear the relay
operate after operating the reverse travel lever?
NO
Remove the connector from relay K3. Is there a voltage of +12 V

YES Replace the relay
at terminal 86 (white/black) after the reverse travel lever is
NO
Are the cable wires of the reverse travel lever properly Reconnect the wires to the
NO
connected? switch
YES
Does the reverse travel lever switch operate correctly? NO Replace the switch
YES
Check the main power
Are the indicators on the instrument panel correctly lighted supply between the battery
after operating the key switch? NO
and the starter motor key
YES switch. Pin 2 (red wire) of
the ignition key connector.
Are the cable wires of the key switch connected correctly?
YES NO
Replace the key switch. Reconnect the wires to the key

switch
CHECKING THE STARTER MOTOR SYSTEM

To troubleshoot the starter motor system rapidly and
easily, it is recommended that a battery-starter motor
testing device (quick discharge) be used, which in-
cludes a 0-20 V voltmeter and a 0-500 A ammeter to
detect problems in the starter motor system.
Use a testing device in accordance with the manu-
facturer’s instructions. If a testing device of the type
indicated is not available, use a standard 0-20 V volt-
meter and a 0-500 A ammeter to check the operation
of the starter motor on the vehicle.
Before testing:
Z Check that the battery is properly charged.
Z Check the state of the starter motor system, by
making sure that no wire is cut or stripped and that
the connections are not loose.
Z Check that the motor is not seized.
Current draw of the starter motor system:

1. Disconnect the ground cable (negative) from the
battery (3).
2. Disconnect the positive cable from the battery on
the solenoid of the starter motor. Connect the
positive cable of the ammeter (1) to the positive
terminal of the battery and the negative cable to
the input terminal of the solenoid.
3. Reconnect the ground cable (negative) of the
battery to the negative terminal of the battery.
4. Connect the positive cable of the voltmeter (2) to
the positive terminal of the battery and the neg-
ative cable of the voltmeter to the negative termi-
nal of the battery.
5. Disconnect the injection pump fuel inlet cut-off
wire from the solenoid.
6. Start the motor and observe the values indicated
by the voltmeter and ammeter. The voltage must
remain steady at around 12 V with a current
draw of 250 to 300 A.
Z If the current draw is within the indicated range, the
starter motor (4) is operating correctly. If the voltage
reduces during the test, refer to the “Resistance of
the starter motor system” section below.
Z If the current draw is higher than the specified
range, check the system as indicated below. If tests
of the starter motor system have proved satisfacto-
ry, the starter motor is defective and must be re-
moved in order to identify the source of the
problem.
Z If the current draw is less than the specified range,
the starter motor is defective and must be removed
in order to identify the source of the problem.
RESISTANCE OF THE STARTER MOTOR

SYSTEM
(Voltage lowering)
If the current draw is excessive, check the system by
noting down the voltage lowers at various compo-
nents of the system.
IMPORTANT: disconnect the injection pump fuel in-

let cut-off wire from the solenoid.
Positive cable of the battery:

the positive terminal of the battery (2).
2. Connect the negative terminal of the voltmeter
(1) to the terminal connected to the battery of the
starter motor solenoid (3).
3. Start the starter motor and observe the reading
on the voltmeter. If the voltage lower is greater
than 0.2 V, check and retighten the cable con-
nections. Check the voltage again. If it is still ex-
cessive, replace the cable.
Connections to the starter motor ground:

the body of the starter motor (2).
2. Connect the negative cable of the voltmeter (1)
to the motor block (3).
than 0.2 V, check and retighten the cable con-
nections, check the ground connections be-
tween the starter motor clamp and the
undercarriage.
Ground cable of the battery:

the motor block (2).
2. Connect the negative cable of the voltmeter (1)
to the negative terminal of the battery (3).
than 0.2 V, check and retighten the ground cable
connections. Check the voltage again. If it is still
excessive, replace the ground cable.
5.3 STARTER MOTOR
TECHNICAL SPECIFICATIONS
Manufacturer............................................................................................................................................. Denso
Voltage......................................................................................................................................................... 12 V
Rated power........................................................................................................................ 2.7 kW (2000 ft.lb/s)
Starting system ....................................................................................................................................... Positive
Operating time ..............................................................................................................................................30 s
Direction of rotation.................................................................................... Clockwise seen from the pinion side
Weight........................................................................................................................................8.4 kg (18.5 lbs)
Maximum consumption without load at 11 V and 3000 rpm minimum...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm (14.5 lbf.ft) at 8 V and 1130 rpm minimum 600 A maximum
Maximum consumption when shimming at 3 V with a torque of 39.2 Nm (28.9 lbf.ft) minimum.... 1400 A maxi-
mum
MAIN COMPONENTS
1. Motor
2. Induction coils
3. Armature
4. Commutator
5. Brush assembly
6. Pinion gear
7. Intermediate pinion
8. Solenoid
9. Clutch
10. Drive pinion
1. Felt washer
2. Ball bearings
3. Armature
4. Ball bearings
5. Housing and induction coils assembly
6. Protection
7. Brush spring
8. Brush assembly
9. Brush bracket
10. Rear protective cover
11. Screw and washer
12. Screw
13. Ventilation drain of the rear hood
14. Screw and washer
15. Solenoid hood
16. Union
17. Spring washer
18. Nut
19. Push-rod
20. Connection assembly
21. Screw
22. Connection assembly
23. Nut
24. Retaining ring
25. Roller
26. Roller cage
27. Pinion
28. Ball
29. Spring
30. Ventilation drain of the solenoid housing
31. Screw
32. Flat washer
33. O-ring
34. Starter motor box
35. Pinion, rings and spring assembly
36. Union
37. Ball bearings
38. Ball bearings
39. Spring
40. Shaft pinion
41. Solenoid housing
42. Clutch assembly
REMOVING AND INSTALLING THE STARTER

MOTOR
Z Disconnect the ground cable (negative) from the
battery.
Z Remove the rear protective cover and disconnect
all cables connected to the starter motor.
Z Remove the three retaining bolts of the starter mo-
tor and remove the starter motor.
Z To install the starter motor, proceed in the reverse
order to that of removal.
TEST BENCH CHECK
Checking the starter motor without load
NOTE: before carrying out the test, check that the

battery is fully charged then obtain a battery-starter
motor testing device (quick discharge) and a carbon
cell (variable load resistance).
Z Lock the starter motor in a vice with soft jaws.

Z Connect the negative cable (4) of the battery to the
mounting clip of the starter motor.
Z Connect a short cable (6) between the solenoid
battery wire and the terminals of the solenoid
switch.
Z Connect the positive cable of the voltmeter (3) to
the positive terminal of the battery, the negative ca-
ble of the voltmeter to the negative terminal of the
battery, the positive cable of the ammeter (1) to the
positive terminal of the battery and the negative ter-
minal of the ammeter to the terminal of the battery
or the starter motor.
Z Install a tachometer (5) at the end of the armature
shaft. Activate the starter motor by adjusting the
carbon cell (2) to obtain a voltage of 11 V. When
the armature is rotating at 3000 rpm, the maximum
current draw must not exceed 200 A.
Z If the starter motor does not fulfil these conditions,
check that the field coils are not grounded, that the
armature is not rubbing and that its shaft is not de-
formed.
Armature
Z The surface of the commutator must be clean and
without traces of burns. If necessary, remove trac-
es of burns using fine sandpaper. Do not use em-
ery cloth. Then, clean the commutator with a cloth
soaked in gasoline.
Z After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in gas-
oline.
NOTE: make sure not to graze the metal of the com-

mutator during rectification of insulating notches.
Z The resistance of the armature insulation may be

checked by connecting an ohmmeter (1) between
the blades of the commutator (2) and the armature
shaft (3). The resistance must be infinite (no conti-
nuity).
Z To check that the armature is not short-circuited, a
special device for armatures must be used. The
other solution is to replace the armature.
Z If the circumference of the armature has come into
contact with the starter pole shoes, the bearings of
the armature are probably excessively worn out.
First check that the starter pole shoes have been
tightened and that the armature rotates without any
concentric defect. If necessary, replace the arma-
ture bearings.
Field coils
Z To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
Z To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
Z If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Drive pinion
Z The drive pinion must only rotate clockwise. If the
pinion is seized or turns in both directions or if its
teeth are damaged, change the complete drive as-
sembly.
NOTE: if the teeth of the drive pinion are damaged,

also check the teeth of the engine flywheel ring gear,
as described in section 10 “Engine circuit”.
FAULT FINDING

Poor battery specific gravity and
Inspect battery.
level
Starter does not rotate (magnetic
Poor ignition switch system
switch does not make an Replace wiring and ignition switch.
connection or contact
operating noise)
Malfunction of the magnetic
Replace magnetic switch.
switch pull-in coil or plunger
Poor battery specific gravity and
Inspect battery.
level
Poor start-up circuit contact

Repair wiring.
Starter does not rotate (magnetic
switch makes an operating noise) Poor contact of magnetic switch
contact
Motor assembly malfunction (e.g.

Repair or replace motor assembly.
layer short, brush wear)
Poor contact of magnetic switch
contact
Starter rotation is slow
Motor assembly malfunction (e.g.
Repair or replace motor assembly.
layer short, brush wear)
Pinion gear does not engage with Repair or replace the clutch and
Starter rotation cannot crank the ring gear drive lever.
engine
Clutch sliding Replace clutch.
Abnormal bushing wear Replace bushing.
Wear on pinion gear or ring gear Replace clutch and ring gear.
Abnormal noise
teeth tips
Poor pinion gear sliding Lubricate or replace clutch.

Pinion gear springing out Poor ignition switch return
Replace ignition switch.
Field coil loss Pinion gear disengagement fault
caused by a coil layer short in the Replace magnetic switch.
Magnetic switch coil burn, etc. magnetic switch
6. ALTERNATOR
Manufacturer............................................................................................................................................. Denso
Rated voltage............................................................................................................................................... 12 V
Polarity .................................................................................................................... Negative terminal grounded
Current ........................................................................................................................................................ 90 A
Minimum charging speed..................................................................................................................... 1400 rpm
Maximum speed................................................................................................................................... 9000 rpm
Operating temperature................................................................................... -30 °C to 90 °C (-22 °F to 194 °F)
Direction of rotation.................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 °C (77 °F) .............................................................14.2 - 14.8 V
Maximum load that can be applied at terminal L ............................................. 12 V, 3.4 W x 6 (2519 ft.lb/s x 6)
The alternator, installed on the motor, on the front

RH side of the vehicle, is driven by the crankshaft
pulley with the help of a belt. The alternator contains
built-in regulators.
Current draw of the starter motor circuit:

When the ignition key is turned, a current of low in-
tensity is sent by the battery to the field winding of
the rotor (terminal IG).
At this stage, the indicator lamp (terminal L) turns on
and the rotor is partially magnetized.
When the motor starts and the partially magnetized
rotor rotates inside the stator, a three-phase alter-
nating current is generated (terminal B+). A constant
1. Ground connection
portion of this current is transformed into a direct cur-
2. Terminal P: motor tachometer
rent by three excitation diodes installed in the rectifi-
3. Terminal L: charge indicator
er.
4. Terminal B+: charge +12 V
The direct current is sent as reinforcement through
5. Terminal IG: +12 V after ignition (10 A fuse)
the field winding of the rotor.
Using this method an increase in the magnetic field
of the rotor is obtained, as well as a rapid rise in the
voltage and current generated at the output.
The luminosity of the indicator lamp decreases when
the voltage generated at the output is increasing (ter-
minal L). The indicator lamp turns off when the volt-
age at terminal “L” is equal to that of the battery.
The voltage continues to increase up to the value
predefined by the regulator.
In case the alternator belt is broken, the voltage does
not accumulate in the alternator and the load indica-
tor lamp remains lighted to indicate the problem.
DIAGRAM OF THE CHARGING CIRCUIT
1. Alternator
2. Output winding of the rotor
3. Rectifier
4. Regulator
5. Starter motor
6. Battery
7. Key switch
8. Charge indicator
9. Motor tachometer
6.3 COMPONENTS
1. Front housing 16. Seal ring

2. Rear housing 17. Seal ring
3. Rectifier 18. Washer
4. Brush holder 19. Screw with washer
5. Regulator 20. Electrical terminal
6. Rear protective hood 21. Screw
7. Insulation ring 22. Ball bearing
8. Insulation ring 23. Ball bearing flange
9. Screw 24. Ball bearing flange
10. Screw 25. Stator
11. Nut 26. Stud bolt
12. Nut 27. Ball bearing
13. Rotor 28. Retaining plate
14. Pulley 29. Screw
15. Pulley nut
6.4 REMOVAL
Electrical disconnections of the alternator

1. Disconnect the negative cable from the battery.
2. Disconnect the battery cable (1) from terminal
B+ (2).
3. Disconnect the connector (3).
Removing the alternator

1. Free the tension roller (1) using a suitable
wrench, then remove the belt (2).
2. Remove the screw (3) and the nut (4).
3. Remove the screw (5).
4. Remove the alternator.
6.5 PRELIMINARY CHECK AND TESTS
To prevent damage to components of the alternator

charging circuit, the following precautions must be
taken during maintenance:
Z NEVER connect or disconnect a charging circuit
connection, including the battery, when the motor is
running.
Z NEVER dead short to ground any component of the
charging circuit.
Z ALWAYS disconnect the ground cable from the
battery (negative) to recharge the battery on the ve-
hicle using a battery charger.
Z ALWAYS respect the polarity when connecting the
battery on the vehicle or when connecting an auxil-
iary starter battery to the motor.
IMPORTANT: connect the positive cable to the pos-

itive terminal and the negative cable to the negative
terminal.
PRELIMINARY CHECKS
Before undertaking an electrical inspection, check
the charging circuit and the electrical circuit carefully.
Check the state of cables and the tightening of con-
nections.
Checking the battery

Check each cell of the battery with a hydrometer.
The battery must be charged at least 70% and be in
good condition.
Checking the drive belt

Check that the belt and the pulley of the alternator
are clean, without any trace of oil and grease and
that they are in good condition.
Checking the indicator lamp

Turn the ignition key and check that the charge indi-
cator is well lit.
If it is not fully lighted, check its bulb. If the bulb is OK,
check the alternator wire connections as described
in the “Preliminary tests” section below.
If the indicator lamp is lighted, start the motor and run
it at a speed that is higher than the idling speed. The
indicator lamp must turn off.
If the indicator lamp does not turn off, turn off the mo-
tor and disconnect the ground cable L. If the indicator
lamp turns off, an alternator component is defective.
Follow the instructions given in the “Checking the al-
ternator components” section below.
If the indicator lamp stays lighted, look for a dead
short to ground between the terminal “L” cable and
the indicator lamp.
PRELIMINARY TESTS
The preliminary tests may be carried out without re-
moving the charging circuit components, these tests
help check the following items:
Z Connections of the alternator cables
Z Charging current and regulated voltage of the alter-
nator
Z Voltage lowers in the alternator charging circuit
Z Maximum flow of the alternator
Required devices:
Z Voltmeter (0-30 V, moving coil)
Z Millivoltmeter (0-1 V)
Z Ammeter (0-110 A, moving coil)
Z Variable resistance of 1.5 Ohm, 110 A
NOTE: most testing instruments sold in shops group

together several measurement functions in a single
device. Use these devices in accordance with the
manufacturer’s instructions.
CHECKING THE CONNECTIONS OF THE

ALTERNATOR CABLES
Z Disconnect the terminals B+ (2) and L (3) from the
alternator.
Z Reconnect the battery and turn the ignition key
without starting the motor. Connect a voltmeter (4)
between each terminal (B+ or L) and the ground
(1). The voltmeter must show the battery voltage.
Z If there is no battery voltage, the external cable has
a continuity fault; in this case, check the entire cir-
cuit and carry out the necessary repairs.
Z Connect the terminal L indicator lamp wire to the
ground. The indicator lamp should turn on.
Z Disconnect the battery and reconnect the cables to
the alternator.
NOTE: if the indicator lamp does not turn on after

having reconnected the alternator, the regulator of
the alternator or the rotor circuits is defective. Make
sure that terminal L is clean, then check the compo-
nents of the alternator as indicated in this chapter.
CHECKING THE CHARGING CURRENT AND

THE REGULATED VOLTAGE
Z Make sure that all electrical components are pow-
ered off and that the ignition is turned off (key on
“off”).
Z Disconnect the negative terminal from the battery
and disconnect terminal B+ (4) from the alternator.
Z Connect an ammeter (1) between the disconnect-
ed cable (3) and terminal B+ of the alternator.
Z Connect a voltmeter (2) between terminal B+ of the
alternator and the ground.
Z Reconnect the battery. Start the motor and run it at
a speed of 2000 rpm. Observe the values shown
on the ammeter and the voltmeter.
The voltage shown on the voltmeter should at first be
too high and then should stabilize between 14.2-
14.8 V when the value on the ammeter lowers below
10 A.
If the voltmeter stabilizes at a voltage greater than
14.8 V, the regulator of the alternator needs to be re-
placed.
On the other hand, if the voltmeter stabilizes below
14.2 V, a component of the alternator is defective or
the resistance in the external connections of the
charging circuit is too high.
If the ammeter indicates zero amps, an alternator
component is defective.
Turn off the motor and carry out the operations de-
scribed in the “Checking the alternator components”.
CHECK THE VOLTAGE LOWERINGS IN THE

CHARGING CIRCUIT
Voltage lowers on insulated side

Check that the ignition is turned off (key on “off”).
Z Disconnect the negative cable from the battery and
disconnect cable B+ (1) from the alternator.
Z Connect a millivoltmeter (4) between the positive
terminal of the battery and cable B+ (5) (positive
side on cable).
Z Connect an ammeter (2) between terminal B+ of
the alternator and cable B+ (negative side on ca-
ble).
Z Reconnect the negative cable of the battery and
connect a variable resistance (3) between the bat-
tery terminals by adjusting the cursor to the mini-
mum current draw (maximum resistance).
Z Start the motor and increase its speed to 2000 rpm.
Z Gradually reduce the resistance until the ammeter
shows 90 A.
Z Observe the millivoltmeter, which must not indicate
a value that is greater than 400 millivolts.
If the value exceeds 400 millivolts, the resistance of
the external circuit is too high. If the output value of
the alternator is not sufficient and the millivoltmeter
indicates a value that is less than 400 millivolts, an
alternator component is defective. Carry out the op-
erations described in the “Checking the alternator
components”.
Z Switch off the motor.
Voltage lower on ground side

Z Check that the ignition is turned off (key on “off”).
Z Check the same circuit as the one in the previous
test, but by connecting the millivoltmeter (4) be-
tween the negative terminal of the battery and the
alternator body (negative side on body).
NOTE: make sure that the variable resistance (3) is

in the minimum current draw position (maximum re-
sistance).
Z Start the motor and increase its speed to 2000 rpm.

Z Gradually reduce the resistance until the ammeter
(2) shows 90 A.
Z Observe the millivoltmeter, which must not indicate
a value that is greater than 200 millivolts.
If the value exceeds 200 millivolts, the resistance of
the external circuit is too high.
If the output value of the alternator is not sufficient
and the millivoltmeter indicates a value that is less
than 200 millivolts, an alternator component is defec-
tive. Carry out the operations described in the
“Checking the alternator components”.
Z Switch off the motor.
CHECKING THE MAXIMUM OUTPUT OF THE

ALTERNATOR
Z Make sure that the ignition is turned off (key on
“off”).
Z Disconnect the negative cable from the battery and
disconnect cable B+ (5) from the alternator.
Z Connect an ammeter (2) between terminal B+ (1)
of the alternator and the disconnected cable B+
(negative side towards the cable).
Z Connect a voltmeter (4) between terminal B+ of the
alternator and the ground.
Z Reconnect the battery, start the motor and in-
crease its speed to 2000 rpm.
Z Gradually reduce the resistance (3) until the am-
meter shows 90 A.
Z Observe the voltmeter, which must not indicate a
value that is less than 14.2 V.
If the value lowers below 14.2 V, an alternator com-
ponent is defective.
Carry out the operations described in the “Checking
the alternator components”.
CHECKING THE ALTERNATOR COMPONENTS

Checking of components must be done only if the
PRELIMINARY TESTS reveal an alternator defect
which relates to the following components:
Z Regulator
Z Continuity of the rotor field winding
Z Brushes, springs and slip rings
NOTE: these checks may be carried out without re-

moving the alternator from the vehicle.
The alternator must be removed to check the other
components of the alternator.
Refer to the “Removal” section in this chapter.
IMPORTANT: before disconnecting the cables from

the alternator, make sure that the ignition is turned
off (key on “off”) and the negative cable of the battery
is disconnected.
Required devices:
Z 12 V battery
Z Multimeter
Z 2.2 W test lamp
CHECKING THE REGULATOR AND THE FIELD

CIRCUIT OF THE REGULATOR
Z Disconnect all cables from the alternator.
Z Connect a 12 V battery and a 2.2 W test lamp (2) in
series between terminal L (1) and the alternator
body (negative side on body).
Z The test lamp must turn on.
If the lamp does not turn on, the rotor circuit is defec-
tive. Check the brushes, the slip rings and the conti-
nuity of the rotor field windings.
If the inspection reveals that these components are
in good condition, the defect may be due to the reg-
ulator.
CHECKING THE CONTINUITY OF THE ROTOR

FIELD WINDING
Z Remove the regulator with the brush holder.
Z Connect an ohmmeter (3) between the slip rings
(2). The resistance must be 2.6 ohms at 20 °C.
If the resistance is not correct, replace the rotor (1)
as described in the “Removal” section below.
RECTIFIER - CHECKING THE POSITIVE /

NEGATIVE DIODES
Check each of the six diodes separately by proceed-
ing as follows:
Z Connect a multimeter (2) in series with one of the
diodes. Place one wire of the multimeter on the
connecting pin (1) of the diode and the other wire
on the plate where the diode is installed.
Z Note down the value of the resistance indicated by
the multimeter. Reverse the wires of the multime-
ter.
Z The multimeter should indicate infinite resistance
(open circuit) only during the first half of the test. If
this check reveals that a diode is defective, replace
the entire rectifier.
RECTIFIER - CHECKING THE EXCITATION

DIODES
Check each excitation diode separately by proceed-
ing as follows:
Z Connect a multimeter (2) in series on the excitation
diode module. Place the negative wire on terminal
L (1) and the other wire on the connection of each
excitation diode (3).
Z Note down the value of the resistance indicated by
the multimeter. Reverse the wires of the multime-
ter.
Z The multimeter should indicate infinite resistance
(open circuit) only during the first half of the test. If
this check reveals that a diode is defective, replace
the entire rectifier.
STATOR - CHECKING THE CONTINUITY OF THE
WINDING
Check each excitation diode separately by proceed-
ing as follows:
Z Connect the wires of the ohmmeter (3) between
wires A, B and C (2). The resistance between each
of the wires must be low (0.1 W). If the resistance
is greater than this value, it indicates a possible
break in the winding, i.e. an open circuit. A lower
value (0.0. for example) indicates a short circuit in
the winding. If the result of this check is not satis-
factory, replace the stator (1) and its casing.
STATOR -CHECKING THE INSULATION

Z Check the insulation of each winding with respect
to the alternator casing. There must not be any
continuity between the winding and the casing. If
the ohmmeter (2) indicates any value other than an
open circuit, replace the entire stator (1).
CHECKING THE ROTOR

Before checking the rotor components, inspect the
slip rings to make sure that they are in good condi-
tion.
Z Check that the slip rings are clean and smooth. If
necessary, clean them with a cloth soaked in gas-
oline. If the slip rings are burnt, scrape them with
very fine sandpaper (do not use emery cloth) and
wipe them
NOTE: make sure that the sandpaper is sufficiently

fine in order to obtain a perfect finish of the slip ring
surfaces and avoid premature wear of the brushes.
Z If the slip rings are excessively worn, replace the

rotor.
ROTOR - CHECKING THE CONTINUITY OF THE
FIELD WINDING
Z Connect an ohmmeter (3) between the two slip
rings (2). The resistance must be 2.6 ohms at
20 °C (68°F).
If the resistance is incorrect, replace the rotor (1).
ROTOR - CHECKING THE INSULATION OF THE

FIELD WINDING
Z Using an ohmmeter (3), measure the resistance
between each slip ring (2) and the rotor terminals
(1). The resistance should always be infinite. If a re-
sistance is not infinite, replace the rotor.
6.6 FAULT FINDING

Recharge circuit cut out (warning Check the connections of recharge
light, fuse, connector, etc. circuit, clean and tighten the
alternator and battery tags.
Not recharged Voltage regulator inefficient Replace the part.
Rotor winding cut out Replace the part.
Worn brushes Replace the part.

Slackened fan belt
Supply correct voltage.
Voltage regulator faulty
Replace the part.
Excessive wear of rotor rings or
Replace the part.
Recharge insufficient brushes
Diodes short-circuited
Replace the part.
Stator windings or rotor winding
Replace the part.
short-circuited
Circuit connections loosen Check the connections of battery
terminals and tag blocks starter and
alternator.
Excessive recharge
Replace the part
Voltage regulator inefficient
Ground connection fault Check connections for leakages.

7. BATTERY
For the loader backhoe models two different kinds of installation are provided:
Z with a battery.
Z with two batteries (for harsh climates).
Single battery
Voltage:........................................................................................................................................................ 12 V
Capacity (20 h):.......................................................................................................................................... 95 Ah
Discharge current:...................................................................................................................................... 900 A
Weight with electrolyte: ..................................................................................................................25 kg (55 lbs)
Double battery
Voltage:........................................................................................................................................................ 12 V
Capacity (20 h):.......................................................................................................................................... 60 Ah
Discharge current:...................................................................................................................................... 600 A
Weight with electrolyte: ...............................................................................................................17 kg (37.5 lbs)
All models feature one or two 12 V, negative ground,

“maintenance free” lead calcium (Pb-Ca) type bat-
tery, of six cell construction.
IMPORTANT: “Maintenance Free” means that un-

der normal charging conditions the battery does not
lose water from the electrolyte. Conditions that may
cause water loss include prolonged charging above
14.4 V where gassing occurs as it approaches full
charge. This can be caused by a faulty charging cir-
cuit or boost/recovery charging equipment.
The battery has four major functions:

Z To provide a source of current for starting, lighting
and instrumentation.
Z To help control the voltage in the electrical system.
Z To furnish current when the electrical demands ex-
ceed the alternator output.
Z To support quiescent loads from radio and micro
processor memory.
The battery is constructed in such a manner that
each cell contains positive and negative plates
placed alternatively next to each other. Each positive
plate is separated from a negative plate by a non
conducting porous envelope separator. If any of the
positive plates should make contact with negative
plates within a cell, the cell will short circuit and suffer
irreparable damage. All of the positive plates are
welded to a bus-bar, forming a positive terminal and
all of the negative plates are welded to a similar bus-
bar forming a negative terminal.
Each positive plate is composed of a lead grid with
lead peroxide pasted into the grid openings.
The negative plates are composed of a lead grid with

spongy lead pasted into the grid openings.
The plates are submerged in a liquid electrolyte so-
lution of diluted sulphuric acid.
7.3 REMOVAL AND INSTALLATION
Use the ignition switch key to open the battery box

and then remove the toll box.
SWARNING
A spark or flame can cause the hydrogen in a battery
to explode. To prevent any risk of explosion, observe
the following instructions:
Z Place the battery master switch key in the OFF po-
sition (disconnected).
Z When disconnecting the battery cables, always dis-
connect the negative cable (-) first.
Z When reconnecting the battery cables, always con-
nect the negative (-) cable last.
Z Never short-circuit the battery terminals with metal
objects.
Z Do not weld, grind or smoke near a battery.
SWARNING
Batteries produce explosive gases. Keep away any
flame, spark or cigarettes. Always provide good ven-
tilation when charging a battery or using a battery in
an enclosed space. Always protect your eyes when
working near a battery.
SWARNING
Before carrying out any welding on the machine or
repair work on the electrical circuit, disconnect the
battery and disconnect the B+ and D+ wires on the
alternator. When reconnecting, check the wire mark-
ings.
SWARNING
Always store batteries in a safe place, out of the
reach of children.
SWARNING
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
Z Remove the battery master switch support (6) with-

out disconnect the battery cables.
Z Remove the terminal covers and disconnect the
cables, first from the negative terminal (1) then the
positive terminal (2).
Z Remove the nuts and washers (3), the clamping
bar (4) and the brackets (5) and remove the old bat-
tery.
Z Install the new battery.
Z Install the brackets (5), the clamping bar (4) and the
washers and nuts (3).
Z Clean the cables and the connecting terminals and
coat them with grease.
Z Connect the cables, first to the positive terminal (2),
then the negative terminal (1) and install the termi-
nal covers.
Z Remove the battery master switch support (6).
SWARNING
Never reverse the battery terminals. Connect the
positive cable to the positive terminal (+) and the
negative cable to the negative terminal (-).
7.4 MAINTENANCE
SPECIFIC GRAVITY SERVICING

The specific gravity of the battery electrolyte indi-
cates the state of charge. SWARNING
Fully charged the specific gravity of the electrolyte is Battery electrolyte causes severe burns. The bat-
1.280 minimum at 25 °C (77 °F). tery contains sulphuric acid. Avoid any contact with
Alternatively the approximate state of charge can be the skin, eyes or clothing.
measured by using an accurate digital volt meter(+/ Antidote:
-0.01V) as follows: EXTERNAL: rinse well with water, removing any
Less than.................. 10.5 V Battery unserviceable* soiled clothing.
Less than........................ 11.8 V Battery discharged INTERNAL: avoid vomiting. Drink water to rinse
Less than.......................12.3 V Battery 1/2 charged your mouth. Consult a doctor.
Better than................... 12.6 V Battery fully charged EYES: rinse abundantly with water for15 minutes
* See note under tests for possible recovery of a and consult a doctor.
mildly sulphated battery.
Battery terminal tightness check ... Every 250 hours
Battery voltage to be taken with the battery unload- Electrolyte level inspection .......... Every 1000 hours
ed and:
A. After the battery has rested unloaded for at least When servicing a battery the following steps should
4 hours. be observed:
B. If the vehicle has recently run or battery has re- Z Maintain the electrolyte to the recommended level
cently been charged, switch on headlamps for 2 of 6 mm (0.25 in.) above the plates. If this is not ob-
minutes. served the acid will reach a high concentration that
When a battery discharges, sulphuric acid in the will damage the separators and impair the perfor-
electrolyte combines chemically with the plates and mance of the plates.
this action lowers the specific gravity of the solution. Z Use only distilled or de-mineralized water, do not
A battery hydrometer will determine the specific overfill and never use tap water or water from a
gravity of the electrolyte in a cell and the amount of rain barrel or other source.
unused sulphuric acid in the solution is a measure of Z Always keep the battery at least 75% charged oth-
the degree of charge of that cell. erwise the plates will become sulphated and loss
The lower the temperature at which a battery is re- of efficiency will result with possible damage from
quired to operate, the more necessary it is that the freezing at low temperatures.
battery is maintained in a fully charged condition. Z Avoid overcharging the battery as excessive
For example a battery with a low specific gravity of charging will create high internal heat that will
1.225 at 27 °C (80 °F) will operate the starting motor cause plate grid deterioration and produce water
at warm ambient temperatures but may not, due to loss.
lower battery efficiency at a low temperature. Z When fast charging ensure the battery tempera-
Table shows the effect of temperature on the effi- ture does not exceed 50 °C (122 °F).
ciency of a typical battery. Z Do not add sulphuric acid to a cell unless the elec-
trolyte has been lost through spilling. Before re-
Efficiency of a fully plenishing ensure the solution is at the correct
Temperature charged battery specific gravity. A slow charge is the only method
temperature to be employed to fully charge a battery. A high
25.0 °C (77.0 °F) 100% rate charger can be used to quickly boost the bat-
-4.5 °C (23.9 °F) 82% tery capacity but this must be followed by a slow
-24.0 °C (-11.2 °F) 64% charge rate to bring the battery to full capacity.
-27.5 °C (-17.5 °F) 58%
-31.0 °C (-23.8 °C) 50%
-34.5 °C (-30.1 °C) 40%
-37.5 °C (-35.5 °C) 33%
Maximum battery life will be obtained if the correct

care and periodic inspection is given. It is important
that output capacity should not be exceeded by con-
stant and excessive overloading and that charging
requirements are maintained.
DRY CHARGED RECHARGING DEEPLY DISCHARGED

Z Remove the battery cell vent plugs. The recommended method to recharge a mainte-
Z Fill each cell to the recommended level with elec- nance free Pb-Ca battery is to use a constant volt-
trolyte of 1.260 specific gravity. age charger. For deeply discharged batteries a 48
Dry charged batteries must be prepared for service hours charging period at 16 V is recommended, with
as follows: current limitation, (47.5 A for 95 Ah).
This circuit is self regulating: high current is deliv-
NOTE: the electrolyte must be diluted sulphuric acid ered at the beginning (when battery voltage is low),
preferably at a temperature of 21°-32°C (70°-90°F). lower and lower current is then absorbed when bat-
tery reaches full charge (and its voltage is high).
Z After filling, allow the battery to stand for 15 min- If only constant current chargers are available it is
utes then re-check the electrolyte level and top up recommended to use the current levels and times
if necessary. shown Table 2 below. The figures are intended for
Z Charge the battery for 4 hours at a rate of 5-8 am- deeply discharged batteries. If the battery is only
peres and check that all cells are gassing freely. 50% discharged use one half of the time listed (slow
Z Install the battery cell vent plugs. charge programs). For other states of discharge re-
duce proportionally the time of charge. Whenever
CHARGING THE BATTERY possible use the slowest charge program to in-
Before charging a battery: crease the battery’s life.
Z Thoroughly clean the battery casing and cell cov- If when charging the battery, violent gassing or
ers with dilute ammonia or hot water and clean the spewing of electrolyte occurs, or the battery case
terminals. feels hot (50 °C or greater), reduce or temporarily
Z Check the level of the electrolyte in each cell and, halt charging to avoid damaging the battery.
if below plates, add distilled water to bring above
plate level.
NORMAL (TOP-UP) CHARGING

Z With a slow charger use a rate of 3 to 6 amperes
for the time necessary to bring the battery to full
charge. This may take 36 hours or more if the bat-
tery is heavily discharged. A severely sulphated
battery might not accept a charge. When the bat-
tery is fully charged the cells will gas freely and the
specific gravity will remain constant. Remove the
charger after three consecutive hydrometer read-
ings taken at hourly intervals indicate that the spe-
cific gravity has stopped rising.
Z When using a fast or high rate of charge carefully
follow the manufacturers instructions. High rate
charging raises the temperature of the electrolyte
and unless the charger is equipped with an auto-
matic time or temperature device, the electrolyte
temperature could exceed 50 °C (122 °F), which
may cause violent battery gassing and damage to
internal components.
Z Re-check the level of electrolyte in each cell and
add distilled water as necessary.
SWARNING
When a battery is being charged an explosive gas is
produced. Do not smoke or use an exposed flame
when checking the electrolyte level and ensure the
charger is switched off before connecting or discon-
necting to avoid sparks which could ignite the gas.
7.5 TESTS
Before commencing battery tests check the battery 5. Should the corrected specific gravity be below
for clogged vents, corrosion, raised vent plugs or a 1.280, charge the battery and inspect the charg-
cracked case. ing circuit to determine the cause of the low bat-
Test equipment required: tery charge.
Z Hydrometer.
Z Battery starter tester (High rate discharge tester). NOTE: if distilled water has recently been added the
Z Thermometer. battery should be recharged for a short period oth-
Z Battery Charger. erwise accurate hydrometer readings will not be ob-
tained.
SPECIFIC GRAVITY
This test will determine the state of battery charge. If the battery has been charged under static condi-
1. With the float in the vertical position take the tions, denser electrolyte will accumulate at the bot-
reading. tom of the cells. The battery should be shaken
2. Adjust the hydrometer reading for electrolyte periodically to mix the electrolyte, this will improve
temperature variations by subtracting 4 points the charge rate and provide a more accurate hy-
(0.004 specific gravity) for every 5.5°C (41.9°F) drometer reading when tested.
below the temperature at which the hydrometer
PERFORMANCE TEST
is calibrated and by adding 4 points (0.004 spe-
cific gravity) for every 5.5°C (41.9°F) above this The performance test is to determine if the battery
temperature. has adequate capacity to turn the engine. The volt-
The following examples are calculated using a hy- age reading obtained is used to determine the bat-
drometer calibrated at 30°C (86°F). tery condition. Prior to testing, ensure the electrolyte
level is correct and the open circuit voltage is 12.5 V
Example 1: or more. The battery may be tested on or off the
Temperature below 30 °C (86 °F) loader backhoe.
Electrolyte temperature ........................ 19°C (66°F) 1. Set the current control switch of the battery
Hydrometer reading ....................................... 1.270 starter tester (high rate discharge tester) to the
Subtract (11.0 / 5.5) x 0.004........................... 0.008 “off” position and the voltage selector switch
Corrected specific gravity............................... 1.262 equal to, or slightly higher than, the rated battery
voltage. Connect the tester positive leads to the
Example 2: battery positive terminal and the negative leads
Temperature above 30°C (86°F) to the negative battery terminal.
Electrolyte temperature ...................... 40°C (104°F) 2. Turn the current control knob until the ammeter
Hydrometer reading ....................................... 1.220 reading is half the CCA rating of the battery and
Add (10.0 / 5.5) x 0.004.................................. 0.007 take the voltage reading.
Corrected specific gravity............................... 1.227 Z If the reading is 9.6 V or more after 15 seconds, the
3. Use the following table to determine the state of battery has an acceptable output capacity and will
charge. readily accept a normal charge.
Z If however the reading is below 9.6 V, the battery
Correcte Correcte is considered unsatisfactory for service and should
d specific d specific Average be test charged as described below.
State of
gravity @ gravity @ battery
Charge
15°C 25°C voltage SCAUTION
(59°F) (77°F)
Do not leave the high discharge load on the battery
100% 1.295 1.287 2.76 for periods longer than 15 seconds.
75% 1.253 1.246 12.52
50% 1.217 1.210 12.30
25% 1.177 1.170 12.06
Discharged 1.137 1.130 11.84
NOTE: specific gravity should not vary more than

0.025 points between cells.
4. If the specific gravity is 1.280 or more the battery

is fully charged and in good operating condition.
TEST CHARGING COMMON CAUSES OF BATTERY FAILURES

This test is designed only for batteries that have Z Internal open circuit.
failed the previous capacity test. Z Internal short circuit.
1. Attach the battery starter (high rate discharge Z Loss of electrolyte.
tester) positive leads to the battery positive ter- Z Separation of active materials from grids.
minal and the negative leads to the battery neg- Z Accumulation of sulphate crystals too large to dis-
ative terminal. perse.
2. Connect the battery charger positive lead to the These failures are normally caused by the following:
battery positive terminal and the negative lead Z Failure of inter cell components.
to the battery negative terminal. Z Excessive crystal growth may puncture the sepa-
3. Turn the charger timer past a “3 minutes” charge rators and cause short circuits.
indication and then back to the “3 minutes” Z Excessive over charging (charging circuit malfunc-
mark. tion, boost/recovery techniques with high voltage,
4. Set the charging rate as close as possible to 40 operation in very high temperatures.
amperes. Z Freezing of electrolyte. A fully charged battery
5. After 3 minutes at this fast charge take the volt- does not freeze until -65°C (-85°F). A 50% charged
meter reading. battery freezes between -17°C (1.4°F) and -27°C (-
Z If the total voltage is over 15.5 V the battery is un- 16.6°F). Fully discharged electrolyte freezes at -
satisfactory and is probably sulphated or worn out 3°C (-26.6°F) to -11°C (-12.2°F). Excessively high
and should be replaced. boost charging and gassing will also cause sepa-
ration of active materials from the grids. Separa-
NOTE: a mildly sulphated battery can be recovered tion destroys the chemical function of the battery.
by using a multiple battery type charger, with an Z Crystal growth occurs whenever batteries are left
open circuit upper voltage limit of 50 V. Owing to the discharged. High temperatures and extended dis-
high resistance of a sulphated battery, it will prima- charged periods increase this condition.
rily require a high voltage setting to overcome the At room temperature after one week the battery is
resistance of the sulphation initially there may be no unlikely to recover on the vehicle.
visible acceptance of the charge. After a few min- Recharge will require a higher constant voltage.
utes of inactivity a small charge will be apparent, fol- After 3 weeks the battery will have suffered perma-
lowed by a rapid increase in the charge rate. The nent degradation and the procedure detailed previ-
charge rate must not exceed 14.0 amperes or the ously for charging a “Deeply Discharged” battery
electrolyte temperature 50°C (122°F). When the should be followed.
ampere rate has stablished, reset the volts until the When fully charged, batteries have a long shelf life.
charge rate is a steady 5 amperes. Continue at this The lead calcium type battery self discharges at 3%
rate until the electrolyte specific gravity stops rising per month. This means that it will take 16 months to
at approximately 1.275 - 1.280 at 20°C (68°F), this lower to 50% charged. On the loader backhoe the
can take up to 48 hours of charging. Stand the bat- quiescent
tery for 24 hours and then conduct the capacity test load is about 50 mA. To predict rundown on a static
detailed previously. vehicle this should be added as approximately 8 Ah
per week.
Z If the total voltage is under 15.5 V, test the specific It is worth stressing that when cranking, if a battery
gravity of each cell and re-charge the battery to the starts to fade, it is beneficial to stop and allow two
following scale: minutes for the battery to recover. The recovery time
Specific Gravity Fast charge up to: should be increased as the temperature decreases.
1.150 or less 60 minutes
1.151 to 1.175 45 minutes
1.176 to 1.200 30 minutes
1.201 to 1.225 15 minutes
(Slow charge only)
NOTE: when battery problems are experienced the

fan belt tension and the complete charging circuit
should be checked.
7.6 CONNECTING A BOOSTER BATTERY
SWARNING
When the electrolyte of a battery is frozen, it can ex-
plode if you attempt to charge the battery or if you try to
start the engine using a booster battery. Always keep
the battery charged to prevent the electrolyte freezing.
SWARNING
Connecting jumper cables wrongly or short-circuiting
battery terminals can cause an accident. Connect
the jumper cables following the instructions in this
manual.
IMPORTANT: make sure that the voltage of the

booster batteries is the same as that of the machine
circuit (12 V).
Z Open the battery box and then remove the tool box.
Z Remove the terminal covers.
Z Connect the positive (+) jumper cable to the posi-
tive (+) terminal of the machine's battery.
Z Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Z Start the engine.
Z First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Z Install the terminal covers.
Z Install the tool box and close the battery box.
7.7 BATTERY MASTER SWITCH
The battery master switch is located into battery

compartment and is used to disconnect the electrical
system completely from the battery.
When the master switch has un inclination of 45°,
the circuit is disconnected.
When the master switch is in vertical position, the
circuit is connected.
SWARNING
The battery master switch must be switched off at
the end of each working day, for machine service or
for any operations on the electrical system.
It acts as an anti-theft device when the cab doors
and windows are locked.
8. COMPONENT TESTING
8.1 GENERAL INTRODUCTION
No special tools are required to remove or replace

electrical components.
Refer to the appropriate section of this Service Man-
ual for overhaul procedures to cover the starter mo-
tor and alternator.
Fault finding of electrical systems should be carried
out in a logical and methodical fashion. A few min-
utes spent understanding the system and analysing
the symptoms can save considerable time.
An essential piece of equipment for checking electri-
cal systems is a good quality multimeter with a high
impedance which can measure voltage, current and
resistance. F28375
NOTE: labelling of connectors prior to disassembly

will greatly assist when reconnecting any harness.
Where it is necessary to clean the multiple connec-

tors, a contact spray should be used.
IMPORTANT: DO NOT use a cleaner that contains

trichloroethylene which will dissolve the plastic con-
nectors.
The wiring harnesses contain wires which are color

coded for identification.
Each harness can be removed and replaced, but
certain precautions must be observed:
Z Disconnect or isolate the battery, negative terminal
first, prior to disconnection or removal of any wiring
harness.
Z Prior to removal, note the harness routing, clamp-
ing positions and terminal connections.
Z On replacement, be sure that the harness routing
is not in contact with sharp edges, the exhaust sys-
tem or moving parts.
Z Check connections for wire color matching.
Z Use a light coating of di-electrical grease on the
connector pins to prevent corrosion.
Z Be sure that all connectors are fully engaged and
no conductor is exposed.
Z Tape back unused connectors.
Z Be sure that ground connections are clean with
metal-to-metal contact. Use toothed lock washers
for good ground connections.
Z Be sure that fuses are of the specified rating.
Z Check the circuit current draw before connecting
power to the harness.
Z Check polarity of the battery before connecting
power to the harness.
Z When it is necessary to remove or partially discon-
nect a wiring harness, label each connector before
removal from its mating instrument.
8.2 COMPONENT TESTING
In general with the key start on there should be 12 V

found at the component connections.
Where 12 V is not present check fuses, relays and
wiring for breaks.
8.3 GROUND POINTS
NOTE: always ensure the ground points are clean

and functional. A poor ground will cause the electrics
to fail.
Ground point A - Starter motor (Engine harness)

Ground point A is also linked to ground point B.
Ground point B - Right hand console (front con-

sole harness)
This is also linked to ground points A, C, and D.
F32641
Ground point C - Rear of chassis (Chassis har-

ness)
This is also linked to ground point E.
Ground point D - Fuse board

XC5 K5
Air seat F5/B
This is also a back-up ground point for Location E. K6
F5/A
F6/C F7/C F8/C K7
F6/B F7/B F8/B K8
F6/A F7/A F8/A K9
15v 30v GND D

F28379
Ground point E - Top right hand B pillar (roof

harness) E
This is also linked to ground point F.
F28380
Ground point F - Interior lamp

This is also linked to ground point E.
F28381
8.4 KEY-START AND STOP SWITCH
NOTE: when the key-start/stop switch is turned to

the “ON” position the audible alarm will be activated
until the engine is started or the key returned to the
off position.
Key start
1. Not used
2. Off
3. Ignition “ON”
4. Engine start
MAXIMUM MAXIMUM
CONTACTS CURRENT CURRENT TIME
12 V 24 V
30 - 58 8A 4A ∞
30 - 15/54 35 A 17.5 A ∞
70 A 40 A
30 - 50a 1 min
18 A 5A
8.5 ALTERNATOR
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
turn off. If not, disconnect the wire connected to the
terminal D+ (pink wire).
When D+ is not connected and the warning light
turns off, there is a fault with the alternator. If it does
not turn off, then check the bulb and the wiring loom.
F28388
8.6 TRANSMISSIONS
POWERSHUTLE DISCONNECT -X23 / X28

Energizes the transmission dump solenoid at 12 V.
Test procedure
Continuity should be found between pin 1 and pin 2 X23
when switch is operated.
2: RM:A-R:1
1: RM:B-R:1
X28
2: RM:A-R:1
4: RM:C-N:1
1: RM:B-R:1
3: RM:N:1
F28391
POWERSHIFT EGS CONNECTOR

The EGS receives input from the FWD Switch,
brakes, switches, transmission disconnect switch,
temperature sensor and speed sensor. The EGS
also sends signals to the transmission control valve.
For input and output tests to check correct operation
of the EGS, refer to Section 21 chapter 1.
POWERSHIFT CONTROL UNIT

The control valve receives signals switching ON or
OFF the solenoids allowing the desired gears to be
selected. A variable current solenoid receives a re-
ducing signal from the EGS controlling modulator.
The control unit is fitted with a combined tempera-
ture and speed sensor which sends signals back to
the EGS.
Test procedure
Test between pin indicated in the left hand column
and either pin H or M as detailed in the table below.
F28394
DESCRIPTION
Pin
H M
No.
A 27.5 Ω -
B 27.5 Ω -
C 27.5 Ω -
D 27.5 Ω -
E 27.5 Ω -
F 27.5 Ω - F28395
G - 14 Ω
K - 31 Ω
*A Speed sensor plus output 24

B Forward Lo/Hi solenoid
C Forward/neutral solenoid
D Range 1/2 solenoid
E FWD solenoid
F Reverse neutral solenoid
G Direction modulation solenoid
K Range modulation solenoid
L Transmission temperature out ground
M Control valve common plus
POWERSHIFT SPEED SENSOR TEST

Disconnect from control valve and fit the 12 pin con-
nector from special tool.
Connect the power socket into the 12 V power sock-
et. Install the probes from a multimeter into the tool.
Raise the unit off the ground and observe voltage
(V1). Turn the rear wheel which in turn rotates the
transmission output shaft, observe the second volt-
age (V2).
F28394
Test procedure
Pin
V1 V2
No.
A 0.6 - 0.8 1.3 - 1.5
The special tool connects to pin A speed sensor plus
output, and pin J speed sensor/temperature sensor
ground.
F28397
Description
A Speed sensor +
B FWD request
C Disconnect request input A
B M
D Speedometer output
C N L
E Diagnostic link input P U
F Analogue Input 1 D V K
G Analogue Input 0 R T
H - E S J
J - F H
G
K PWM solenoid supply
L Solenoid 3
M PWM 1 F28398
N Range solenoid 27
P Forward solenoid
R Solenoid 2
S Solenoid 1
T VCS
U Ground
V Battery +
POWERSHIFT EGS OVERRIDE

In situations where a “MANUAL” gearshift (up or
downshift) is required the powershift auto change
can be overridden by selection of this console
mounted switch.
Test procedure
Continuity should be found between pin 1 and pin 2
when switch is operated.
7: Z/N1
5: N1
F28400
OIL PRESSURE SWITCH - POWERSHIFT

Energized at 12 V if the transmission pressure is to
low, the warning lamp will flash.
F28402
Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
Pin
Sender Resistance Z-B:1
No.
1 12 V at low pressure 0.3 Ω N:1
F28403
OIL PRESSURE SWITCH - POWERSHUTTLE

If the transmission pressure is to low, the warning
lamp to flash.
F28404
Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
Pin
Sender Resistance Z-B:1
No.
1 12 V at low pressure 0.3 Ω N:1
F28403
8.7 PARKING BRAKE SWITCH
When the handbrake has been applied, the switch

will be closed and the warning lamp is illuminated.
An alarm / klaxon will sound if the handbrake is on
with the transmission shuttle lever applied.
Test procedure
Brake engaged:
switch closed warning light illuminated.
S18
Brake disengaged:
switch open warning light off. 1: FM:G-R:1
1: FM:N:1
F28407
8.8 CAB
FRONT INSTRUMENT PANEL

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 instrument panel are connectors
that are attached to the vehicle harness circuit.
These connectors and functions are listed on the fol-
lowing pages.
SIDE INSTRUMENT PANEL

Receives signal from sensors to display, hours, en-
gine RPM, oil pressure, fuel level and signals to
warning and indicator lights.
FRONT PANEL - CONNECTOR -AMPERE 070 12

VIE - POWERSHUTTLE
5 1
Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. 12 V key start
2. Ground:
check continuity
3. Tachometer:
Signal from W output of the alternator
4. Dipped beam: 12 6
green warning light illuminates at 12 V with multi F28412
function light switch on
5. High beam -blue warning light illuminates at 12
V with multi function switch on
6. 12 V and instrument backlighting
7. Not used
8. Not used
9. Not used
10. Not used
11. Direction indicators:
green warning light illuminates at 12 V with light
switch on.
12. Brake oil level:
red warning light when the input is connected to
ground with Ignition on 12 V
SIDE INSTRUMENT
Calibrations

LOW FUEL LAMP
TACH Can message 0-3000 RPM ± 50 RPM
Can message Minimum reading (65°C)(149°F) ± 3°C(± 37.4°F)
COOLANT
Can message Left edge of red band (106°C)(223°F) ± 2°C (± 35.6°F)
TEMPERATURE
Can message Maximum reading (112°C)(234°F) ± 3°C (± 37.4°F)
11V Right edge of lower red band ± 3°C (± 37.4°F)
VOLT
16V Edge of upper red band ± 3°C (± 37.4°F)
385 OHMS Minimum reading (75°C)(167°F) ± 3°C (± 37.4°F)
TRANSMISSION
149 OHMS Left edge of red band (105°C)(221°F) ± 2°C (± 35.6°F)
TEMPERATURE
112 OHMS Maximum reading (115°C)(239°F) ± 3°C (± 37.4°F)
Connectors
CN1
PIN FUNCTION NOTE

1 Not used
2 Key on power Wake up
3 In gear input Digital input
4 Driving lights Digital input
6 Rear work lights Digital input
7 Not used
8 Not used
9 Not used
10 Air conditioning system pressure Digital input
11 Display input switch Digital input
12 Enter input switch Digital input
13 Up input switch Digital input
14 Down input switch Digital input
15 Cranking Digital input
16 Air filter restriction Digital input
17 Not used
18 Park brake Digital input
19 Not used
20 Idle validation switch Digital input
21 One touch deceleration Digital input
22 Not used
23 Not used
24 Not used
25 Transmission oil pressure Digital input
26 Not used
CN2
PIN FUNCTION NOTE

1 Keep alive power Need to fuse at 1 ampere without disconnect
2 Not used
3 Can bus input Twisted pair, with 120 OHM terminator
4 Can bus input Twisted pair, with 120 OHM terminator
5 Not used
6 Audible alarm buzzer Floyd bell under 80 mA
7 Starter interlock 40 OHM relay = 300 mA
8 Not used
9 Not used
10 Not used
11 Not used
12 Not used
13 Fuel level gauge Variable resistance
14 Transmission temperature Thermistor
15 Not used
16 Foot accelerator 0.5-4.5 V
17 Hand accelerator 0.5-4.5 V
18 Foot acceleratoraccelerator Output monitored for diagnostics
19 Hand accelerator Output monitored for diagnostics
20 Foot accelerator
21 Hand accelerator
22 Not used
23 Not used
24 Alternator excitation Low alternator output signals fault
25 Not used
FRONT PANEL - CONNECTOR - AMPERE 070 12

VIE - POWERSHIFT
5 1
Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. 12 V key start
2. Ground:
check continuity
3. Tachometer:
signal from W output of the alternator
4. Dipped beam: 12 6
green warning light illuminates at 12 V with multi F28412
function light switch on
5. High beam - Blue warning light illuminates at 12
V with multi function switch on
6. 12 V and instrument backlighting
7. Not used
8. 4 wheel steer - Green warning light four wheel
input. With Ignition ON and 4WS selected 0.5 V
should be indicated. With 2WS or crab steer se-
lected 0 V should be indicated
9. Crab steer - Green warning light
10. 2WS - Green warning light two wheel steer input.
With Ignition ON and 2WS selected 1.5 V should
be indicated. With 4WS or crab steer selected 12
V should be indicated
11. Direction indicators:
green warning light illuminates at 12 V with light
switch on
12. Brake oil level:
red warning light when the input is connected to
ground with ignition on 12 V
8.9 4WD SWITCH
8.10 BRAKE PEDAL SWITCHES
Test procedure
Continuity:
Brakes not applied: no continuity.
Brakes applied: continuity, between the two center
pins of each switch.
Both brake pedals must be applied to allow 12 V to
relay.
F28419
Voltage:
Left switch:
White / red wire 12 V continuous with ignition ON
Red wire 12 V pedal depressed
0 V pedal released
Right switch:
Red wire 12 V pedal depressed
1: R:1 1: R:1
0 V pedal released
Red - Black wire 12 V pedal depressed 2: R-N:1 2: B/R:1
0 V pedal released
F28420
8.11 BRAKE OIL LEVEL LAMP
When the lamp is activated due to low oil level this

sends a signal to the instrument cluster to illuminate
the low brake fluid level warning lamp.
Test procedure:
Continuity:
With the fluid level correct there should be no conti-
nuity through the switch. Continuity should be seen
when the level is low or the test button pushed.
Voltage:
With the Ignition ON there should be 12 V at the 1: G-R:1
Red/Black terminal.
2: R/N:1
F28422
8.12 FRONT WORK LAMP SWITCH - REAR

WORK LAMP SWITCH (2) MAIN LIGHT
SWITCH
12 V should be found at the switch only after main

light switch is on and key start activated.
Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 3
and 2 and 8.
F28417
8.13 HAZARD SWITCH
12 V should be found at this switch at all times re-

gardless of key start position.
Test procedure
Pin No. Switch OFF Switch ON

1 to pin 4 -
3 - to pins 5/6/7
4 to pin 1 - 1: S-N 3: A-G
5 - to pins 2/3/6/7 7: A/V 4: H-R
6 - to pins 2/3/5/7 6: L/B 5: L/R
7 - to pins 2/3/5
F28428
8.14 FLASHER RELÈ
Operational at all times in conjunction with the haz-

ard switch.
K10 K12
XC1 XC2
F1/C F2/C
Continuity
Pin Hazard / Indicator

No. Switch OFF Switch ON
CL 12 V 12 V
+ - 12 V - 0 V - 12 V - 0 V
31 - 12 V - 0 V - 12 V - 0 V
PR - -
F28431
8.15 MULTI FUNCTION SWITCH
Switch Continuity
All Indicator Beam Wiper
Wind-
Pin switc
screen
No. hes Left Right Low High On
washer
OFF
1
2 pin 7
3 pin 4
4 pin 5 pin 3
5 pin 4
6 pin 8
7 pin 2 pin 8
8 pin 6 pin 7
9 pin 11
10 pin 11
11 pin 9 pin 10 2: L-B:1
4: G/R:1
12 12
5: V/N:1.5
6: A/B:1
7: A/N:1
8: A/R:1 1 7
9: L:1
10: A-V:1 6
11: L-N:1
F28433
8.16 FRONT WIPER MOTOR (1) - REAR

WIPER MOTOR (2)
Energized at key start at 12 V.
Test procedure
Pin No. Continuity Continuity

1 pin 3 pin 5 2 Ω
3 pin 5 2 Ω -
8.17 4WS -STEERING SELECTOR SWITCH
At key start 12 V should be found at the switch and

is directed to the steering sensors when a switch se-
lection is made.
Test procedure
With ignition ON
Pin 2WS 4WS CRAB

A 12 V 12 V 12 V
B - - 12 V
C
C - 12 V - V/N
B L-R
C-G
A
F28438
8.18 STEERING CONTROL UNIT
The steering control unit controls the different steer-

ing functions that can be selected from the switch.
When changing steering mode, the light for the cur-
rent mode is extinguished and the light for the new
mode starts to flash. When movement of the steer-
ing wheel is detected, the light for the new mode re-
mains steady.
Connector pin out description

12 pin connector -X95:
X95
1: CM:Z/B:1.5
Pin Function Signal 2: CM:C:1
3: CM:H-L:1.5
1 Crab steering warning light - 4: CM:A-R:1
5: CM:V-B:1 12
2 Buzzer configuration -
6: CM:V/N:1
3 Front alignment sensor input +12 7: CM:R-G:1
8: CM:N:1 7
4 Crab steering control +12 9: CM:A-B:1 1
10: CM:L/N:1
5 Buzzer output - 11: CM:M:1 6
12: CM:V/B:1
6 Rod iron steering control +12 F28441
7 Control unit supply +12

8 Ground -
9 Speed sensor input -
10 Rear alignment sensor input +12
11 2WS warning light -
12 4WS warning light -
8 pin connector -X96:
Pin Function Signal X96
1 EV2A output +12 1: CM:L/R:1

2: CM:S/N:1
2 EV2B output +12 3: CM:H/N:1
4: CM:L-N:1 8
3 EV3A output +12
5: CM:A/V:1
4 Ground - 6: CM:R/N:1
7: 5
1
5 Front sensor supply output +12 8: CM:M/B:1
4
6 Rear sensor supply output +12
7 Available optional output +12 F28442
8 EV3B output +12

Solenoid valve operation Speed pulses

Crab/4WS > 2WS Speed pulses are drawn from EGS-CLARK control
When the rear axle sensor detects alignment of its unit. Output reference values of clark transmission
axis, the control unit de-energizes the active steer- are;
ing solenoid valves and activates the solenoid Z 7 Hz for 1 km Æ
valves for 2WS. Z 14 Hz for 2 km Æ
2WS > Crab/4WS Z 35 Hz for 5 km Æ
When the rear axle sensor detects bridge align- values in volts -8 and +8.
ment, all the solenoid valves for 2WS are de-activat- The speed calculation has been determined with a
ed and the solenoid valves for the selected mode tire having a circumference of 4.165 m (13.7 ft).
are energized.
Crab > 4WS and 4WS > Crab Steering type storage
When the rear axle sensor detects alignment the The steering type is stored in a non-volatile memory
2WS temporarily activates (energizing the corre- each time the machine is turned off. This information
sponding solenoid valves) until, after overcoming is therefore stored for an indefinite time even with
the condition of rear bridge alignment, the desired the supply cut off.
steering type activates when, by reversing the steer-
ing swing direction, the rear axle sensor detects Start-up and axle recovery
alignment. The control units are supplied with a storage of the
last steering selected at two wheels. With this steer-
Solenoid valve failure ing type selected, it is always possible to recover the
The operation condition of any solenoid valve output axle alignment; “short-circuit” the sensor or front and
is tested each time the selected steering requires its rear axles, supply the machine (with the switch in 2
supply. Even when only one solenoid valve output is wheel position) and select the type of 4 wheel steer-
short circuited or open, the control unit provides to ing enabling the bridge alignment.
cut the supply to all the solenoid valves by means of
the self protection (the control unit is locked) and to
signal this condition (short - or open - circuit) by
means of the three warning lights relative to steering
flashing at the same time. Once the solenoid valve
causing the failure has been de-energized or the
correct operation has been reset.
Buzzer operation
Buzzer operation depends on setting of pin 2 of the
12-way connector:
Z Pin 2 not connected (North America only) If 12 km/
h is exceeded in crab mode, the buzzer sounds.
Z Pin 2 grounded (Outside of N/America). If 12 km/h
is exceeded in crab or 4WS mode, the buzzer
sounds.
Buzzer operation is intermittent, 250 ms on and 250
ms off.
The control unit is set at 9 km/h; steering mode
change is not possible when this speed is exceed-
ed.
Solenoid valve output
Solenoid 2WS 4WS CRAB

EVA2 X
EVA3 X X
EVB2 X X
EVB3 X
8.19 4WS REAR AXLE STEERING SENSOR

is directed to the steering sensor when the switch
selection is made.
F28443
X98
Pin 2WS 4WS CRAB X98
A 12 V 12 V 12 V
B - - -
C - - - A: RM:L/N:1
B: RM:N:1
C: RM:R/N:1
F28444
8.20 4WS FRONT AXLE STEERING

SENSOR

is directed to the steering sensor when a switch se-
lection is made.
F28445
X97
Pin 2WS 4WS CRAB X97
A 12 V 12 V 12 V
B - - -
C - - - A: RM:H-L:1
B: RM:N:1
C: RM:A/V:1
F28446
8.21 STEERING SOLENOID VALVE
Energized at 12 V but governed by the steering pro-

cessor.
F28447
Valve solenoid connection, viewed from the top. Ar-

row denotes front of loader backhoe.
EVA2 - X91 EVB2 - X92
Solenoid 2WS 4WS CRAB
EVA2 0V 0V 12 V
EVA3 0V 12 V 12 V
EVB2 12 V 12 V 0V
EVB3 12 V 0V 0V
EVA3 - X93 EVB3 - X94

F28448
Pin No. Solenoid Resistance X91

1 0V 5.0 Ω
X92
1: RM:L/R:1
2: RM:N:1
1: RM:S/N:1
2: RM:N:1
F28449
Pin No. Solenoid Resistance X93

1 0V 5.0 Ω
X94
1: RM:H/N:1
2: RM:N:1
1: RM:M/B:1
2: RM:N:1
F28450
8.22 DIFFERENTIAL LOCK SWITCH (1)
At key start the spring loaded switch has 12 V and

when operated energizes the differential solenoid
valve.
Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity should be found between pins 1 and 5.
1: M/B1
5: C-B1
F28452
Pin No. Solenoid Resistance

X8
1 0V 5.0 Ω
1: RM:CL:1
2: RM:N:1
F28453
8.23 LOADER
RIDE CONTROL
Designed to reduce loader bounce when travelling
with an unladen bucket.
SWARNING
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF.
Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
1: C/N1
5: A-N1
F28456

X34
1 0V 5.0 Ω
1: RM:A-N:1
2: RM:N:1
F28457
LOADER LOCK (1)

The loader lock when actuated is designed to pre-
vent movement of the front loader during road travel.
Continuity should be found between pin 1 and 3.
F28417

1 0V 5.0 Ω
1: RM:N:1
2: RM:C-L:1
F28461
8.24 BACKHOE
BACKHOE ATTACHMENT LOCK SWITCH (1)

At start-up, the key start switch should have 12 V to
activate / deactivate the backhoe attachment lock
cylinders.
Test procedure
(Switch Off) - X25
(Switch On)
1: C-B1
7: L/G1
5: C/B1
F28472

1 12 V 7.5 Ω
1: R-V:1
2: N:1
F28473
BACKHOE HAMMER SWITCH

At key start the foot switch should have 12 V for op-
eration of an attachment.
When switch is operated 12 V should be found at pin

2.
2: R-V
1: R-V:1
F28476
BACKHOE HAMMER SOLENOID

1 12 V 7.5 Ω
1: R-V:1
2: N:1
F28473
HAND HAMMER SWITCH (1)

At key start 12 V should be found at the switch for
operation of a hammer.
When the switch is operated 12 V should be found

at pin 1.
1: C-B1
5: C/B1
F28479

1 12 V 7.5 Ω
1: H-N
2: N:1
F28480
BACKHOE SWITCH (1)

An accessory for attachment of buckets and tools
activated at 12 V.
When switch is operated 12 V should be found at pin

5.
1: C/N1
5: V1
F28483
8.25 REVERSING BUZZER
Activated by 12 V at key start when reverse gear is

selected.
With reverse selected 12 V should be found at pin

connector.
Resistance of the buzzer 162 Ω.
M/B
N
F28488
8.26 FUEL LEVEL INDICATOR
The signal from the fuel sender potentiometer deter-

mining the fuel level displayed on the instrument
cluster gauge.
Test procedure
Approximate resistance:
Gauge indication Sensor resistance

Full 9Ω
Half 129 Ω
Empty 333 Ω
2: N
1: Z:1
F28490
NOTE:
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 4

2. LOADER BUCKET SELF LEVELING ........................................................................................................... 7
3. LOADER ATTACHMENT SAFETY STRUT................................................................................................ 10
3.1 LOADER ATTACHMENT SAFETY STRUT (B90B - B95B - B110B) .................................................. 10
4. LOADER BUCKET REMOVAL ................................................................................................................... 13
4.1 REPLACING BUCKET TEETH............................................................................................................ 18
5. LOADER ARM REMOVAL.......................................................................................................................... 19
5.1 LOADER ARM REMOVAL (B90B - B95B - B110B) ............................................................................ 19
5.2 LOADER ARM REMOVAL (B95BTC - B115B).................................................................................... 21
2 SECTION 82 - LOADER
SECTION 82 - LOADER 3
The loader assy consists essentially of an arm hinged to the loader backhoe chassis, on which is installed a
linkage moving the bucket frontally.
Three kind of loader arm are provided:
Z loader arm (B90B - B95B - B110B);
Z bent loader arm (B95BTC);
Z bent loader arm (B115B).

1. LOADER ATTACHMENT CONTROLS

WITH STANDARD LOADER BUCKET
Located on the right of the steering wheel, this nine
position lever operates all the loader attachment
controls. The speed of movement of each control de-
pends on the tilting angle of the lever. In the interme-
diate position, two movements can be obtained
simultaneously.
WITH 4 x 1 LOADER BUCKET

The function of the lever is identical to that of the ma-
chine fitted with the standard loader bucket, with the
addition of the clam control.
LOADER CONTROLS, NEUTRAL AND HOLD

When in the neutral/hold position (0) the attachment
movement can be stopped. As soon as the lever is
released, it automatically returns to the neutral posi-
tion (0) and the attachment remains in the position
where was when movement stopped.
RAISING THE LOADER ATTACHMENT

With the lever in position (1), the attachment rises.
LOWERING THE LOADER ATTACHMENT

With the lever in position (2), the attachment lowers.
LOADER BUCKET FLOAT CONTROL

With the lever in position (3), the bucket follows the
contours of the ground without it being necessary to
operate the lever.
NOTE: in this position the lever does not automati-

cally return to neutral when it is released. It is neces-
sary to move it manually.
FILLING THE LOADER BUCKET

With the lever in position (4), the bucket rolls back
(fills).
DUMPING THE LOADER BUCKET

With the lever in position (5), the bucket rolls forward
(dumps).
LOADER ATTACHMENT AUTOMATIC RETURN

TO DIG
With the lever in position (6), the attachment lowers
and simultaneously the loader bucket places itself in
the digging position.
NOTE: it is possible to adjust the tilt angle for bucket

dig.
4 x 1 LOADER BUCKET CONTROL (if fitted)

This control operates the opening and closing of the
4 x 1 loader bucket clam.
This control is proportional:
When releasing the switch (7), this returns automat-
ically in the initial position (neutral) and the loader
bucket remains positioned in the place where the
motion has ceased.
It is possible to lock the roller into detent by moving
the roller to the full forward (raised) position. To re-
lease the detent, press on the lower portion of the
roller as your return it to the neutral position.
When shifting the switch (7) forward: the loader
bucket clam closes (A).
When shifting the switch (7) backward: the loader
bucket clam opens (B).
4x1 loader bucket control roller detent procedure

The operator may install a detent position for the 4x1
bucket operation.
This position alters operation in order to allow the op-
erator to lock the switch in the open circuit position,
so that this position is held until the operator unlocks
the switch.
The standard position of the switch is with the open
U shape pointing upwards. In this configuration, the
switch will automatically spring back to the neutral
position when released, from any position.
To set the detent position to the bucket open posi-
tion, it is necessary to remove the top of the switch,
rotating it by 180°.
Remove the screw (2) of the roller (1) using a small
fillips screwdriver.
Lift and remove the top portion (3) of the roller switch,
rotate it by 180° and tighten the screw in the top por-
tion of the roller.
NOTE: the open U shape must point downwards.
Carefully restore the screw (2) into place and do not

overtighten.
Test the switch by lifting it up into detent position be-
fore restoring the cap into place. The switch should
lock into position.
In this condition, the 4x1 loader bucket control roller
is locked. To unlock it, it is necessary to rotate the top
portion again and take it back to its initial position.
2. LOADER BUCKET SELF LEVELING

The self leveling linkage mounted on the right hand
loader arm and chassis automatically controls the
angle of the loader bucket during the raising cycle of
the lift arms to maintain a constant bucket level.
There is no self leveling during lowering.
Self leveling begins at the point where the tube (2) on
the loader arm contacts the washer on the bell crank
(1) and lifts the vertical linkage rod (3).
The linkage then moves the bucket control valve into
the roll out position to level the bucket.
AUTOMATIC SELF LEVELING CONTROL

ADJUSTMENT
Z Disconnect the vertical linkage (3) at the lower bell
crank.
Raise loader arms so that the bottom pin is 800 mm

(31.5 in) above the ground and fully roll back the
bucket.
Z Rotate the bell crank (1) till it touches the tube (2)
on the loader arm. Make sure the lower bell crank
arm is directing upwards.
Z Adjust the length of the vertical rod (3) so that when
re-connected, the end of the loader arm tube re-
mains in contact with the bell crank.
Z Securely tighten locknuts on vertical rod.
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.
RETURN TO DIG SENSOR ADJUSTMENT

The return to dig system consists of an electromag-
net mounted on the bucket spool, a sensor (1)
mounted on top of the loader arm and a pointer at-
tached to the tube of the bucket self leveling linkage.
Z Place the bucket on the ground in the preferred dig-
ging position.
Z Adjust the position of the sensor such that when the
bucket is in digging position and loader arms are
lowered, half (50%) of the sensor face is obscured
by the self leveling linkage pointer.
Z Ensure the face of the sensor (1) is 3-6 mm (0.12-
0.24 in) from the pointer (2) on the self leveling link-
age.
As a visual aid for the operator, while seated in the
cab, the pointer mounted on the loader arm can be
seen to align with the pointer on the self leveling link-
age, when the loader arms are lowered and the
bucket is in the level digging position.
B115 (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.
RETURN TO DIG SENSOR ADJUSTMENT

The return to dig system consists of an electromag-
net mounted on the loader bucket control valve
spool, a sensor (1) mounted on top of the loader arm
and a pointer attached to the tube of the bucket self
leveling linkage.
Z Place the bucket on the ground in the preferred dig-
ging position.
Z Check the dimensions of 88.5 mm and 7.5 mm
(3.48 in and 0.30 in) are maintained as shown.
Z Ensure the face of the sensor (1) is 6 mm (0.24 in)
from the rod (2).
As a visual aid for the operator, while seated in the
cab, the pointer mounted on the loader arm can be
seen to align with the pointer on the return to dig link-
age, when the loader arms are lowered and the
bucket is in the level digging position.
3. LOADER ATTACHMENT SAFETY STRUT

3.1 LOADER ATTACHMENT SAFETY
STRUT (B90B - B95B - B110B)
Located on the left-hand side of the loader attach-

ment, this safety strut enables the loader attachment
to be locked in the raised position in case of defects
in the system.
LOCKED POSITION
Completely raise the loader attachment. Stop the en-
gine and remove the starter switch key.
Remove the split pin (1) and the lock pin (2).
Place the strut (3) on the cylinder rod and install the
pin (2) and the split pin (1) back into the holes in the
strut.
SWARNING
It is mandatory to install the safety strut when carry-
ing out any operation requiring the loader attachment
to be in the raised position.
UNLOCKED POSITION
Remove the split pin (1) and the lock pin (2).
Remove the strut (3) from the attachment and install

the pin (1) and the split pin (2) back into the holes in
the strut.
Start the engine and lower the loader attachment.
3.2 LOADER ATTACHMENT SAFETY

STRUT (B95BTC - B115B)
Located on the left-hand side of the loader attach-

ment, this safety strut enables the loader attachment
to be locked in the raised position in case of defects
in the system.
LOCKED POSITION
Completely raise the loader attachment. Stop the en-
gine and remove the starter switch key.
Remove the split pins (1) and the safety strut (2) from
the arm. Put the split pins back in place.
Place the strut (2) on the cylinder rod and fasten it by
means of the fastening flip (3).
SWARNING
It is mandatory to install the safety strut when carry-
ing out any operation requiring the loader attachment
to be in the raised position.
UNLOCKED POSITION
Remove the flip (3) and the strut (2) from the cylinder
rod.
Install the safety strut (2) on the loader arm by means

of the split pins (1).
Start the engine and lower the loader attachment.
4. LOADER BUCKET REMOVAL

4.1 LOADER BUCKET
(B90B - B95B - B110B)
REMOVAL
Move the machine to a level and firm ground.
Lower the bucket to the ground in dump position (tilt-
ed completely forward).
Stop the engine and remove the starter switch key.
If the machine is fitted with a 4x1 bucket, release the
pressure from the bucket circuit.
Remove the fastening screws, then remove the pins
(1).
SWARNING
Always wear eye protection when using a tool which
might project metal particles. Use a hammer with a
soft face, such as copper, for pins assembly/disas-
sembly.
(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. Re-
move any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Install the arm/bucket pins (1) and then install the rel-
evant retaining bolts.
Use the bucket controls to align the connecting rod
orifices with the bucket lugs.
(4x1 bucket) release the pressure from the bucket
circuit.
Install the rod/bucket pins (2), and then install the rel-
evant retaining bolts.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic lines.
4.2 LOADER BUCKET (B95BTC - B115B)
REMOVAL
Lower the bucket to the ground in dump position (tilt-
ed completely forward).
If the machine is fitted with a 4x1 bucket, release the
pressure from the bucket circuit.
Remove the retaining rings and pins, then drive out
the pins (1).
SWARNING
might project metal particles. Use a hammer with a
soft face, such as copper, for pins assembly/disas-
sembly.
(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. Re-
move any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Reinstall the arm/bucket pins (1) and then install the
relevant retaining pins and rings.
Use the bucket controls to align the connecting rod
holes (3) with the bucket lugs.
(4x1 bucket) release the pressure from the bucket
circuit.
Install the rod/bucket pins (2) and then install the rel-
evant retaining pins and rings.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic lines.
4.3 LOADER BUCKET WITH QUICK

COUPLER (B95BTC)
The loader hydraulic coupler allows the operator to

change front end attachments without using special
tools or additional manpower.
INSTALLATION
Make sure the bucket is in a safe area, on a level and
firm ground and with the upper pins in place.
Tilt the quick coupler forwards and engage the top
pins (1) into the upper hooks (2) of the bucket.
Press and hold the quick coupler switch (3) located

left of the front instrument panel as indicated in the
decal (4).
This will retract the lock pins (5).

Lift the loader attachment and rotate the quick cou-

pler rearwards until the lock pins (6) are aligned with
the lower bores of the bucket.
Release the switch (3) allowing the lock pins (5) to
engage in the mounting bores of the bucket.
Visually confirm that the lock pins have correctly se-

cured the bucket.
IMPORTANT: make sure the loader bucket is cor-

rectly installed before using the loader attachment.
REMOVAL
With the attachment resting on the ground, press
and hold the switch to disengage the lock pins.
Raise the loader attachment off the ground and slow-
ly rotate the top of the quick coupler outwards until
the lock pins are clear of the bucket mounting bores.
Release the switch.
Slowly lower the loader attachment to the ground
while rotating the top of the quick coupler outwards.
When the upper pins of the quick coupler are free
from the bucket hooks, back away from the bucket.
4.4 LOADER BUCKET WITH FORKS

(Optional)
SWARNING
The forks are heavy, so use great care when swing-
ing them into their working and stowage position.
INSTALL FORKS IN WORKING POSITION

Move the bucket to a level and firm ground. Stop the
engine and remove the starter switch key. Raise the
parking brake lever.
Remove the retained pin and the pin (1).
Lower the fork (2) manually and carefully until it is
laying in position against the bucket cutting edge.
IMPORTANT: the forks must be laying against the

cutting edge of the bucket, and never against bucket
teeth.
Install the pin (1) and the safety pin.

Repeat the same operations for the other fork.
Slide the forks until they are suitably spaced for the
intended job.
IMPORTANT: the two forks must be positioned at

the same distance from the centre of the bucket.
IMPORTANT: never use the forks to lift the machine.
SWARNING
When using the forks with a 4x1 bucket, never at-
tempt to use the bucket jaw opening function.
INSTALL THE FORKS IN REST POSITION

Rest the loader bucket on a level and firm ground.
Disengage the parking brake lever.
Remove the retained pin and the pin (1).

Tilt the fork (2) manually and carefully until it is rear-
wards into transport position.
Reinstall the pin (1) and the safety pin into their hous-
ing.
NOTE: if necessary, slide the fork to the side to bring

it into its housing.
Repeat the same operations for the other fork.
IMPORTANT: the forks must be securely retained in

their proper storage position using the pins and split
pins provided for this purpose. If forks are not cor-
rectly secured, they can cause serious injury.
4.5 REPLACING BUCKET TEETH

Position the loader bucket so that the bucket teeth
can be replaced.
Place the director-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Loosen and remove the screws (2) with the nuts (3).
Extract the tooth (1).
Clean the area around the tooth.
Assemble the new tooth (1).
Reinstall and tighten the screw (2) with the nuts (3).
)
5. LOADER ARM REMOVAL

5.1 LOADER ARM REMOVAL (B90B - B95B - B110B)
Remove the loader bucket (see procedure described

previously).
Disconnect the self leveling linkage rod (3) from the
bell crank (1).
Strap the linkage rod (2) to loader arm.
Disconnect the loader lift cylinder rod end the retain-

ing pin (4).
Lower the lift cylinder onto the chassis. Disconnect
and cap hoses to bucket cylinder and multi-purpose
bucket pipework where fitted.
IMPORTANT: examine pipework to ensure that any

clamps securing the hoses to the loader arms have
also been released
Support the loader arms using a suitable sling.

Install the loader pivot shaft bolt retainer 380000723.
Using heavy duty socket remove the pivot bolt.
Ensure loader arms are properly supported and re-

move the pivot bar (5).
Remove the loader arms from the machine.

INSTALLATION
Installation follows removal procedure in reverse.
When installing the pivot rod retaining bolts tighten
retaining bolt to 500 Nm (368 lbf·ft).
5.2 LOADER ARM REMOVAL (B95BTC - B115B)
Remove the loader bucket (see procedure described

previously).
Fully retract bucket cylinders and raise arm until lift
cylinder pivots can be seen above engine cover.
Place a suitable stand under the end of the arm to
take the weight while disconnecting the lift cylinder
pivots.
Switch off the engine and relieve hydraulic pressure.
Remove the retaining rings (2) and the locking pins
and then drive out the pivot pins (1). Lower the lift cyl-
inders carefully onto the chassis.
Release the retainers (3) and drive out the pivot pins
(4) from the self leveling arms. Lower the arms onto
the lift cylinders.
Disconnect and cap the lift cylinder hoses (5) at the

top of the loader arm on each side of the machine
and disconnect the return to dig sensor cable (7) on
the right hand side. If the multi purpose bucket is fit-
ted disconnect and cap hose (6) on each side of the
loader arm.
Support the loader arm using a suitable sling.
Remove the retaining ring and locking pin (8) and

then pull out the pivot pin.
Remove the loader arm from the machine.
INSTALLATION
Installation follows removal procedure in reverse.
B90B
B95B - B95BLR
B95BTC
B110B
B115B
SECTION 84 - BACKHOE

2. BACKHOE ATTACHMENT MECHANICAL CONTROLS ............................................................................. 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS .............................................................................. 15
4. REMOVAL AND INSTALLATION ............................................................................................................... 17
4.1 BACKHOE BUCKET REMOVAL ......................................................................................................... 19
5. TELESCOPIC DIPPER (HED) REVISION.................................................................................................. 24
2 SECTION 84 - BACKHOE
SECTION 84 - BACKHOE 3
1. DESCRIPTION AND OPERATION

Loader backhoes are and with a center pivot.
The backhoe pivots on a fixed central point at the
rear of the machine.
Independently operated stabilizers are attached to
the base of the chassis and pivot about an arc to
raise or lower each side of the machine.
Each stabilizer is independently operated using:

Z levers (1) and (2) on loader backhoe control mod-
els mechanical;
Z control levers (3) and (4) on loader backhoe pilot

control models.
The backhoe is locked in position during transporta-

tion using a hydraulically and mechanically operated
boom lock (5).
The lock is operated by the lever (6) or the switched

(7).
The backhoe on the mechanical control models are

controlled using two main control levers.
Three types of control pattern for two (8) and (9) le-
ver systems are available as shown on the following
pages. A four lever dealer installed system is also
available as a Dealer installed optional.
The backhoe on the hydraulic control models are

controlled using two rear hydraulic control levers (10)
and (11).
Machines may be fitted with an optional telescopic

dipper (HED) which can be operated simultaneously
with other boom, dipper and bucket movements.
The telescopic dipper (HED) on mechanical control

models is controlled using a pedal (12) operated
pedal at the rear of the cab.
The telescopic dipper (HED) on pilot control modes,

is controlled using the two buttons (13) and (14) on
the left hydraulic control lever.
2. BACKHOE ATTACHMENT MECHANICAL CONTROLS

Four backhoe attachment control configurations ex-
ist:
Z standard configuration;
Z ISO configuration;
Z cross-pattern configuration;
Z four lever pattern configuration.
The operating pattern of the control levers is differ-
ent.
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 boom lowers.
Position (B): the boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.
Backhoe dipper and backhoe bucket right-hand

control lever

Position (E): the dipper extends.
Position (F): the dipper retracts.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.
ISO CONFIGURATION
Backhoe dipper and backhoe attachment swing

left-hand control lever

Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
left.
right.
Backhoe boom and backhoe bucket right-hand

control lever

Position (E): the backhoe boom lowers.
Position (F): the backhoe boom rises.
CROSS-PATTERN CONFIGURATION
Backhoe boom and backhoe attachment swing

left-hand control lever

Position (0): Neutral/hold. This position enables the
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.

control lever

Position (0): Neutral/hold. This position enables the
Position (E): The backhoe dipper extends.
Position (F): The backhoe dipper retracts.
Position (G): The backhoe bucket closes.
Position (H): The backhoe bucket opens.
FOUR-LEVER PATTERN CONFIGURATION
Lever (1) for dipper

This lever has three positions:
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
Lever (2) for boom

Position (C): the backhoe boom rises.
Position (D): the backhoe boom lowers.
Lever (3) for backhoe bucket

Position (E): the backhoe bucket closes.
Position (F): the backhoe bucket opens.
Lever (4) for backhoe attachment swing

Position (G): the backhoe attachment swings to the
right.
Position (H): the backhoe attachment swings to the
left.
STABILIZER MECHANICAL CONTROLS
Left-hand stabilizer left-hand control lever

Position (0): neutral. This position stops the move-
ment of the left-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral po-
sition (0) and the left-hand stabilizer stops raising or
lowering.
Position (1): the left-hand stabilizer lowers.
Position (2): the left-hand stabilizer rises.
Right-hand stabilizer right-hand control lever

ment of the right-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral po-
sition (0) and the right-hand stabilizer stops raising or
lowering.
Position (1): the right-hand stabilizer lowers.
Position (2): the right-hand stabilizer rises.
NOTE: to raise or lower the stabilizers at the same

time, operate the two levers simultaneously.
TELESCOPIC DIPPER (HED) MECHANICAL

CONTROL PEDAL
This pedal has three positions:
Position (0): neutral. This position enables the move-
ment of the telescopic dipper (HED) to be stopped.
NOTE: the pedal automatically returns to this posi-

tion as soon as it is released.
Position (1): the telescopic dipper (HED) extends.

Position (2): the telescopic dipper (HED) retracts.
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS

BACKHOE CONTROLS
Backhoe boom and backhoe attachment swing

left-hand hydraulic control lever

Position (A): the boom lowers.
Position (B): the boom rises.
left.
right.

hydraulic control lever

Position (E): the dipper extends.
Position (F): the dipper retracts.
STABILIZER CONTROLS
These controls are located on the left-hand control
arm and may be used to operate the stabilizers inde-
pendently or simultaneously.
Left-hand stabilizer left-hand control lever
This lever has four positions:

ment of the left-hand stabilizer. As soon as the lever
is released from positions (1) or (2), it automatically
returns to the neutral position (0) and the left-hand
stabilizer stops raising or lowering.
When held in position (1): the left-hand stabilizer low-
ers.
When held in position (2): the left-hand stabilizer ris-
es.
Position (3): see “stabilizer auto-up feature”.
Right-hand stabilizer right-hand control lever
This lever has four positions:

ment of the right-hand stabilizer. As soon as the lever
is released from positions (1) or (2), it automatically
returns to the neutral position (0) and the right-hand
stabilizer stops raising or lowering.
When held in position (1): the right-hand stabilizer
lowers.
When held in position (2): the right-hand stabilizer
rises.
Position (3): see “Auto-Up feature”.
TELESCOPIC DIPPER CONTROLS (If fitted)

Press and hold down the right-hand button (1) to
extend the telescopic dipper. As soon as the button
is released the dipper stops and remains in the posi-
tion it occupied when the button was released.
Press and hold down the left-hand button (2) to
retract the telescopic dipper. As soon as the button
is released the dipper stops and remains in the posi-
tion it occupied when the button was released.
By pressing button (3), it is possible to set the
engine rpm to idle run disabling accelerator handle
and accelerator pedal. By pressing again button (3)
the engine rpm are restored and the accelerator
handle and accelerator pedal as well.
Before using these controls, make sure the tele-
scopic dipper is mechanically unlocked.
NOTE: operating the backhoe attachment control
levers and these controls simultaneously will enable
numerous possibilities of progressive functioning.
4. REMOVAL AND INSTALLATION

BACKHOE REMOVE
tion the backhoe on the ground.
SWARNING
Lower stabilizers sufficiently and however ensure

that the rear tires are in contact with the ground to re-
move the weight from the rear wheels.
IMPORTANT: the rear wheels must remain in con-

tact with the ground.
On machines fitted with telescopic dipper (HED) in-

stall locking pin in transport hole (1).
Fully retract telescopic dipper.
Fully retract dipper cylinder and lower boom until

bucket is firmly resting on the ground.
Support the backhoe using suitable stand and hoist
capable of carrying 1500 Kg (3307 lbs).
Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.
Re-check that backhoe elements are fully supported.
Disconnect all hoses that travel through the swing
bracket reach the backhoe.
Unscrew and remove the nut (2) to disconnect the

backhoe lock (3).
Loosen and remove the nut (4) and the screw (5).
Slide out the rod pin (6) of swing cylinder.
Repeat the operation with both swing cylinders.
Loosen and remove the nut (7) and the screw (8).
Slide out the lower pin (9) from swing bracket.
Unscrew the screw (10).

Remove the upper pin (11) of swing bracket.
Now it is possible to remove from the backhoe the

backhoe assembly.
4.1 BACKHOE BUCKET REMOVAL
REMOVAL
Lower the stabilizers until they are resting on the
ground.
Place the bucket on the ground.
Remove the lock rings and pins and the rod/bucket
link pin (1).
SWARNING
might project metal particles.
Start the engine.

Retract the bucket cylinder rod.
Operate the attachment controls so that the dipper/
bucket pin is not supporting the load of the dipper.
Remove the lock rings and pins and the arm/bucket
link pin (2).
Start the engine.
Operate the attachment controls so as to disconnect
the dipper from the bucket.
INSTALLATION
Start the engine.
Extend the bucket cylinder rod to bring the connect-
ing rod to their housing.
Reinstall the rod/bucket link pin (1), then install the
lock rings and pins.
Slightly raise the attachment, then operate the buck-
et and dipper control to align the dipper hole with the
bucket lugs.
Reinstall the arm/bucket link pin (2), then install the
lock rings and pins.
BACKHOE BUCKET DIGGING ANGLE

It is possible to change the backhoe bucket opening
angle, depending on the work which is to be carried
out.
Position (1): bucket maximum power.
Position (2): enables the bucket to open by 10° more
and, therefore, to dig vertical side trenches closer to
the machine.
BUCKET TEETH REPLACEMENT

Position the backhoe bucket so that the bucket teeth
can be replaced.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Remove the safety pin (2) using a hammer and a
chisel.
Extract the tooth (1).
Clean the area around the tooth.
Assemble the new tooth (1).
Install the safety pin (2).
DIPPER REMOVE
tion the backhoe on the ground.
SWARNING
Lower stabilizers sufficiently to remove the weight

from the rear wheels.

Install locking pin in transport hole (1) [on machines

fitted with telescopic dipper (HED)].
Lower the backhoe to the ground and support using

a suitable stand.
Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.
Disconnect hoses to dipper cylinders.

Telescopic dipper (HED) hoses:
- telescopic dipper
- standard dipper
Support the dipper cylinder unscrew and remove the

screw (2), slide out the pivot pin (3).
Lower cylinder onto boom. Use suitable cylinder sup-
ports to ensure weight of cylinder does not damage
the hydraulic tubes attached to the dipper.
Support dipper using suitable hoist. Unscrew and re-

move the screw (4), slide out the pivot pin (5) and
carefully lower dipper to the ground.
5. TELESCOPIC DIPPER (HED) REVISION

INSPECTION OF WEAR PADS
Park the machine on level ground and retract the
telescopic dipper (HED).
Position the dipper on a suitable stand with the buck-
et raised from the ground.
Clean the area around the pads.
Inspect each upper wear pad and if the chamfered

edge (1) on the corner of the pads is no longer visible
the pads have worn beyond their limit and must be
replaced.
If pads do not require replacement visually check if
the gap between the inner section of the dipper and
upper wear pad is greater than 1.5 mm (0.06 in).
If the gap is greater than 1.5 mm (0.06 in) the wear
pads must be adjusted.
ADJUSTMENT OF WEAR PADS

Position the dipper in the vertical position.
Count the number of shims behind the adjusting
bolts on the left and right hand sides of the dipper to
determine which side has the most shims.
Remove one shim from behind an adjusting bolt on
the side of the dipper which contains the most shims.
Refit the bolt and tighten to a torque of 350 - 400 Nm
(259 - 296 lbf·ft). DO Not over torque the bolt.
Repeat the procedure for the remaining three bolts
on the same side of the dipper.
Recheck the gap.
If the gap remains greater than 1.5 mm (0.06 in) re-
move a shim from behind each of the adjusting bolts
on the opposite side of the dipper.
After performing an adjustment apply a coat of Dry
Moly-coat grease to the slide rails of the dipper.
NOTE: when all shims have been removed the wear

pads must be replaced.
REPLACEMENT OF WEAR PADS

To replace the wear pads it is necessary to separate
the inner and outer sections of the dipper using either
of the following procedures which are dependent on
workshop facilities.
Procedure No. 1
Park the machine on level ground and lower loader

bucket.
Lower stabilizers sufficiently to remove the weight
from the rear wheels.

Position dipper on a suitable stand.

Attach hoist to inner section of dipper.
Disconnect hose connections to bucket and tele-
scopic dipper (HED) cylinders.
Remove telescopic dipper (HED) cylinder retaining
pin and (1) separate inner and outer sections of dip-
per.

Remove the wear pads (3). Install new upper wear
pads and apply thread sealant part No. 82995773 to
the retaining bolts. Tighten to a torque of 29 - 31 Nm
(21 - 23 lbf·ft). Do not over tighten or damage to the
threaded inserts may occur.
Re-assemble inner and outer sections of dipper.

Place 5 shims beneath the heads of each adjusting
bolt.
Adjust wear pads as described previously.
Procedure No. 2
This procedure requires the use of a loading dock or

service pit.
Park the machine with backhoe positioned over load-
ing dock or service pit.
Place the loader bucket on the ground and lower sta-
bilizers sufficiently to remove the weight from the
rear wheels.
Attach suitable hoist to top of inner section of dipper
and position boom so that dipper is hanging vertical-
ly.
Disconnect hose connections at bucket and tele-
scopic dipper (HED) cylinders.
Remove telescopic dipper (HED) cylinder retaining
pin.
Slowly lower hoist allowing inner and outer sections
of dipper to separate.

Remove the wear pads (3). Install new upper wear
pads and apply thread sealant 82995773 to the re-
taining bolts. Tighten to a torque of 29 - 31 Nm (21 -
23 lbf·ft). Do not over tighten or damage to the
threaded inserts mat occur.
Position new lower wear pads in the outer section of
the dipper.
Re-assemble inner and outer sections of dipper.

Place 5 shims beneath the heads of each adjusting
bolt.
Adjust wear pads as described previously.

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REPAIR MANUAL

Bur • Issued 01Feb 08

This unit first became available 02-2008

Read carefully this manual to collect correct infor-

For any question or remark, or in case of any error

VOLUME MACHINE TYPE PRINT NUMBER

CNH AMERICA LLC

LOADER BACKHOE MODELS

B90B B95B - B95BTC B110B B115B

SECTION 02 - TECHNICAL SPECIFICATIONS

SECTION 17 - TORQUE CONVERTERS

SECTION 25 - FRONT AXLES

SECTION 27 - REAR AXLE

SECTION 33 - BRAKE SYSTEM

SECTION 35 - HYDRAULIC SYSTEM

5. HYDRAULIC CYLINDERS........................................................................................................................ 110

SECTION 41 - STEERING SYSTEM

SECTION 50 - CAB HEATING AND AIR CONDITIONING

3.5 FLUSHING THE SYSTEM................................................................................................................... 45

SECTION 55 - ELECTRICAL SYSTEM

SECTION 00 - SAFETY PRECAUTIONS

ELECTRICAL SYSTEMS REMOVAL AND INSTALLATION

IMPORTANT ECOLOGICAL CONSIDERATIONS

HOSES AND TUBES NOTE: to ensure a leak-free joint is obtained, it is

Z place the sealing lip towards the fluid. In case of a

O-RINGS NOTES FOR EQUIPMENT

O-RING FLAT FACE SEAL FITTING

O-RING FLAT SEAL FITTING TORQUE VALUES

MINIMUM HARDWARE TIGHTENING TORQUES lfb·ft (Nm)

INCH HARDWARE AND LOCKNUTS

METRIC HARDWARE AND LOCKNUTS

Description P/N CNH Typical Applications

General purpose metallic thread and pipe sealant.

Clear, flexible adhesive and sealant.

Non hardening sealant-enhances sealing of all types of

General high strength metallic locking and sealing of all

Description P/N CNH Typical Applications

1. LOADER BACKHOE MODELS .................................................................................................................... 3

1. LOADER BACKHOE MODELS

2. IDENTIFICATION OF MAIN COMPONENTS

1. Loader bucket 8. Backhoe attachment boom

82 kW - 110 HP ENGINE (B110B - B115B)

2WD/2WS TRANSMISSION - POWERSHUTTLE (B90B)

4WD/2WS TRANSMISSION - POWERSHUTTLE (B90B - B95B - B110B)

4WD/2WS TRANSMISSION - POWERSHIFT (B110B)

4WD/4WS TRANSMISSION - POWERSHIFT (B115B)

Front 2WD/2WS axle (B90B)

Front 4WD/2WS axle (B90B - B95B - B110B)

Front 4WD/4WS axle (B115B)

Rear 2WS axle (B90B - B95B - B110B)

Rear 4WS axle (B115B)

BRAKES (B90B - B95B - B110B)

2WS ............................................................................................................................................... 2 wheel steer

3.6 HYDRAULIC SYSTEM

72 kW - 97 HP pump (B90B - B95B)

82 kW - 110 HP pump (B110B - B115B)

3.7 FRONT COUNTERWEIGHT

3.8 NOISE AND VIBRATION LEVELS

VIBRATION LEVEL INSIDE THE CAB

4WS 2350 mm 2350 mm 2350 mm

“HEAVY DUTY” buckets

m3 0.0775 0.1143 0.2475

“HIGH CAPACITY” buckets

“EXTRA HEAVY DUTY” buckets