Professional Documents
Culture Documents
19900
WORKSHOP MANUAL
Print 604.13.028
edition 09/2000
TO THE READER
VOLUME
- Workshop Manual
"TERNA"
MACHINE TYPE
FB90.2 FB100.2 FB110.2
FB200.2 4WS
PRINT No.
604.13.028
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or
on the highway, are caused by the failure of some individuals to follow
simple and fundamental safety rules or precautions. For this reason
MOST ACCIDENTS CAN BE PREVENTED by recognising the real
cause and doing something about it before the accident occurs.
Regardless of the care used in the design and construction of any type
of equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient
operation.
Carefully read indications, cautions and safety warning quoted in the
SAFETY RULES section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many
thousand serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.
ATTENTION
On machines having hydraulically, mechanically and/or cable
controlled equipment (such as showels, loaders, dozers, scrapers
etc.) be certain the equipment is lowered to the ground before
servicing, adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised to
gain access to certain items, be sure the equipment is suitably
supported by means other than the hydraulic lift cylinders, cable
and/or mechanical device used for controlling the equipment.
CONTENTS
SECTION 00 HEALTH, SAFETY, MAINTENANCE
CHAPTER 1 General
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 3 Tooling
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Tooling and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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LB 75115 / FB 90.2200.2
CONTENTS
.............................................................................
CHAPTER 3 Turbocharger
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LB 75115 / FB 90.2200.2
CONTENTS
SECTION 21 TRANSMISSIONS
CHAPTER 1 4x4 Compact Shuttle
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LB 75115 / FB 90.2200.2
CONTENTS
CHAPTER 2 Rear Axle with Electrically Operated Diff Lock (2 and 4 Wheel Drive
Only)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LB 75115 / FB 90.2200.2
CONTENTS
Overhaul
................................................................. 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
......................................................................2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
.............................................................................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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LB 75115 / FB 90.2200.2
CONTENTS
LB 75115 / FB 90.2200.2
CONTENTS
CHAPTER 4 Alternator
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHAPTER 5 Battery
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance & Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONTENTS
.............................................................................
LB 75115 / FB 90.2200.2
SECTION 00 MAINTENANCE
Chapter 1 General Instructions
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by authorised
workshops. All instructions detailed should be carefully observed and special equipment indicated should be
used if necessary.
Everyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible of deriving damages.
SHIMMING
At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up
recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value
indicated for each shim.
O RINGS
Lubricate the O rings before inserting them into their seats. This will prevent the O rings from rolling over and
twine during mounting which will jeopardise sealing.
SEALERS
Apply FLEXIBLE GASKET SEALANT 82995770 or a suitable equivalent, over the mating surfaces marked with
an X.
Before applying the sealer, prepare the surface as follows:
remove possible scales using a metal brush;
thoroughly degrease the surfaces using DEGREASER 82995779, or a suitable equivalent.
BEARINGS
It is advisable to heat the bearings to 80 to 90C before mounting them on their shafts and cool them down before
inserting them into their seats with external tapping.
SPRING PINS
When mounting split socket spring pins, ensure that the pin notch is oriented in the direction of the effort to stress
the pin.
Spiral spring pins should not be oriented during installation.
FB 90.2200.2
604.13.028
Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
Machine model (commercial name) and frame number;
engine type and number;
part number of the ordered part, which can be found on the Microfiches or the Spare Parts Catalogue,
which is the base for order processing.
NOTICES
Wear limits indicated for some details should be intended as advised, but not binding values. The words front,
rear, right hand, and left hand referred to the different parts should be intended as seen from the operators
seat oriented to the normal sense of movement of the Machine.
604.13.028
FB 90.2200.2
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL
This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this manual you will find this symbol together with the following keywords:
WARNING (ATTENZIONE) it gives warning about improper repair operations and
deriving potential consequences affecting the service technicians personal safety.
DANGER (PERICOLO) it gives specific warning about potential dangers for personal safety of the operator or other persons directly or indirectly involved.
TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in
workshops are due from nonobservance of some
simple and essential prudential rule and safety precautions. For this reason, IN MOST CASES THEY
CAN BE AVOIDED. It suffices to foresee possible
causes and act consequently with necessary caution
and care.
The possibility that an accident might occur with any
type of machines should not be disregarded, no matter how well the machine in question was designed
and built.
A wise and careful service technician is the best precautions against accidents.
Careful observance of this only basic precaution
would be enough to avoid many severe accidents.
DANGER: Never carry out any cleaning, lubrication
or maintenance operations when the engine is running.
SAFETY RULES
FB 90.2200.2
604.13.028
604.13.028
ensure that there are no persons within the Machine or attachment operating range.
Do not keep into your pockets any object which
might fall unobserved into the Machines inner
compartments.
Whenever there is the possibility of being
reached by ejected metal parts or similar, use
protection eye mask or goggles with side guards,
helmets, special footwear and heavy gloves.
Wear suitable protection such as tinted eye
protection, helmets, special clothing, gloves and
footwear whenever it is necessary to carry out
welding procedures. All persons standing in the
vicinity of the welding process should wear tinted
eye protection. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY
PROTECTED.
Metal cables with the use get frayed. Always
wear adequate protections (heavy gloves, eye
protection, etc.)
Handle all parts with the greatest caution. Keep
your hands and fingers far from gaps, moving
gears and similar. Always use approved protective equipment, such as eye protection, heavy
gloves and protective footwear.
START UP
ENGINE
Always loosen the radiator cap very slowly before removing it to allow pressure in the system
to dissipate. Coolant should be topped up only
when the engine is stopped or idle if hot.
Do not fill up fuel tank when the engine is running,
mainly if it is hot, to avoid ignition of fires in case
of fuel spilling.
Never check or adjust the fan belt tension when
the engine is running.
Never adjust the fuel injection pump when the
Machine is moving.
Never lubricate the Machine when the engine is
running.
FB 90.2200.2
HYDRAULIC SYSTEMS
FB 90.2200.2
604.13.028
PRODUCT IDENTIFICATION
The Backhoe Loader and its major components are
identified by serial numbers and letters for recognition in After Sales Service. The following information
provides the locations of these identification plates,
stamped numbers and examples of what can be
found on the machine.
VEHICLE SERIAL NUMBER (1), Figure 1.
The Serial Number is stamped on the top of the right
hand main frame, in front of the right hand loader
post, in position (1). . . . . . . . . . .
Example: *000005017*
1
ENGINE IDENTIFICATION, Figure 2.
The engine identification information is located on
the right hand engine sump rail. Record the information below for quick reference.
MODEL NO.
Example: *EA5*
SERIAL NO.
Example: *57018*
DATE CODE.
Example:*5J25*=5(1995),J(September),25(Day)
1
2
604.13.028
FB 90.2200.2
TAP424011
3
TRANSMISSION, P/SHUTTLE
The serial number and type is printed on the plate (1),
on the lower right side of the transmission. Record
the information below for quick reference.
MODEL NO.
Example: *COMT42025*
SERIAL NO.
Example: *15647 E95 01*
4
TRANSMISSION, P/SHIFT Figure 5
The serial number and type is printed on the plate (1),
on the lower right side of the transmission. Record
the information below for quick reference.
MODEL NO.
Example: *GT PRODUCTION *
SERIAL NO.
Example: *TBEA 419323 09/96*
1
5
REAR AXLE IDENTIFICATION, Figure 6
The serial number (1) is stamped on the left side of
the rear axle housing. Record the serial number
below for quick reference.
MODEL NO.
Example: *85801201*
DATE CODE
Example: 5D05=5(1995), D(APRIL), 05(DAY)
6
FB 90.2200.2
604.13.028
Date Code
5.
6.
HELPFUL HINTS
1. Avoid filling tanks using jerry cans or inappropriate pressurised fuel delivery systems which may
cause considerable spillage.
2. In general, avoid skin contact with all fuels, oils,
acids, solvents, etc. Most of them contain substances which can be harmful to your health.
3. Modern oils contain additives. Do not burn contaminated fuels and/or waste oils in ordinary
heating systems.
4. Avoid spillage when draining off used engine
coolant mixtures, engine, gearbox and hydraulic
604.13.028
7.
8.
9.
FB 90.2200.2
GENERAL
Clean the exterior of all components before carrying
out any form of repair. Dirt and abrasive dust can reduce the efficient working life of a component and
lead to costly replacement.
Time spent on the preparation and cleanliness of
working surfaces will pay dividends in making the job
easier and safer and will result in overhauled components being more reliable and efficient in operation.
Use cleaning fluids which are known to be safe. Certain types of fluid can cause damage to O rings and
cause skin irritation. Solvents should be checked that
they are suitable for the cleaning of components and
also that they do not risk the personal safety of the
user.
Replace O rings, seals or gaskets whenever they
are disturbed. Never mix new and old seals or O
rings, regardless of condition. Always lubricate new
seals and O rings with hydraulic oil before installation.
When replacing component parts, use the correct
tool for the job.
FB 90.2200.2
WARNING
NEVER DISCONNECT OR TIGHTEN A HOSE OR
TUBE THAT IS UNDER PRESSURE. IF IN DOUBT,
ACTUATE THE OPERATING LEVERS SEVERAL
TIMES WITH THE ENGINE SWITCHED OFF
PRIOR TO DISCONNECTING A HOSE OR TUBE.
1. Release the fittings and separate the hose or
tube assembly, then remove and discard the O
ring seal from the fitting.
2. Dip a new O ring seal into clean hydraulic oil
prior to installation. Install a new O ring into the
fitting and, if necessary, retain in position using
petroleum jelly.
3. Assemble the new hose or tube assembly and
tighten the fitting finger tight, while holding the
tube or hose assembly to prevent it from turning.
4. Use two suitable wrenches and tighten the fitting
to the specified torque according to the size of the
fitting. Refer to the following torque chart.
NOTE: To ensure a leak-free joint is obtained, it is important that the fittings are not over or under torqued.
604.13.028
10
Dash
Size
0.250
0.375
0.500
0.625
0.750
0.875
1.000
1.250
1.500
-4
-6
-8
-10
-12
-14
-16
-20
-24
6.35
9.52
12.70
15.88
19.05
22.22
25.40
31.75
38.10
Thread
Size
In.
9/16-18
11/16-16
13/16-16
1-14
1 3/16-12
1 3/16-12
1 7/16-12
1 11/16-12
2-12
Swivel Nut
Torque
lbf. Ft
Nm
12
18
37
51
75
75
105
140
160
16
24
50
69
102
102
142
190
217
SEALER SPECIFICATIONS
The following sealers should be used as directed in the manual:
SEALERS
Anaerobic sealer
82995770/1
82995775/6
Pipe sealant
82995768
Thread-locking compound
82995773
604.13.028
cedure is specified in this manual for a specific application. Torque values listed are for general use
only.
Make sure fastener threads are clean and not damaged.
NOTE: A torque wrench is necessary to properly
torque hardware.
FB 90.2200.2
11
CLASS 8.8
CLASS 10.9
PLATED
W/ZnCr
UNPLATED
PLATED
W/ZnCr
LOCKNUT
CL.8
W/CL8.8
BOLT
23* (2.6)
30* (3.4)
33* (3.7)
42* (4.8)
16* (1.8)
67* (7.6)
79* (8.9)
102* (12)
115* (13)
150* (17)
56* (6.3)
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)
338 (458)
NOMINAL
SIZE
UNPLATED
PLATED
W/ZnCr
M4
15* (1.7)
19* (2.2)
M6
51* (5.8)
M8
UNPLATED
IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
MANUFACTURERS IDENTIFICATION
PROPERTY CLASS
PROPERTY CLASS
FB 90.2200.2
CLOCK MARKING
604.13.028
12
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
SAE GRADE 5
UNPLATED
or
PLATED
SILVER
PLATED
W/ZnCr
PLATED
W/ZnCr
GOLD
UNPLATED
or
PLATED
SILVER
55* (6.2)
115* (13)
17 (23)
27 (37)
42 (57)
60 (81)
83 (112)
146 (198)
142 (193)
213 (289)
72* (8.1)
149* (17)
22 (30)
35 (47)
54 (73)
77 (104)
107 (145)
189 (256)
183 (248)
275 (373)
86* (9.7)
178* (20)
26 (35)
42 (57)
64 (87)
92 (125)
128 (174)
226 (306)
365 (495)
547 (742)
112* (13)
229* (26)
34 (46)
54 (73)
83 (113)
120 (163)
165 (224)
293 (397)
473 (641)
708 (960)
GOLD
SAE GRADE 8
UNPLATED
or
PLATED
SILVER
LOCKNUTS
PLATED
W/ZnCr
GR.B
w/GR5
BOLT
GR.C
w/GR8
BOLT
NOMINAL
SIZE
61* (6.9)
125* (14)
19 (26)
30 (41)
45 (61)
65 (88)
90 (122)
160 (217)
258 (350)
386 (523)
86* (9.8)
176* (20)
26 (35)
42 (57)
64 (88)
92 (125)
127 (172)
226 (306)
364 (494)
545 (739)
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
GOLD
121* (14)
157* (18)
250* (28)
324* (37)
37 (50)
48 (65)
59 (80)
77 (104)
91 (123)
117 (159)
130 (176)
169 (229)
180 (244)
233 (316)
319 (432)
413 (560)
515 (698)
667 (904)
773 (1048) 1000 (1356)
IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS
SAE GRADE 2
SAE GRADE 5
SAE GRADE 8
REGULAR NUTS
SAE GRADE 5
HEX NUTS
SAE GRADE 8
HEX NUTS
LOCKNUTS
GRADE IDENTIFICATION
GRADE IDENTIFICATION
GRADE A NO NOTCHES
GRADE A NO MARKS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
604.13.028
FB 90.2200.2
SECTION 00 SPECIFICATIONS
Models FB90.2
Refer to pages 3 to 12
Models FB100.2, FB110.2
Refer to pages 13 to 22
604.13.028
LUBRICANTS
30 C 25 C
15 C
+20 C
+40 C
SAE 10W30
SAE 15W40
22 F 13 F
+5 F
+104 F
RECOMMENDED FLUIDS
AND APPLICATION
ENGINE OIL
Ambra Super Gold (15W40)
Ambra Super Gold (10W30)
NH 330 G
NH 324 G
API CF-4/SG
CCMC D4
75 to 108 hp
75 to 108 hp
NH 900 A
Antifreeze
H2O
75 to 108 hp
75 to 108 hp
75 to 108 hp
75 to 108 hp
COOLING SYSTEM
Ambra Agriflu 50%
Water 50%
MODELS
+68 F
APPROXIMATE
QUANTITY
HYDRAULIC SYSTEM
Ambra Multi G (10W30)
Hydrosystem Biodegradable
NH 410 B
NH 646 H BS
POWERSHUTTLE TRANS
Ambra Multi G (10W30)
NH 410 B
75 to 108 hp
POWERSHIFT TRANS
Ambra Hydrodex 3
NH 530 B
ATF
75 to 108 hp
NH 410 B
75 to 92 hp
108 hp 4WS
75 to 108 hp
BRAKE OIL
Ambra LHM
NH 610 A
75 to 108 hp
litres
1.0
FUEL
Diesel
Cetane40 (minimum)
75 to 108 hp
NH 720 A
75 to 108 hp
75 to 108 hp
As required
As required
GREASE GENERAL
Ambra GR 75MD
Dry Molycoat Grease
604.13.028
NLGI 2
NLGI 00
(US Pint)
(0.3)
7
(PER SAE J 732 C) WITH TYRES
With Two or Four wheel drive and 1.0m3 bucket.
FB 90.2
604.13.028
8
(PER SAE J 732 C) WITH TYRES
A. Loading Reach
B. Bucket Rotation
C. Operating Height, Fully Raised
D. Loading Height Maximum
E. Reach from swing post
F. Reach from rear axle centre line
G. Maximum Length of Surface Excavation
H. Maximum Digging Depth
To Achieve a 0.6m (2ft). Flat Bottom Trench
To Achieve a 2.43m (8ft). Flat Bottom Trench
J. Maximum Digging Depth
K. Stabilizer Spread Transport
L. Stabilizer Spread Working (pads reversed)
M. Stabiliser Pad Levelling Angle
Swing Arc
Maximum digging force (general purpose bucket)
crowd cylinder
bucket cylinder
Lift capacity through dipper arc
Lift capacity, dipper 3.66m (12ft) above ground
Lift capacity at 4.2m (14ft) above ground
Extendible dipper extension length
604.13.028
FB 90.2
9
Standard
Dipper A
HED (Retracted)
Boom B
Dipper A
HED (Extended)
Boom B
Dipper A
Height/ Depth:
m (ft)
Boom B
590 (1305)
+5.4 (18)
830 (1830)
+4.9 (16)
1230 (2710)
1035 (2285)
1515 (3340)
1345 (2970)
1610 (3550)
975 (2150)
+4.3 (14)
2180 (4805)
1670 (3690)
1920 (4240)
1455 (3205)
1535 (3390)
1040 (2290)
+3.6 (12)
2105 (4640)
1690 (3730)
1855 (4090)
1465 (3230)
1515 (3345)
1065 (2350)
+3.0 (10)
2165 (4770)
1690 (3730)
1895 (4175)
1445 (3185)
1545 (3405)
1075 (2370)
+ 2.4 (8)
2425 (5365)
1600 (3525)
2070 (4565)
1410 (3110)
1625 (3585)
1075 (2370)
+ 1.8 (6)
3620 (7980)
1540 (3400)
2725 (6015)
1355 (2990)
1800 (3970)
1065 (2355)
+ 1.2 (4)
1520 (3350)
3495 (7705)
1330 (2940)
2215 (4885)
1060 (2335)
+ 0.6 (2)
1525 (3360)
1305 (2880)
3635 (8020)
1050 (2315)
0 Ground
1495 (3295)
1275 (2815)
1040 (2300)
0.6 (2)
1470 (3245)
1255 (2765)
1040 (2300)
1.2 (4)
1465 (3230)
1240 (2740)
1040 (2300)
1.8 (6)
1485 (3275)
1250 (2760)
1050 (2320)
2.4 (8)
1590 (3510)
1315 (2900)
1080 (2385)
3.0 (10)
1735 (3825)
1500 (3310)
1155 (2545)
3.6 (12)
1385 (3055)
4.2 (14)
1725 (3800)
4.8 (16)
FB 90.2
604.13.028
10
(PER SAE J 732 C) WITH TYRES
With Four Wheel Drive (Bucket 1.0m3)
A. Overall Operating height
Lift Capacity at Maximum Height
Breakout Force
B. Height to Hinge Pin Full Raise
C. Dump Height
D. Maximum Roll back at ground level
E. Dump Angle
F. Reach fully raised
G. Height to Top Of Cab
H. Digging Depth
I. Centre line of axle to Bucket Lip at ground level
J. Wheelbase
K. Centre Line of rear axle to Centre line of swing post
L. Centre Line of rear axle to edge of backhoe bucket
M. Overall Length
N. Overall Height Lip of Bucket to top of Boom
P Overall Width With Bucket
P Overall Width Less Bucket
Weight of machine Loader/Backhoe*
*example (4WD, 6 in 1 Bucket, Counterweights)
604.13.028
FB 90.2
11
(PER SAE J 49) WITH TYRES FWD FRONT = 1216.5 REAR = 19.5L28 R4
A.
B.
C.
D.
E.
F.
G.
H.
Loading Reach
Bucket Rotation
Operating Height, Fully Raised
Loading Height Maximum
Reach from Swing Post Pivot
Reach from Rear Axle C/L
Maximum Length of Surface Excavation
Maximum Digging Depth
To Achieve a 0.6m (2ft) Flat Bottom Trench
To Achieve a 2.4m (8ft) Flat Bottom Trench
J. Maximum Digging Depth
K. Stabilizer Spread Transport
L. Stabilizer Spread Working (pads reversed)
M. Stabiliser Pad Levelling Angle
Swing Arc
Maximum digging force (general purpose bucket)
crowd cylinder (ICED)
bucket cylinder (ICED)
Lift capacity through dipper arc
(SAE)
Lift capacity, dipper 3.66m (12ft) above ground (SAE)
Lift capacity at 4.2m (14ft) above ground
(SAE)
Extendible dipper extension length
Standard Dipper
1683mm (5ft 5in)
204
5504mm (17ft.9in)
3705mm (12ft.0in)
5540mm (18ft.0in)
6660mm (21ft.6in)
6050mm (19ft.7in)
H.E.D. Extended
2657mm (8ft 6in)
204
6250mm (20ft 3in)
4453mm (14ft 5in)
6651mm (21ft 6in)
7771mm (25ft.3in)
7190mm (23ft 4in)
4234mm (13ft.8in)
3854mm (12ft.5in)
4265mm (15ft.0in)
2230mm (7ft.4in)
3200mm (10ft 5in)
14
180
FB 90.2
604.13.028
B
Lifting capacities kgs (lbs) are shown with Standard
Dipper, Extendible Dipper (HED) in retracted position
and Extendible dipper in full extended position.
12
Standard
Dipper A
HED (Retracted)
Boom B
Dipper A
HED (Extended)
Boom B
Dipper A
Height/ Depth:
m (ft)
Boom B
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)
604.13.028
FB 90.2
ISO
CEE
ISO
CEE
mm
(in)
mm
(in)
cm3
(in3)
rev/min
rev/min
rev/min
rev/min
rev/min
Nm
lb ft
Nm
lb ft
92 hp / 69 kw Naturally Aspirated
84 hp / 63 kw Naturally Aspirated
108 hp / 80.5 kw Turbocharged
106 hp / 79 kw Turbocharged
Diesel
4
111.8
(4.4)
127.0
(5.0)
4987
(304)
17.5:1
1.3.4.2
750800
23252375 Naturally Aspirated
21952245 turbocharged
2200 Naturally Aspirated
2070 Turbocharged
355 Naturally Aspirated
262 Naturally Aspirated
445 Turbocharged
328 Turbocharged
0.36 0.46mm (0.014 0.018 in)
0.43 0.53mm (0.017 0.021 in)
COOLING SYSTEM
Type: Pressurized Full Flow Bypass with Expansion Chamber
Fan Belt Deflection:
Naturally Aspirated
13 19mm (0.50 0.75 in)
Turbocharged
10 16mm (0.38 0.62 in)
Air Conditioning Compressor
Tensioner
Thermostat:
Start to Open at
82C (180F)
Fully Open at
95C (203F)
Radiator Cap
0.90 bar (13 lb in2)
FUEL SYSTEM
Injection Pump Type
Cold Start Device
Excess Fuel Device
Fuel Shut Off
Lift Pump
Injection Pump Type
Cold Start Device
Excess Fuel Device
Fuel Shut Off
Lift Pump
Timing
Injectors
FB 90.2
604.13.028
10
TRANSMISSION
POWER SHUTTLE 4x4= 4 Forward and 4 Reverse Gears
Torque Convertor Ratio
POWER SHIFT 4X2= 4 Forward and 2 Reverse Gears
Torque Convertor Ratio
ELECTRICAL SYSTEM
Alternator
Battery Type
Non Turbo
2.63:1
Turbocharged
2.54:1
70 amp
12 volt Negative Earth
95 amp hr (12v/580A/900 CCA) SAE
on Negative / chassis cable
Transistorised
Negative
Positive Engagement, Solenoid Operated (3.1 kw)
55/60W H4 Halogen
5/21W Bayonet Cap
10W Festoon and 10W Bayonet Cap
21W Bayonet Cap
55W H3 Halogen
1.2W Capless
1.2W Capless
BRAKES
Type
Disc Diameter
Parking Type
STEERING
Power Steering Type
Turns Lock to Lock
2WD
FWD Left
Right
Pump Type
System Pressure
Front Wheel Toein 2WD
Front Wheel Toein 4WD
2.9
3.1
3.0
Gear
140 bar (2030 psi)
0 6mm (0 0.24 in)
0 6mm (0 0.24 in)
REAR AXLE
Type
Differential Lock (Power Shuttle Transmission)
Differential Lock (Power Shift Transmission)
HYDRAULIC SYSTEM
Twin Gear Pump
Hydraulic System Pressure:
Main Relief Valve Pressure (All Models)
Stabiliser Relief Valve Pressure (All Models)
604.13.028
Hydrostatic
FB 90.2
11
lbf.ft
130
200
400
715
280
Kgf.m
17.9
27.5
55.3
98.9
38.7
10 12
17 20
32 39
46 57
63 79
93 105
125 140
150 182
1.4 1.7
2.4 5.4
4.4 5.4
6.3 7.8
8.8 10.9
12.7 14.5
17.2 19.4
20.7 25.1
136 kg
300 lb
FRONT WEIGHTS
Chin Weight
RADIATOR COOLANTS
Antifreeze should be changed every 1200 hours or 24 months.
NOTE: In order to reduce deposits and corrosion, water in the cooling system should not exceed the following
limits:
Total hardness Chloride
Sulphates
300 parts per million
100 parts per million 100 parts per million
Ply
rating
1.5
1.7
1.9
2.1
2.2
2.4
2.6
2.8
3.0
3.3
3.6
3.9
3870
10
2240
2420
2620
2770
2850
3000
3140
3320
3420
3610
3800
11L 16
10
1400
1480
1620
1720
1790
1880
2000
2080
2210
2340
2460
12.5/8018
10
1550
1665
1790
1890
1940
2040
2140
2265
2330
2425
2575
2720
1417.5
2780
3000
3205
3335
3465
3650
3830
3925
Tyre
size
Ply
rating
22
25
28
30
32
44
48
52
57
8530
38
41
10
4440
5335
5775
6105
6285
6615
6920
7320
7690
7960
8375
11L 16
10
3086
3262
3571
3791
3946
4144
4409
4585
4872
5158
5423
12.5/8018
10
3416
3669
3945
4165
4275
4496
4716
4992
5135
5344
5675
5994
1417.5
6130
6615
7065
7360
7640
8045
8445
8700
The above tables are for guidance only. For exact information regarding inflation pressures and loads for your
particular tyres consult your Dealer.
FB 90.2
604.13.028
12
Ply
rating
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.2
2.3
2.4
2.6
16.924
10
3556
3675
4040
4260
4408
4625
4890
5100
5300
5470
5810
16.928R4
10
3800
4000
4200
4460
4780
4900
5090
5380
5660
5800
6190
17.5L24
10
3430
3740
3995
4160
4275
4530
4675
4780
4950
5200
5450
5610
5820
18.4/1526
12
4490
4720
4950
5180
5420
5654
5890
6140
6380
6630
7100
7320
7540
19.524R4
10
3990
4245
4610
4220
5150
5300
5580
5805
5990
6170
6710
6710
7120
Tyre
size
Ply
rating
16
17
19
20
22
29
32
33
35
38
12782
25
26
28
16.924
10
7823
8085
8888
9372
9698
10175
10758
11220
11660
12034
16.928R4
10
8380
8820
9260
10275
10540
10805
11220
11860
12480
12785
13465
17.5L24
10
7546
8228
8789
9152
9405
9966
10285
10516
10890
11440
11990
12342
12804
18.4/1526
12
9896
10402
10909
11416
11946
12461
12981
13532
14061
14612
15648
16133
16618
19.524R4
10
8800
9360
10160
10400
11360
11680
12300
12800
13200
13600
14800
14800
15700
ROAD SPEEDS
The following tables show the approximate ground speeds in km/h and miles/h at rated engine speed.
# = Tyres used outside of North America, ## = Tyres used in North America
Naturally Aspirated Engine with Powershuttle Transmission
Gear
Ratio
1st Forward
2nd Forward
3rd Forward
4th Forward
1st Reverse
2nd Reverse
3rd Reverse
4th Reverse
Rear Tyre
16.9 28 ##
km/h
miles/h
5.39
3.34
8.68
5.39
18.47
11.47
32.84
20.4
6.47
3.97
10.41
6.48
22.16
13.7
39.41
24.48
Rear Tyre
19.5L 24 ##
km/h
miles/h
5.12
3.18
8.24
5.12
17.54
10.89
31.19
19.3
6.14
3.8
8.19
5.1
21.04
13.07
37.42
23.25
Rear Tyre
16.9 24 ##
km/h
miles/h
4.99
3.1
8.03
4.98
17.09
10.6
30.38
18.87
5.99
3.7
9.63
5.98
20.5
12.7
36.46
22.6
Rear Tyre
17.5L 24 ##
km/h
miles/h
4.82
2.99
7.76
4.82
16.53
10.2
29.83
18.5
5.79
3.59
9.32
5.8
19.82
12.3
35.26
21.9
604.13.028
FB 90.2
13
Rear Tyre
16.9 28 ##
km/h
miles/h
5.16
3.2
8.31
5.16
17.69
11.0
31.45
19.5
6.2
3.8
9.97
6.19
21.22
13.17
37.74
23.45
Rear Tyre
19.5L 24 ##
km/h
miles/h
4.9
3.04
7.89
4.9
16.8
10.4
29.86
18.6
5.88
3.65
9.47
5.88
20.15
12.5
35.84
22.26
Rear Tyre
16.9 24 ##
km/h
miles/h
4.78
2.97
7.69
4.77
16.37
10.17
29.1
18.1
5.73
3.54
9.22
5.73
19.63
12.2
34.91
21.69
Rear Tyre
17.5L 24 ##
km/h
miles/h
4.62
2.87
7.43
4.61
15.83
9.8
28.13
17.48
5.54
3.44
8.92
5.54
18.98
11.8
33.76
21.0
Rear Tyre
16.928 #
km/h
6.26
10.07
21.44
38.11
7.51
12.08
25.71
45.73
Rear Tyre
18.426 #
miles/h
3.89
6.26
13.3
23.06
4.66
7.5
15.97
28.4
km/h
6.39
10.28
21.88
38.9
7.66
12.33
26.24
46.48
miles/h
3.97
6.39
13.6
24.17
4.76
7.66
16.3
28.9
Rear Tyre
16.9 28 #
km/h
5.99
9.64
20.53
36.49
7.19
11.57
24.62
43.79
Rear Tyre
18.426 #
miles/h
3.66
5.99
12.75
22.67
4.46
7.18
15.3
27.2
km/h
6.12
9.84
20.95
37.25
7.34
11.81
25.13
44.7
miles/h
3.8
6.11
13.01
23.14
4.56
7.34
15.6
27.7
FB 90.2
Rear Tyre
16.9 28 #, ##
km/h
5.9
11.2
22.2
39.2
7.1
13.3
Rear Tyre
18.426 #, ##
miles/h
3.66
6.95
13.79
24.41
4.4
8.26
km/h
6.0
11.2
21.8
39.2
7.1
13.2
miles/h
3.7
7.0
13.5
24.35
4.4
8.2
604.13.028
14
NOTES
604.13.028
FB 90.2
15
13
(PER SAE J 732 C) WITH TYRES
With Two or Four wheel drive & 1.0m3 bucket.
LB 95 / FB 100.2, 110.2
16
14
(PER SAE J 732 C) WITH TYRES
A. Loading Reach
B. Bucket Rotation
C. Operating Height, Fully Raised
D. Loading Height Maximum
E. Reach from swing post
F. Reach from rear axle centre line
G. Maximum Length of Surface Excavation
H. Maximum Digging Depth
To Achieve a 0.6m (2ft). Flat Bottom Trench
To Achieve a 2.4m (8ft). Flat Bottom Trench
J. Maximum Digging Depth
K. Stabilizer Spread Transport
L. Stabilizer Spread Working (pads reversed)
M. Stabiliser Pad Levelling Angle
Swing Arc
Maximum digging force (general purpose bucket)
crowd cylinder
bucket cylinder
Lift capacity through dipper arc
Lift capacity, dipper 3.66m (12ft) above ground
Lift capacity at 4.2m (14ft) above ground
Extendible dipper extension length
LB 95 / FB 100.2, 110.2
17
A
B
15
Standard
Dipper A
HED (Retracted)
Boom B
Dipper A
HED (Extended)
Boom B
Dipper A
Height/ Depth:
m (ft)
Boom B
600 (1325)
+5.4 (18)
900 (1985)
+4.9 (16)
1165 (2575)
1090 (2400)
1560 (3445)
1460 (3220)
1455 (3215)
1030 (2275)
+4.3 (14)
1925 (4250)
1680 (3710)
1815 (4005)
1570 (3460)
1400 (3085)
1095 (2415)
+3.6 (12)
1865 (4115)
1700 (3745)
1755 (3875)
1585 (3495)
1380 (3045)
1125 (2485)
+3.0 (10)
1900 (4185)
1560 (3440)
1785 (3940)
1440 (3180)
1400 (3085)
1115 (2460)
+ 2.4 (8)
2045 (4510)
1475 (3250)
1925 (4250)
1355 (2985)
1460 (3220)
1065 (2350)
+ 1.8 (6)
2480 (5470)
1425 (3140)
2345 (5175)
1300 (2870)
1585 (3495)
1035 (2280)
+ 1.2 (4)
3645 (8045)
1405 (3100)
3475 (8065)
1280 (2825)
1835 (4045)
1020 (2245)
+ 0.6 (2)
1415 (3115)
1285 (2835)
2615 (5770)
1020 (2245)
0 Ground
1450 (3200)
1320 (2915)
3625 (7995)
1035 (2280)
0.6 (2)
1525 (3370)
1395 (3075)
1070 (2360)
1.2 (4)
1550 (3420)
1395 (3075)
1130 (2490)
1.8 (6)
1570 (3465)
1410 (3110)
1150 (2535)
2.4 (8)
1645 (3630)
1470 (3250)
1180 (2600)
3.0 (10)
1965 (4340)
1755 (3875)
1240 (2760)
3.6 (12)
1395 (3080)
4.2 (14)
2055 (4530)
4.8 (16)
LB 95 / FB 100.2, 110.2
18
16
(PER SAE J 732 C) WITH TYRES
With Four Wheel Drive (Bucket 1.0m3)
A. Overall Operating height
Lift Capacity at Maximum Height
Breakout Force
B. Height to Hinge Pin Full Raise
C. Dump Height
D. Maximum Roll back at ground level
E. Dump Angle
F. Reach fully raised
G. Height to Top Of Cab
H. Digging Depth
I. Centre line of axle to Bucket Lip at ground level
J. Wheelbase
K. Centre Line of rear axle to Centre line of swing post
L. Centre Line of rear axle to edge of backhoe bucket
M. Overall Length
N. Overall Height Lip of Bucket to top of Boom
P Overall Width With Bucket
P Overall Width Less Bucket
Weight of machine Loader/Backhoe*
*example (4WD, 6 in 1 Bucket, Counterweights)
LB 95 / FB 100.2, 110.2
19
17
Loading Reach
Bucket Rotation
Operating Height, Fully Raised
Loading Height Maximum
Reach from Swing Post Pivot
Reach from Rear Axle C/L
Maximum Length of Surface Excavation
Maximum Digging Depth
To Achieve a 0.6m (2ft) Flat Bottom Trench
To Achieve a 2.4m (8ft) Flat Bottom Trench
J. Maximum Digging Depth
K. Stabilizer Spread Transport
L. Stabilizer Spread Working (pads reversed)
M. Stabiliser Pad Levelling Angle
Swing Arc
Maximum digging force (general purpose bucket)
crowd cylinder (ICED)
bucket cylinder (ICED)
Lift capacity through dipper arc
(SAE)
Lift capacity, dipper 3.66m (12ft) above ground (SAE)
Lift capacity at 4.2m (14ft) above ground
(SAE)
Extendible dipper extension length
Standard Dipper
1956mm (6ft 3in)
204
5728mm (18ft.6in)
3910mm (12ft.7in)
5843mm (18ft.10in)
6963mm (22ft.6in)
6000mm (19ft.5in)
H.E.D. Extended
2902mm (9ft 4in)
204
6425mm (20ft 9in)
4628mm (15ft 0in)
6927mm (22ft 5in)
8047mm (26ft.1in)
7400mm (24ft 0in)
4562mm (14ft.8in)
4214mm (13ft.7in)
4592mm (14ft.9in)
2230mm (7ft.4in)
3200mm (10ft 5in)
14
180
LB 95 / FB 100.2, 110.2
20
B
Lifting capacities kg (lbs) are shown with Standard
Dipper, Extendible Dipper (HED) in retracted position
and Extendible dipper in full extended position.
18
Standard
Dipper A
HED (Retracted)
Boom B
Dipper A
HED (Extended)
Boom B
Dipper A
Height/ Depth:
m (ft)
Boom B
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 (2480)
+ 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 (13038)
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)
LB 95 / FB 100.2, 110.2
ISO
CEE
ISO
CEE
mm
(in)
mm
(in)
cm3
(in3)
rev/min
rev/min
rev/min
rev/min
rev/min
Nm
lb ft
Nm
lb ft
21
92 hp / 69 kw Naturally Aspirated
84 hp / 63 kw Naturally Aspirated
108 hp / 80.5 kw Turbocharged
106 hp / 79 kw Turbocharged
Diesel
4
111.8
(4.4)
127.0
(5.0)
4987
(304)
17.5:1
1.3.4.2
750800
23252375 Naturally Aspirated
21952245 Turbocharged
2200 Naturally Aspirated
2070 Turbocharged
355 Naturally Aspirated
262 Naturally Aspirated
445 Turbocharged
328 Turbocharged
0.36 0.46mm (0.014 0.018 in)
0.43 0.53mm (0.017 0.021 in)
COOLING SYSTEM
Type: Pressurized Full Flow Bypass with Expansion Chamber
Fan Belt Deflection:
Naturally Aspirated
13 19mm (0.50 0.75 in)
Turbocharged
10 16mm (0.38 0.62 in)
Air Conditioning Compressor
Tensioner
Thermostat:
Start to Open at
82C (180F)
Fully Open at
95C (203F)
Radiator Cap
0.90 bar (13 lb in2)
FUEL SYSTEM
Injection Pump Type
Cold Start Device
Excess Fuel Device
Fuel Shut Off
Lift Pump
Injection Pump Type
Cold Start Device
Excess Fuel Device
Fuel Shut Off
Lift Pump
Timing
Injectors
LB 95 / FB 100.2, 110.2
22
TRANSMISSION
POWER SHUTTLE 4x4= 4 Forward and 4 Reverse Gears
Torque Convertor Ratio
POWER SHIFT 4X2= 4 Forward and 2 Reverse Gears
Torque Convertor Ratio
ELECTRICAL SYSTEM
Alternator
Battery Type
Non Turbo
2.63:1
Turbocharged
2.54:1
70 amp
12 volt Negative Earth
95 amp hr (12v/580A/900 CCA) SAE
on Negative / chassis cable
Transistorised
Negative
Positive Engagement, Solenoid Operated (3.1 kw)
55/60W H4 Halogen
5/21W Bayonet Cap
10W Festoon and 10W Bayonet Cap
21W Bayonet Cap
55W H3 Halogen
1.2W Capless
1.2W Capless
BRAKES
Type
Disc Diameter
Parking Type
STEERING
Power Steering Type
Turns Lock to Lock
2WD
FWD Left
Right
Pump Type
System Pressure
Front Wheel Toein 2WD
Front Wheel Toein 4WD
2.9
3.1
3.0
Gear
140 bar (2030 psi)
0 6mm (0 0.24 in)
0 6mm (0 0.24 in)
REAR AXLE
Type
Differential Lock (Power Shuttle Transmission)
Differential Lock (Power Shift Transmission)
HYDRAULIC SYSTEM
Twin Gear Pump
Hydraulic System Pressure:
Main Relief Valve Pressure (All Models)
Stabiliser Relief Valve Pressure (All Models)
Hydrostatic
LB 95 / FB 100.2, 110.2
23
lbf.ft.
130
200
400
715
280
Kgf.m
17.9
27.5
55.3
98.9
38.7
10 12
17 20
32 39
46 57
63 79
93 105
125 140
150 182
1.4 1.7
2.4 5.4
4.4 5.4
6.3 7.8
8.8 10.9
12.7 14.5
17.2 19.4
20.7 25.1
136 kg.
300 lb.
FRONT WEIGHTS
Chin Weight
RADIATOR COOLANTS
Antifreeze should be changed every 1200 hours or 24 months.
NOTE: In order to reduce deposits and corrosion, water in the cooling system should not exceed the following
limits:
Total hardness Chloride
Sulphates
300 parts per million
100 parts per million 100 parts per million
Ply
rating
1.5
1.7
1.9
2.1
2.2
2.4
2.6
2.8
3.0
3.3
3.6
3.9
3870
10
2240
2420
2620
2770
2850
3000
3140
3320
3420
3610
3800
11L 16
10
1400
1480
1620
1720
1790
1880
2000
2080
2210
2340
2460
12.5/8018
10
1550
1665
1790
1890
1940
2040
2140
2265
2330
2425
2575
2720
1417.5
2780
3000
3205
3335
3465
3650
3830
3925
Tyre
size
Ply
rating
22
25
28
30
32
44
48
52
57
8530
38
41
10
4440
5335
5775
6105
6285
6615
6920
7320
7690
7960
8375
11L 16
10
3086
3262
3571
3791
3946
4144
4409
4585
4872
5158
5423
12.5/8018
10
3416
3669
3945
4165
4275
4496
4716
4992
5135
5344
5675
5994
1417.5
6130
6615
7065
7360
7640
8045
8445
8700
The above tables are for guidance only. For exact information regarding inflation pressures and loads for your
particular tyres consult your Dealer.
LB 95 / FB 100.2, 110.2
24
Ply
rating
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.2
2.3
2.4
2.6
16.924
10
3556
3675
4040
4260
4408
4625
4890
5100
5300
5470
5810
16.928R4
10
3800
4000
4200
4460
4780
4900
5090
5380
5660
5800
6190
17.5L24
10
3430
3740
3995
4160
4275
4530
4675
4780
4950
5200
5450
5610
5820
18.4/1526
12
4490
4720
4950
5180
5420
5654
5890
6140
6380
6630
7100
7320
7540
19.524R4
10
3990
4245
4610
4220
5150
5300
5580
5805
5990
6170
6710
6710
7120
Tyre
size
Ply
rating
16
17
19
20
22
29
32
33
35
38
12782
25
26
28
16.924
10
7823
8085
8888
9372
9698
10175
10758
11220
11660
12034
16.928R4
10
8380
8820
9260
10275
10540
10805
11220
11860
12480
12785
13465
17.5L24
10
7546
8228
8789
9152
9405
9966
10285
10516
10890
11440
11990
12342
12804
18.4/1526
12
9896
10402
10909
11416
11946
12461
12981
13532
14061
14612
15648
16133
16618
19.524R4
10
8800
9360
10160
10400
11360
11680
12300
12800
13200
13600
14800
14800
15700
ROAD SPEEDS
The following tables show the approximate ground speeds in km/h and miles/h at rated engine speed.
# = Tyres used outside of North America, ## = Tyres used in North America
Naturally Aspirated Engine with Powershuttle Transmission
Gear
Ratio
1st Forward
2nd Forward
3rd Forward
4th Forward
1st Reverse
2nd Reverse
3rd Reverse
4th Reverse
Rear Tyre
16.9 28 ##
km/h
miles/h
5.39
3.34
8.68
5.39
18.47
11.47
32.84
20.4
6.47
3.97
10.41
6.48
22.16
13.7
39.41
24.48
Rear Tyre
19.5L 24 ##
km/h
miles/h
5.12
3.18
8.24
5.12
17.54
10.89
31.19
19.3
6.14
3.8
8.19
5.1
21.04
13.07
37.42
23.25
Rear Tyre
16.9 24 ##
km/h
miles/h
4.99
3.1
8.03
4.98
17.09
10.6
30.38
18.87
5.99
3.7
9.63
5.98
20.5
12.7
36.46
22.6
Rear Tyre
17.5L 24 ##
km/h
miles/h
4.82
2.99
7.76
4.82
16.53
10.2
29.83
18.5
5.79
3.59
9.32
5.8
19.82
12.3
35.26
21.9
LB 95 / FB 100.2, 110.2
25
Rear Tyre
16.9 28 ##
km/h
miles/h
5.16
3.2
8.31
5.16
17.69
11.0
31.45
19.5
6.2
3.8
9.97
6.19
21.22
13.17
37.74
23.45
Rear Tyre
19.5L 24 ##
km/h
miles/h
4.9
3.04
7.89
4.9
16.8
10.4
29.86
18.6
5.88
3.65
9.47
5.88
20.15
12.5
35.84
22.26
Rear Tyre
16.9 24 ##
km/h
miles/h
4.78
2.97
7.69
4.77
16.37
10.17
29.1
18.1
5.73
3.54
9.22
5.73
19.63
12.2
34.91
21.69
Rear Tyre
17.5L 24 ##
km/h
miles/h
4.62
2.87
7.43
4.61
15.83
9.8
28.13
17.48
5.54
3.44
8.92
5.54
18.98
11.8
33.76
21.0
Rear Tyre
16.928 #
km/h
6.26
10.07
21.44
38.11
7.51
12.08
25.71
45.73
Rear Tyre
18.426 #
miles/h
3.89
6.26
13.3
23.06
4.66
7.5
15.97
28.4
km/h
6.39
10.28
21.88
38.9
7.66
12.33
26.24
46.48
miles/h
3.97
6.39
13.6
24.17
4.76
7.66
16.3
28.9
Rear Tyre
16.9 28 #
km/h
5.99
9.64
20.53
36.49
7.19
11.57
24.62
43.79
Rear Tyre
18.426 #
miles/h
3.66
5.99
12.75
22.67
4.46
7.18
15.3
27.2
km/h
6.12
9.84
20.95
37.25
7.34
11.81
25.13
44.7
miles/h
3.8
6.11
13.01
23.14
4.56
7.34
15.6
27.7
LB 95 / FB 100.2, 110.2
Rear Tyre
16.9 28 #, ##
km/h
5.9
11.2
22.2
39.2
7.1
13.3
Rear Tyre
18.426 #, ##
miles/h
3.66
6.95
13.79
24.41
4.4
8.26
km/h
6.0
11.2
21.8
39.2
7.1
13.2
miles/h
3.7
7.0
13.5
24.35
4.4
8.2
26
NOTES
LB 95 / FB 100.2, 110.2
27
19
(PER SAE J 732 C)
With Bucket m3
1.15m3
(with clam)
Breakout Force
45
45
45
E. Dump Angle
45
45
45
H. Peel Depth
I. Centre line of axle to Bucket Lip
M. Overall Length
LB 115 / FB 200.2
28
A.
Loading Reach
B.
Bucket Rotation
204
204
C.
D.
E.
F.
G.
H.
J.
4302mm (14ft 1)
K.
L.
M.
14
14
Swing Arc
180
180
LB 115 / FB 200.2
29
20
Standard
Dipper A
HED (Retracted)
Boom B
Dipper A
HED (Extended)
Boom B
Dipper A
Height/ Depth:
m (ft)
Boom B
565 (1245)
+5.4 (18)
1110 (2445)
1025 (2260)
850 (1875)
+4.9 (16
1500 (3305)
1395 (3075)
1525 (3365)
995 (2195)
+4.3 (14)
2425 (5345)
1645 (3625)
2315 (5105)
1530 (3370)
1625 (3585)
1070 (2360)
+3.6 (12)
2350 (5190)
1685 (3715)
2245 (4950)
1565 (3450)
1625 (3585)
1110 (2415)
+3.0 (10)
2395 (5280)
1685 (3715)
2280 (5030)
1560 (3440)
1650 (3645)
1130 (2490)
+ 2.4 (8)
2575 (5675)
1670 (3680)
2455 (5415)
1540 (3395)
1735 (3830)
1135 (2510)
+ 1.8 (6)
3115 (6875)
1645 (3630)
2980 (6580)
1515 (3335)
1885 (4160)
1140 (2515)
+ 1.2 (4)
4555 (10045)
1620 (3375)
4385 (9665)
1485 (3275)
2125 (4690)
1140 (2515)
+ 0.6 (2)
1600 (3525)
1460 (3220)
3315 (7310)
1135 (2510)
0 Ground Level
1580 (3485)
1435 (3615)
4565 (10065)
1135 (2510)
0.6 (2)
1570 (3460)
1420 (3135)
1140 (2515)
1.2 (4)
1575 (3670)
1420 (3130)
1145 (2530)
1.8 (6)
1600 (3530)
1440 (3175)
1165 (2570)
2.4 (8)
1690 (3725)
1515 (3340)
1200 (2645)
3.0 (10)
2095 (4620)
1875 (4135)
1270 (2800)
3.6 (12)
1440 (3175)
4.2 (14)
2255 (4970)
4.8 (16)
LB 115 / FB 200.2
30
1.15m3
(with clam)
Breakout Force
45
45
45
E. Dump Angle
45
45
45
With Bucket
m3
H. Peel Depth
I. Centre line of axle to Bucket Lip
1.15m3
1324mm (4ft.3in)
1324mm (4ft.3in)
1324mm (4ft.3in)
M. Overall Length
LB 115 / FB 200.2
31
A.
Loading Reach
B.
Bucket Rotation
204
204
C.
D.
E.
F.
G.
H.
J.
K.
L.
M.
14
14
Swing Arc
180
180
LB 115 / FB 200.2
32
21
Lifting capacities kgs (lbs) are shown with Standard
Dipper, Extendible Dipper (HED) in retracted position
and Extendible dipper in full extended position.
Standard
Dipper A
HED
(Retracted)
Boom B
Dipper A
HED
(Extended)
Boom B
1085 (2390)
1005 (2215)
1485 (3275)
1385 (3050)
Dipper A
Height/ Depth:
m (ft)
Boom B
545 (1205)
+5.4 (18)
835 (1840)
+4.9 (16
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)
LB 115 / FB 200.2
Compression Ratio
Firing Order
Idle Speed
Maximum NoLoad Speed
Maximum Full Load Speed
Maximum Torque ISO
ISO
CEE
mm
(in)
mm
(in)
cm3
(in3)
108 hp / 80.5 kw
106 hp / 79 kw
Diesel and Turbocharged
4
111.8
(4.4)
127.0
(5.0)
4987
(304)
rev/min
rev/min
rev/min
Nm
lb ft
17.5:1
1.3.4.2
750800
21952245
2070
445
328
33
COOLING SYSTEM
Type: Pressurized Full Flow Bypass with Expansion Chamber
Fan Belt Deflection:
Turbocharged
10 16mm (0.38 0.62 in)
Air Conditioning Compressor
Tensioner
Thermostat:
Start to Open at
82C (180F)
Fully Open at
95C (203F)
Radiator Cap
0.90 bar (13 lb in2)
FUEL SYSTEM
Injection Pump Type
Cold Start Device
Excess Fuel Device
Fuel Shut Off
Lift Pump
Timing
Injectors
TRANSMISSION
POWER SHIFT 4X2= 4 Forward and 2 Reverse Gears
Torque Convertor Ratio
ELECTRICAL SYSTEM
Alternator
Battery Type
Battery Disconnect via the Isolator Switch
Regulator
Ground (Earth)
Starting Motor
Headlight Bulb
Stop/Tail Light Bulb
LB 115 / FB 200.2
Turbocharged
2.54:1
70 amp
12 volt Negative Earth
95 amp hr (12v/580A/900 CCA) SAE
on Negative / chassis cable
Transistorised
Negative
Positive Engagement, Solenoid Operated (3.1 kw)
55/60W H4 Halogen
5/21W Bayonet Cap
604.56.061.00 / 604.13.028.00 09/2000
34
BRAKES
Type
Disc Diameter
Parking Type
STEERING
Power Steering Type
Turns Lock to Lock
Left
Right
Pump Type
System Pressure
Front Wheel Toein
3.1
3.0
Gear
140 bar (2030 psi)
+0 to 2mm (0 to 0.078in)
REAR AXLE
Type
Differential Lock (Power Shuttle Transmission)
Differential Lock (Power Shift Transmission)
Rear Wheel Toein
HYDRAULIC SYSTEM
Twin Gear Pump
Hydraulic System Pressure:
Main Relief Valve Pressure (All Models)
Stabiliser Relief Valve Pressure (All Models)
TORQUES
Front and Rear Wheel Nuts
Backhoe Attaching Bolts
Cab/ROPS Attaching Bolts
Turbocharger Oil Inlet Pipe
Oil Outlet Pipe
Hydraulic Hoses/Tubes/ ORS Connections
9/ 18
Thread Size:
16
11/ 16
16
13/ 16
16
1 14
13/16 12
17/16 12
111/16 12
2 12
Hydrostatic
590
715
280
15
25
13.5 16.5
23 28
45 53
62 77
86 107
125 142
169 190
203 246
10 12
17 20
32 39
46 57
63 79
93 105
125 140
150 182
LB 115 / FB 200.2
35
The tyres fitted to your machine with four wheel drive have been carefully selected to match the gearing of the
transmission and axles. When renewing worn or damaged tyres, always install tyres of the same make, model
and size as those removed. The installation of other tyre combinations may result in excessive tyre wear, loss
of usable power or severe damage to drive line components. If in doubt, consult your Dealer.
FRONT AND REAR TYRE PRESSURES AND PERMISSIBLE LOADS
The following charts give the carry capacity of the axle at the tyre pressures indicated.
These charts are for guidance only. For exact information regarding inflation pressures and loads for your
particular tyres, consult your Dealer.
Inflation Pressures in bar
Tyre
size
1.0
1.1
1.3
1.4
1.5
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
1650
1775
2020
2130
2240
2445
2550
2650
2735
2820
2905
2990
3080
3165
3250
16.928R4
1760
1895
2155
2775
2390
2610
2720
2830
2920
3005
3095
3190
3280
3370
3465
440/80 R28
1770
1975
2089
2205
2225
2580
2680
2720
2910
2995
3120
3080
3275
3250
3590
Tyre
size
14.5
16.0
18.9
20.3
21.8
24.7
30.5
31.9
33.4
34.8
36.3
37.7
27.6
29.0
3630
3905
4444
4686
4849
5379
5610
5830
6017
6204
6391
6578
6776
6963
7150
16.928R4
3872
4169
4741
6105
5258
5742
5984
6226
6424
6611
6809
7018
7216
7414
7623
440/80 R28
3894
4345
4595
4851
4895
5676
5896
5984
6402
6589
6864
6776
7205
7150
7898
FRONT WEIGHTS
Chin Weight
RADIATOR COOLANTS
Antifreeze should be changed every 1200 hours or 24 months.
NOTE: In order to reduce deposits and corrosion, water in the cooling system should not exceed the following
limits:
Total hardness
300 parts per million
Chloride
100 parts per million
Sulphates
100 parts per million
ROAD SPEEDS
The following table shows the approximate ground speeds in km/h and miles/h at rated engine speed (2070
rev/min).
# = Tyres used outside of North America, ## = Tyres used in North America
Turbocharged Engine with Powershift Transmission
Gear
Ratio
1st Forward
2nd Forward
3rd Forward
4th Forward
1st Reverse
2nd Reverse
LB 115 / FB 200.2
Rear Tyre
16.9 28 #, ##
km/h
miles/h
5.9
3.66
11.2
6.95
22.2
13.79
39.2
24.41
7.1
4.4
13.3
8.26
Rear Tyre
18.426 #, ##
km/h
miles/h
6.0
3.7
11.2
7.0
21.8
13.5
39.2
24.35
7.1
4.4
13.2
8.2
Tire 440/80R 28 ##
km/h
5.9
11.2
22.2
39.2
7.1
13.3
miles/h
3.6
6.95
13.79
24.35
4.4
8.26
36
NOTES
LB 115 / FB 200.2
Description
Page
00 000
Tooling and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
The following data is for general guidance. Where specific data or dimensions are required and not quoted in
this section, refer to the section in the Repair Manual relating to the component under repair.
IMPORTANT: The following Tool listing is for all applications (unless otherwise stated)
1
2. Internal Micrometer for Bore measurement
TA6010040
2
3. Dial Indicator Eccentricity checking Valve Seats,
guides and bores
LB 75115 / FB 90.2200.2
4
5. Dial Indicator for checking Concentricity, End
Floats, Crankshaft Seal seating.
TA6010056
5
6. Internal Bore Gauge for Valve Guides and general measurement
TA6010018
6
7. Bearing Heater
7
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
8
9. 3 Legged Puller for general application
9
10. Spring Compressor Valve Springs
TA6010011
10
11. Square Valve Springs
11
LB 75115 / FB 90.2200.2
12
13. Piston Ring Remover Pistons
13
14. Puller General
TA6010027
14
15. ALL MODELS Splitting Kit for Machine Disassembly
15
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
9cm
20mm
O = 18mm x 3
12cm
35mm
18mm
11.5cm
9cm
1
17. Spring Retainer Gear Shift Detent Springs
23mm
18mm
2
18. Bearing Installer 35mm Transmission Idler and Output Shaft Bearing Installation
45mm
35mm
150mm
3
19. Bearing Installer 4WD, Counter Shaft, Transmission Input Shaft Front
50mm
300mm
40mm
LB 75115 / FB 90.2200.2
20. POWER SHUTTLE TRANSMISSION Bearing Installer 50mm Transmission Input Shaft Rear
60mm
150mm
50mm
5
21. Oil Pump Seal Transmission Oil Pump Seal Installation
70mm
6
22. Bush Installer Transmission Input Shaft Bush Installation
22mm
7
23. REAR AXLE Holding Bracket Rear Axle Pinion Nut Removal Aid
1.
2.
3.
4.
5.
6.
7.
8.
9.
46mm (1.811in)
65mm (2.559in)
9mm (0.354)
40mm (1.575in)
220mm (8.66in)
140mm (5.51in)
95mm (3.74in)
10mm (0.394in)
110mm (4.33in)
LB 75115 / FB 90.2200.2
65 mm
45 mm
10 mm (x4)
5 mm
9
25. ENGINE Camshaft Bush Removal / Installation #297117
TA6010071
10
26. Step Plates, Front cover Seal Installation #297108
11
27. ENGINE & TRANSMISSION (not 75hp) Lifting Bracket #297392
12
LB 75115 / FB 90.2200.2
TA6010055
13
29. FUEL PUMP (not 75hp) Timing tool C.A.V Injection Pump Timing #297119,#297512,#297513
14
30. POWER SHUTTLE TRANSMISSION Compression Transmission Clutch Pack #297394
15
31. Gauge Tool Bolt Aid Measurement Of Shaft End Floats #297395
16
LB 75115 / FB 90.2200.2
17
33. Locking Tool Holds output couplings solid to remove attaching nut #297397
18
34.
*60mm Thin wall socket Remove output couplings attaching nut #297400
19
35. Lift Hook Clutch Shaft 1st Reverse Shaft or 2nd Forward Shaft lifting tool #297398
20
LB 75115 / FB 90.2200.2
10
36. POWER SHIFT TRANSMISSION Compression Tool Transmission Clutch Packs #297401
21
37. Seal Installer Front and rear cover seal installer #297402
22
38. Pressure Gauge Adapter Torque Convertor Pressure Test #297403
7/
16 x
20 UNF
M10 x 1.0
23
39. Pressure Gauge Adapter General Gauge Testing #297404
7/
16 x 20 UNF
7/ x 20 UNF
16
M10 x 1.0
24
LB 75115 / FB 90.2200.2
11
40. POWER SHIFT TRANSMISSION Pressure Gauge 20 bar (290 psi) general
25
41. 100 ohm Test Lead Testing Speed Sender #297405
26
42. Limp home lead Total Failure Microprocessor Override #297406
27
43. FRONT AXLE Seal Removal Axle #297111
28
LB 75115 / FB 90.2200.2
12
29
45. Seal Removal Tool Hub #297101, #297504
30
46. Seal Insertion Tool Hub #297103
31
47. Bush Removal Tool Axle #297111
32
LB 75115 / FB 90.2200.2
13
33
49. Pinion Socket Tool #297511
34
50. Gauge Tool Differential Setting #297132
35
51. REAR AXLE Lifting Bracket Half Shaft #297413
36
LB 75115 / FB 90.2200.2
14
52. REAR AXLE Removal and Installation Tool Ring Gear #297326
37
53. Bearing Cup Removal Tool Half shaft, #297101, #297504
38
54. Bearing removal Axle #297390, #297391
39
55. Bearing Pre Load Differential #297146
40
LB 75115 / FB 90.2200.2
15
41
57. HYDRAULIC Pressure Test Valve to Check and Adjust all Relief Valves #297418
42
58. Seal Installer Tool Seal Installation, Hydraulic Valve #297149
43
59. Flow Test Fittings #297166
44
LB 75115 / FB 90.2200.2
16
60. HYDRAULIC Pressure Test Gauge 250 bar Hydraulic System/Steering 2 20bar Trans/Four Wheel Drive
61. Quick Release Fitting Steering and Hydraulic Relief Valve Testing #291924
46
62. Fitting * 13/16in ORFS Hand pump to rod end of bucket cylinder to test relief valve rod end.
47
63. POWER SHUTTLE Fitting * 9/16in ORFS to test Transmission clutch, and Torque Convertor.
48
LB 75115 / FB 90.2200.2
17
64. CYLINDERS x3 Peg Spanner #297190 Lift Crowd, #297191 Bucket & Swing, #297192 Stabilisers
49
65. x4 Peg Spanner
80mm
90
80mm
66. C Spanner
50
#297185 Dipperstick, #297185 Stabilisers, #297188 Bucket, #297193 Swing & Dipstick
51
67. Locking Tool Loader Pivot Pin #297189
52
LB 75115 / FB 90.2200.2
18
68. Lead Diagnostic Lead 85820162 (NH ENG), 85820164 (FH ENG ), 85820163 (ITA)
PC
53
LB 75115 / FB 90.2200.2
SECTION 10 ENGINE
Chapter 1 Engine Overhaul New Holland
CONTENT
Section
Description
Page
10 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
Type
Output
No. of cylinders
Bore
Stroke
Displacement
Compression Ratio
Compression @ Cranking Speed
Firing Order
Idle Speed
Maximum NoLoad Speed
Engine Speed at Maximum Torque
Rated Speed
Tappet Clearance (cold) Intake
Exhaust
LB 85115 / FB 90.2200.2
in.
(mm)
in.
(mm)
in3
(cm3)
bar
lbs in2
rev/min
rev/min
rev/min
rev/min
Diesel
Diesel
92hp
108 hpT
4
4.4
(111.8)
5.0
(127.0)
304
(4987)
17.5:1
25.5
375
1.3.4.2
700800
2320
21952245
1600
1400
2200
2070
0.36 0.46mm (0.014 0.018 in)
0.43 0.53mm (0.017 0.021 in)
CYLINDER BLOCK
Taper of Cylinder Bore
Cylinder Bore out of Round
Cylinder Bore Diameters
Rear Oil Seal Bore Diameter
Block to Head Surface Flatness
CYLINDER HEAD
Valve Guide Bore Diameter
Head to Block Surface Flatness
EXHAUST VALVES
Face Angle
Stem Diameter
Head Diameter
Stem to Guide Clearance
Lash Clearance (Cold)
INTAKE VALVES
Face Angle
Stem Diameter
Head Diameter
Stem to Guide Clearance
Lash Clearance (Cold)
VALVE SPRINGS
Number per Valve
Free Length
Length, loaded at 27.731.3kg (61.69 lb)
Length, loaded at 6169kg (135153 lb)
1
60.7mm (2.39 in)
48.26mm (1.900 in)
35.69mm (1.405 in)
LB 85115 / FB 90.2200.2
VALVE TIMING
Intake Opening
Intake Closing
Exhaust Opening
Exhaust Closing
VALVE INSERTS
Exhaust Valve Insert
Insert Oversize
VALVE SEATS
Exhaust Valve Seat Angle
Intake Valve Seat Angle
Interference Valve Face Angle
to Valve Seat Angle
Concentricity With Guide
Diameter
Seat Width Exhaust Valve
Intake Valve
4500 4530
3000 3030
030 115
0.051mm (0.002 in) Total Indicator Reading Max
1.82.3mm (0.0720.092 in)
1.92.5mm (0.0780.098 in)
47
0.0760.35mm (0.0030.014 in)
50.81350.838mm (2.00052.0015 in)
50.75750.770mm (1.99831.9988 in)
0.150.46mm (0.0060.018 in)
0.150.46mm (0.0060. 018 in)
0.100.53mm (0.0040.021 in)
CAMSHAFT GEAR
Number of Teeth
LB 85115 / FB 90.2200.2
52
ROCKER ARM
Inside Diameter
TAPPETS
Clearance to Bore
Tappet Diameter
Tappet Bore Diameter
CAMSHAFT
Bearing Journal Diameter
Bearing Clearance
End Play
CONNECTING RODS
Small End Bushing (Internal Diameter)
Normally Aspirated
Turbocharged
Clearance Bushing to Piston Pin
Side Float
Maximum Twist
Maximum Bend
PISTON PIN
Outside Diameter
Normally Aspirated Engine
Turbocharged Engine
PISTONS
Skirt to Cylinder Clearance
Naturally Aspirated
New, unrun engines
LB 85115 / FB 90.2200.2
PISTON RINGS
Compression rings,
Number and Location
Naturally Aspirated,
Top Compression Ring
2nd Compression Ring
Turbocharged,
Top Compression Ring
2nd Compression Ring
Oil Control,
Number and Location
Type
Side Face Clearance To Ring Groove,
Top Compression Ring
2nd Compression Ring (Turbocharged)
2nd Compression Ring (Naturally Aspirated)
Oil Control Ring
Gap Width,
Top Compression Ring
2nd Compression Ring
Oil Control Ring
CRANKSHAFT
Main Journal Diameter
Main Journal Length
(except thrust, rear, or intermediate)
Maximum permitted wear limits
Thrust Bearing Journal Length
Intermediate Bearing Journal Length
Rear Bearing Journal Length
Crankpin Journal Length
Crankpin Diameter
End Play
Crankpin Out of Round
Taper Surface Parallel to Centre Line
of Main Journal
Crankshaft Rear Oil Seal Journal Diameter
Crankshaft Pulley Journal Diameter
Crankshaft Timing Gear Journal Diameter
Crankshaft Flange Runout
LB 85115 / FB 90.2200.2
26
MAIN BEARING
Liner length (except thrust liner)
CRANKPIN BEARINGS
Liner Length
Vertical Assembled Bearing Clearance
CRANKSHAFT REGRINDING
When regrinding a crankshaft the main and crankpin journal diameters should be reduced the same amount
as the undersize bearings used, and the following dimensions apply. The rear end of the crankshaft should be
located on the 60 Chamfer of the pilot bearing bore.
BALANCER
Gear Backlash
Shaft to bushing clearance
Shaft Diameter
Backlash between balancer / crankshaft gear
End float balancer gear to support
FLYWHEEL
Ring Gear Runout
Flywheel Runout
Maximum depth to be skimmed from face
LB 85115 / FB 90.2200.2
API
Classification
SF/CD / CF4
150
150
150
12C to 4C
(10F to 40F )
SF/CD / CF4
150
300
0C to 32C
(32F to 90F)
SF/CD / CF4
300
300
Above 24C
( 75F )
SF/CD / CF4
300
12C
(Below 10F)
NOTE: When using diesel fuel with a sulphur content below 1.0%, Series 3 diesel engine oil with an A.P.I. classification of CD may be used instead of CF4 oil , but the oil and filter interval must be reduced to 150 hours .
When using diesel fuel with a sulphur content between 1% and 1.3% use only oils listed above but reduce the
oil and filter change period to every 50 hours .
Litres
US Gals
92 to 108hp
12
3.17
THERMOSTAT
Opening Temperature
Fully Open
7983C (174181F)
9396C (199205F)
RADIATOR CAP
Opening Pressure
WATER PUMP
Type
Drive
Centrifugal
V Belt
Litres
U.S. gals
92 to 108hp
16
4.2
COOLING FLUID
Content Mixture
Type
LB 85115 / FB 90.2200.2
55* (6.2)
115* (13)
17 (23)
27 (37)
42 (57)
60 (81)
83 (112)
146 (198)
142 (193)
213 (289)
SAE GRADE 5
PLATED
W/ZnCr
PLATED
W/ZnCr
GOLD
UNPLATED
or
PLATED
SILVER
72* (8.1)
149* (17)
22 (30)
35 (47)
54 (73)
77 (104)
107 (145)
189 (256)
183 (248)
275 (373)
86* (9.7)
178* (20)
26 (35)
42 (57)
64 (87)
92 (125)
128 (174)
226 (306)
365 (495)
547 (742)
SAE GRADE 8
PLATED
W/ZnCr
GOLD
UNPLATED
or
PLATED
SILVER
112* (13)
229* (26)
34 (46)
54 (73)
83 (113)
120 (163)
165 (224)
293 (397)
473 (641)
708 (960)
121* (14)
250* (28)
37 (50)
59 (80)
91 (123)
130 (176)
180 (244)
319 (432)
515 (698)
773 (1048)
157* (18)
324* (37)
48 (65)
77 (104)
117 (159)
169 (229)
233 (316)
413 (560)
667 (904)
1000 (1356)
LOCKNUTS
GR.B
w/GR5
BOLT
GR.C
w/GR8
BOLT
NOMINAL
SIZE
61* (6.9)
125* (14)
19 (26)
30 (41)
45 (61)
65 (88)
90 (122)
160 (217)
258 (350)
386 (523)
86* (9.8)
176* (20)
26 (35)
42 (57)
64 (88)
92 (125)
127 (172)
226 (306)
364 (494)
545 (739)
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
GOLD
IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS
SAE GRADE 2
SAE GRADE 5
SAE GRADE 8
REGULAR NUTS
SAE GRADE 5
HEX NUTS
SAE GRADE 8
HEX NUTS
LOCKNUTS
GRADE IDENTIFICATION
GRADE A NO NOTCHES
GRADE B ONE CIRCUMFERENTIAL NOTCH
GRADE C TWO CIRCUMFERENTIAL NOTCHES
GRADE IDENTIFICATION
GRADE A NO MARKS
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
GRADE A NO MARKS
GRADE B THREE MARKS
GRADE C SIX MARKS
MARKS NEED NOT BE LOCATED
AT CORNERS
LB 85115 / FB 90.2200.2
Nm
lbf ft
Kgf m
197
145
20.0
149
110
15.2
217
160
22.0
35
26
3.5
38
28
3.9
Exhaust PipetoFlange
31
23
3.2
FlywheeltoCrankshaft
197
145
20.0
41
30
4.2
24
18
2.4
224
210
23.0
24
18
2.4
23
17
2.3
Cover Bolts
31
23
3.1
23
17
2.3
48
35
3.6
27
20
2.8
38
28
3.9
24
18
2.4
11
1.1
24
18
2.4
237
175
24.0
24
18
2.4
24
18
2.4
69
51
7.0
47
35
4.8
42
31
4.2
34
25
3.5
31
23
3.2
79
58
8.0
31
23
3.2
44
33
4.5
27
21
2.8
Initial Tightening
12
1.2
Final Tightening
23
17
2.3
Temperature Senders
20
15
2.0
54
40
5.5
24
18
2.4
Crankshaft PulleytoCrankshaft
LB 85115 / FB 90.2200.2
10
Nm
Kgf m
lbf ft
11
1.1
29.8
22
3.0
38
28
3.8
27
20
2.7
SPECIAL TOOLS
DESCRIPTION
TOOL No.
297102
Shaft Protectors
297107
297108
Bushing Kit
297466
295006
297117
295007
297116
297194
TYPE
NAME
Ambra GR9
NH 1 710 A
Ambra GR75MD
NH 1 720 A
GreaseMolybdenum Disulphide
82995768
ESEM4G194B
82995776
ESEM4G195A
SealerSilicone
82995774
SPM4G9112A
SealerPolyester Urethane
82995773
SPM4G9112C
SealerPolyester Urethane
82995772
ESEM4G217A
SealerAnaerobic
82995771
SPM2G9121B
82995782
LB 85115 / FB 90.2200.2
11
POSSIBLE CAUSES
REMEDY
2. Clean
3. Faulty injectors
4. Incorrect
adjustment
valve
exhaust
Water
temperature
gauge fails to reach
normal
operating
temperature
LB 85115 / FB 90.2200.2
Excessive
smoke
lash
or
as
1. Renew bulb
pressure
1. Overhaul turbocharger
3. clean
2. Renew thermostat
3. Faulty
gauge
water
temperature
12
PROBLEM
Engine knocks
REMEDY
POSSIBLE CAUSES
1. Diluted or thin oil
4. Excessive
play
crankshaft end
8. Crankshaft
ofround
out
9. Excessive
pistonto
cylinder bore clearance
10. Excessive
clearance
journals
piston
ring
16. Excessive
backlash
timing
gear
LB 85115 / FB 90.2200.2
PROBLEM
Engine overheats
POSSIBLE CAUSES
LB 85115 / FB 90.2200.2
REMEDY
3. Radiator leakage
3. Repair/renew radiator
6. Faulty thermostat
6. Renew thermostat
11. Cylinder
head
improperly installed
13
gasket
15.Clean
14
PROBLEM
POSSIBLE CAUSES
REMEDY
3. Blocked
screen
Excessive oil
consumption
Engine tends to
keep firing after fuel
is shut off
oil
pump
sump
6. Overhaul pump
7. Excessive
connecting
clearance
main
or
rod
bearing
3. Renew
6. Repair/renew
assembly
7. Change filter
2. Overhaul turbocharger
oil
cooler
LB 85115 / FB 90.2200.2
LB 85115 / FB 90.2200.2
15
16
1
Engine Oil Flow
LB 85115 / FB 90.2200.2
17
AP101002
2
The thermostat is located in the top of the water
pump body, and controls the flow of the water as required by temperature changes.
NOTE: A faulty thermostat may cause the engine to
operate at too hot, or cold, an operating temperature.
If not replaced this could result in a damaged engine,
or impaired engine performance.
When the thermostat is closed Figure 2, a recirculating bypass is provided to allow the coolant to recirculate from the head to the block to effect a faster
warmup.
AP101003
3
Once the engine has reached its normal operating
temperature, the thermostat will open Figure 3 and
allow water to be drawn through the radiator by the
pump action. Cooled water then returns to the engine system.
Cooling occurs as the coolant passes down through
the radiator cores, which are exposed to the air as it
is drawn through the radiator by the fan.
The cooling system incorporates a drain plug on the
right hand side of the cylinder block (1), Figure 4.
LB 85115 / FB 90.2200.2
18
5
1.
2.
3.
4.
5.
6.
7.
Thermostat
Coolant Radiator
Air Conditioning Condenser (when fitted)
Water Pump
Transmission OIl Cooler
Battery
Engine Oil Level Dipstick
WARNING
Allow the engine to cool too ambient temperature before cleaning. Cleaning a hot engine in cool water
could result in damage to the Fuel Pump and other
components.
In the following procedures and illustrations the engine in the main is shown removed from the tractor.
The engine overhaul procedure initially describes the
assembly process for rebuilding an engine using all
new components. Following this section are defined
headings which describe detailed repair specifications and procedures, where components are suitable for reuse. Refer to the specifications section to
ensure components are serviceable.
Where overhaul of components is required without
engine being removed from the tractor refer to the
following headings, and the relevant paragraphs, in
the main overhaul procedure.
Operations or repairs that can be performed with the engine still in the tractor.
Operations or repairs that can be performed with the engine removed from the
vehicle and separated from the transmission housing, with oil pan removed.
LB 85115 / FB 90.2200.2
19
6
1.
2.
3.
LB 85115 / FB 90.2200.2
20
AP101007
7
14. Remove the cab mat
15. Remove the cab floor access panel
16. Disconnect the electrical connections
Forward Reverse solenoids (on top of the
transmission)
Transmission lever at base of lever
FWD solenoid
17. Disconnect the transmission to lock out valve
pipe
18. Disconnect lock out return pipe and plug the hole
(oil will leak out of transmission)
AP101008
8
19. Remove front drive shaft and remove rear drive
shaft
20. Disconnect the hand brake cable
21. Disconnect the gear lever
22. Pull back hydraulic pumps (leaving all pipes attached). Check that the oil pump drive shaft does
not slide out with the pump
23. Check return from steering motor is on the outside of transmission oil level tube.
AP101009
9
24. With the engine supported and using a hoist capable of supporting a total weight of 800 kgs
1760 lbs loosen and remove the Engine and
Transmission mounting bolts
25. Using lifting tool 297392 very carefully raise the
hoist and guide the engine/transmission assembly from the vehicle
10
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
21
11
2. Remove the starter motor assembly
3. Remove the torque convertor attaching bolts accessed through the starter motor aperture (1)
4. Remove the engine timing tab (2)
12
5. Remove the bell housing bolts
6. Gently slide the transmission with the torque
convertor from the engine
Engine Installation
Installation of the engine is the reversal of the
removal procedure, noting the following points:
2
AP10012
13
14
LB 85115 / FB 90.2200.2
22
ENGINE DISASSEMBLY
Cylinder Head, Valves, And Related Parts
(Op. 10 101)
Cylinder head removal
NOTE: The cylinder head can be removed with the
engine installed in the tractor.
Remove or disconnect the following components to
allow removal of the cylinder head:
Drain the engine coolant into a clean receptacle.
Drain any fuel from the filter (3) into a clean receptacle.
IMPORTANT: Refer to the fuel section relevant to
your machine for correct setting procedures
Example 92hp, or 108hp
15
16
LB 85115 / FB 90.2200.2
23
2
AP101018
17
CYLINDER HEAD DISASSEMBLY (10 101)
TA6010010
18
Valve and Spring Assembly Removal
2. Using a valve spring compressor (1) remove the
retainer locks (2), springs (3), seals, rotators and
place in a numbered rack.
2
3
TA6010011
19
NOTE: The exhaust valves are fitted with inner (1)
and outer (2) rotators
20
LB 85115 / FB 90.2200.2
24
1. Clean the cylinder head, and remove carbon deposits from around the valve heads.
2. Cylinder head core plugs if discoloured (rusty), or
leaking will require changing. Before fitting new
plugs remove all old sealer from the cylinder
head. Apply sealant (82995772), refer to Specifications, to the new plug mating faces, and drive
the new plugs into location, .
21
Core plugs required in the Cylinder Head:
4 off, In the top of the cylinder head
1 off, in the rear of the cylinder head.
3 off, are mounted in the intake face.
3. Scrape all gasket surfaces clean and wash cylinder head in a suitable solvent, also cleaning
valve guide bores.
4. Inspect cylinder head for nicks and burrs on mating face, Remove using a suitable abrasive and
ensure faces are clean after repair.
TA6010012
22
7. Ensure rocker shaft supports are fitted with long
bolts (1). Using a feeler gauge (2), check clearance between underside of bolt heads and cylinder head or rocker shaft support.
8. If a 0.25mm (0.010 in) feeler gauge can be inserted under the bolt head the bolt has bottomed.
Therefore the cylinder block thread must be increased using a 9/1613 UNC2A Thread tap.
Identify the bolt heads and ensure they are reinstalled in the bolt holes they were checked in.
23
LB 85115 / FB 90.2200.2
25
3
1
2
TA6010013
24
NOTE: Valve inserts of 0.25mm (0.010 in) and
0.5mm (0.020 in) oversize on diameter are sometimes installed during manufacture. Cylinder Heads
with oversize inserts are stamped SO15OS,
SO20OS, on the exhaust manifold side in line with
the valve seat concerned.
3. Check the width of the valve seat inserts, and as
required reface by grinding.
4. Measure the concentricity of valve seats, using
a dial indicator and measure concentricity of seat
to the valve guide bore.
Total Indicator Reading should not exceed
0.051mm (0.002 in).
25
LB 85115 / FB 90.2200.2
26
26
Raise, the valve seats, by removing material from the
bottom of seat (2) by using:
60 grinding wheel for, Exhaust valves and a 45
grinding wheel for, Intake valves.
Valve Guides
1. Using a telescopic gauge (1), and micrometer
(2), measure the valve guide bore clearance, and
ensure it does not exceed,
0.0230.069mm (0.00090.0027 in),
on the intake valve stem,
0.0480.094mm (0.00190.0037 in),
on the exhaust valve stem.
TA6010018
27
NOTE: Production cylinder heads may have one or
more machined, oversize valve guide bores, or
valves installed, 0.38mm (0.015 in). Such cylinder
heads have 15 or VO15OS stamped on the cylinder
head exhaust manifold side adjacent to the valve
concerned.
2. Using a suitable reamer, ream out the valve stem
guide, with three reamer and pilot combinations
as follows:
3. When going from a standard valve stem to an
oversize, always use reamers in sequence.
0.076mm (0.003 in) oversize reamer, and standard
diameter pilot.
0.38mm (0.015 in)
oversize
reamer,
and
0.076mm (0.003 in) oversize pilot.
0.76mm (0.030 in)
oversize
reamer,
and
0.38mm (0.015 in) oversize pilot.
LB 85115 / FB 90.2200.2
27
Valve Springs
1. Checked on a flat surface squareness, should
not exceed 1.52mm (0.060 in), between the
square, and spring at the top edge.
Length of valve springs should be checked on both
free length, and loaded length.
Free length = 60.7mm (2.39 in)
Installed length = 47.249.6mm (1.861.95 in)
28
Loaded length = 48.26mm (1.9 in) using a weight of
2831 kg (6169 lb)
Loaded length = 35.69mm (1.4 in) using a weight of
6169 kg (135153 lb)
Ensure the valve spring retainer locks are in good
condition, and replace if worn or damaged.
Rocker Shaft Inspection and Reassembly
1. Inspect rocker arm adjusting screws, and push
rod ends of the rocker arm, including the ball end
of the screws for nicks, damage, or excess wear.
2. Also inspect the inside diameter of the rocker
arm for damage or wear. If any of these characteristics are not to specification replace with new
parts.
3. Check the ends of the push rods for damage or
wear. If not to specification or push rods were
found not to be straight during dismantling install
new rods.
NOTE: Do not attempt to straighten bent push rods,
replace with new.
TA6010023
29
4. Check the rocker shaft for signs of wear or damage, on internal and external diameters respectively. If not to specification replace with new. If
reused, before reassembly clean thoroughly
in solvent making sure all oil passages are clear.
5. Position the shaft identification groove, Figure 31, forwards and upwards. This ensures oil
grooves and holes face downwards.
6. Assemble rocker shaft support with long head
bolts, ensuring springs and spacers are reassembled and torque to 217 Nm (160 lbf ft).
TA6010024
30
LB 85115 / FB 90.2200.2
28
TA6010014
31
3. Coat all components with clean engine oil prior to
assembly, and insert each push rod into its original position, ensuring each ball end is seated in
its cam follower.
CYLINDER HEAD INSTALLATION
Installation of the cylinder head assembly and components is the reverse of the removal procedure, observing the following,
1. Install new cylinder head, intake and exhaust
manifold gaskets.
NOTE: Ensure exhaust manifold gasket is fitted correctly to suit profile of exhaust ports.
2. Tighten the cylinder head bolts in sequence from
the centre of the head, progressively in three
stages.
Stage 1, 156 Nm (115 lbf ft) 15.6 kgf m
Stage 2, 190 Nm (140 lbf ft) 19.3 kgf m
Stage 3, 217 Nm (160 lbf ft) 22.0 kgf m
32
NOTE: Bolts to be lubricated prior to assembly, and
should be tightened to torque specification, with the
engine cold.
3. Adjust valve lash setting with each piston in turn
at Top Dead Centre, and rockers free to move, by
adjusting the rocker bolt.
Intake Valve Lash,
0.360.46mm (0.0140.018 in).
Exhaust Valve Lash,
0.430.53mm (0.0170.021 in).
NOTE: Valve lash is to be set, only when the engine
is cold.
33
LB 85115 / FB 90.2200.2
29
34
6. Exhaust manifold bolts are to be refitted and
tightened to a torque of, 38Nm (28 lbf ft).
7. Refit intake manifold bolts and tightened to a
torque of, 38Nm (28 lbf ft).
ENGINE FRONT COVER AND TIMING GEAR
REMOVAL (Op. 10 102 & 10 106)
NOTE: Timing cover and gears can only be serviced
after removing the radiator.
1. Remove the fan belt and withdraw the bolt and
washer, from the crankshaft pulley.
2. Using puller, 297102 or 297498, and shaft protector 297107 or 297261, remove pulley, spacer
and Oring from the shaft.
TA6010027
35
3. Withdraw the bolts retaining the front cover plate,
and remove the front plate.
IMPORTANT: The crankshaft timing gear must not
be removed. The gear is heat shrunk on to the crankshaft and aligned to the crankshaft No1 pin, to within
0.10mm (0.004 in). If the gear is damaged a new
crankshaft is required.
4. Before removing the timing gears, use a dial indicator or feeler gauge, to measure the backlash
between each set of gears.
TA6010029
36
LB 85115 / FB 90.2200.2
30
37
CAMSHAFT DRIVE GEAR
1. Pry the camshaft gear using a lever (1), away
from thrust plate. Using a dial indicator or feeler
gauge (2), check the clearance, if outside of
0.0760.35mm (0.0020.007 in) limit, fit a new
camshaft thrust plate.
2. Remove the camshaft idler gear retaining bolt,
gear, and adaptor from the block, then remove
the camshaft gear bolt and disassemble.
38
3. Wash the gears using a suitable solvent, and examine gear teeth for wear, burrs, or scratches.
Minor marks can be removed using a fine abrasive, thoroughly clean before reassembly.
4. Ensure the camshaft idler gear adaptor is free
from obstruction and bushing is not damaged.
Camshaft key and keyway should be checked
for damage and repaired as required.
Installation
1. Position piston no.1 at Top Dead Centre, set using flywheel timing marks, install the camshaft
gear, and tighten bolt to 69 Nm (51 lbf ft) 7.0
kgf m.
2. Install the camshaft idler gear to the block, aligning the timing marks to the crankshaft and camshaft gears and torque to 250 Nm (184lbf ft).
39
IMPORTANT: Refer to the fuel section relevant to
your machine for correct setting procedures
Example 92hp, or 108hp
LB 85115 / FB 90.2200.2
31
1
APB10008
40
NOTE: DO NOT TIGHTEN THE INJECTION PUMP
SHAFT NUT AT THIS STAGE. PROCEED TO
REASSEMBLE THE FRONT COVER.
3. Initially tighten the injection pump gear nut to a
torque of 20 Nm, (14.7 lbf.ft.) while holding the
gear in a counter clockwise position to remove
backlash from gears. UNLOCK the pump by releasing the locking bolt and installing the spacer
between the pump body and bolt head (1), Figure 41 . The pump gear retaining nut can now be
fully tightened to a torque value of 81 Nm, (60
lbf.ft.)
41
42
3. Install the front cover ensuring alignment with
dowel pins and tighten the bolts in order of sequence, Figure 42.
5/16 in18 UNC bolts tighten to 1824 Nm
(1318 lbf ft).
3/8 in16 UNC bolts tighten to 2434 Nm
(1825 lbf ft).
4. Clean all parts and install new O ring.
43
LB 85115 / FB 90.2200.2
32
Seal Installation
1. Lubricate a new seal (1) and push onto the seal
installer, (3). Special tool 297116
2. Press seal into front cover using tool Install the
seal sleeve into the seal.
44
3. Install the Access cover for the injection pump
gear nut. Clean surfaces and apply a 3mm bead
of flexible gasket sealant. Tighten the retaining
bolts to 37 Nm (28 lbf.ft.)
45
OIL PAN REMOVAL (Op. 10 102)
1. Drain engine oil through oil pan plug (1) and into
a suitable clean receptacle and remove oil level
indicator.
NOTE: To facilitate the oil pan (2) removal it may be
necessary to first remove the propshaft.
2. Remove oil pan bolts and lower to ground.
46
LB 85115 / FB 90.2200.2
33
47
NOTE: Bearing caps and liners must be kept with
their respective connecting rods.
3. Turn the crankshaft again and repeat the process for the remaining pistons.
4. Remove piston pin snap rings from each side of
piston and remove pin. Using an expander, remove the piston rings.
5. Ensure each piston and rod assembly, remains
matched together for reassembly into the same
location within the cylinder block.
48
LB 85115 / FB 90.2200.2
34
49
3. Check piston pin bushing for damage or wear in
the following manner.
Measure the outside diameter of the piston pin, and
inside diameter of the connecting rod bushing, to the
following,
Piston Pin Outside Diameter
Naturally Aspirated,
38.09538.100mm (1.49981.500 in).
Turbocharged,
41.27041.275mm (1.62481.625 in).
Connecting Rod Bush Internal Diameter
Naturally Aspirated,
38.11338.120mm (1.50051.5008 in).
Turbocharged,
41.28841.295mm (1.62551.6258 in)
50
LB 85115 / FB 90.2200.2
35
T1B10029
51
1.
2.
3.
4.
5.
6.
7.
Washer
Collar
Installation Insert 1
Bush
Installation Insert 2
Pins
Fixture
LB 85115 / FB 90.2200.2
36
5. Where special tooling is not available for the removal or fitment of the connecting rod bush, a
standard bush can be fitted in the following manner.
6. Place the connecting rod securely in a bench
press. Manufacture from suitable bar stock, a
press tool with the end face ground at an angle,
to suit the connecting rod bush side face. Position the tool on the bush, and gently drive the
bush from its position. It is recommended a guide
is manufactured to assist alignment of the bar
stock during this operation.
7. A new bush can then be fitted in a similar manner,
by using a suitable piece of bar stock, with an end
face machined flat to suit the standard parallel
bush. Use a guide as described, and gently drive
in the new bush into the connecting rod.
NOTE: The seam of the new bush must be placed at
90 to the centre line of the connecting rod.
8. After installation, grind the side faces of the new
bush to match the side faces of the connecting
rod. Ensure all sharp edges are removed, and
loose chippings are cleaned from the connecting
rod before reassembly into the engine.
6010035
52
9. With a new bush fitted drill a hole through the top
of the connecting rod using a 4.6mm (0.187 in)
bit. Drill through the existing oil hole.
10. Use an expanding reamer to obtain correct bushing to piston pin clearance referring to specification section. Remove burrs, and chippings, before refitting.
TA6010036
53
CYLINDER BLOCK OVERHAUL. (Op. 10 105)
1. Cylinder block plugs, and senders, require
changing if leaking or rusty, and must be replaced. Clean the old sealant off the block, and
fit new plugs with sealer, figure 46 refers to the
front and left hand side of the cylinder block.
NOTE: New part mating faces, and threads, should
be coated in sealant, refer to Specifications. Assemble in the following manner.
LB 85115 / FB 90.2200.2
37
1
Plug (1) Apply sealant 82995772 and drive in to
block.
Plug (2) Apply sealant 82995768 and torque to
814 Nm (610 lbf ft).
Fitting (3) Apply sealant 82995768 and torque to
2434 Nm (1825 lbf ft).
Plug (4) Apply sealant 82995768 and torque to
6895 Nm (5070 lbf ft).
4
APB10052
54
Rear and right hand side of the engine block.
Plug (1) Apply sealant 82995772 and drive in to
block.
Oil Jets (2) replace with new if damaged, apply engine oil only on reassembly Do not use sealant.
Fitting (3) Apply sealant 82995768 and torque to
814 Nm (610 lbf ft).
3
APB10053
55
LB 85115 / FB 90.2200.2
38
CYLINDER BORE
1. Check the cylinder bore for scuffing or rings
around the ring travel area. Irregularities can be
felt by running a finger over the surface. To check
ovality, wear, or taper, use a telescopic gauge.
Measure lengthwise,
A, to B, and C, to D, and compare dimensions. Variances between the readings will indicate taper.
Measure crosswise,
C, to D, and compare dimensions lengthwise. A, to
B. Variances will indicate ovality.
TA6010040
56
NOTE: Repair Limit refers to the tolerance allowed
after a repair has been performed. The Wear Limit
is the tolerance prior to repair.
Taper of cylinder bore,
repair limit0.025mm (0.001 in)
wear limit 0.127mm (0.005 in)
Cylinder bore out of round,
repair limit0.03mm (0.0015 in)
wear limit0.127mm (0.005 in)
Cylinder bore diameter,
111.778111.841mm (4.40074.4032 in).
C
A
B
TA6010041
D
57
58
LB 85115 / FB 90.2200.2
39
0.127
1.0
45
210.8
215
204.7
1.5
9.6
10.16
113.13113.18
APB10057
59
8. Break the sharp edge at the bottom of the sleeve
prior to honing.
9. Hone the cylinder bore to give the correct cylinder to bore clearance.
NOTE: Surface finish to be an average of 20 to 30
Microns, cross hatched at 355555.
Maximum Taper,
0.025mm (0.001in) through to bottom of the bore.
Maximum Ovality,
0.038mm (0.0015in) through to bottom of the bore.
ReAssembly
NOTE: Pistons that are replaced must be of the
same type that were removed and have the same
identification letters and numbers, as embossed on
the underside of the old piston.
1. Upon reassembly with the piston at Top Dead
Centre, ensure the piston to block height is correct using a dial indicator.
Naturally Aspirated,
0.280.58mm (0.0110.023 in)
TA6010043
Turbocharged,
00.3mm (00.000.012 in)
LB 85115 / FB 90.2200.2
60
40
2. Check the piston to bore clearance in the following manner:Measure the cylinder bore diameter
from the top of the block to point
A, 82.6mm (3.25 in.)
Measure the diameter of the piston at point:
B, 97.28mm (3.83 in) for 5.0 in
B
TA6010044
61
Subtract piston diameter from the bore diameter and
the resultant figure for a new, unrun engine should
be:
0.1400.171 mm (0.00550.0067 in )
Naturally Aspirated
0.1660.196 mm (0.00640.0077 in)
Turbocharged engines.
After an engine has run and settled down the maximum bore to piston clearance allowed is 0.250mm
(0.011in)
NOTE: Pistons are only available as standard. New
pistons should always be fitted if the clearance exceeds specification.
If clearance is greater try a similar new piston, if
limit is still exceeded it will be necessary to rebore
and resleeve.
If the clearance is less hone bore to obtain desired
clearance.
IMPORTANT: Prior to reassembly ensure the letter
or grade mark on the piston is aligned to the pip on
the connecting rod and installed facing to the front of
the engine.
62
3. Lubricate all of the components with engine oil
and assemble the connecting rod/piston.
4. Check the piston ring gap width, using a feeler
gauge, in a vertical position at the top, middle,
and bottom of the bore to:
Top compression ring.
0.380.84mm (0.0150.033 in),
2nd compression ring.
0.661.12mm (0.0260.044 in),
Oil control ring.
0.380.84mm (0.0150.033 in),
TA6010046
63
LB 85115 / FB 90.2200.2
41
6010048
64
6010047
65
8. Install the top and second compression rings
with the word top towards the top of the piston.
A = Turbocharged
B = Naturally Aspirated
NOTE: Before installing new pistons and rings into
a used cylinder bore , remove the high polish from
the cylinder walls by honing as previously described.
TA6010049A
66
Ensure the ring gaps are staggered equally around
the piston circumference.
TA6010049B
67
LB 85115 / FB 90.2200.2
42
68
NOTE: Replaceable bearing liners are installed in
production, to ensure correct crankshaft journal to
bearing clearance is maintained in service. The main
bearings can be overhauled with the engine in the
tractor. The crankshaft can only be serviced after removal from the tractor.
69
3. Ensure the connecting rod bearing liner, seats on
the crankpin with the bearing cap fitted, to the
connecting rod as a matched assembly. It is recommended that new bolts are fitted and lubricated with oil and tightened to a torque value of
149Nm (110 lbf ft).
4. Using feeler gauges, check the side clearance of
each connecting rod to crankshaft and continue
for remaining assemblies.
0.130.33mm (0.0050.013 in)
70
BALANCER / VIBRATION DAMPER
(OP NO 10 110)
Removal
1. Remove the oil pan to expose the balancer, and
using a dial indicator gauge, check backlash between crankshaft gear, and balancer drive gear.
Position the dial plunger to the face of one of the
drive gear teeth, then rock the gear to measure
backlash. Readings should be taken at 90 intervals
around
the
drive
gear,
to
0.050.30mm (0.0020.012 in). If the specification is exceeded, install new balancer gears.
71
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
43
72
1.
2.
3.
Roll Pins
Balancer Housing
Washers
Balancer Assembly
4. Balancer Gears
5. Washers
6. Balancer Gear Shafts
Disassembly
1. Extract the roll pins (1), securing the shafts to the
housing and disassemble the balancer.
Inspection and repair
1. Measure the outside diameter of shafts (6) and
the inside diameter of the gear bushings (4), and
establish if clearance is to specification
0.07620.114mm (0.00300.0045 in). If exceeded replace shaft and or gear assembly.
ReAssembly
1. Position balancer gears and thrust washers in
the housing, with timing marks aligned, and facing the roll pin side of the balancer. Install shafts
from the opposite side and secure with roll pins.
2. Using a feeler gauge measure end float, of assembled gears is to the specification of,
0.200.56mm (0.0080.022 in).
3. Position a dial indicator gauge to the tooth of one
gear, and hold the other firmly. Rocking the free
gear measure backlash at 90 intervals, around
the gears to, 0.050.20mm (0.0020.008 in).
4. Examine shafts and balancer gear teeth for wear
and damage, and replace as necessary. Ensure
lubrication holes in the shafts are free from obstruction upon reassembly.
LB 85115 / FB 90.2200.2
73
44
Installation
1. Clean all the mating surfaces, and install a new
seal around the lubrication passage.
2. Rotate crankshaft until timing mark on crankshaft gear aligns with timing mark on balancer
drive gear, position balancer on dowels install the
bolts and torque to 108120 Nm (8090 lbf ft)
3. Recheck the gear backlash between crankshaft
and balancer gear, as previously described and
replace the oil pan.
APB10072
74
MAIN BEARING REMOVAL
1. Remove oil pan, and balancer, to gain access to
the crankshaft. Remove the main bearing caps,
and install one set at a time.
Inspection and Repair
1. Thoroughly clean bearing liners, journals, caps,
and inspect for wear, scores, or damage replace
as required.
TA6010033
75
Installation
2. Coat all parts in new engine oil prior to assembly.
Position bearing cap with locking tang, towards
camshaft side of engine and fit the bolts,
190203Nm (140150 lbf ft) 19.320.1 kgm
3. If fitting a new thrust bearing liner it must be
aligned as in the following crankshaft chapter.
FLYWHEEL REMOVAL
NOTE: To remove the flywheel, the engine requires
to be split from the transmission housing refer to
Separating the Unit.
1. To gain access to the flywheel separate the engine to transmission.
NOTE: Prior to removal and using a dial indicator, rotate the flywheel and measure to specification
0.127mm (0.005 in) Total Indicator Reading. If not to
specification check crankshaft to flywheel seating.
Inspection and Repair
Ring Gear
1. Inspect the flywheel ring gear, and if damaged
renew in the following manner,
Cut old ring gear free from the flywheel.
Clean the mating surfaces of the new ring gear, and
flywheel.
TA6010053
76
LB 85115 / FB 90.2200.2
45
77
5. Quickly place the hot gear on the flywheel, with
flat face against the shoulder on the flywheel.
The gear to flywheel runout should be checked
using a dial indicator and should not exceed a Total Indicator Reading of 0.63mm (0.025 in).
Flywheel Surface
1. In the event of flywheel surface damage due to
excessive clutch wear the surface may be
skimmed. A maximum of 3 mm (0.118 in) is to be
removed from the face of the flywheel.
Installation
1. Clean the crankshaft rear flange and mating surface of the flywheel, install the flywheel, and
torque the bolts to,197N m (145 lbf ft) 20 kgf m.
REAR COVER PLATE REMOVAL (Op. 10 102)
To gain access to the engine oil pump, camshaft
gear, or end of crankshaft remove the oil pan as previously described along with the rear cover, in the following manner.
1. With rear of engine exposed loosen and remove
the 12 attaching bolts, and gently pry off cover
plate.
2. Clean off all sealer, remove crankshaft oil seal,
and check for damage or distortion around the
sealing faces.
APB10076
78
P396E54
79
Installation
1. Ensure rear of block face is clean and install a
new gasket. With the plate in the recess install
and leave the bolts loose.
2. Apply a liberal coating of new engine oil on a new
oil seal and position the rear seal over the end of
the crankshaft. Locate tool, No 297194, on the
end of the crankshaft using the three attaching
bolts. Tighten evenly, and squarely, until the seal
is fully seated.
TA6010054
80
LB 85115 / FB 90.2200.2
46
TA6010055
81
6. Tighten the twelve bolts, in sequence (1) to:
Step 1: Initial Torque 1114 Nm (810 lbf ft)
Step 2: Final Torque 1623 Nm (1217 lbf ft)
11
9
7
2
4
6
5
3
1
10
12
TA6010128
82
7. With new crankshaft seal installed, place a dial
indicator, on the end of the crankshaft and ensure seal runout is within 0.51mm (0.020 in) Full
Indicator Movement.
TA6010056
83
LB 85115 / FB 90.2200.2
47
1
TA6010057
84
2. Loosen and remove the camshaft gear, to expose the oil pump, detach the 3 pump mounting
bolts, and withdraw the pump from the block.
TA6010058
85
Installation
1. Clean and coat parts in new engine oil.
2. Fit a new ORing to the pump output tube and
into suction port. lubricate and insert the pump
into the block tightening the bolts, to,
23.028.4N m (1721lbf ft) 2.32.9kgfm
TA6010059
86
3. Insert tube/screen assembly into pump through
bottom of engine. Fitting a new gasket, and
torque
the
attaching
bolts
to,
2734N m (2025 lbf ft) 2.73.4 kgf m.
TA6010062
87
LB 85115 / FB 90.2200.2
48
1
TA6010063
88
APB10087
89
CRANKSHAFT REMOVAL (Op. 10 103)
1. Remove the engine from the tractor and place on
an engine stand.
2. Remove the flywheel, rear cover plate, crankshaft pulley and engine front cover.
NOTE: If crankshaft is removed with cylinder head
in position ensure all timing marks are realigned prior
to reassembly. This action will prevent possible interference between valves and pistons during reassembly.
3. Remove the oil pan and oil pump.
4. Remove the connecting rod caps, main bearing
caps and liners, and identify to facilitate reassembly.
5. Carefully remove crankshaft from cylinder block.
APB10088
TI
90
LB 85115 / FB 90.2200.2
49
B
A
TA6010067
91
If replacing the oil jets gently tap out the old ones and
replace with new.
396E26
TI
92
CRANKSHAFT REASSEMBLY
NOTE: Normally main bearing journals wear evenly
and will not be outofround, but if a liner which is to
specification is fitted to an outof round journal, ensure liner suits maximum diameter of journal
1. If these combinations of liners do not produce
specified clearance refinish crankshaft and fit
suitable service bearings.
IMPORTANT: Engines may be assembled with liners of different material, but liners of the same material must be used on the same journal.
396E9
TI
93
LB 85115 / FB 90.2200.2
50
6010069
94
TA6010070
95
CAMSHAFT REMOVAL (Op. 10 106)
NOTE: The camshaft bearings and tappets can only
be serviced with engine removed from the tractor.
1. Remove the engine front cover, and cylinder
head.
2. Check the camshaft end play, see timing gears
section, and remove gear, or remove the thrust
plate bolts for removal of gear and camshaft as
an assembly.
3. After removal of the flywheel, and rear cover, remove the camshaft oil pump drive gear.
4. Invert the engine on the stand, if camshaft bearings are to be replaced, and remove the oil pan.
5. Carefully withdraw the camshaft from the rear of
engine.
APB10094
96
LB 85115 / FB 90.2200.2
51
396E23
TI
97
Inspection and repair
1. Inspect the camshaft journals, lobes, for damage, pitting, or heat discolouration. If any of these
conditions exist install a new camshaft.
2. Inspect the oil pump drive gear on camshaft for
broken or worn teeth, and mating gear on oil
pump. If any wear or damage is apparent fit new
gears.
3. Check each tappet for wear or damage and
check diameters, if not to specification renew,
25.1525.17mm (0.99000.9910 in).
4. Measure the diameter and outofround condition of bearing journals, if exceeded fit a new
camshaft,
60.69360.719mm (2.3892.390 in).
CAMSHAFT BEARINGS
1. Inspect the camshaft bearings for wear or damage. Measure the clearance between the internal
diameter of bearing and outside diameter of respective journal, 0.0250.076mm
(0.0010.003 in).
2. If specification is exceeded install new bearings
using, Remover/Replacer tool.
3. To remove, Position tool against bearing to be removed and attach handle, driving bearing from
bore.
4. To install, Align oil holes of new bearing with
holes in block, and drive bearing into bore using
tools as described.
NOTE: A positive alignment check can only be made
with crankshaft removed when an 4.6mm (0.018 in)
rod can be passed down the oil passage from the
crankshaft main bearing. Liner is correctly positioned
when end of rod passes through oil hole in the liner.
LB 85115 / FB 90.2200.2
TA6010071
98
52
Installation
1. Apply petroleum jelly to each tappet foot, and
coat tappet body with oil. Install tappets in bores
from which they were removed.
2. Oil camshaft journals and apply petroleum jelly to
the cam lobes, and install camshaft into engine.
3. Install new spacer and keyway on end of camshaft.
4. Install a new thrust plate prior and torque
4154 Nm (3040 lbf ft).
5. Install camshaft gear, and align the camshaft
gear timing mark and torque bolt to 5577 Nm
(4358 lbf ft), and recheck end play.
6. Apply sealant 82995782 to the sealing flange of
the front cover plate on reassembly.
TEST CONCLUSION
To determine whether the rings or the valves are at
fault, squirt the equivalent of a tablespoon of heavy
oil into the combustion chamber. Crank the engine to
distribute the oil and repeat the compression test.
The oil will temporarily seal any leakage past the
rings. If approximately the same reading is obtained,
the rings are satisfactory, but the valves are leaking.
If compression has increased over the original reading, there is leakage past the rings.
During a compression test, if the pressure fails to
climb steadily and remains the same during the first
two successive strokes, but climbs higher on the
succeeding strokes, or fails to climb during the entire
test, suspect a sticking valve.
LB 85115 / FB 90.2200.2
SECTION 10 ENGINE
Chapter 2 Fuel General
CONTENT
Section
Description
Page
10 200
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overhaul
................................................................... 8
SPECIFICATIONS
Fuel
Diesel
Fuel Tank capacity
106 Litres (28 US. gals)
Injection Pump Type Lucas C.A.V
Rotary
DP 203 Series, integral speed governor and advance device
Cold Start Device
Thermostart
Excess Fuel Device
Automatic Governor
Fuel Shut Off
Solenoid
Lift Pump
Electric
Turbocharger type:
Garrett T250
LUCAS C.A.V. pump
Type DP 203
Pump rotation
Firing order
Injection pump timing
LUCAS C.A.V.Injectors
Adjustment
Quantity, nozzle holes
Pressure Setting (all)
Injector change interval
Fuel Filter
Fuel Filter Change Interval
Fuel Sedimentor
Maximum No-Load Speed
Idle Speed
Rated Speed
Variable
5 Hole
292300 bar (4235 4350 psi)
1200 hours
Single Disposable Element
600 Hours
Single and Serviceable
21952245 Rev/min
700800 Rev/min
2070 Rev/min
LB 85115 / FB 90.2200.2
Nm
50
10
2.5
25
14
14
24
37
10
24
2.5
10
30
35
55
2.5
12
ft. lbs.
kgf/m
37
7
1.8
18
10
10
18
27
7
18
1.8
7
22
26
40
1.8
9
5.1
1.0
0.25
2.5
1.4
1.4
2.4
3.8
1.0
2.4
0.25
1.0
3.1
3.6
5.6
0.25
1.2
LB 85115 / FB 90.2200.2
1
1.
2.
3.
4.
5.
6.
7.
LB 85115 / FB 90.2200.2
1
2
LIFT PUMP ELECTRIC (OP NO 10 210)
Mounted on the right hand side of the engine above
the fuel filter is an electrical lift pump (1). The pump
draws fuel through the sediment separator (2) and
the fuel filter (4). The fuel is then pressurised and fed
into the fuel injection pump.
3
SEDIMENT SEPARATOR (OP NO 10 206)
Positioned on the right hand side of the engine is the
fuel sediment separator. The assembly consists of a
cast head which is bolted to the engine, and a glass
sediment separator.
The fuel is drawn into the sediment separator side of
the head to be directed down and around the edges
of the separator cone, the larger particles of dirt and
water (which are heavier than fuel oil) are separated
out and sink to the collecting bowl. The cleaned fuel
is then drawn into the fuel filter.
4
FUEL FILTER (OP NO 10 206)
The filter (3) positioned on the right hand side of the
engine behind the fuel pump directs the fuel through
the filter head (2) to be directed down through the filter paper (3) into the base chamber. The filtered fuel
then flows up the center tube of the element to the
filter head outlet and flows onto the injection pump.
The drain plug (4) permits contaminated fuel to be
drained from the filter.
5
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
6
Fuel is gravity fed to the plug assembly and, when
operating the key start/stop switch and the thermostart switch, the heater and igniter coils are both energized. The heater coil opens a check valve which
allows diesel fuel to flow through the thermostart.
The fuel is ignited by the igniter coil in the manifold,
heating the intake manifold air prior to it entering the
combustion chamber.
When the thermostart switch is released to the off position, the electrical current is disconnected from the
thermostart and the check valve closes.
FUEL PUMP (OP NO 10 210)
The fuel injection pump fitted to these engines is the
Lucas/CAV DP203. The fuel pump which is fed by an
electric lift pump draws fuel into itself via the transfer
pump and supplies fuel at high pressure to the fuel
injectors.
7
INJECTORS
The fuel injectors mounted in the cylinder head supply fuel in the form of a spray pattern into the cylinder
bores. The controlled amounts of fuel ensure optimum engine performance throughout the operating
range.Emissionised and non emissionised injectors
have different characteristics and are not interchangeable.
LB 85115 / FB 90.2200.2
DIESEL ENGINES
IMPORTANT: Whenever making a repair, the reason for the cause of the problem must be investigated and corrected to avoid repeat failures.
The following tables list problems and their possible causes with recommended corrective action.
GENERAL
PROBLEM
Fuel not reaching injection pump
POSSIBLE CAUSES
CORRECTION
1.
1.
2.
Air in system
2.
3.
Fuel leakage
3.
1.
1.
2.
Incorrect throttle
adjustment
2.
3.
3.
4.
Fuel leakage
4.
5.
Faulty injectors
5.
See injector
troubleshooting
6.
Low compression
6.
1.
1.
2.
2.
3.
3.
Replace filters
4.
Contaminated fuel
4.
5.
Low compression
5.
6.
Air in system
6.
1.
Fuel starvation
1.
2.
Contaminated fuel
2.
3.
3.
4.
Engine overheating
4.
5.
Air in system
5.
LB 85115 / FB 90.2200.2
PROBLEM
Erratic engine operation (surge,
misfiring, poor governor
regulation)
LB 85115 / FB 90.2200.2
POSSIBLE CAUSES
CORRECTION
1.
Fuel leakage
1.
2.
Fuel starvation
2.
3.
3.
4.
Contaminated fuel
4.
5.
Air in system
5.
6.
6.
See injector
troubleshooting
7.
7.
1.
1.
2.
Engine overheating
2.
3.
Incorrect timing
3.
4.
Faulty injectors
4.
See injector
troubleshooting
5.
Low compression
5.
6.
6.
1.
Incorrect throttle
adjustment
1.
2.
2.
3.
Fuel starvation
3.
4.
Air in system
4.
5.
Incorrect timing
5.
6.
Low compression
6.
7.
7.
10
3. With the throttle in the maximum no-load speed
position, operate the starting motor to crank the
engine. The fuel injection pump is self-venting
and does not require bleeding.
IMPORTANT: Do not crank the starting motor continuously for more than 60 seconds as doing so may
cause starting motor failure.
LB 85115 / FB 90.2200.2
11
LB 85115 / FB 90.2200.2
10
3
4
1
2
12
13
LB 85115 / FB 90.2200.2
11
14
2. With the tank drained of fuel disconnect the fuel
line to the lift pump. Plug the exposed pipes to
prevent contamination.
3. Loosen and remove the tank to frame attaching
bolts and lower the tank to the ground
15
LB 85115 / FB 90.2200.2
12
Removal
1. Drain the filter and sediment separator of fuel, by
removing the bowl drain screw (3).
2. Disconnect and remove the fuel lines from the
head of the filter/sediment separator assembly
and plug the exposed openings to prevent contamination.
3. Remove the retaining bolts, then remove the assembly from the tractor.
16
Disassembly
1. Remove the center retaining bolts and separate
the filter components.
2. Using clean fuel, wash out the filter bowl and the
glass bowl on the sediment separator.
Reassembly
Reassembly of the fuel filter/sediment separator follows the disassembly procedure in reverse. On reassembly, observe the following requirements:
3. Install a new filter element and sealing rings, be
sure the sealing rings are correctly positioned.
4. Tighten the center retaining bolts.
Installation
Installation of the fuel filter/sediment separator assembly follows the removal procedure in reverse. On
installation, observe the following requirements:
5. Tighten the retaining bolts.
6. Assemble the fuel pipes to the connectors in the
head and tighten the nuts until the stop is
reached (metal to metal contact).
7. Bleed the fuel system as previously described.
LB 85115 / FB 90.2200.2
13
SECTION 10 FUEL
Air Cleaners
CONTENT
Section
Description
Page
10 202
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS
AIR CLEANER
Type . . . . . . . . . . . . . . . . . . . . . . . . . . Dry, Dual Element
Change Interval . . . . . . . . . . . . . . . 600 hours (or more frequently when operating in adverse conditions)
TORQUE VALUES
DESCRIPTION
Air Cleaner Retaining Bolts
Air Cleaner Hose Clamps
Air Cleaner Restriction Indicator Switch
LB 85115 / FB 90.2200.2
ft. lbs.
Nm
kgf/m
40
1.8
9
55
2.5
12
5.6
0.25
1.2
14
18
IMPORTANT: The safety element must be replaced
if damaged or clogged with dust, or if, after cleaning
or installing a new outer element, the warning light remains on when the engine is running.
If the warning light remains on after installation of
both inner and outer elements, check the switch for
faulty operation by replacing with a switch known to
function correctly.
19
LB 85115 / FB 90.2200.2
15
POSSIBLE CAUSES
REMEDY
1. Clean or renew
outer element
OVERHAUL
REMOVAL
1. Remove the engine side panels and lift off the
pre-cleaner assembly.
2. Loosen the outlet hose clamp.
3. Remove the attaching bolts and withdraw the air
cleaner assembly.
2
20
DISASSEMBLY
1. Remove the wing nut and extract the outer element.
2. With the outer element removed extract the inner
element.
21
LB 85115 / FB 90.2200.2
16
22
23
24
D Remove the adhesive tape and shake excess water from the filter element and allow
to dry naturally. The element will need 24-48
hours to dry thoroughly. Install a new element at this stage, retaining the washed element for the next service.
LB 85115 / FB 90.2200.2
17
INSTALLATION
Installation of the dry type air cleaner is the removal
procedure in reverse, on installation observe the following requirements:
1. Tighten the retaining bolts.
2. Tighten the outlet hose clamp.
REASSEMBLY
Reassembly of the dry type air cleaner is the disassembly procedure in reverse.
On reassembly, make sure the outer element sealing
ring is secure.
LB 85115 / FB 90.2200.2
18
NOTES PAGE
LB 85115 / FB 90.2200.2
19
SECTION 10 FUEL
CONTENT
Section
Description
Page
10 210
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter head mounted 12 volt supply Electric Lift Pump
Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanically Actuated
Output Pressure at 2000 revs/min . . . . . . . . . . . 0.270.47 bar (36 psi)
LB 85115 / FB 90.2200.2
20
25
1. If there is no/little delivery, and voltage and fuel
are present at the pump, the pump should be replaced.1.
2. With the key start on is there 12V between the
terminals of the pump (1)? If 12V is not present
check fuses, relay and wiring.
26
LB 85115 / FB 90.2200.2
21
FAULT FINDING
PROBLEM
Low pressure at pump outlet
POSSIBLE CAUSES
CORRECTION
1. Refill tank
2. Clean filter
3. Replace Shaft
4. Pump Worn
4. Replace Pump
1. Clear blockage
3. Replace Pump
4. Replace Pump
5. Pump Worn
5. Replace Pump
27
Pump Testing
Fuel pump may be checked on the vehicle.
Ensure initially that the filter is serviceable and there
are no other restrictions between the fuel tank and filters (2).
Disconnect the filter outlet to pump tube and reconnect to the filter, allowing the outlet to be positioned
into a suitable measuring jar.
Turn the key start to the first position for a measured
amount of time and record the fuel delivered (1).
Compare against specification
28
LB 85115 / FB 90.2200.2
22
NOTES
LB 85115 / FB 90.2200.2
23
SECTION 10 FUEL
Injectors
CONTENT
Section
Description
Page
10 218
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INJECTORS
Adjustment
Quantity, nozzle holes
Pressure Setting
Injector change interval
SPECIFICATIONS
LUCAS C.A.V.
Variable
5 Hole
292300 bar (42344350 psi)
1200 hours
TORQUE VALUES
Application
Nm
ft. lbs.
kgf/m
48
22
12
32
33
35
17
10
23
23
4.9
2.2
1.2
3.3
3.3
TOOLS
Application
TOOLS
Injector Cleaning Kit*
29367
Includes Nozzle Cleaning Wires Pressure Chamber Drills Pressure Chamber Scraper Valve Seat Scraper
Brass Wire Brush Pin Vise.
Tallow
Obtain Locally
Obtain Locally
Polishing Sticks
Obtain Locally
Obtain Locally
Pump Timing Tools
LB 85115 / FB 90.2200.2
297119 / 297194
24
FAULT FINDING
PROBLEM
POSSIBLE CAUSES
CORRECTION
1. Faulty injectors
1. Overhaul or replace
injectors
3. Tighten nut
1. Tighten nut
3. Clean nozzle
LB 85115 / FB 90.2200.2
25
OVERHAUL
1. Loosen the high pressure fuel pipe gland nuts at
the injection pump.
2. Clean the area around the injectors.
3. Remove the banjo bolts (1) and discard the two
copper washers from each bolt. Remove the
leak-off pipe (3).
4. Unscrew the gland nuts and disconnect the high
pressure pipes (2) from the injectors.
5. Remove the two retaining bolts from each injector and withdraw from cylinder head.
6. If a replacement set of injectors is not immediately available, cover the ends of the pipes and the
cylinder head openings to prevent the entry of
dirt and foreign material.
7. Discard the cork dust washer (1) and the copper
sealing washer(2).
29
30
TESTING
WARNING
The spray from a fuel injector tester can pierce
human skin with fatal results. When an injector is
spraying, the nozzle holder should be turned away
from the operator and any other persons.
During the Nozzle Opening Pressure and Spray Pattern Tests, collect the spray in a container partly filled
with rags to absorb the spray.
When conducting the Nozzle Seat Leakage Test, release the injector tester pump pressure before touching the nozzle tip with a sheet of blotting paper.
WARNING
The spray is flammable make sure no open flames
are in the area of the tester and do not generate excessive vapor.
1. Fill the injector tester with a calibrating type fuel
oil and leave the filler cap loose to prevent a vacuum forming during testing.
LB 85115 / FB 90.2200.2
TA6010115
31
26
APB10004
32
33
LB 85115 / FB 90.2200.2
27
DISASSEMBLY
1. Place the injector in a holding fixture with the
nozzle uppermost. Do not clamp the injector
body in a vise. Use a socket tool to loosen the
nozzle retaining nut.
2. Remove the nozzle retaining nut, complete with
the nozzle body and needle valve.
3. Remove the injector body from the holding fixture
and invert, carefully remove the top nut, spring
tensioner and seat. To avoid damage, place all
dismantled components in suitable baths of
clean fuel oil.
34
NOTE: To prevent corrosion of injector components
after cleaning, rinse in clean fuel oil and place in a
suitable bath of clean fuel oil.
INSPECTION AND REPAIR
1. Clean the injector body by soaking in a carbon
solvent and brushing with a brass wire brush. Inspect the body for damaged threads and pressure face, making sure the holes in the injector
nozzle are thoroughly clean with no signs of corrosion or pitting.
35
2. Clean the spring and spring seat using a brass
wire brush and check for scoring, pitting or corrosion.
3. Clean the dowelled adaptor plate using a brass
wire brush. Inspect the plate for loose or bent dowels, a damaged pressure face or corrosion.
4. Clean the needle valve and body by soaking in a
carbon solvent and brushing with a brass wire
brush. Using the tools included in the Injector
Nozzle Cleaning Kit, clean the nozzle as follows:
36
NOTE: If the needle valve is in any way damaged or
blued, it must be discarded and a new matched
needle valve and nozzle body assembly obtained. It
is not possible to grind or lap the three special angles
on the valve point.
37
LB 85115 / FB 90.2200.2
28
38
B
39
5. Use a Reverse Flush Nozzle Adaptor, on an injector tester and reverse flush the nozzle to remove the carbon loosened during cleaning, Step
4.
6. After flushing the nozzle, polish the valve seat by
placing a very small amount of tallow on the end
of a polishing stick and rotate in the nozzle.
40
7. Clean the top of the needle valve using a needle
valve scraper.
8. Clean the nozzle retaining nut using a brass wire
brush and check to see that the threads are not
damaged and are free from carbon deposits.
APB10013
41
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
29
REASSEMBLY
1. Make sure all parts are absolutely clean and undamaged prior to reassembly. Rinse all parts in
clean fuel oil and assemble the components
while still wet.
2. Place the spring and spring seat into the injector
body bore. Place the injector body into the holding fixture.
3. Refit spring tensioner and top nut then invert injector in holding fixture
42
4. Carefully locate nozzle assembly onto dowels
and retighten nozzle retaining nut to 48 Nm
(35 lbf ft)
To set the nozzle opening pressure, connect the injector to the test rig as described in Testing and
alter the adjusting nut until the specified opening
pressure is achieved.
INSTALLATION
1. Remove any blanking plugs from cylinder head
openings and pipe ends.
2. Insert the new/replacement injector in the cylinder head, having used a new cork dust washer
and a new copper sealing washer.
3. Secure each injector with the two retaining bolts
and tighten to 22 Nm (17 ft. lbs).
4. Reconnect the leak-off pipe using new washers
either side of the banjo fittings and tighten banjo
bolts to the 12 Nm (10 ft. lbs).
5. Reconnect high pressure fuel pipes to injectors
and tighten gland nuts to 32 Nm (23 ft. lbs).
6. Tighten high pressure fuel pipe gland nuts at the
injection pump to 32 Nm (23 ft. lbs).
7. Bleed the fuel system as detailed previously.
8. If the injectors are to be stored before installation,
clean in calibrating oil. Storage for longer than 6
months may result in the necessity of disassembling and cleaning the injectors before installation.
LB 85115 / FB 90.2200.2
43
30
NOTES PAGE
LB 85115 / FB 90.2200.2
31
SECTION 10 FUEL
Injection Pump
CONTENT
Section
Description
Page
10 248
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pump Removal, Timing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SPECIFICATIONS
LUCAS C.A.V. pump
Type
Pump rotation
DPS/DP203
Series Distributor type, integral speed governor and advance device
Clockwise
Model
4 Cylinder
N/Asp
4 Cylinder
Turbo
Pump Type
DPS
DPS
29
28
29
28
IMPORTANT: The above table shows several types of engine application, some of which will not be available
for your type of machine
DESCRIPTION
Fuel Inlet Connection
Delivery Valve Holders
Fuel Injection Pump to Front Plate
Front Plate Bolts Cover Bolts
Pump Locking Bolt DP203
Drive Gear
LB 85115 / FB 90.2200.2
TORQUE VALUES
Nm
59
41
2024
22
13
7581
lbf.ft
43
30
1518
16
10
5560
32
TOOLS
Fuel Injection Pump Drive Gear Puller
If the pump drive gear is tight It may be necessary to
manufacture a gear puller, this can be achieved by
following the guidlines as shown:
1. Use a plate of (HRLC P&O Steel material) with
a Diameter 80mm (3.15in) and a thickness of
10mm (0.394 in).
Drill x3 Holes (A) 9.5mm (0.375 in) equally
spaced with a diameter 56.87mm (2.2 in) on the
plate.
56.87mm
A
44
B
45
DP200 fuel injection pump timing TOOLS
V.L. Churchill Ltd tools are available and recommended, to check the fuel injection pump timing of all
Lucas CAV D.P.S. type fuel injection pumps. These
tools are used for:
Engine front plate timing marks in relation to flywheel timing marks.
Fuel injection pump internal timing.
IMPORTANT: Whenever a replacement fuel injection pump is being installed or poor engine performance is evident, the use of the following timing tool is
recommended.
1. Timing gauge, splined shaft and slotted arm
Tool #297119
297119
46
LB 85115 / FB 90.2200.2
33
297512
47
3. D.P.S. Fuel injection pump timing mark, checking fixture Tool # 297513
297513
48
A suitable woodruff key will be required to be installed
on the pump shaft when attaching the timing tools
49
LB 85115 / FB 90.2200.2
34
50
The DP203 fuel pumps are basically sealed items
with only minimal parts being supplied in service.
Components that are replaceable during normal service are the Fuel Shut off Solenoid (1).
If the fuel injection pump is suspected of being faulty
the pump assembly should be taken to a specialist
Lucas/CAV agent for repair. Without specialist
equipment these pumps cannot be correctly set up.
Unauthorised repair will also invalidate warranty and
may cause the vehicle to break local emission regulations.
51
SOLENOID SHUTOFF VALVE
The electrically operated fuel shutoff valve is fitted
into the top of the fuel pump. The unit consists of a
solenoid, which controls a spring loaded piston and
is located between the transfer pump outlet and the
metering valve.
When the valve is energized on starting the solenoid
lifts the piston against spring pressure and allows
fuel at transfer pressure to pass to the metering
valve.
52
When the solenoid is de-energized, by cutting the
electrical supply, the return spring pushes the piston
back against its seat and prevents the rotor from filling thereby stopping the engine.
LB 85115 / FB 90.2200.2
35
PUMP REMOVAL
NOTE: Dismantling, assembly, testing and adjustment of the pump must be carried out by an authorized CAV Dealer.
1. Clean all dirt from the injection pump and the surrounding parts.
WARNING
When pressure washing, ensure the engine and fuel
pump have cooled to ambient temperature. Cleaning
a hot engine with cold water can damage the fuel
pump and engine components
2. Disconnect and remove all fuel lines from the injection pump and cap all openings to prevent
entry of dirt.
3. Disconnect the throttle cable, fuel shutoff solenoid wire and wax motor wire, where fitted.
4. Remove the pulley guard.
5. Remove the fan drive belt.
6. Remove the idler pulley
7. Remove the rocker cover breather tube.
8. Remove the engine timing cover from the engine
front cover.
9. If the pump is to be reinstalled without being serviced, rotate the engine to approximately 40
BTDC compression stroke, loosen the pump timing gear bolt. DO NOT REMOVE GEAR. Rotate
the engine in the direction of rotation to (BTDC as
shown in the table on page 1) and lock the pump
locking tag using the bolt 1315Nm ( lbsft). Locking tab location 1 is unlocked, Location 2 is
locked.
10. Remove the pump timing gear bolt.
11. Fabricate a puller (see tools) and Install the puller
to the drive gear using three bolts and remove
the gear.
12. Remove the pump retaining bolts, then remove
the pump from the engine front cover plate. Cap
all openings to prevent entry of dirt.
LB 85115 / FB 90.2200.2
53
36
54
Obtain a suitable woodruff key and install the tool to
the pump and engage the timing gauge on to the
checking fixture with the slotted arm (1) over the
pump flange.
55
With the tool set to the correct ( ) lock the pump at
this point.
56
Rotate the gauge until the slotted arm aligns with the
scribed mark on the pump (1).
Lock the pump at this point and remove the timing
tools.
57
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
37
APB10008
58
INSTALLATION
1. Install a new pump to front engine plate O-ring on
the pump mounting flange.
2. Install the three injection pump to engine front
plate mounting bolts.
3. Tighten the mounting bolts.
4. Pump Mounting Bolts: 40 Nm (29 lbf.ft)
5. Install the pump drive gear
6. Install the lock washer and retaining nut to the
pump drive shaft and tighten.
Tighten the Gear Nut.
Gear Retaining Nut: 7581 Nm (5560 lbf.ft)
7. Position a new inspection cover gasket and install the inspection cover to the engine front
cover. Tighten the retaining bolts.
8. Connect the fuel lines to the injection pump and
tighten.
9. Reconnect the throttle and fuel shutoff controls
to the injection pump.
10. Turn on the key start and prime the system using
the electric lift pump or hand primer. Start the
tractor and adjust the engine idle and maximum
no-load speeds, see Adjustments for the DPS
Distributor Type Fuel Injection Pump earlier in
this section.
LB 85115 / FB 90.2200.2
38
NOTES PAGE
LB 85115 / FB 90.2200.2
SECTION 10 FUEL
Chapter 3 Turbocharger
CONTENT
Section
Description
Page
10 250
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TURBOCHARGER
Compressor Shaft Axial End Play
Bearing Radial Clearance
LB 85115 / FB 90.2200.2
GENERAL TORQUES
Turbine Housing Bolts
Turbocharger to Manifold
Oil Feed Tube to Turbocharger
(Banjo Bolt)
Oil Feed Tube to Filter Head
Connector
Connector to Filter Head
Oil Return Tube bolts from
Turbocharger
Oil Return Tube to 6070
Block Connector
Oil Return Connector to Block
Inlet Hose Clamps
Nm
2025
4147
3040
lbf ft
1518
3035
2230
kgf m
2.02.5
4.14.7
3.04.0
1820
1315
1.82.0
5481
2025
4060
1518
5.48.1
2.02.5
4550
6.07.0
27
1.72.3
20
(1520 lbs in)
2.7
TOOLS
SEALER
Type
Part No 82995768
LB 85115 / FB 90.2200.2
B
APB10501
LB 85115 / FB 90.2200.2
Furthermore, failure to take appropriate steps to ensure correct installation, such as repairing or replacing defective clamps or ducting, could cause the replacement unit to fail in a similar manner.
The follow chart contains information pertaining to
probable failure modes of turbocharged engines,
possible causes for such failures, and the maintenance action required to remedy each possible cause.
It is not represented that this information is all-inclusive. On the contrary, this information should be considered primarily as representative of the methods or
techniques that should be employed in troubleshooting a turbocharged engine malfunction.
In general, those troubleshooting procedures that
can be performed with the least effort and in the least
amount of time should be performed first. No removal or disassembly procedures should be performed until all visual inspections and sensory tests
(sight and feel) that can be accomplished with the
turbocharger installed have been performed. The
possible causes and procedure are generally arranged in the order of ease of accomplishment.
LB 85115 / FB 90.2200.2
FAULT FINDING
POSSIBLE CAUSES
PROBLEMS
1. Engine lacks power or emits black
smoke
4. Noisy turbocharger
LB 85115 / FB 90.2200.2
POSSIBLE CAUSES
Dirty air cleaner
Restricted duct between air cleaner and turbocharger
Loose compressor-to-intake manifold dust connections
Leaks at engine intake manifold
Restricted turbocharger oil drain line
Plugged engine crankcase breather
Worn or damaged compressor wheel (worn bearings, bores
or journals)
Excessive piston blowby or high internal crankcase
pressure
Excessive pre-oiling
Plugged engine crankcase breather
Restricted turbocharger oil drain line
Sludged or coked center housing
Worn turbocharger bearings, bearing bores, or shaft
journals.
LB 85115 / FB 90.2200.2
WARNING
Always start the engine from the tractor seat. never
start the engine from the ground.
C With engine running at idle speed, lightly
spray duct connections with starting fluid.
Leaks at connections will be indicated by an
increase in engine speed due to the starting
fluid being drawn into the compressor and
pumped into the engine combustion
chambers.
D With engine running at idle speed, check
duct connections for leaks by applying lightweight oil or soap suds to areas of possible
leakage and looking for bubbles. Exhaust
gas leakage between the cylinder head, exhaust manifold and the turbocharger inlet will
also create a noise level change.
E With engine running at idle speed, check for
unusual noise and vibration. If either condition is noted, shut down the engine immediately to protect the turbocharger and engine
from further damage. With the engine
stopped, check the turbocharger shaft steel
assembly for damage as outlined in Note I,
below.
F With engine running, a change in the noise
level to a higher pitch can indicate air leakage
between the air cleaner and the engine, or a
gas leak between the engine block and the
turbocharger inlet.
G Exhaust gas leakage may be indicated by
heat discoloration in the area of the leak.
H With the engine running, noise level cycling
from one level to another can indicate a
LB 85115 / FB 90.2200.2
OVERHAUL REMOVAL
1. Remove the engine side covers (1), release the
exhaust muffler pipe clamp and remove the pipe.
2. Remove the exhaust muffler by removing the
turbocharger to exhaust muffler clamp (2).
3. Disconnect the air cleaner to turbocharger tube
and the turbocharger to intake manifold tube (4)
by loosening the tube hose clamps.
4. Disconnect the oil supply and return tubes from
the turbocharger (3). Cap the ends of the tubes
and the oil ports of the turbocharger to prevent future bearing failures due to entry of foreign material.
5. Remove the turbocharger and gasket from the
exhaust manifold. Cover the opening in the exhaust manifold to prevent the entry of dirt which
could cause damage to the turbine wheel blades
after installation and start-up.
NOTE: Before removing and cleaning the charger
look for signs of oil or gas leakage or wear to the
wheel that may not be evident after cleaning.
DISASSEMBLY
1. Clean the exterior of the turbocharger using a
non-caustic cleaning solvent to remove outside
dirt before disassembly.
2
1
3
4
LB 85115 / FB 90.2200.2
NOTE: Exercise care when removing the compressor housing to avoid damaging the compressor
wheel blades. Tap the turbine housing with a soft
faced hammer if force is needed to remove
6
4. Loosen and remove bolts from the turbine housing exhaust side, and lockplates
CLEANING
Before cleaning inspect all parts for burning, rubbing,
or impact damage that may not be evident after
cleaning. Clean all parts in a non caustic solution,
using a soft bristle brush, a plastic blade scraper, and
dry compressed air to remove residue.
DO NOT use abrasive cleaning methods which
might damage or destroy machined surfaces.
DO NOT immerse CHRA in solvent.
DO NOT blow under compressor wheel with compressed air.
DO NOT permit wheel/shaft assembly to spin when
blowing off solvent and residue.
INSPECTION
1. Inspect the compressor housing assembly for
the following defects,
Wheel rub damage in the contour area that cannot be
polished out with 80 grit silicon carbide abrasive
cloth.
Worn, broken, or corroded snap ring grooves
Nicks, dents, or distortion that could prevent proper
sealing between the compressor housing and the
CHRA.
NOTE: Replace the compressor housing if any of the
above defects are found.
2. Inspect the turbine housing assembly for the following defects,
Wheel rub damage in the contour area that cannot be
polished out with 60 grit silicon carbide abrasive
cloth.
Worn, broken, or corroded snap ring grooves (snap
ring turbine housing models).
Nicks, dents, or warpage that could prevent proper
sealing between the turbine housing and the CHRA.
NOTE: If there is any compressor or turbine wheel
blade damage, the CHRA must be replaced. Operating a turbocharger with damaged blades will result in
further damage to component parts or the engine.
Blades cannot be straightened in service.
LB 85115 / FB 90.2200.2
10
8
3. Set the dial indicator to zero.
4. Manually apply equal and simultaneous pressure to the wheels to move the shaft as far as it
will go toward the plunger. Make a note of the
shaft movement shown on the indicator dial.
NOTE: To make sure the reading indicated is the
maximum possible, roll the wheels slightly in both
directions while applying pressure.
5. Manually apply equal, and simultaneous pressure to the compressor, and turbine wheels, to
move the shaft away from the plunger again.
Note that the indicator pointer returns exactly to
zero.
6. Repeat the steps 2 to 5 several times, to ensure
that maximum radial clearance is indicated by
maximum shaft movement, has been measured
7. If the maximum clearance is less than
0.056mm (0.0022 in),
or
greater
than
0.127mm (0.0050 in), replace the CHRA.
Trouble shoot the engine to find the cause of the
bearing failure, and correct the problem before resuming operations.
LB 85115 / FB 90.2200.2
LB 85115 / FB 90.2200.2
11
10
12
11
11. Carefully rotate the CHRA in the turbine housing
to line up the scribed marks. Recheck for proper
alignment and position the locking plates.
12. Coat the bolts (1) in a suitable anti seize compound, and tighten to 2025Nm (1518 lbf ft).
12
Installation
1. Prior to installation fill the turbocharger centre
housing with new clean oil, and rotate the main
shaft to lubricate the bearings.
2. Installation of the turbocharger follows the removal procedure in reverse. Install a new manifold gasket, and tighten manifold bolts to,
4147Nm (3035 lbf ft).
Hose connections torque to 67 Nm (5065 lb in)
3. Replace the washers and reconnect the oil
Feed tube banjo bolt and torque to 3040Nm
(2230 lbf ft).
13
4. The oil feed tube connector, to oil filter head assembly if disturbed should be refitted. Apply
sealer to connector See Specifications and
torque to, 5481Nm (4060 lbf ft).
14
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
13
LB 85115 / FB 90.2200.2
14
NOTES PAGE
LB 85115 / FB 90.2200.2
15
SECTION 10 FUEL
Manifolds
CONTENT
Section
Description
Page
10 254
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
Inlet Manifold
Exhaust Manifold
TORQUE VALUES
TORQUE VALUES VARIOUS
Intake ManifoldtoCylinder Head
Exhaust ManifoldtoCylinder Head
Exhaust PipetoFlange
LB 85115 / FB 90.2200.2
Nm
35
38
31
lbf ft
26
28
23
Kgf m
3.5
3.9
3.2
16
tight at all times. Considerable damage to the cylinder bores, may be incurred by entry of grit or other
foreign material if the plug is left loose or missing.
Also dirt and grit may be drawn through the air
cleaner connections if they are not properly secured.
The inlet manifold attached to the left hand side of the
engine block is a one piece cast aluminium plenum
chamber that directs the air from the air cleaner and
into the cylinder head.
The exhaust manifold attached to the right hand side
of the engine block is a one piece cast iron unit that
channels the spent exhaust fumes into the muffler by
way of tubing and clamps.
FAULT FINDING
IMPORTANT: When effecting a repair the cause of
the problem must be investigated and corrected to
avoid repeat failures.
PROBLEM
POSSIBLE CAUSES
REMEDY
Excessive
smoke
exhaust
LB 85115 / FB 90.2200.2
17
OVERHAUL
IMPORTANT: Whenever it is necessary to remove
the intake or exhaust manifolds from the engine new
sealing gaskets must be fitted upon reassembly.
INSPECTION
1. Clean the intake manifold in a solvent that is suitable for aluminium and check for cracks or damage repair where practical. Small imperfections
on the joint face can be dressed with a stone, but
where they exceed a stone repair the manifold
must be changed.
2. Clean the exhaust manifold in a suitable solvent
removing the carbon deposits with a wire brush.
check for cracks or damage to the joint face that
could create an air leakage. Small imperfections
can be dressed with a stone, but where they exceed a stone repair the manifold must be
changed.
15
INSTALLATION
1. Prior to refitting the manifolds clean the cylinder
head faces with light grit paper to remove any
trace of old gaskets that may have remained on
the head face during disassembly.
2. Place the bolts through the manifold to be fitted
and through a new gasket, attach the manifold
and gasket onto the cylinder head and torque the
bolts on the:
Intake manifold to 35Nm (26 lbf ft)
Exhaust manifold bolts to 38Nm (28 lbf ft)
16
17
LB 85115 / FB 90.2200.2
18
NOTES PAGE
LB 85115 / FB 90.2200.2
SECTION 10 ENGINE
Chapter 4 Lubrication
CONTENT
Section
Description
Page
10 304
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
Oil Pump
Rotor Clearance
Rotor to Pump Housing Clearance
Rotor End Play
Oil Pressure
Pump Gear to Camshaft Gear Backlash
Oil Type
Temperature
12C
(Below 10F)
12C to 4C
(10F to 40F)
SF/CD/CF4
150
300
0C to 32C
(32F to 90F)
SF/CD/CF4
300
300
Above 24C
(75C)
SF/CD/CF4
300
LB 85115 / FB 90.2200.2
API
Classification
SF/CD/CF4
150
150
150
NOTE: When using diesel fuel with a sulphur content below 1.0%, Series 3 diesel engine oil with an A.P.I. classification of CD may be used instead of CF4 oil , but the oil and filter interval must be reduced to 150 hours .
When using diesel fuel with a sulphur content between 1% and 1.3% use only oils listed above but reduce the
oil and filter change period to every 50 hours .
Litres
U.S Gals
4 CYL
17.5
4.5
Model
Litres
U.S Gals
4 CYL
18.5
4.8
TORQUE VALUES
Nm
lbf ft
Kgf m
41
30
4.2
23
17
2.3
42
31
4.2
34
25
3.5
31
23
3.2
54
40
5.5
24
18
2.4
SPECIAL TOOLS
AS REQUIRED REFER TO SECTION 00 CHAPTER 4
LB 85115 / FB 90.2200.2
1
Engine Lubrication System With Turbocharger Fitted
LB 85115 / FB 90.2200.2
Engine knocks
REMEDY
POSSIBLE CAUSES
1. Renew bulb
pressure
4. Excessive
backlash
timing
gear
Engine overheats
3. Renew
6. Repair/renew
assembly
oil
cooler
LB 85115 / FB 90.2200.2
PROBLEM
POSSIBLE CAUSES
REMEDY
3. Blocked
screen
oil
pump
sump
6. Overhaul pump
7. Excessive
connecting
clearance
main
or
rod
bearing
2
2. Loosen and remove the camshaft gear, to expose the oil pump, detach the 3 pump mounting
bolts, and withdraw the pump from the block.
LB 85115 / FB 90.2200.2
Disassembly
1. Loosen and remove the pump face plate to body
bolts (1). Disassemble the pump and discard the
Orings (2).
4
Inspection and Repair
1. Wash all parts in a suitable solvent and inspect
inside of pump plate, and body, for excessive
wear or damage. If visually okay check in the following manner.
2. Invert pump plate/rotor assembly, and place
outer rotor over inner rotor. Placing a ruler (1)
across top of both, slide a feeler gauge (2), between
ruler
and
inner
rotor,
to
0.0250.089mm (0.0010.0035 in).
NOTE: If not to specification replace the oil pump, as
reduced pump pressure through wear could result in
reduced engine life.
5
3. Place outer rotor in pump body and check clearance, by inserting a feeler gauge (1) between the
rotor and body. Check
to a max of
0.55mm (0.022 in). If exceeded a new pump is
required.
6
Installation
1. Clean and coat parts in new engine oil. Place
outer rotor in pump body, and ensure free rotation. Insert inner rotor, and pump plate assembly,
into the body and ensure that shaft is fully seated
into bushing.
2. Assemble the front plate to the body
bolts,and torque to,
23.028.4Nm (1721 lbf ft) 2.32.9kgf m.
IMPORTANT: After tightening ensure the drive gear
rotates freely by hand, at least 5 revolutions, if not
disassemble and repeat the exercise.
7
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
8
6. Ensure the engine backplate is fitted correctly
and the bolts are torqued up in sequence. Refer
to chapter 1.
9
Oil Filter Support Assembly
Removal
1. Unscrew and discard the old filter, place to one
side the modine oil cooler body. Loosen the 4 attaching bolts and oil connections and remove the
filter support assembly from the block. Discarding the ORings.
2. Clean the filter support in a suitable solvent.
10
3. Remove pressure relief valve plug (3), removing
valve (1) and spring (2). To ensure correct operation of the pressure relief valve, check spring
length,
Free length = 52.8mm (2.08 in).
Compressed length = 37.0mm (1.46 in) using a
weight of 15.6 kgs (34.3 lbs).
4. Check the parts for damage, wear, and replace
as necessary. Failure to do so could result in premature wear to the engine, due to oil bypassing
the filter and returning back to the system.
11
LB 85115 / FB 90.2200.2
Installation
1. Lubricate the pressure relief valve and spring
and insert into housing, ensuring free movement.
Fit a new ORing to the plug and torque to,
55N m (42 lbf ft).
NOTE: On some models including the turbocharged
version the pressure relief valve end plug is replaced by an oil return tube from the engine block.
Where this pipe is fitted a plug is used to blank the oil
return port to the engine block.
2. Fit tube (1) to the connector and torque to 27Nm
(20 lbf ft).
3. Refit the oil filter head to the engine block with
new Orings (2) and plug where required as
above and torque the bolts to,
3447Nm (2635 lbf ft)
APB10011
12
LB 85115 / FB 90.2200.2
SECTION 10 ENGINE
Chapter 5 Cooling
CONTENT
Section
Description
Page
10 400
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
THERMOSTAT
Opening Temperature
Fully Open
7983C (174181F)
9396C (199205F)
RADIATOR CAP
Opening Pressure
WATER PUMP
Type
Drive
Centrifugal
V Belt
FAN BELT
Belt Tension
Litres
22.0
U.S. Gals
5.8
COOLING FLUID
Content Mixture Water 50%, Antifreeze 50% . If the recommended antifreeze is not used, a heavy duty antifreeze must be used with a 5% solution of Inhibitor. This inhibitor must be added to the cooling system and is
available from Dealers Part No FW 15.
LB 85115 / FB 90.2200.2
Nm
lbf ft
Kgf m
48
35
3.6
27
20
2.8
24
18
2.4
27
21
2.8
Temperature Senders
20
15
2.0
SPECIAL TOOLS
AS REQUIRED REFER TO SECTION 00 CHAPTER 4
SEALANTS
Code
Name
82995768
82995776
SealerSilicone
82995774
SealerPolyester Urethane
82995773
SealerAnaerobic
LB 85115 / FB 90.2200.2
1
Once the engine has reached its normal operating
temperature, the thermostat will open and allow
water to be drawn through the radiator by the pump
action. Cooled water then returns to the engine system.
LB 85115 / FB 90.2200.2
POSSIBLE CAUSES
REMEDY
3. Radiator leakage
3. Repair/renew radiator
6. Faulty thermostat
6. Renew thermostat
11. Cylinder
head
improperly installed
gasket
15.Clean
LB 85115 / FB 90.2200.2
PROBLEM
Water
temperature
gauge fails to reach
normal operating temperature
POSSIBLE CAUSES
REMEDY
2. Renew thermostat
3. Faulty
gauge
water
temperature
OVERHAUL
LB 85115 / FB 90.2200.2
Radiator Removal
Raise the Loader to full height and secure with the
loader arm support.
4. Detach the right and left hand engine side panels.
Switch of battery at the isolator key
5. Remove the engine coolant drain plug (1) situated behind the oil filter body on the left hand side
of the engine and drain the coolant into a suitable
clean container.
4
Remove:
5
7. Attached in front of the radiator is the hydraulic
system oil cooler (1).
6
8. The airconditioning condenser (when fitted) is
mounted in front of the radiator.
9. Ensure all pipes are disconnected, looms are unclipped, and away from the radiator assembly.
10. Remove the attaching bolts and lift the radiator
up and clear of the vehicle.
LB 85115 / FB 90.2200.2
7
3. Withdraw the thermostat (2) from the housing,
along with the gasket.
LB 85115 / FB 90.2200.2
9
Installation
Installation of the thermostat is the reverse of the removal procedure but observing the following:
1. Prior to reassembly ensure the thermostat
housing faces are clean and free of old sealer or
gasket material. Clean the faces with a small
stone or fine grit paper.
2. Coat a new gasket with sealer 82995774 and
position in the recess on the thermostat housing,
prior to installing the thermostat.
3. Coat the edge of the thermostat with grease and
install, with the heat element located in the cylinder head.
4. Refit the thermostat housing and torque the two
bolts to 2028Nm (1521 lbs ft).
5. Ensure the correct grade, and quantity of antifreeze, is added to the coolant. Recommended
content mixture is Water 50%, with 50% Antifreeze to WSNM97B18D specification.
TEMPERATURE WARNING SENDER
1. The engine temperature sender for the gauge
(1), and the temperature warning light (2), (where
fitted), are located on the thermostat housing.
Installation
1. If a fault occurs fit a new sender and apply sealant to the threaded portion of the sender body
and torque to, 1624Nm (1218 lbf ft).
10
LB 85115 / FB 90.2200.2
12
Disassembly
1. Withdraw the attaching bolts and remove the fan
from the pump pulley.
2. Use Puller (1) and a sleeve slightly smaller in diameter than the pulley shaft to remove the pump
pulley.
3. Remove the retaining bolts, then separate the
pump covers and discard the gasket.
13
4. Using a press and an adaptor with a diameter
slightly smaller than the bearing shaft, press the
bearing assembly out of the pump housing and
discard the bearing.
5. Use a suitable sleeve and press the seal assembly
out of the impeller side of the pump housing. Discard the seal assembly.
14
LB 85115 / FB 90.2200.2
10
15
2. Check both parts of the pump housing (1) and (3)
for cracks or signs of leakage. Replace any defective parts, figures 10 and 11.
16
Reassembly
1. Use a sleeve, which passes over the shaft and
rests on the outside diameter of the bearing.
Press the bearing and shaft assembly into the
housing until the bearing is flush with the face of
the housing or within 0.08mm (0.003in). Use a
straightedge to check the final position.
2. Turn the pump housing over and position in a
press with the seal bore facing upwards.
3. Place Tool (1) over the shaft and onto the seal assembly. Press the seal into the bore until the
flange is flush with the top of the housing.
17
4. Coat the outer diameter of the seal flange with a
thin application of thread sealer and position the
seal assembly over the shaft in the center bore
of the housing.
18
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FB 90.2200.2
11
Pulley
Front housing
Rear housing
Attaching bolts
Impellor
Bearing seal
Bearing shaft
19
5. Support the shaft on a block of wood and use a
length of pipe of suitable internal diameter to
press the impeller onto the shaft and flush with
the rear face of the housing. Check the final position with a straightedge to 00.38mm
(00.014in).
20
6. Support the shaft on a block of wood and press
the pulley onto the shaft to the dimension (1) of
62.48463.144mm (2.4602.486in). This dimension is from the rear face of the front cover
to the center of the 1st pulley V-groove (closest
to the water pump). After installation, be sure that
the pulley runs true on the shaft.
21
7. Install a new gasket and assemble the front and
rear halves of the pump together and tighten the
bolts to 27Nm (20 lbf ft) torque.
8. Install the fan on the pulley and tighten the bolts
to the 27Nm (21lbf ft) torque.
LB 85115 / FB 90.2200.2
12
22
Installation
Installation of the water pump follows the removal
procedure in reverse. On installation observe the following requirements:
1. Install a new pump gasket.
2. Adjust the alternator drive belt tension. Deflection of the V-Belt should be:
10mm (0.4in) Midway between pulleys.
3. After installation of the radiator, fill the cooling
system and run the engine to check for leaks.
23
LB 85115 / FB 90.2200.2
Description
Page
17 100
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
Engine Stall Speeds
Power Shuttle Transmission . . . . . . . . . . . . . . . . 20092065 revs/min
Torque Convertor Ratio
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 : 1
Lubricant
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..........................................
..........................................
..........................................
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Tests
Tachometer Setting . . . . . . . . . . . . . . . . . . . . . . . .
Test temperature, oil . . . . . . . . . . . . . . . . . . . . . .
Cold Start Valve (For reference only) . . . . . . . . .
System Pressure Test . . . . . . . . . . . . . . . . . . . . . .
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . .
2000 revs/min
8085C (176185F)
26 bar (377 psi)
13.715.2 bar (198220 psi)
711 bar (101159 psi)
Sealant
Gasket sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995774
Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995768
TORQUE SPECIFICATIONS
Item Description
Cooler return pipe union
Cooler return pipe elbow
Stator support retaining bolt
Flywheel to flex plate
Flex plate to converter
LB 75110 / FH 90.2110.2
Nm
ft. lbs.
49-78
49-78
26
43
43
36-58
36-58
19
32
32
1
604.56.061.00 / 604.13.028.00 09/2000
LB 75110 / FH 90.2110.2
LB 75110 / FH 90.2110.2
IMPORTANT: When effecting a repair the cause of the problem must be investigated and corrected to avoid
repeat failures.
The following table lists problems and their possible causes with recommended remedial action.
PROBLEM
1. Low stall speed
POSSIBLE CAUSES
CORRECTION
Replace
Replace seals
Replace Torque Convertor
OVERHAUL
NOTE: To remove the torque convertor refer to the
transmission section 21 000 for disassembly procedure.
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 converter
cleaner may be used to clean the converter. However, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.
4
1. Drain as much oil as possible from the hub of the
converter by tilting the converter in all directions.
2. Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning
solvent specified for cleaning transmissions.
3. Plug the opening in the hub, then circulate the
solvent inside the converter by rotating and shaking.
4. Drain the solvent from the converter.
5. Repeat Steps 1 to 4, as required, until the solvent
that is drained from the converter is clean.
5
LB 75110 / FH 90.2110.2
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.
REASSEMBLY
1. Secure the drive plate to the torque converter,
with the attaching bolts and flat washers (1) .
Tighten bolts to 41 Nm (30 lbf ft).
2. Prior to fitting the transmission place the torque
convertor carefully over the transmission shaft
and into the transmission housing.
3. With the transmission bolted to the engine secure the drive plate to the flywheel accessed
through the starter motor aperture, with the attaching bolts and washers (2). Tighten bolts to 41
Nm (30 lbf ft).
STALL TEST
The purpose of this test is to determine if the torque
converter and hydraulic clutch assemblies are operating satisfactorily. For the test to be conclusive, the
transmission hydraulic pump and pressure regulating valve must be operating correctly. They can be
checked by performing the Line Pressure Test. The
engine and brakes must also be in good working
order.
1. Check the coolant level in the radiator and the oil
level in the transmission. If low, add fluid as required to bring to the proper level.
2. 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).
3. 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 position. This will position the control
valve so as to direct high pressure oil to the front
clutch.
LB 75110 / FH 90.2110.2
STALL SPEED:
1980
. . . . revs/min
.
. . 2082
. . . . revs/min
LB 75110 / FH 90.2110.2
Description
Page
17 200
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
Engine Stall Speeds
95 PS Turbocharged . . . . . . . . . . . . . . . . . . . . . . . 20092065 revs/min
Torque Convertor Ratio
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 : 1
Lubricant
Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambra Hydrodex 3
Hydraulic Tests
Tachometer Setting . . . . . . . . . . . . . . . . . . . . . . . .
Test temperature, oil . . . . . . . . . . . . . . . . . . . . . .
Torque Converter relief valve . . . . . . . . . . . . . . . .
Oil temperature converter out,
Normal operating range . . . . . . . . . . . . . . . .
Maximum temperature . . . . . . . . . . . . . . . . .
2200 revs/min
8293C (180200F)
10 bar (101159 psi)
8090C (175193F)
120C (284F)
Sealant
Gasket sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995774
Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995768
TORQUE SPECIFICATIONS
Item Description
Cooler return pipe union
Cooler return pipe elbow
Stator support retaining bolt
Flywheel to flex plate
Flex plate to converter
LB 85115 / FH 90.2200.2
Nm
ft. lbs.
49-78
49-78
26
43
43
36-58
36-58
19
32
32
1
Torque converter and lubrication pressure test ports.
1.
2.
3.
4.
5.
6.
2
Left Hand Side View
1.
LB 85115 / FH 90.2200.2
LB 85115 / FH 90.2200.2
IMPORTANT: When effecting a repair the cause of the problem must be investigated and corrected to avoid
repeat failures.
The following table lists problems and their possible causes with recommended remedial action.
PROBLEM
1. Low stall speed
POSSIBLE CAUSES
CORRECTION
Replace
Replace seals
Replace Torque Convertor
OVERHAUL
NOTE: To remove the torque convertor refer to the
transmission section 21 000 for disassembly procedure.
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 converter
cleaner may be used to clean the converter. However, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.
5
1. Drain as much oil as possible from the hub of the
converter by tilting the converter in all directions.
2. Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning
solvent specified for cleaning transmissions.
3. Plug the opening in the hub, then circulate the
solvent inside the converter by rotating and shaking.
4. Drain the solvent from the converter.
5. Repeat Steps 1 to 4, as required, until the solvent
that is drained from the converter is clean.
6
LB 85115 / FH 90.2200.2
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.
REASSEMBLY
1. Secure the drive plate to the torque converter,
with the attaching bolts and flat washers (1) .
Tighten bolts to 41 Nm (30 lbf ft).
2. Prior to fitting the transmission place the torque
convertor carefully over the transmission shaft
and into the transmission housing.
3. With the transmission bolted to the engine secure the drive plate to the flywheel accessed
through the starter motor aperture, with the attaching bolts and washers (2). Tighten bolts to 41
Nm (30 lbf ft).
STALL TEST
The purpose of this test is to determine if the torque
converter and hydraulic clutch assemblies are operating satisfactorily. For the test to be conclusive, the
transmission hydraulic pump and pressure regulating valve must be operating correctly. They can be
checked by performing the Line Pressure Test. The
engine and brakes must also be in good working
order.
1. Check the coolant level in the radiator and the oil
level in the transmission. If low, add fluid as required to bring to the proper level.
2. 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).
3. 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 position. This will position the control
valve so as to direct high pressure oil to the front
clutch.
LB 85115 / FH 90.2200.2
STALL TORQUE:
Power Shift Transmission Models 110.2-200.2
. . . . . . . . . . . . .T.B.A
. . . . . revs/min
..
LB 85115 / FH 90.2200.2
SECTION 21 TRANSMISSION
Chapter 1 4X4 Compact Shuttle
CONTENT
Section
Description
Page
21 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake disc and calliper assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four Wheel Drive Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication and Oil Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shimming procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
56
33
42
10
36
15
52
SPECIFICATIONS
Stall Speeds
92 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19291982 revs/min
108 hp Turbocharged . . . . . . . . . . . . . . . . . . . . . . 20092065 revs/min
Torque Convertor Ratio
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 : 1
Gear Ratios
Synchronized 4x4 Transmission . . . . . . . . . . . . . Forward 1st 4.824:1
Forward 2nd 2.998:1
Forward 3rd 1.408:1
Forward 4th 0.792:1
Lubricant
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..........................................
..........................................
..........................................
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealant
Gasket sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995774
Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995768
Cold Start Bypass Valve Spring
Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.4mm +/ 0.96mm (2.10in +/ 0.038in)
Fwd Clutch Spring
LB 75110 / FH 90.2110.2
0.05080.41mm (0.0020.016in)
0.05080.41mm (0.0020.016in)
1st Gear 0.330.508mm (0.0130.020in)
2nd Gear 0.350.558mm (0.0140.022in)
3rd Gear 0.380.838mm (0.0150.033in)
4th Gear 0.200.558mm (0.0080.022in)
0.0500.28mm (0.0020.011in)
0.0250.076mm (0.0010.003in)
0.050/0.076/0.127/0.177/0.381/0.508mm
(0.002/0.003/0.005/0.007/0.015/0.020in)
Hydraulic Tests
Tachometer Setting . . . . . . . . . . . . . . . . . . . . . . . .
Test temperature, oil . . . . . . . . . . . . . . . . . . . . . .
Cold Start Valve (For reference only) . . . . . . . . .
System Pressure Test . . . . . . . . . . . . . . . . . . . . . .
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four Wheel Drive Drive Supply . . . . . . . . . . . . . .
2000 revs/min
8085C (176185F)
26 bar (377 psi)
13.715.2 bar (198220 psi)
711 bar (101159 psi)
13.715.2 bar (198220 psi)
13.715.2 bar (198220 psi)
13.715.2 bar (198220 psi)
Revs/min
700
1000
1500
2000
2200
2500
TORQUE SPECIFICATIONS
Item Description
Cooler return pipe union
Cooler return pipe elbow
Stator support retaining bolt
Flywheel to flex plate
Flex plate to converter
Nm
ft. lbs.
49-78
49-78
26
43
43
36-58
36-58
19
32
32
LB 75110 / FH 90.2110.2
LB 75110 / FH 90.2110.2
DESCRIPTION
Bearing Cone Drift 40mm
Bearing Cone Drift 35mm
Bearing Cone Drift 40mm
Bearing Cone Drift 50mm
Slide Hammer
Bush Insertion Tool 22mm
Welch Plug Drift
Oil Seal Drift
*Spring Compressor
Spring Compressor
Circlip Pliers .
Feeler Gauges
*Dial Indicator Bolt
SPECIAL TOOLS
APPLICATION
Counter Shaft, Rear Main Shaft and 4WD Bearing
Reverse Idler and Front Main Shaft Bearing
Front Input Shaft Bearing
Rear Input Shaft Bearing
Bearing cone removal
Pump rod Insertion Tool
Shim Adjustment Cover
Pump Seal
Main Clutches Tool no 297394
Detent Ball Spring
Where applicable
Where applicable
Shaft end float Tool no 297395
LB 75110 / FH 90.2110.2
3
NOTE: A conventional clutch is not used with this
transmission.
The transmission case serves as an oil reservoir for
the torque converter and hydraulic clutch assemblies.
The gearbox receives power from the engine (1) by
a fluid coupling in the torque converter (2) and hydraulic clutch assemblies in the transmission (3).
N
R
6
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LB 75110 / FH 90.2110.2
8
GEAR TRAIN (Op. 21 146)
The front and rear cases of the transmission sandwich a series of parallel shafts which support the helically cut gears, between tapered roller bearings.
Polymer lip seals on the hydraulic pump output and
FWD shafts prevent leakage from the sump. A
breather at the top of the filler tube prevents pressure
damage to the seals.
9
GEAR SHIFT MECHANISM (Op. 21 136)
A mechanical arrangement of shift rails, forks and
synchronisers allows static or rolling engagement of
any of the 4 transmission ratios from a standard H
gate pattern lever.
The synchronisers prevent engagement of the selected gear until its shaft speed is synchronised with
that of the output shaft. A detent interlock system
prevents gear jumpout and the simultaneous engagement of 2 gears.
10
PARKING BRAKE (Op. 21 136)
At the rear of the transmission and on the output
coupling a cast iron disc acts as the mounting flange
and parking brake. The disc runs in a mechanical calliper which reacts through a bracket connected to the
transmission rear housing. The calliper has replaceable friction pads and is manually adjustable as the
pads wear
11
LB 75110 / FH 90.2110.2
TAB21096
13
14
LB 75110 / FH 90.2110.2
15
Pressure Oil
Lubrication
Disengaged
LB 75110 / FH 90.2110.2
10
16
1.
2.
3.
4.
5.
Pump Pressure
Return to Sump
Lubrication
6.
7.
8.
Suction
Cold Start Pressure protection Valve Prevents system pressure exceeding 26 bar (377 psi) at initial
cold start.
Oil Pump Port OUT, to oil filter assembly through
internal drillings.
Oil returned from the oil cooler lubricates shafts,
gears and bearings and returns oil to reservoir.
LB 75110 / FH 90.2110.2
1.
2.
3.
4.
Pump Pressure
Return to Sump
Lubrication
LB 75110 / FH 90.2110.2
5.
6.
7.
8.
11
17
Suction
12
20
19
18
Viewed From Front and Rear Housings
1. Oil supply port to Reverse clutch pack, rear casing.
11. Torque convertor pressure regulating valve.
2. Oil supply port to forward clutch pack, rear casing.
12. Oil supply from pump to solenoid valve pack.
3. Oil supply port to pressure test reverse clutch pack.
13. Oil supply port to Reverse clutch pack, front casing.
4. Oil supply port too pressure test forward clutch pack.
14. Oil port to reservoir (dump) from solenoid.
5. Front Wheel Drive Solenoid.
15. Oil supply port to Reverse clutch pack, front casing.
6. System pressure test point, connected to test block.
16. Oil supply port to forward clutch pack, front casing.
7. Locating Dowel
17. Oil supply port to forward clutch pack, front casing.
8. Cold start oil pressure protection valve.
18. Manufacturing drilling only.
9. Torque convertor pressure test point, connected to
19. FWD oil supply port (front casing)
test block.
20. FWD oil supply port (rear casing)
10. System pressure sequencing valve.
LB 75110 / FH 90.2110.2
13
19
On the underside of the solenoid valve are the 4 ports
for directional oil flow to and from the solenoid valve.
1.
2.
3.
4.
5.
20
When the shuttle lever in the cab is in neutral position
the solenoid valve spool (1) will be static and oil (2)
will not flow into either reverse (3) or forward (4)
clutch pack oil gallery.
21
When forward direction is selected on the the shuttle
lever the solenoid valve spool (1) will move to the left
(as shown) and the oil (2) will flow into the forward
clutch pack oil gallery (4)
When reverse direction is selected on the the shuttle
lever 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).
22
LB 75110 / FH 90.2110.2
14
23
Selection of the forward / reverse shuttle lever in the
cab directs a current flow to the forward or reverse
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
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 pressure at the clutch builds up gradually to give
a smooth jerk free clutch engagement.
24
25
NOTE: The control valve also includes a pressure
regulating (feathering) valve and a fill time metering
valve for the reverse clutch pack.
= Regulated Pressure Oil
= Return Oil
= Pressure Oil
LB 75110 / FH 90.2110.2
15
11
26
NOTE: All pressure test ports are 9/16 in UNF thread size
1.
2.
3.
4.
5.
6.
7.
8.
9.
LB 75110 / FH 90.2110.2
16
27
LB 75110 / FH 90.2110.2
17
28
Input
Output
Intermediate
LB 75110 / FH 90.2110.2
18
29
LB 75110 / FH 90.2110.2
19
30
LB 75110 / FH 90.2110.2
20
31
STALL PROCEDURE
Apply the brakes and block wheels. Place the transmission in 4th gear and select forward. With the engine running, gently increase speed to around half
throttle and hold until oil temperature reaches the operating range. Do not stall for more than 30 seconds.
Select neutral for 15 seconds then repeat to reach
the temperature range.
Having achieved temperature, gently increase engine speed to full throttle. Record engine speed. Repeat this test in reverse. Engine speed should be:
STALL SPEED:
.....
......
1980 revs/min
2082 revs/min
LB 75110 / FH 90.2110.2
21
POSSIBLE CAUSES
CORRECTION
1. Low or no oil
4. Blockage at strainer
between filter and pump
4. Drain
and
flush
the
transmission, clean strainer,
replace filter
or
5. Repair
1. Retest at 8085C
1. Inspect
valve
LB 75110 / FH 90.2110.2
converter
relief
1. Inspect
valve
converter
relief
2. Raise Temperature
1. Wiring fault
1. Wiring fault
22
POSSIBLE CAUSES
CORRECTION
1. Restrictions in cooler
4. Worn
plates
clutch
6. Temperature sensor
6. Check
7. Clean
or
slipping
Noise in gear
Noise in FWD
POSSIBLE CAUSES
CORRECTION
2. Worn bearings
1. Worn
or
damaged
countershaft or drive gears
2. Worn bearings
2. Worn bearings
LB 75110 / FH 90.2110.2
23
FAULT FINDING
PROBLEM
Gear selection Hard shifting
LB 75110 / FH 90.2110.2
POSSIBLE CAUSES
CORRECTION
7.Replace
2. Worn
or
broken
synchronizer cones or cups
2. Fractured
drive rod
transmission
24
32
Shuttle Valve Disassembled
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Solenoid Retainer
Dirt Seal
Solenoid
Washer
Solenoid Body
Guide
Spring
Solenoid Pin
Seal
Support Body Solenoid
End Cap *
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Circlip *
Clutch fill metering valve *
Spring *
Spool
Piston Clutch fill
Spring
Retainer
Spring
Seal
End Plug
NOTE: *These items are not serviceable other than for cleaning
LB 75110 / FH 90.2110.2
25
34
Reassembly
Reassemble in reverse order but observe the following:
The Coils must align with the pins on the body before
tightening the coil retaining rings, ensure the O rings
are fitted.
Assembly of the valve onto the transmission must
align with the locating pin to ensure correct alignment
of oil feed ports and correct forward / reverse shuttle
operation.
Reassemble the attaching bolts and torque to
2027 Nm (1520 lbf ft)
35
37
LB 75110 / FH 90.2110.2
26
38
2.
1
2
39
IMPORTANT: A worn oil pump will reduce the efficiency of the transmission and the machine if not corrected.
4. A single lipped seal (1) is incorporated in the front
oil pump housing and should be changed when
ever a complete teardown has taken place. Push
out the old seal and replace with new, grease
outer seal and push in ensuring it is fully seated
into the housing.
Reassemble the pump in reverse order, fit new
seals and copper washers under the bolt heads and
torque the retaining bolts to 2027 Nm (1520 lbf ft)
40
IMPORTANT: Ensure the pump outer ring face with
chamfer enters the pump body first.
LB 75110 / FH 90.2110.2
27
TRANSMISSION OVERVIEW
IMPORTANT: Before commencing any dismantling procedure it is essential to thoroughly clean the transmission
and work area.
41
1.
2.
3.
4.
5.
LB 75110 / FH 90.2110.2
28
TRANSMISSION OVERHAUL
IMPORTANT: Before commencing any dismantling procedure it is essential to thoroughly clean the transmission
and work area. If new clutch friction discs are to be installed it will be necessary to soak the discs in clean new
oil for a minimum of 3 hours before fitting.
42
4x4 Power Shuttle
LB 75110 / FH 90.2110.2
29
3
1
2
5
43
44
NOTE: To aid disassembly use the hand brake to
lock the shafts, to enable both the FWD coupling and
the disc bolts to be removed.
Loosen and remove the Four Wheel Drive coupling
where fitted (4).
Remove the transmission handbrake, loosen and
withdraw the output coupling and disc (1).
Remove the gear shift attaching bolts and withdraw
the gear lever (2).
Loosen and remove the control valve and oil filter assembly, gaskets and adapters (3) if required.
Remove all pipes and connectors that may be easily
damaged or interfere with the disassembly.
45
LB 75110 / FH 90.2110.2
30
46
47
1. Lift out the FWD shaft assembly where fitted.
48
2. Remove the gear shift detent retaining bolt and
remove the outer spring and ball, replace bolt before remove rails.
NOTE: The inner rail detent balls and springs will no
longer be captive in position when the rails are removed and may fly out with some force.
3. Using a right angled hexagonal key loosen the
selector forks on the rail. Angle the output shaft
and lift out the gear selector forks and rails.
Place all of the springs and balls to one side.
49
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LB 75110 / FH 90.2110.2
31
50
5. With the counter shaft and reverse idler shaft
held to one side remove the input shaft and place
on a bench for inspection.
51
6. Remove the counter shaft and reverse idler shaft
and place on a bench for inspection
52
Before attempting any disassembly of the gear train
ensure all the components are clean and inspect for
signs of wear, scoring, or chipping of the gear teeth
or wear on related components.
LB 75110 / FH 90.2110.2
32
53
1.
2.
3.
4.
5.
6.
7.
O ring
Sealing Ring
Piston Body
O ring
Sealing Ring
Spring
End Plate
54
LB 75110 / FH 90.2110.2
33
55
3. Compress the clutch spring (1) sufficiently to
allow the release of the retaining circlip (2). Using
circlip pliers (3) remove the circlip and carefully
release the spring tension.
56
4. Disassemble the washer, spring, drive clutch and
seals from the shaft and inspect for damage,
scoring or wear marks that may be apparent, replace suspect parts as necessary.
57
PISTON SEALS
5. With the piston completely disassembled discard
the old O ring and sealing ring and replace with
new. Place the new O ring and seal in position
into the piston.
58
LB 75110 / FH 90.2110.2
34
REASSEMBLY OF SHAFT
IMPORTANT: Where new parts are fitted ensure a
coating of new transmission oil is liberally applied to
all mating surfaces before reassembly.
1. Prior to reassembly ensure a new clutch seal is
fitted onto the shaft. Place the seal (1) in warm
water prior to fitting, when pliable carefully seat
the seal in the groove on one side of the shaft and
pull the seal onto the shaft around the circumference. Use a pliable PVC tube (2) or similar material that will not damage the seal.
59
To size the seal in position place a band of tape
over the seal, a jubilee clip can then be placed
over the tape to compress the seal fully into the
groove prior to fitting the FWD piston.
2. Reassemble the clutch housing along with
spring, washer and apply pressure as in, Figure
15, and refit the circlip. Using a 40mm bearing
tool (1) refit the bearing onto the shaft.
60
3. Ensure when the bearing is seated an end float
of gear to washer 0.050.28mm (0.002 0.011
in) is maintained between the thrust washer and
gear (1).
61
4. Fit a new oil seal (1) to the end of the shaft, gear
end.
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LB 75110 / FH 90.2110.2
35
63
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
2nd GEAR
Ouput Shaft
Bearing
Out put Gear to 4WD Shaft
1st GEAR
Spacer
Bearing 2 places
Sleeve
Bulk Pin Synchronizer 2 places
Synchronizer Hub 2 places
Circlip
LB 75110 / FH 90.2110.2
Output Shaft
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
3rd GEAR
Gear Selection Fork Lower
Gear Selection Fork Upper
Fork Locking Allen Key
Detent Ball
Detent Spring
Gear Selection Rail
Gear Selection Rail
Bearing
Thrust Washer
4th GEAR
36
64
2. With the bearing, washer and 4th gear removed,
withdraw the baulk ring synchroniser, circlip, hub
sleeve and 3rd gear. Inspect all parts for scoring
wear marks and discolouration, replace suspect
parts as necessary.
3. The baulk pin synchronizer assembly can be disassembled for inspection for wear patterns or
scoring and for cracking of the outer cones, if in
any doubt replace with new.
65
The baulk pin synchroniser assembly consists of a
sliding clutch mounted on and splined to the appropriate transmission shaft, with a friction synchronising inner cone located on each side. The inner
cones are mounted on three locking pins which pass
through holes on the sliding clutch.
1.
2.
3.
4.
5.
6.
Outer Cone
Inner Friction Cone
Baulk Pin Assembly
Sliding Clutch
Locking Pin
Baulk Pin
66
The baulk pin synchroniser ensures the shaft speed
and the gear speed is equal before allowing the
sliding coupling to positively engage the shaft to the
gear.
1.
2.
3.
Gear
Locking Pins
Outer Cone
67
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LB 75110 / FH 90.2110.2
37
Sliding Clutch
Inner Friction Cone
Leaf Springs
68
When the gear and shaft speeds are equal the locking pins become free and move to the centre of the
holes in the sliding clutch allowing the sliding clutch
to move connecting the shaft to the gear selected.
The three split sleeves are expanded by the inner
leaf springs, positively locking the sliding clutch into
position.
1.
2.
Locking Pin
Leaf Spring
69
71
LB 75110 / FH 90.2110.2
38
72
73
2. With the 1st gear removed withdraw the needle
bearing, spacer, 2nd needle bearing, sleeve,
bulk ring synchronizer, hub sleeve and 2nd gear.
Inspect for scoring wear marks and or discolouration, replace suspect parts as necessary.
74
75
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LB 75110 / FH 90.2110.2
39
76
5. Refit the needle bearing, spacer, 2nd needle
bearing, synchronizer assembly, 1st gear, output
gear and washer prior to fitting the bearing.
77
6. Refit the bearing, when fully seated ensure the
freeplay between the gears is at least 0.330.58
mm (0.0130.020in) to allow free rotation of the
1st and output gears.
78
COUNTERSHAFT Disassembly
1. The counter shaft support bearings can be removed by using a suitable puller. Inspect for
scoring wear marks and or discolouration, replace suspect parts as necessary.
2. To refit the bearings use a 40mm press tool
79
LB 75110 / FH 90.2110.2
40
80
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Input Shaft
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Piston
Piston Seal Inner
Piston O ring Inner
Piston O ring Outer
Roller Bearing
Thrust Washer
Gear Hub
Clutch Pack Retaining Circlip
Clutch Pack Retaining Plate
Friction Disc (x6 Each Clutch)
Circlip
Spring Retainer
LB 75110 / FH 90.2110.2
41
81
NOTE: Prior to removal of the snap ring the wear factor of the clutch plates should can be checked.
Measure the distance between the face of the top
plate to to underside of retainer, approx. dimensions:
When new Approx. 2.224.93mm (0.080.19in)
When run in Approx. 5.648.35mm (0.220.32in)
Anything exceeding or close to 8.35mm should be
considered as worn and replaced with new.
82
2. Release the snap ring (1), retaining the clutch
pack drive rings and remove from the clutch
housing.
The discs must be flat and not discoloured in any
way, if in doubt renew the discs.
83
3. Using a press and tool NH 21 102 (1), compress
the clutch piston spring (2) to enable release of
the circlip (3). Carefully release the press pressure on the spring. Remove the circlip, washer
and spring.
84
LB 75110 / FH 90.2110.2
42
85
5. The piston seals should be removed and discarded prior to reassembly.
Inspect all parts for scoring wear marks and or discolouration, replace suspect parts as necessary.
86
NOTE: The grove depth on the friction disc when
new is 0.38mm (0.014in) and is acceptable down to
0.10mm (0.004in). However any depth close to or
below 0.10mm (0.004in) when a teardown has taken
place should be considered as worn and replaced
with new.
87
LB 75110 / FH 90.2110.2
43
89
IMPORTANT: Soak new clutch friction discs in clean
new oil for a minimum of 3 hours
8. Continue to refit the clutch discs (6 thin steel with
1 thick retaining plate) and (6 friction plates) back
into the hub, steel first, followed by friction and
then repeat steel, friction. The final steel plate to
be fitted is the thicker retaining plate that the
snap ring seats onto. Refit the snap ring into the
groove of the clutch hub.
90
9. Once the gear is assembled into the clutch plates
the needle bearings and spacer can be assembled into the bore of the gear without removing it from the clutch drum.
91
10. Place the thrust bearing (1) on the gear face with
the thrust washer and refit the bearing using a
press and tool #297402 (2).
92
LB 75110 / FH 90.2110.2
44
11. With the bearing (1) fully seated ensure a freeplay of at least 0.05080.40mm (0.0020.016in)
exists between the thrust washer and gear (2).
93
12. Fit a new sealing ring onto the shaft above the
bearing (1).
94
95
14. Release the snap ring (1) retaining the clutch
pack drive discs and remove from the clutch
housing.
96
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LB 75110 / FH 90.2110.2
45
97
IMPORTANT: When using compressed air always
wear safety goggles.
16. To remove the piston blank off the oil feed holes
that are not required and carefully apply air pressure to the forward clutch oil feed hole (1) in the
third ring, sufficiently to push the piston out
against seal resistance.
The piston can also be removed by using a
hooked tool applied carefully to the land at the
rear of the piston
98
17. The piston seals should be removed and discarded prior to reassembly, refit new ones.
Inspect all parts for scoring wear marks and or discolouration, replace suspect parts as necessary.
99
100
LB 75110 / FH 90.2110.2
46
101
IMPORTANT: Soak new clutch discs in clean new oil
for a minimum of 3 hours
3. Continue to refit the clutch discs (6 thin steel with
1 thick pressure plate) and (6 friction plates) back
into the hub, steel first, followed by friction and
then repeat steel, friction. The final steel plate to
be fitted is the thicker retaining plate that the
snap ring seats onto. Refit the snap ring into the
groove of the clutch hub.
102
4. Once the gear is assembled into the clutch plates
the needle bearings and spacer can be assembled into the bore of the gear without removing it from the clutch drum.
103
5. Refit the thrust bearing (1), thrust washer (2) and
circlip (3).
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LB 75110 / FH 90.2110.2
47
105
7. Using a suitable press and 50mm tool refit the
bearing onto the shaft.
NOTE: New seals must be fitted, however do not fit
the seals until the rear cover shimming procedure is
completed, as the seals may be damaged when the
cover is fitted and removed during the shimming procedure.
106
107
2. Fit a new bearing into the shaft using a small drift
and tap gently into the bore until it is flush with the
end face of the shaft.
108
LB 75110 / FH 90.2110.2
48
109
2
4
6
5
110
1.
2.
3.
Transmission Reassembly
IMPORTANT: Prior to reassembly of the transmission ensure all parts are clean and oiled.
Where Four Wheel Drive is fitted change the lipped
oil seal (1) in the front cover while it is disassembled.
Push out the old seal and push in a new seal to seat
on the shoulder.
Change the double lipped oil seal in the rear cover on
the output shaft (2) while it is disassembled. Push out
the old seal and push in a new seal to seat on the
shoulder and fill the cavity between the seal double
lips with a silicone grease.
111
LB 75110 / FH 90.2110.2
49
23mm
18mm
112
113
Gear Train End float Shimming Procedure
The purpose of this procedure is to create an end
float of 0.0250.076mm (0.0010.003in) on each of
the gear shafts, this is achieved by adding or deleting
the shims (1) between the shaft bearing cone (2) and
spacer (3) in the rear cover on each shaft assembly.
To determine end float the rear cover is seated on the
transmission and securing with four bolts evenly
spread around the cover, checking the end float of
each shaft in turn.
114
IMPORTANT: The mating faces of the front and rear
transmission cases must be scraped clean and free
of dirt and gasket material. Any residue remaining on
theses faces may affect the endfloat shimming procedure when the cases are bolted together.
Before attempting to check the end float in any shaft
assemblies they must be rotated several times to
allow the taper bearing rollers to settle in tracks.
LB 75110 / FH 90.2110.2
50
115
5. REVERSE IDLER GEAR SHAFT Place Tool
297395 in the end of the shaft through the rear
cover and position a dial indicator onto the bolt
head.
Using a small block and lever gently lift the shaft
up (do not use excessive force) and record the
reading. If the result is not to the specification of
0.0250.076mm (0.0010.003in) it will be
necessary to add or delete the shims accordingly
beneath the bearing cone in the rear cover.
116
6. INPUT SHAFT This shaft can raised by placing
a lever and block below the transmission and
levering the input end of the shaft where it protrudes into the bell housing. Alteratively it can be
raised by placing the lever through the side casing access aperture and levering between the
clutch housings.
Position a dial indicator so the indicator rests on
the rear face of the shaft and gently lift the shaft
up (do not use excessive force) and record the
reading. If the result is not to the specification of
0.0250.076mm (0.0010.003in) it will be
necessary to add or delete the shims accordingly
beneath the bearing cone in the rear cover.
117
118
604.56.061.00 / 604.13.028.00 09/2000
LB 75110 / FH 90.2110.2
51
119
9. FOUR WHEEL DRIVE SHAFT It will be
necessary to place the tool 297395 into the bolt
hole on the rear cover before positioning the dial
indicator
This shaft can be raised by placing a lever and
block below the transmission and levering the
output end of the shaft where it protrudes from
the transmission.
Gently lift the shaft up (do not use excessive
force) and record the reading. If the result is not
to the specification of 0.0250.076mm
(0.0010.003in) it will be necessary to add or delete the shims accordingly beneath the bearing
cone in the rear cover.
120
121
122
LB 75110 / FH 90.2110.2
52
123
Apply a 2mm wide band of sealer 82995770 to the
mating face of the front cover and carefully lower the
rear cover. Torque the cover bolts 45 64 Nm
(3347 lbf ft), working out from the middle of the
cover, alternating each side of the cover, to the top
and bottom of the transmission.
124
Replace the 3 off, shaft end bolts and torque to
4564Nm (3347 lbf ft).
125
Replace oil drain plug torque to 3454Nm
(2540 lbf ft)
126
604.56.061.00 / 604.13.028.00 09/2000
LB 75110 / FH 90.2110.2
53
127
Replace oil drain plug torque to 3454Nm
(2540 lbf ft)
128
LB 75110 / FH 90.2110.2
54
129
1.
2.
3.
4.
5.
6.
7.
Lever
Cover
Fixing Bolt
Outer Caliper
Bolt
Inner Caliper
Inner Friction Pad
130
LB 75110 / FH 90.2110.2
55
131
132
TAB21096
133
LB 75110 / FH 90.2110.2
56
NOTES PAGE
LB 75110 / FH 90.2110.2
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation (Transmission Hydraulic Operation) . . . . . . . . . . . . . . . . . . . . . . 2
Removal from Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPECIFICATIONS
STALL SPEED
108hp Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19502050 revs/min
TORQUE CONVERTER RATIO
Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 : 1
GEAR RATIOS
Power shift 4x2 Transmission
LUBRICANT
Capacity...........................................17 Litres (4.4 US. gals) TransOnly 18 Litres (4.7 US. gals) System
Grade...............................................Ambra Hydrodex 3 Specification ATF
TORQUES
Engine / transmission retaining bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine coolant expansion tank retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine / transmission mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic pump pipe connection (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic pump pipe connection (large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering outlet to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic oil cooler to coolant radiator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose transport lock valve to gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose transport lock valve to gearbox dipstick pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spicer universal couplings rear and front (when FWD fitted) . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
Engine / Transmission Lifting Bracket
LB 85115 / FH 90.2200.2
297389
TRANSMISSION CONTROL
The transmission is operated via a control lever
mounted on the left hand side of the steering column.
This includes the processor which monitors and controls the clutch engagement. Directional changes are
made by moving the lever forward and backwards,
gears are selected by twisting the lever anti clock
wise for a higher gear, and clock wise for a lower
gear. The lever must always be twisted after a direction is selected if the lever has been in neutral for
longer than 3 seconds.
Kick down from 2nd to 1st is achieved by depressing
the button on the end of the control lever. This will
only operate when the transmission is in 2nd gear.
Transmission disconnect is operated by depressing
the red button on the loader lever, once the button is
released the transmission will drive.
NOTE: For full instructions on the operation of the
power shift transmission refer to the operators manual.
TORQUE CONVERTER
NOTE: The torque converter is a sealed unit and can
not be serviced as individual parts.
The torque converter which is a fluid coupling transmits drive from the engine to the transmission.
Attachment of the torque convertor to the flywheel is
through a flexiplate using bolts (1) to convertor and
(2) bolts to flywheel.
The main parts of the torque converter are the impeller, the turbine, the stator and the front and rear
covers. The impeller is integrated with the rear cover
which is driven by the engine flywheel by means of
a drive plate.
The torque converter must be full of oil to operate
correctly. The oil must flow constantly through the
converter to the oil cooler to prevent over heating.
When the engine is running the impeller pumps oil to
the turbine this oil acts on the turbine and flows on to
the stator which is fixed. As the flow increases the
turbine starts to rotate at this point we get maximum
torque increase. As the turbine speed increases the
torque multiplication gradually decreases. When the
turbine rotates at the same speed as the impeller oil
now acts on the rear face of the stator blade. This unlocks the oneway clutch, permitting the stator to rotate in the same direction.
LB 85115 / FH 90.2200.2
LB 85115 / FH 90.2200.2
TRANSMISSION ASSEMBLY
Basically the transmission is composed of five main assemblies:
6
4 Wheel Drive Transmission 2 Wheel Steer
Range clutches
Output section
LB 85115 / FH 90.2200.2
7
4 Wheel Drive Transmission 4 Wheel Steer
Range clutches
Output section
LB 85115 / FH 90.2200.2
8
The converter and pump drive
section
The Input Shaft And Directional Clutches
The turbine shaft driven from the turbine transmits
power to the forward low, high or reverse clutches.
The clutch packs consists of housing, piston steel
disc and then friction disc and so on. Each clutch
pack has a different number of discs.
The clutches are pressure engaged, spring disengaged. The forward high, low and reverse clutch
pack engagement is modulated by an electronic controlled valve.
9
The input or directional clutches
LB 85115 / FH 90.2200.2
10
The range clutches
The Output Section
With the range clutch engaged power is finally transmitted to the output shafts.
The rear output is opposite to engine rotation, the
front output rotation is the same as engine rotation
when forward gear is selected.
The ratio from the front to the rear output is 0.951:1.
The front output is controlled by a clutch which is hydraulically engaged and spring disengaged. There is
no modulation on the 4WD clutch. With no electrical
signal to the control valve the clutch is engaged.
11
The output section
LB 85115 / FH 90.2200.2
Transmission gear
Activated solenoids
Activated clutches
Forward 4
Forward 3
Forward 2
Forward 1
Forward
Forward, 2nd/1st
Forward, Forward Hi/Low
Forward, Forward Hi/Low 1st/2nd
Reverse 1
Reverse 2
Reverse, 2nd/1st
Reverse
Reverse, 1st
Reverse, 2nd
None
Four wheel drive
12
Forward Low
Input
Forward High
2nd
Disconnect
LB 85115 / FH 90.2200.2
POWER FLOWS
4
13
LB 85115 / FH 90.2200.2
10
POWER FLOWS
5
14
6
15
LB 85115 / FH 90.2200.2
24
18
11
22
23
21
19
17
20
16
7
14
15
13
12
10
6
11
4
8
3
2
1
16
Operating Valves and Solenoids.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Transmission sump.
Transmission breather.
Suction strainer.
Gerotor oil pump.
Pressure oil filter.
Filter by pass valve 4.3 bar (62.4 psi).
System pressure regulating valve 20 bar (290 psi)
Oil to converter circuit..
Neutral reverse shift spool.
Pressure booster 0 20 bar(0 292 psi).
Neutral forward solenoid.
High / low shift spool.
High / low solenoid.
Neutral reverse solenoid.
LB 85115 / FH 90.2200.2
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
12
LB 85115 / FH 90.2200.2
13
17
Torque converter and cooler circuit
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Suction Oil
Return to Reservoir
Transmission sump.
Transmission breather.
Suction strainer.
Gerotor oil pump.
Pressure oil filter.
Filter bypass valve. 4.3 bar (62.5 psi).
System pressure test port 20 bar (292 psi).
Oil flow to control valve.
System pressure regulating valve 20 bar (292 psi)
Converter circuit safety valve 10 bar (145 psi).
LB 85115 / FH 90.2200.2
11.
12.
13.
14.
15.
16.
17.
18.
19.
14
Transmission gear
Activated clutches
Forward 4
Forward 3
Forward 2
Forward 1
Forward
Forward, 2nd/1st
Forward, Forward Hi/Low
Forward, Forward Hi/Low 1st/2nd
Reverse 1
Reverse 2
Reverse, 2nd/1st
Reverse
Reverse, 1st
Reverse, 2nd
None
Four wheel drive
LB 85115 / FH 90.2200.2
15
18
Servo pilot pressure circuit
Suction Oil
Return to Reservoir
Pilot Pressure
Transmission sump.
Transmission breather.
Suction strainer.
Pressure filter.
Gerotor oil pump.
Filter by pass valve 4.3 bar (62.5 psi).
System pressure test port 20 bar (292 psi).
System pressure regulating valve 20 bar (292 psi).
Oil flow to converter.
Oil flow to shift spools.
Pressure reducing valve 5.5 bar (80 psi).
LB 85115 / FH 90.2200.2
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
16
LB 85115 / FH 90.2200.2
17
19
Servo control forward second gear, four wheel drive engaged.
Suction Oil
Return to Reservoir
High Pressure Oil
Torque Converter and Lubrication Oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Transmission sump.
Transmission breather.
Suction strainer.
Pressure filter. 20 bar (292 psi).
Gerotor oil pump.
Filter by pass valve 4.3 bar (62.4 psi)
System pressure test port
System pressure regulating valve 20 bar (292 psi).
Oil flow to converter.
Oil flow to shift spools 0 20 bar (0 292 psi).
Pressure reducing valve 5.5 bar (80 psi).
LB 85115 / FH 90.2200.2
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Pilot Pressure
Modulated Pilot Oil
18
LB 85115 / FH 90.2200.2
19
20
Servo control forward third gear, four wheel drive disengaged.
Suction Oil
Return to Reservoir
High Pressure Oil
Torque Converter and Lubrication Oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Transmission sump.
Transmission breather.
Suction strainer.
Pressure filter.
Gerotor oil pump.
Filter by pass valve 4.3 bar (62.4 psi).
System pressure test port 20 bar (292 psi).
System pressure regulating valve20 bar (297 psi).
Oil flow to converter.
Oil flow to shift spools.
Pressure reducing valve 5.5 bar (80 psi).
LB 85115 / FH 90.2200.2
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Pilot Pressure
Modulated Pilot Oil
20
LB 85115 / FH 90.2200.2
21
21
Servo control reverse first gear, four wheel drive engaged.
Suction Oil
Return to Reservoir
High Pressure Oil
Torque Converter and Lubrication Oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Transmission sump.
Transmission breather.
Suction strainer.
Pressure filter.
Gerotor oil pump.
Filter by pass valve 4.3 bar (62.4 psi)
System pressure test port 20 bar (292 psi).
System pressure regulating valve 20 bar (292 psi).
Oil flow to converter.
Oil flow to shift spools.
Pressure reducing valve 5.5 bar (80 psi).
LB 85115 / FH 90.2200.2
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Pilot Pressure
Modulated Pilot Oil
22
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Transmission sump.
Transmission breather.
Suction strainer.
Gerotor oil pump.
Pressure oil filter.
Filter by pass valve 4.3 bar (62.4 psi).
System pressure test port.
System pressure regulating valve20 bar (290 psi).
Oil to converter circuit.
Pressure reducing valve 5.5 bar (80 psi).
2nd / 1st Solenoid.
2nd / 1st shift spool.
2nd gear clutch.
1st gear clutch.
Range modulation solenoid.
Range modulation spool.
Range modulation restriction.
Four wheel drive solenoid.
Four wheel drive shift spool.
Four wheel drive clutch.
High / low solenoid.
High / low shift spool.
Forward high clutch.
Forward low clutch.
Neutral reverse solenoid.
Neutral reverse shift spool.
Reverse clutch.
Neutral forward solenoid.
Neutral forward shift spool.
Electronic modulation valve 0 5.5 bar
(0 80 psi).
31. Accumulator.
32. Pressure booster 0 20 bar(0 292 psi).
LB 85115 / FH 90.2200.2
23
22
Control valve operation forward second gear with four wheel drive engaged.
Suction Oil
Return to Reservoir
High Pressure Oil
Torque Converter and Lubrication Oil
LB 85115 / FH 90.2200.2
Pilot Pressure
Modulated Pilot Oil
24
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Transmission sump.
Transmission breather.
Suction strainer.
Gerotor oil pump.
Pressure oil filter.
Filter by pass valve 4.3 bar (62.4 psi).
System pressure test port.
System pressure regulating valve 20 bar (290 psi).
Oil to converter circuit.
Pressure reducing valve 5.5 bar (80 psi).
2nd / 1st Solenoid.
2nd / 1st shift spool.
2nd gear clutch.
1st gear clutch.
Range modulation solenoid.
Range modulation spool.
Range modulation restriction.
Four wheel drive solenoid.
Four wheel drive shift spool.
Four wheel drive clutch.
High / low solenoid.
High / low shift spool.
Forward high clutch.
Forward low clutch.
Neutral reverse solenoid.
Neutral reverse shift spool.
Reverse clutch.
Neutral forward solenoid.
Neutral forward shift spool.
Electronic modulation valve 0 5.5 bar
(0 80 psi).
31. Accumulator.
32. Pressure booster 0 20 bar(0 292 psi).
LB 85115 / FH 90.2200.2
25
23
Control valve operation forward third gear with four wheel drive disengaged.
Suction Oil
Return to Reservoir
High Pressure Oil
Torque Converter and Lubrication Oil
LB 85115 / FH 90.2200.2
Pilot Pressure
Modulated Pilot Oil
26
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Transmission sump.
Transmission breather.
Suction strainer.
Gerotor oil pump.
Pressure oil filter.
Filter by pass valve 4.3 bar (62.4 psi).
System pressure test port.
System pressure regulating valve 20 bar
(290 psi).
Oil to converter circuit.
Pressure reducing valve 5.5 bar (80 psi).
2nd / 1st Solenoid.
2nd / 1st shift spool.
2nd gear clutch.
1st gear clutch.
Range modulation solenoid.
Range modulation spool.
Four wheel drive solenoid.
Range modulation restriction.
Four wheel drive shift spool.
Four wheel drive clutch.
High / low solenoid.
High / low shift spool.
Forward high clutch.
Forward low clutch.
Neutral reverse solenoid.
Neutral reverse shift spool.
Reverse clutch.
Neutral forward solenoid.
Neutral forward shift spool.
Electronic modulation valve 0 5.5 bar
(0 80 psi).
Accumulator.
Pressure booster 0 20 bar (0 292 psi).
LB 85115 / FH 90.2200.2
27
24
Control valve operation reverse first gear with four wheel drive engaged.
Suction Oil
Return to Reservoir
High Pressure Oil
Torque Converter and Lubrication Oil
LB 85115 / FH 90.2200.2
Pilot Pressure
Modulated Pilot Oil
28
LB 85115 / FH 90.2200.2
29
25
1.
2.
3.
LB 85115 / FH 90.2200.2
30
LB 85115 / FH 90.2200.2
31
26
1.
2.
3.
4.
LB 85115 / FH 90.2200.2
32
1
2
4
27
1.
2.
2
1
28
1.
Top View
2.
LB 85115 / FH 90.2200.2
33
29
Front View
1.
1
9
8
7
6
5
4
3
30
1.
2.
3.
4.
5.
LB 85115 / FH 90.2200.2
Rear View
6.
7.
8.
34
31
1.
Bottom View
2. Pressure check port convertor out to cooler
1,062512 UN 2B SAE O ring port
LB 85115 / FH 90.2200.2
35
32
Transmission / Engine Removal from Backhoe Loader
Removal
WARNING
Before performing any service
or maintenance on the machine ensure the wheels
are choked / blocked to prevent the machine from
moving.
1. Lower the loader to the ground or raise and secure (dependant upon lifting apparatus) and release any pressure in the system as required.
Apply the handbrake and chock the wheels.
2. Drop 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 machine does not require the system to be
discharged
LB 85115 / FH 90.2200.2
36
18. Disconnect the 12 pin connector from the transmission 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)
AP101008
33
21. Remove front drive shaft (where fitted) and remove rear drive shaft
22. Disconnect the hand brake cable
23. Disconnect and pull back hydraulic pump (leaving 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 outside of transmission oil level tube.
AP101009
34
25. With the engine supported and using a hoist capable of supporting a total weight of 800 kgs
1760 lbs loosen and remove the Engine and
Transmission mounting bolts
IMPORTANT: If the hydraulic oil pump is removed
from the transmission/Engine assembly the balance
of the assembly when hoisted will be front end heavy.
26. Using lifting tool 297392 very carefully raise the
hoist and guide the engine/transmission assembly from the vehicle
35
LB 85115 / FH 90.2200.2
37
36
3. Remove the torque convertor attaching bolts accessed through the starter motor aperture (1)
4. Remove the engine timing tab (2)
5. Remove the bell housing bolts
6. Gently slide the transmission with the torque
convertor from the engine
37
Installation
Place a stud in one tang of the flexi plate and as the
transmission is offered upto the engine guide the
stud through a bolt hole of the flywheel remove the
stud and refit a bolt.
Refit the attaching bolts transmission to engine
Turn the engine crankshaft using a torque bar to expose in turn each attaching bolt hole of the flywheel
through the flexi plate and refit all of the bolts
Hoist the engine / trans assembly back into the vehicle and centralise in the machine using a measure
between the chassis and centre line of the crankshaft
pulley. This ensures the engine is centrally positioned before torque up of the engine / trans to chassis bolts.
reconnect all ancillary equipment as previously described
Ensure all attaching hardware is tightened to the correct torque value as detailed in the specifications.
Ensure after installation that all fluid levels are correct prior to start up. Start and run the engine until
correct operating temperature is achieved to purge
air from cooling system. Stop engine, check for
leaks, rectify as required and recheck fluid levels.
LB 85115 / FH 90.2200.2
38
38
NOTES
LB 85115 / FH 90.2200.2
Description
Page
21 300
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Driving with Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powershift Microprocessor Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
ENVIRONMENTAL STANDARDS AND LIMITS
The Microprocessor is designed to operate continuously under the environmental conditions which are
controlled by the various international authorities.
Subject
Standard
SAEJ 1455
SAEJ 1455
Reverse polarity
SAEJ 1455
ISO 76371/1
Class IV
Commutation noise
Class IV
Voltage drop
Load dump
Class IV
Electrostatic discharge
IEC 801 2
Class IV
LB 85115 / FH 90.2200.2
Class IV
1
4X2 Power Shift Transmission Operating Lever and Related Switches
2.
3.
4.
5.
LB 85115 / FH 90.2200.2
TRANSMISSION CONTROL
The transmission fitted to this machine is designed
to Powershift gear changes while supplying drive to
the vehicle wheels, dependant upon the gear and
direction selected.
The transmission is controlled by a microprocessor
in the Power Shift Lever unit (1) which is mounted
below and to the left of the steering column.
LED Number 8: illuminates green when the vehicle is at a standstill (in normal mode).
1
LB 85115 / FH 90.2200.2
4
Limp home:
If a fault is detected at power up (ignition on) the limp
home facility is automatically selected.
IMPORTANT: If limp home is active, only 1st and 2nd
gear will be selectable but without modulation. This
means that the take off will be abrupt.
Limp home active can be identified by the illumination of the following LEDs.
5
T LED
N LED
CONDITION
Flashing
ON
Flashing
Flashes Slower
Flashing
Flashes in Phase
Flashing
Flashes Faster
LB 85115 / FH 90.2200.2
7
Selecting Reverse
To select reverse travel pull the lever towards you
and the reverse LED will illuminate orange.
NOTE: When reverse is selected actually engagement depends on the status of the vehicle, that is if
on the move road speed and direction will be considered by the microprocessor.
LB 85115 / FH 90.2200.2
Up Shifting
Up shifting to a desired gear from neutral is achieved
by twisting the handgrip counter clockwise (+) in
single movements, If held in this position the processor will advance the shift selection from 2 though
to 4 in 1.8 sec intervals.
NOTE: An upshift request after a downshift is
delayed for 2 seconds. Should an Fault 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 ascending up a steep incline select 2nd
gear and proceed. Only if speed and power allow, upshift onto 3rd and 4th subject to the speed shift sensing.
Down Shifting
WARNING
If descending a steep incline select 2nd and proceed,
upshifting only when safe to do so. YOU CAN NOT
DOWNSHIFT TO REDUCE SPEED IF THE VEHICLE SPEED IS ABOVE 15 km/h (9 mph) due to
transmission overspeeding protection.
Downshifting to the desired gear is achieved by twisting the handgrip clockwise () in single movements,
If held in this position the processor will decrease the
shift from 4, if the shift lever was in this gear, though
to 1 in 1.5 sec intervals.
NOTE: If the gear requested and the shift attainable
are not the same because of torque convertor turbine
RPM being too high, the gear position LED(e.g. LED
4) will flash and the shift lever position will illuminate,
not flashing, (e.g. LED 2), until the requested gear is
reached. When a gear position LED is flashing this
indicates that the vehicle has to reduce speed to
reach the requested gear.
Direction Changes
Changing driving direction is achieved simply by
shuttling the power shift lever between forward and
reverse and vice versa which is allowed at any time.
The system response however depends on vehicle
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
10
11
LB 85115 / FH 90.2200.2
LB 85115 / FH 90.2200.2
12
F
1
13
Kick Down
The kick down facility (2nd to 1st gear only) on this
transmission increases torque instantly to the driving
wheels and hence pushing power. For example
when the loader is pushing into a pile and more
torque is required at the wheels.
This is achieved by the instant gear change from 2nd
to 1st by the use of the button (1) without the need
to use the twist grip on the power shift lever.
NOTE: The kick down facility is only available when
the transmission is in 2nd gear and the kickdown button (1) is depressed. If kick down can not be achieved
(Vehicle speed is too high) the LED 1 will be illuminated and LED 2 will be flashing. The instant change
is achieved if the speed is low enough (within 6 seconds) of the kickdown request.
14
Transmission Disconnect
The disconnect feature is useful when loading, for
example; when pushing the loader into a pile and you
require higher digging force press the disconnect
switch which disengages the transmission which allows the full power of the engine to be directed to the
hydraulic oil pump.
NOTE: Transmission disconnect is selectable, when
the vehicle speed is less than 5 km/h and by depressing the button on the loader lever and remains active until the switch is released.
15
Speed Ranges
The microprocessor controlling the power shift transmission is pre programmed to control the speed at
which the gear changes take place.
This effectively protects the transmission from excess forces, should gear changes be selected at
higher speeds than is desirable.
Shown in the chart opposite (within 10%) maximum
speed available and at which speed an automatic
shift takes place in each gear.
As can be seen when down shifting from 4th gear at
maximum speed 39.5 km/h the microprocessor will
not allow the down shift to take place until the speed
has dropped too approximately 19.9 km/h. Refer to
the chart, for complete upshift and downshift speed
change details.
NOTE: In some countries the road speed of 40 km/h
is not allowed. In these circumstances the transmission is governed to a maximum of 25 km/h and
the shift speed range will reduce accordingly.
16.9x24/19.5x24
1st
2nd
6.1 (5.6) []
11.4 (10.5) []
3rd
4th
7.2
13.6
39.5 () [19.9]
1st (6.6) []
2nd () [6.3]
16
km/h
LB 85115 / FH 90.2200.2
WARNING
These machines should not be allowed to exceed 40
km/h (25 mph). Over speeding or coasting downhill
may cause loss of control, personal injury, or failure
of the drive line. Keep the machine in the same gear
going downhill as would be used when going uphill.
17
18
Powershift Lever
The operating lever (2) as previously explained controls all transmission related functions using a microprocessor (1). Transmission control is achieved by
the electronic control of the transmission hydraulic
valves.
19
LB 85115 / FH 90.2200.2
10
Forward Solenoid
Reverse Solenoid
1/2 Solenoid
Lo/Hi solenoid
4WD/2WD Solenoid
Direction Modulator
Range Modulator
Speed / Temperature Sensor
20
LB 85115 / FH 90.2200.2
11
21
1.
2.
3.
4.
LB 85115 / FH 90.2200.2
12
Wire
Pin
Function
CV04
CV05
CV06
CV07
CV08
CV09
CV10
CV11
CV12
CV13
CV14
CV15
A
B
H
M
G
K
C
L
F
22
Powershift Operating Lever Connector
The connector between the operating lever and the transmission harness is a 19 Pole ITT Trident Neptune
Male Connector. The Input wires as listed identify all of the pins and their functions:
23
LB 85115 / FH 90.2200.2
13
Wire
Pin
Function
Type
Comment
Control Valve
E01
Battery +
Use 6A fuse
E02
Ground
CV08H / CV07J
E03
VCS
switch to ground
Direction Modulation
Solenoid
CV09G
E04
Solenoid 1
CV12D
E05
Solenoid 2
CV14B
E06
Forward Solenoid
Forward/Neutral
selection Solenoid
CV13C
E07
Reverse Solenoid
Reverse/Neutral
selection Solenoid
CV10F
E08
PWM1
Range Modulation
Solenoid
CV06K
E09
Solenoid 3
0=FWD
12V = RWD
CV11E
E10
CV04M
E11
Not used
E12
Not used
E13
Analogue input 0
5k Ohm Temperature
sensor
CV05L
E14
Analogue input 1
Braking request
Braking
E15
E16
Speedometer
Output/Diagnosis. out
RS232 TXD
E17
Transmission Disconnect
request
E18
4WD/2WD request
E19
Speed Sns +
RS232 RXD
Microprocessor
+
PTP
STP
Microprocessor
PTG
STG
CV15A
24
LB 85115 / FH 90.2200.2
14
FAULT FINDING
Before attempting any fault finding ensure you have
a suitable Multimeter for checking component continuity.
When fault finding remember that with an electrical
concern it is often a minor fault that may have occurred and could be as simple as:
Poor continuity between connector pins
Condensation in the connectors
Disconnected cables
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 problems could result in fault codes appearing on the LED
display
25
Indication of faults
In case a fault is present during normal operation and
is detected by the microproccesor, both the Tled
and Nled may be blinking in some way as shown in
the table below.
NOTE: That on an open circuit or connection to battery plus on ON/OFF outputs can only be detected
while the corresponding output is in the OFF position. Also a short to ground is only detected while the
output is on.
26
TLED
(Orange)
NLED
(Red)
Condition
Situation
Off
Off
Normal operation
Off
On
Off
Blinks
On
Off
On
On
Fault
On
Blinks
Blinks
On
Fault
Blinks
Blinks slower
Fault
Blinks
Blinks in Phase
Fault
Blinks
Blinks Faster
Fault
Blinks Fast
Fault
LB 85115 / FH 90.2200.2
15
27
Fault Group
The faults are displayed using 2 LEDs on the 8 LED
display. Faults are displayed as 3 subgroups
Group A:
Output related
Other
28
Fault Group
LED (A)
Fault Group
LED (B)
Fault
Fault
Code
None
None
No fault active
1 Red
4 Orange
F1
1 Red
5 Orange
F2
1 Red
5 Red
F3
1 Red
7 Green
F4
2 Red
4 Orange
F5
2 Red
4 Red
F6
2 Red
5 Orange
F7
2 Red
5 Red
F8
2 Red
6 Orange
F9
2 Red
6 Red
F10
3 Red
5 Red
F11
LB 85115 / FH 90.2200.2
16
FAULT CODE F1
SHIFT LEVER INPUT FAULT
Perform Input test:
This test is used to verify operation of the shiftlever
and its inputs.
In this mode driving is possible
NOTE: The gear position indicators on the Microprocessor top cover are used to display the test information.
29
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
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 respective LED (only 2 at the same time).
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 (ignition off).
30
LED
NUMBER
LED COLOUR
DISPLAYED = Okay
Neutral
RED
RED
RED
Forward
GREEN
GREEN
GREEN
Reverse
ORANGE
ORANGE
ORANGE
GREEN
GREEN
RED
RED
LB 85115 / FH 90.2200.2
17
FAULT CODE F1
Shift lever input Fault
Key Start ON
TLED Blinks
NLED Blinks Slower
Select Neutral and push kickdown
button:
= LED 1 red
= LED 4 Orange
No Input Fault
31
LB 85115 / FH 90.2200.2
18
32
Turbine Rev/Min
LED
1 blinks
0 249
1 on
250 499
2 on
500 749
3 on
750 999
4 on
1000 1249
5 on
1250 1499
6 on
1500 1749
7 on
1750 1999
8 on
above 2000
8 blinks
LB 85115 / FH 90.2200.2
19
Key
Start
ON
End
TLED Blinks
NLED Blinks Slower
Repair
No Input Fault
= LED 1 red
= LED 5 Red (F3)
Refer to F1, F4
or F11
CV07 (J)
100 ohms
+ 12 volts
Replace Sensor
If Static is not 0.60.8v
or 1.31.5v
33
LB 85115 / FH 90.2200.2
20
FAULT CODE F4
BATTERY OVERVOLTAGE
17 VOLTS PLUS
Overvoltage
Even power supply levels up to 30V will not damage
circuit components.
Above a power supply of 17 Vdc:
Group Fault 1 Fault code 7
NOTE: The speed sensor circuit will not operate
when an overvoltage is present
34
35
36
LB 85115 / FH 90.2200.2
21
FAULT CODE F4
Battery Overvoltage
Key
Start
ON
TLED Blinks
NLED Blinks Slower
Select Neutral and
push Kickdown Button
1 Red 7 Green
No Input Fault
Other Input
Fault
Check through F1,F2,
F3 or F11
Repair or
Replace
37
LB 85115 / FH 90.2200.2
22
39
Gear Shifts
low/high solenoid :
inactive forward high is selected
active forward low is selected
Forward
Reverse.
4
rev/n
fwd/n
low/high
1st/2nd
LB 85115 / FH 90.2200.2
23
During the output test LEDs 1234567 one by one are used and by
colour identifies the possible component at fault.
Red = short circuit
yellow = open circuit or short to battery plus
Green =
No fault
found
1 Forward solenoid
2 Reverse solenoid
3 1/2 Solenoid
4 Forward Hi / Lo Solenoid
5 4WD / RWD Solenoid
6 Direction modulation solenoid
7 Range modulation solenoid
1 Forward solenoid
2 Reverse solenoid
3 1/2 Solenoid
4 Forward Hi / Lo Solenoid
5 4WD / RWD Solenoid
6 Direction modulation solenoid
7 Range modulation solenoid
Example : LED 1
(red)
Forward
solenoid
output
shorted to ground
or a component.
Check component
and continuity of
the cables and
connectors
Example : LED 2
(orange) Reverse
Solenoid Output
open circuit or
shorted to battery
plus
Check component
and continuity of
the cables and
connectors
Output Test
40
LB 85115 / FH 90.2200.2
24
COLOUR
STATUS
GREEN
Output OK
ORANGE
RED
Output shorted to
ground (or to another
output)
41
LED
NUMBER
OUTPUT
WIRE
OUTPUT
FUNCTION
E06
Forward
solenoid
E07
Reverse
solenoid
42
LB 85115 / FH 90.2200.2
25
TLED Blinks
NLED Blinks Faster
Led 1 Orange
Repair or
Replace
Repair or
Replace
Repair or
Replace
Led 2 Orange
check Forward
Solenoid
Resistance is it faulty
Other Output
Fault forced to
plus
(F6)
2 Red 4 Red
in
check Reverse
Solenoid
Resistance is it faulty
in
reverse
43
LB 85115 / FH 90.2200.2
26
COLOUR
STATUS
GREEN
Output OK
ORANGE
RED
Output shorted to
ground (or to another
output)
44
LED
NUMBER
OUTPUT
WIRE
OUTPUT
FUNCTION
E04
1/2 Solenoid
E05
Forward Lo/Hi
solenoid
E09
AWD/RWD
Solenoid
45
LB 85115 / FH 90.2200.2
27
Key
Start
ON
TLED Blinks
NLED Blinks in Phase
Non Critical
Output Fault
Repair or
Replace
Other Output
Fault
(F8) short
circuit
2 Red 5 Red
Proceed to F9 or F10
check
AWD/RWD
Solenoid is it faulty
check
Lo/Hi
Solenoid is it
faulty
46
LB 85115 / FH 90.2200.2
28
47
48
LB 85115 / FH 90.2200.2
29
Key
Start
ON
TLED Blinks
NLED Blinks in Phase
Repair or
Replace
Repair or
Replace
No Fault
(F10)
2 Red 6 Red
Direction modulator
Open Circuit
check
Resistance
is it faulty
Solenoid
Direction modulator
Short Circuit
check Solenoid
Resistance
is it faulty
49
LB 85115 / FH 90.2200.2
30
50
LB 85115 / FH 90.2200.2
31
Key
Start
ON
TLED Blinks
NLED Blinks Slower
No Input Fault
Other Output
Fault
2 Red 6 Red
Refer F1, F2, F3 or F4
51
LB 85115 / FH 90.2200.2
32
FAULTS OTHER F 12
NOT IDENTIFIED BY THE LEDS
There may be situations when an individual component 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 Microprocessor top cover are used to display the test information.
INPUT TEST REQUIREMENTS: Powershift lever to
be in forward position, twist to upshift and turn the
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 respective 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.
LED
NUMBER
LED COLOUR
DISPLAYED
Confirm Input Test Is Okay (Lever Forward, Neutral, Reverse) and In Order Check As Below:
1. Operate Disconnect Button on loader lever
GREEN = OKAY
GREEN = OKAY
RED = OKAY
RED = OKAY
LB 85115 / FH 90.2200.2
33
Key Start
ON
Brake Request
Declutch Request
Direction Request
Speed/Temp sensor
52
Key Start
ON
Repair or
Replace
53
LB 85115 / FH 90.2200.2
34
54
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
home lead in its place.
55
Connect the plug end into the 12 volt auxiliary socket
or any available 12 volt supply
56
When seated in the cab start the engine and ensuring
that all personnel are clear of the machine select
either forward or reverse on the switch and the machine will move as requested.
NOTE: When using the limp home lead only 2nd gear
(forward or reverse) is selectable no other gear
change or modulation is available.
57
604.56.061.00 / 604.13.028.00 09/2000
LB 85115 / FH 90.2200.2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Forward Low High Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1st Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2nd Clutch Drum Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Four Wheel Drive Disconnect Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SPECIFICATIONS
Weight, dimensions, oil capacity
Weight (dry)
Maximum length
Maximum width
Maximum height
Oil capacity:
Stall Speed Test
290 kg
(639 lb)
705,3 mm
(27,8)
465 mm
(18,3)
648 mm
(25,35)
14 Litres (3.7 US Gals) without cooler and hydraulic lines.
T.B.E
297397
297398
297399
297400
297401
297402
297403
297404
297405
297406
TOOLS
LB 85115 / FH 90.2200.2
1
Torque Chart
LB 85115 / FH 90.2200.2
2
Torque Chart
LB 85115 / FH 90.2200.2
3
Tooling Chart
LB 85115 / FH 90.2200.2
LB 85115 / FH 90.2200.2
Hydraulic check:
Also, before checking the transmission clutches,
torque converter, charging pump, and hydraulic circuit 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 circuit 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 ATTEMPT 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 converter stall procedure).
CAUTION
Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall
R.P.M.
CAUTION
Do not operate the converter at stall condition longer
than 30 seconds at one time, shift to neutral for 15
seconds and repeat the procedure until desired temperature is reached. Excessive temperature (120_
C) 250 F maximum) will cause damage to transmission clutches, fluid, converter, and seals.
REMEDY
1.Fill to proper level
2.Clean valve spool and housing
3.Replace pump
4.Replace sealing rings
REMEDY
1.Fill to proper level
2.Clean section pump
3.Replace pump
OVERHEATING
CAUSE
1. Worn oil sealing rings
2. Worn charging pump
3. Low oil level
4. Dirty oil cooler
5. Restriction in cooler lines
REMEDY
1.Remove, disassemble, and rebuild converter
2.Replace
3.Fill to proper level
4.Clean cooler
5.Change cooler lines
NOISY CONVERTER
CAUSE
1. Worn charging pump
2. Worn or damaged bearings
REMEDY
1.Replace
2.A complete disassembly will be necessary to
determine what bearing is faulty
LACK OF POWER
CAUSE
1. Low engine R.P.M. at converter stall
2. See Overheating and make same checks
REMEDY
1.Tune engine check governor
2.Make corrections as explained in Overheating
LB 85115 / FH 90.2200.2
LB 85115 / FH 90.2200.2
Forward High:
4 separator plates, 3 friction plates and two 1side
friction plates.
min. clearance = 1,24 mm
max. clearance = 2,76 mm
4WD Disconnect clutch:
12 separator plates, 11 friction plates and two 1side
friction plates.
min. clearance = 3,66 mm
max. clearance = 6,78 mm
If clearance is more than 5,66 mm, add one separator plate upon last separator plate.
CAUTION
Installation force of disc spring is 3280 N !
Be sure that shielded and sealed bearings are
mounted as shown.
Seals must be pressed in perpendicular upon shaft
axis from bearing side. Except lower rear output.
Plug to be screwed in and torqued but without Loctite.
First clutch springs concave side of first disc spring
to be placed against clutch piston wear sleeve.
Remaining 10 springs to be stacked alternately reversed as shown.
Heat gears up to 150_ C (302 F) before assembling.
IMPORTANT: For disassembly and reassembly of
this unit you will need, besides normal workshop
tools and the special tools mentioned in the last
chapter of this manual, a press capable of minimum
20 tons and an induction heater of minimum 3,5 kW
to heat gears up to 150_ C (302 F).
4
Remove drive plate screws, drive plates and remove
the torque converter as an assembly.
LB 85115 / FH 90.2200.2
8
Oil galleries in the transmission bell housing.
1.
2.
3.
4.
2
1
3
4
LB 85115 / FH 90.2200.2
10
10
LB 85115 / FH 90.2200.2
11
11
Remove control valve protection cover and gasket.
Remove control valve as an assembly and remove
bypass valve spool and spring (1).
12
LB 85115 / FH 90.2200.2
12
CONTROL VALVE
13
Transmission Control Valve Chest as shown (mating face to transmission body)
With reference to Figure 13, listed below are the positions of solenoids, valves, ports and sensor
1. VCS = Variable Current Solenoid
(Direction Modulator Solenoid)
2. Range Modulation Solenoid
3. Oil flow in from pump
4. Oil to torque convertor
5. Hi / Lo Solenoid
6.
7.
8.
9.
10.
11.
12.
LB 85115 / FH 90.2200.2
13
15
6
14
7
13
10
12
11
TAB21243
14
Transmission Control Valve Chest as shown (mating face to transmission body)
1.
2.
3.
4.
5.
6.
7.
8.
LB 85115 / FH 90.2200.2
9.
10.
11.
12.
13.
14.
15.
14
ACCUMULATOR SPOOL
As the current drops to the variable force solenoid it
allows oil to flow through port (6) past the accumulator as pressure and flow increase from the solenoid
the accumulator is pushed down against spring pressure this allows an even and steady increase in pressure acting on the pressure booster valve.
PRESSURE BOOSTER VALVE
Oil is supplied from the VFS past the accumulator
spool onto the pressure booster spool via port (5) as
pressure increases on the spool it moves down allowing system pressure to flow from port (4) to port
(3) as the pressure increases on the directional
clutch, a sensing line senses the clutch pressure and
acts on the bottom of the spool pushing it upward reducing flow and pressure to the directional clutches.
Pressure then increases on the top side of the spool
pushing it down allowing an increase in flow and
pressure to the directional clutches this repeats
many times during clutch engagement enabling
smooth modulation.
REVERSE SPOOL
With the reverse solenoid energised pilot pressure is
supplied to port (30) pushing the spool upwards
against spring pressure this also ensures the forward
spool is pushed into the neutral position. Modulated
oil from the pressure boosting valve flows into port
(33) and out of port (32) to the reverse clutch. When
the solenoid is deenergised the spring returns the
spool to neutral allowing oil in the reverse clutch to
return to tank via port (31).
FORWARD SPOOL
When the forward solenoid is energised pilot pressure builds up in port (38) pushing the spool downwards against spring pressure allowing modulated oil
pressure from the booster valve to flow from port (35)
to port (36) which supply oil to the forward low high
clutch spool. When the solenoid is deenergised the
spring returns the spool to neutral allowing oil to return to tank via port (37).
FORWARD HIGH LOW SPOOL
When the high low solenoid is deenergised the
spring holds the spool down. Oil from port (43) which
comes from the forward spool can flow out of port
(44) to engage the high clutch. When the the high
solenoid is energised pilot pressure acts on the end
of the spool via port (40) thus pushing the spool upwards compressing the spring this allows oil from the
forward spool to enter through port (3) and flow out
of port (42) to the forward low clutch.
LB 85115 / FH 90.2200.2
15
OIL PORTS
15
Transmission Control Valve Chest as shown (mating face to transmission body)
LB 85115 / FH 90.2200.2
16
SPOOLS
1
10
TAB21245
16
1.
2.
3.
4.
5.
LB 85115 / FH 90.2200.2
17
NOTES
LB 85115 / FH 90.2200.2
18
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
1st/2nd spool
Spool Stop
Four Wheel Drive Spool
Four Wheel Spool Spring
Booster Spool
Accumulator Spring
Accumulator Spool
1st and 2nd Spool Spring
Separator Plate
Range Modulation Spool
Forward Low High Spool Spring
Forward Low High Spool
Spool Stop
Forward Spool
Reverse Spool Spring
Reverse Spool
Spacer Plate
Separator Plate
Wiring Strap
Solenoid Clamp
Solenoid Clamp Screw
Bypass Valve Spool
Bypass Valve Spring
Solenoid Plate
Separator Plate
LB 85115 / FH 90.2200.2
19
49
17
LB 85115 / FH 90.2200.2
20
18
Using Tool no 297397 to hold the flange steady remove the upper output nut, washer, O ring and
flange.
19
Remove converter housing to transmission case
screws and lockwashers.
20
To gain access to the output shaft circlip remove the
case plug and gasket.
21
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LB 85115 / FH 90.2200.2
21
22
Carefully raise transmission case to expose shaft assemblies and remove converter housing gasket.
23
Remove Four Wheel Drive (FWD) shaft sealing
rings.
24
Remove FWD shaft rear bearing circlip.
25
LB 85115 / FH 90.2200.2
22
26
Using bearing puller to remove Output shaft rear
bearing.
27
Using bearing puller remove input shaft rear bearing
28
Remove reverse Idler input and 1st Reverse shaft
sealing rings
29
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LB 85115 / FH 90.2200.2
23
30
Remove Input shaft sealing rings
31
Using bearing puller to remove Input shaft rear bearing.
32
Use bearing puller to remove forward high gear from
the input shaft.
33
LB 85115 / FH 90.2200.2
24
34
Remove lower oil baffle to converter housing screws,
you can not remove oil baffle from output shaft.
35
Using a suitable eye bolt remove output shaft, 2nd
shaft and oil baffle at the same time.
36
Remove suction tube retainer screw and lockwasher,
suction tube retainer ring, O ring and washer.
37
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LB 85115 / FH 90.2200.2
25
38
Using lifting tool 297398 remove reverse and forward
shaft at the same time along with the input shaft.
39
Remove safety valve plug, spring and ball and by
pass plug, spring and ball..
40
LB 85115 / FH 90.2200.2
26
41
Powershift Transmission Operating Shafts
Disassembly of the above shafts can be found the
following pages as listed.
Shaft
Page No
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LB 85115 / FH 90.2200.2
27
42
Input shaft and integral Hydraulic pump Drive shaft
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Input Shaft
Circlip
Forward High Drive gear
Piston Ring
Bearing
Bolt
Spring washer
Oil Pump Gasket
Circlip Large
Circlip Small
11.
12.
13.
14.
15.
16.
17.
18.
19.
Bearing
Piston Ring
Pump drive shaft
Forward Low and Reverse Drive Gear
Piston Ring
Bearing
Circlip
Circlip
Circlip
NOTE: The hydraulic pump drive shaft can be removed from the transmission assembly after removing the hydraulic pump. Without disassembly of the
transmission.
LB 85115 / FH 90.2200.2
28
43
Use bearing puller to remove rear bearing.
44
Remove sealing ring from shaft.
45
LB 85115 / FH 90.2200.2
29
46
Install rear bearing on shaft and tap bearing into
place.
47
Install rear bearing retainer ring.
48
LB 85115 / FH 90.2200.2
30
49
Remove input shaft front sealing ring.
50
Use bearing puller to remove input shaft front bearing.
51
Remove input shaft front bearing circlip (1) and forward low gear circlip (2).
52
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LB 85115 / FH 90.2200.2
31
53
Reassembly input shaft
Install forward low gear circlip.
54
Warm gear to 150_ C (302 F), install gear.
Install forward low gear circlip.
input shaft front bearing circlip.
Install input shaft front sealing ring.
55
Warm input shaft front bearing to 120_ C (248 F), install bearing.
Turn shaft and install input shaft
forward high gear circlip
input shaft rear sealing ring.
56
LB 85115 / FH 90.2200.2
32
57
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Roller Bearing
Needle Bearing
Thrust Washer
Snap Ring
Spacer
Friction disc
Steel Disc
Clutch Disc Backing plate
Spring Wear Ring
Piston
Piston Seal outer
Piston Seal Inner
Shaft / Drum Assembly
Bearing
Gear Forward Driven
Circlip
Bearing
Circlip
LB 85115 / FH 90.2200.2
33
58
Remove clutch gear.
59
Remove thrust washer (1), thrust needle bearing (2)
and clutch gear steel bearing.
60
Remove clutch plate snap ring.
61
LB 85115 / FH 90.2200.2
34
62
Compress spring using tool no 297401 and remove
spring retainer circlip
63
LB 85115 / FH 90.2200.2
35
64
LB 85115 / FH 90.2200.2
36
65
Remove gear retainer ring.
66
Use a bearing puller and slice to remove clutch gear
and bearing.
67
Remove circlip and spacer.
68
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LB 85115 / FH 90.2200.2
37
69
Remove 1x friction half disc (1).
9x Steel Discs (2).
8x Friction Discs (3)
1x Half Friction Disc (4).
70
Use a bearing puller to remove clutch gear steel
bearing
71
LB 85115 / FH 90.2200.2
38
72
Compress spring to remove spring retainer circlip
297401.
73
Remove clutch piston spring retainer (1).
clutch piston spring (2).
clutch piston wear plate (3)
clutch piston assembly (4).
74
LB 85115 / FH 90.2200.2
39
75
76
Install one friction 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 half disc with friction material down.
backing plate snap ring.
Spacer.
Spacer snap ring.
steel bearing snap ring.
Clutch gear steel bearing.
77
LB 85115 / FH 90.2200.2
40
78
Install clutch gear bearing locating rings.
79
Install clutch gear bearing. Be sure that bearing
shield is on the outside.
80
Tap bearing into place.
81
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LB 85115 / FH 90.2200.2
41
82
Warm gear to 150_ C (302_ F), install gear.
83
Warm front bearing to 120_ C (248 F), install bearing.
84
Reassembly forward high clutch
Install clutch friction seal. Note: Ring must
be sized before installing in clutch drum. Sealing ring
must be flush with friction diameter of piston.
Install piston steel seal
85
LB 85115 / FH 90.2200.2
42
86
87
LB 85115 / FH 90.2200.2
43
88
1st Reverse shaft
LB 85115 / FH 90.2200.2
44
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Bearing
Snap Ring
Clutch Disc Backing Plate
Modulation Spring
Friction Disc
Steel disc
Outer Half Disc
Spring retainer
Circlip
Spring
Spring wear Ring
Piston
Piston Outer Sealing Ring
Piston Inner Sealing Ring
Bearing
Gear Reverse Driven
Circlip
Bearing
Circlip
LB 85115 / FH 90.2200.2
45
89
Use a bearing puller and slice remove clutch gear
and bearing.
90
Remove backing plate retainer ring (1).
backing plate (2).
modulation spring (3).
91
LB 85115 / FH 90.2200.2
46
92
Use bearing puller to remove clutch gear steel bearing.
93
Compress clutch piston Belleville washer spring
using tool no 297401. Remove spring snap ring.
NOTE: Force of disc spring is 3.280N !
94
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LB 85115 / FH 90.2200.2
47
95
Disassembly reverse clutch
Use a bearing puller to remove gear and front bearing.
96
Remove clutch gear bearing circlip.
97
LB 85115 / FH 90.2200.2
48
98
Remove spacer snap ring
99
Remove spacer (1).
backing plate snap ring (2)
clutch disc backing plate.
100
Use a bearing puller to remove clutch gear steel
bearing.
101
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LB 85115 / FH 90.2200.2
49
102
Remove steel bearing locating ring.
103
Compress spring using tool no 297401 to remove
spring retainer circlip.
104
LB 85115 / FH 90.2200.2
50
105
Reassembly reverse clutch
Install a new clutch piston friction seal.
NOTE: Ring must be sized before installing in clutch
drum. Sealing ring must be flush with friction diameter
of piston. Install clutch piston steel seal.
106
Reassemble in reverse order as for disassembly:
Install clutch piston in clutch drum, use caution as not
to damage sealing rings and install:
piston wear plate on piston (1).
piston spring (2).
piston spring retainer (3).
Install clutch spring circlip.
107
Using tool no 297401 press spring and seat to fit circlip ring. Be sure ring is in full position in groove.
108
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LB 85115 / FH 90.2200.2
51
109
Install steel bearing snap ring.
110
Install clutch gear sealing ring. 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 steel discs.
111
Install clutch gear steel bearing and tap bearing into
place.
112
LB 85115 / FH 90.2200.2
52
113
Install clutch gear bearing.
IMPORTANT: Be sure that bearing shield is on the
outside.
114
Tap bearing into place.
115
Install bearing snap ring.
116
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LB 85115 / FH 90.2200.2
53
117
Warm front bearing to 120_ C (248 F), install bearing.
118
LB 85115 / FH 90.2200.2
54
119
Install clutch piston wear sleeve (1) and Install piston
return disc springs (2).
IMPORTANT: Install first spring with large diameter
of bevel towards the wear sleeve. Alternate eleven
(11) Belleville washers.
Install disc Belleville washer spring circlip and compress the spring using 297401 to install spring . Be
sure ring is in full position in groove.
120
Install one Belleville washer facing downwards and
install one friction half disc with friction material away
from the Belleville washer. Install one steel disc.
Alternate friction and steel discs until the proper
amount of discs are installed. First and last discs are
steel.
one friction half disc with friction material down.
modulation spring with large diameter up to the
backing plate.
backing plate.
backing plate snap ring.
121
Install clutch hub bearing locating rings. Install clutch
gear in clutch drum. Align spines on clutch gear witch
internal teeth of steel discs. Do not force this operation. Gear spines must be in full position with internal teeth of all steel discs.
122
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LB 85115 / FH 90.2200.2
55
123
Install clutch hub bearing.
IMPORTANT: Be sure that bearing shield is on the
outside.
124
Tap friction bearing into clutch hub.
Install friction bearing circlip.
Install clutch shaft sealing rings.
125
LB 85115 / FH 90.2200.2
56
126
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
LB 85115 / FH 90.2200.2
57
127
Press lower output gear from 2nd shaft.
128
Remove gear circlip.
129
Remove clutch shaft sealing rings.
130
LB 85115 / FH 90.2200.2
58
131
Remove bearing washer (1), clutch hub (2) and
bearing (3).
132
Remove backing plate snap ring.
133
LB 85115 / FH 90.2200.2
59
134
Use a bearing puller to remove clutch hub steel bearing.
135
Compress spring using tool no 297401 to remove
spring circlip.
136
LB 85115 / FH 90.2200.2
60
137
Reassembly 2nd clutch drum
Install piston friction seal.
NOTE: Ring must be sized before installing in clutch
drum. Sealing ring must be flush with friction diameter of piston. Install clutch piston steel seal.
138
Reassemble in reverse order as for disassembly:
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings and install:
piston wear plate.
piston return spring.
spring retainer.
spring retainer .
snap ring
Using tool no 297401 compress spring and seat retainer ring. Be sure ring is in full position in groove.
139
Install one friction 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.
Install one friction half disc with friction material
down.
Install Belleville with large diameter up to the backing
plate.
Install backing plate.
Install backing plate retainer ring.
LB 85115 / FH 90.2200.2
61
140
Install clutch hub steel bearing.
Tap clutch gear steel bearing into place.
141
Install clutch hub bearing.
IMPORTANT: Be sure that bearing shield is on the
outside.
142
Tap bearing into place.
143
LB 85115 / FH 90.2200.2
62
144
Warm front bearing to 120_ C (248 F), install bearing.
145
Install clutch shaft sealing rings.
146
Install gear circlip
147
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LB 85115 / FH 90.2200.2
63
148
Warm upper output gear to 150_ C (302 F) install
gear.
149
LB 85115 / FH 90.2200.2
64
NOTES PAGE
LB 85115 / FH 90.2200.2
65
150
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Output Yoke
Bearing
Circlip
Disconnect Hub
Circlip
Front Output Shaft
Bushing
Snap Ring
Spacer
Clutch Disc Backing Plate
Piston Seal Inner
Piston Seal Outer
Piston
Spring Wear Plate
Spring
Spring Retainer
LB 85115 / FH 90.2200.2
66
151
Remove oil baffle.
152
Remove output shaft sealing rings (1) and output
shaft gear circlip (2).
153
Press output gear from shaft
154
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LB 85115 / FH 90.2200.2
67
155
Remove gear circlip.
156
Remove backing plate snap ring.
157
LB 85115 / FH 90.2200.2
68
1
2
3
5
158
Compress spring to remove circlip.
159
Remove spring retainer (2).
clutch piston spring (1)
piston wear plate (3).
piston assembly (4).
160
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LB 85115 / FH 90.2200.2
69
161
Reassemble in reverse order as for disassembly:
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings and install:
piston wear plate.
piston return spring.
spring retainer.
spring retainer .
snap ring
Install spring retainer snap ring. Compress spring
and seat retainer ring. Be sure ring is in full position
in groove.
Install one friction 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.
Install one half disc with friction material down
Install backing plate.
Install backing plate spacer.
Install backing plate snap ring.
162
163
LB 85115 / FH 90.2200.2
70
164
Warm gear to 150_ C (302 F),
165
Install gear.Install output gear circlip.
166
Install output shaft sealing rings and rear oil baffle on
output shaft.
167
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LB 85115 / FH 90.2200.2
71
168
Disassembly disconnect shaft
Use bearing puller to remove disconnect shaft front
bearing.
169
Remove front bearing circlip.
170
Remove clutch hub from shaft.
171
LB 85115 / FH 90.2200.2
72
172
Reassembly disconnect shaft
Install bushing if necessary.
173
Reassemble in reverse order as for disassembly:
Install clutch hub locating ring and install:
clutch hub on shaft.
front bearing circlip.
Install front bearing on shaft.
tap bearing on shaft.
174
Reassembly converter housing
Install safety valve ball spring and plug. Install by
pass valve ball spring and plug.
175
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LB 85115 / FH 90.2200.2
73
176
Install forward low shaft and high shaft into housing.
Using caution as not to damage any sealing rings.
177
Install FWD shaft assembly into housing and open
bearing circlip. Tap shaft into place be sure ring is in
groove.
178
Install 2nd gear output shaft and FWD 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.
179
LB 85115 / FH 90.2200.2
74
180
Install O ring, spacer and snap ring on suction tube.
Install suction tube into housing. Be sure ring is in
groove. Install suction tube retainer, mounting screw
and lockwasher (Use Loctite 243).Tighten mounting
screw to specified torque.
181
Install FWD shaft rear bearing circlip.
182
Warm forward high gear to 150_ C (302 F), install
gear.
183
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LB 85115 / FH 90.2200.2
75
184
Warm reverse and 1st shaft rear bearing to 120_ C
(248 F), install bearing.
185
Warm input shaft rear bearing to 120_ C (248 F), install bearing.
186
Warm forward low and high shaft rear bearing to
120_ C (248 F), install bearing.
187
LB 85115 / FH 90.2200.2
76
Warm FWD shaft rear bearing to 120_ C (248 F), install bearing.
188
Install output shaft rear sealing rings.
189
Install gasket and O rings into O ring grooves.
190
Reassembly Powershift transmission
Remove lower output bore plug. Position transmission
case on converter housing (using lifting bracket).
Using spreading type snap ring pliers, spread ears
on FWD shaft rear bearing circlip. Holding snap ring
open. Tap transmission case into place.
191
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LB 85115 / FH 90.2200.2
77
192
Using spreading type snap ring plier, spread ears on
output shaft rear bearing circlip. Hold snap ring open,
pry or lift output shaft. Be sure circlip is complete in
bearing groove (Using a lifting eye or screw M12)
gently lift shaft.
193
Tighten plug to 13,6 20,3 Nm (10 15 lb ft).
194
Position FWD bore plug and tap bore plug into place.
195
LB 85115 / FH 90.2200.2
78
196
Install upper output flange, O ring, washer and nut
and tighten nut to 339407 Nm. (205300 lb ft).
197
Install pump drive shaft assembly into housing and
Install pump drive shaft rear bearing circlip.
198
Install oil pump, O ring, gasket, screws and lockwashers into converter housing and tighten bolts to
2027 Nm (1520 lbf ft).
199
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LB 85115 / FH 90.2200.2
79
200
Install filter adapter, O ring, lockwashers and
mounting screws.
201
Install front seal and tap into the cover using tool no
297402.
202
Instal output shaft front flange, O ring, washer and
nut. Tighten nut to 339 407 Nm (250 300 lb ft).
203
LB 85115 / FH 90.2200.2
80
204
Reassembly of valve chest to transmission
Install pressure regulating valve spool into solenoid
housing and spring into transmission case, position
control valve on transmission case.
Install control valve mounting screws and lockwashers, tighten screws to specified torque.
IMPORTANT: The torque procedure of the valve
chest to transmission should be carried out in the following manner.
Torque form the centre of the valve body and alternate left to right of the centre line to the outside of the
edge of the valve chest. this ensures that there is
minimum distortion of the valve chest body.
205
206
LB 85115 / FH 90.2200.2
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential Disassembly Powershuttle / Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
Type
Overall width
Oil Capacities
Hubs (each)
Axle differential
Oil change period
Lubricants
0 2.0 mm
Nonadjustable preset
Nonadjustable preset
2.0 Nm (18.0 lbs in)
0.17 0.23 mm (0.067 0.090 in)
110.3 mm (4.301 in)
0.9 Nm (8.2 lbs in)
SEALANTS
Thread sealant
Dowel fixative adhesive
Flange sealant
LB 75110 / FH 90.2110.2
NH 82995773
NH 82995772
NH 82995770
Torque Specification
SPECIAL TOOLS
Pinion setting tool
Pinion nut tool
297132 or 4775
297511
LB 75110 / FH 90.2110.2
DESCRIPTION
2
The 26.18 axle fitted to this unit incorporates
integral steering cylinder
centre drive
double reduction (crown wheel & pinion plus
planetary hubs).
The four wheel drive is electrically operated by a
switch (1) mounted on the front instrument panel.
The four wheel drive should be disengaged for road
work.
NOTE: Four wheel drive will re-engage when both
brakes are applied giving four wheel braking.
LB 75110 / FH 90.2110.2
4
The four wheel drive is engaged and disengaged by a clutch pack mounted in the transmission. Hydraulically
disengaged and mechanically engaged.
5
Drive Gear
Ratio
A
B
C
D
E
F
I
J
Number of
Teeth (ISO)
56
16
37
9
37
35
15
32
Number of
Teeth (NASO)
56
16
37
9
37
35
18
37
K
L
15
75
15
75
Formulae
A+B x C =Rear axle ratio
B D
F =Transfer ratio
E
L+K x J=Front axle ratio
K I
FWD. factor
Ratio
18.5 : 1
0.9459 : 1
12.8 : 1 (ISO)
12.33 :1 (NASO)
1.528 (ISO)
1.586 (NASO)
LB 75110 / FH 90.2110.2
LB 75110 / FH 90.2110.2
SMB25051
1
TAP424011
7
Steering stops (1) are incorporated on the axle at
each end.
The stops are adjustable to prevent the tyres contacting any part of the loader when on full left or right
lock and held by the lock nut (2).
8
When checking the toe in of the front wheels the
measurements should be through the centre of the
hub.
Measuring the front inner wheel rim to rim (1) and
then measuring the rear inner wheel rim to rim (2).
The variance between (1) and (2) should be:
Toe-in should measure: 0 2 mm (0 0.08 ins)
P4241
1
9
Clamp Bolt
Track Rod End
Adjuster
10
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LB 75110 / FH 90.2110.2
11
HUBS
Oil capacity 1 litre (2 US. pints)
Check oil level every 50 hours, with hub level (1) at
plug (2)
Change oil every 1200 hours, with plug (2) at lowest
point.
12
COMPONENT OVERHAUL with Axle in situ
Steering cylinder
Planetary Reduction Hub Assembly
Swivel Casing
Swivel Pin Assembly
Axle Drive Shaft Assemblies, Seals and Bushes
Drive Pinion Oil Seal
13
COMPONENT OVERHAUL with Axle removed
Differential Assembly
Pinion Assembly
Front Axle adjustments
Pinion to Crown Wheel Tooth engagement
Pinion Bearing Preload
Crown Wheel to Pinion Backlash
Differential Bearing Preload
14
LB 75110 / FH 90.2110.2
10
8
5
15
1.
2.
3.
4.
5.
LB 75110 / FH 90.2110.2
FAULT FINDING
IMPORTANT: When making a repair, the cause of the failure must be corrected to avoid a repeat failure.
PROBLEM
No steering or excessive effort
required to steer
Steering wanders
POSSIBLE CAUSES
CORRECTION
2. Air in system
4. Worn pump
7. Broken or damaged
steering column
Noisy pump
LB 75110 / FH 90.2110.2
2. Air in system
3. Water in oil
10
OVERHAUL
Planetary Reduction Assembly and Wheel
Hubs
Turn the hub so that the filler/drain plug is at its lowest
point and drain the hub oil.
16
Remove the two 8mm socket screws and the two
shouldered wheel studs, securing the planetary
carrier assembly to the hub assembly.
17
Gently tap the planetary carrier with a soft face mallet
and, using the slots provided, lever the carrier from
the hub. Carefully withdraw the planetary carrier assembly.
1.
Planetary Assembly
18
Remove the three snap rings and remove the retaining plate.
Remove planetary gears. Note: the needle roller
bearings will fall out.
Finally, remove the thrust washer.
1.
2.
3.
Retaining Plate
Snap Ring
Planetary Gear
19
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LB 75110 / FH 90.2110.2
11
Planetary Carrier
Thrust Pad
Retaining Plate
Snap Ring
Needle Roller Bearings
Planetary Gear
Thrust Washer
20
Remove the sun gear retaining snap ring (1) and remove the sun gear (2) from the axle shaft, followed
by the spacer and thrust washer.
21
Carrier assembly bolts removal.
1.
Carrier Assembly
22
Remove the assembly by installing 4 of the bolts into
the threaded jacking holes in the rear gear. Tighten
the bolts evenly to draw off the planetary ring gear.
1.
2.
Carrier Assembly
Jacking Bolts
23
LB 75110 / FH 90.2110.2
12
Jacking Bolt
Planetary Ring Gear
Master Dowel
24
Planetary disassembly
Remove snap ring and disassemble planetary ring
gear.
1.
2.
3.
Ring Gear
Carrier
Retaining Ring
25
Remove the hub assembly
Using a soft faced mallet carefully withdraw the hub
from the axle.
26
Final reduction hub assembly
Check oil seal and inner and outer bearing cups for
wear and damage.
1.
2.
3.
Oil Seal
Inner Bearing Cup
Outer Bearing Cup
27
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LB 75110 / FH 90.2110.2
13
28
Swivel Pin Removal
Remove the upper and lower swivel pins from the
axle hubs.
1.
2.
29
Hub Removal
Carefully remove the hub from the axle.
NOTE: When removing the hub there are two Belleville washers between the hub and axle, the larger
washer (2) on the bottom and the smaller (1) on the
top.
30
AXLE SHAFT REMOVAL
Withdraw the shaft from the axle
31
LB 75110 / FH 90.2110.2
14
Puller Tool
Oil Seal
32
Axle shaft seal and bush installation
Prior to fitting a new seal and bush thoroughly clean
the inner axle. Using tool 297103 gently tap with a
soft faced hammer the seal and bush into the axle.
1.
2.
33
Swivel hub seal removal
Remove the seal from swivel casing using special
tool 297101 in conjunction with slide hammer 297504
1.
2.
3.
Swivel Casing
Seal
Slide Hammer
34
Install seal into swivel housing
Using tool 297111 refit the seal and bushing into the
housing.
1.
2.
35
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LB 75110 / FH 90.2110.2
15
Slide Hammer
Bearing Cup
36
Installation of swivel pin bearing outer cone.
Before assembly of a new cone, ensure the swivel
area is thoroughly clean. Using a driving tool gently
tap with a soft faced hammer.
1.
37
Removal of lower swivel pin bearing cone.
Hold the swivel in a soft jawed vice and using a suitable drift carefully remove the bearing cone from the
swivel.
38
Press on lower swivel pin bearing cone.
Thoroughly clean the swivel shaft and check for
damage or scoring. Carefully Stone any imperfections away before fitting a new cone. Using a suitable
spacer fit a new cone.
1.
2.
3.
Spacer Block
Bearing Cone
Swivel Pin
39
LB 75110 / FH 90.2110.2
16
40
Reduction Hub, Swivel Housing and Axle Shaft
Assembly
Re-assembly is in the reverse sequence to the disassembly illustrated.
It is important to locate the axle shaft inner end
splines into the differential side gear before fitting
the swivel casings.
Wrap protective tape over the axle shaft outer
end spline to protect the hub drive shaft oil seal,
before location of swivel casing assembly.
There are no swivel pin freeplay adjustments. Two
Belleville washers are now installed to automatically preset swivel free play. The small washer is
installed at the top of the swivel hub and the larger
washer installed on the bottom of the swivel hub
assembly.
1.
2.
Swivel Housing
Belleville Washer
41
LB 75110 / FH 90.2110.2
17
42
Steering Cylinder Removal with Axle in situ
Loosen retaining bolts two turns, turn the steering wheel to the left to unseat cylinder assembly.
Jack up and support front axle and remove left
hand front wheel.
Slacken track rod clamps.
Slacken ball joints from cylinder rod. (Note: High
production tightening torques!)
Remove track rods from steering arms.
Remove track rod end and ball joint assemblies
from the steering cylinder rod.
Disconnect hydraulic hoses and right hand cylinder hose fitting.
Remove cylinder retaining bolts and pull out the
complete assembly.
LB 75110 / FH 90.2110.2
43
18
44
1.
2.
3.
4.
Serviced Parts
The cylinder rod and cylinder barrel are only serviced
as a complete steering cylinder assembly.
The seals and wear rings will only be available as a
complete seal kit.
Steering Cylinder Re-assembly
Replace all seals.
Allow new piston seal, located on O ring, to contract before entering the piston and rod into the
cylinder barrel.
LB 75110 / FH 90.2110.2
19
45
Remove pinion shaft oil seal housing.
1.
2.
46
Remove the differential support casing retaining
bolts and place in a suitable container.
47
Remove differential.
Mark the differential housing with felt pen, which side
the crown wheel is in relation to the assembly (1).
IMPORTANT: Use a Small hoist to support the differential when removing it from the axle, as its combined weight is greater than for safe manual handling.
48
LB 75110 / FH 90.2110.2
20
Differential Disassembly
Before disassembly, mark each bearing cap (1) to
ensure they are not interchanged during re-assembly. Also mark which side the crown wheel is in relation to the assembly (2).
2
1
49
NOTE: Before differential disassembly loosen the
pinion nut.
Place a bar (1) through the steering cylinder lugs to
support the assembly.
Put a screwdriver (2) between the crown wheel and
pinion teeth to hold the pinion still.
Loosen the pinion nut using special tool 297511 (3).
3
50
Remove the locking tabs (1) and cap retaining bolts
(2).
NOTE: Fit new locking tabs upon reassembly
51
Remove the differential assembly from the housing
and place on a clean bench prior to disassembly.
52
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LB 75110 / FH 90.2110.2
21
53
Differential Components
1.
2.
3.
4.
Thrust Washer
Side Gear
Spider Shaft
Differential Casing
54
Differential disassembly
NOTE: This is not a limited slip differential. The side
gear flange is extended and a single thrust washer is
fitted.
1.
2.
3.
4.
5.
6.
7.
8.
Differential Housing
Thrust Washer
Side Gear
Spider Shaft
Side Gear
Thrust Washer
Crown Wheel
Retaining Bolts
55
Pinion Identification marks
1.
2.
56
LB 75110 / FH 90.2110.2
22
Pinion Shaft
Pinion Casing
Collapsible Spacer
Spacer
Retaining Nut
Inner Bearing
Washers
57
LB 75110 / FH 90.2110.2
23
Differential Adjustments
Pinion to Crown Wheel Tooth Engagement
To determine the shim thickness required to provide
the correct pinion to crown wheel tooth engagement,
the differential casing pinion height dimension C,
must be calculated and compared to the dimension
etched on the pinion. This adjustment is only required if new components are being fitted.
Install new pinion bearings in the differential casing and clamp in position with special tool
297132. Make sure bearing cones can just be
turned by hand.
Measure dimension A
Calculate C=BBar + 1/2 A
NOTE: 297132 Bar gauge 25mm dia.
Example:
Dimension A = 90 mm
Dimension B = 90.3 mm
Calculate dimension C
= 90.3 25 + 45 mm
= 110.3 mm
Pinion dimension
= 107 + 0.2 mm
= 107.2 mm
Required shim thickness
= 110.3 107.2 mm
= 3.1 mm
58
Measuring dimension A
Differential housing bearing bore diameter
59
Measuring dimension B
1.
2.
3.
4.
5.
Depth gauge
Bar gauge part of tool 297132
Pinion shaft bearing
Pinion setting gauge 297132
Differential Support Casing
60
LB 75110 / FH 90.2110.2
24
Press
Protector
Pinion
Shim
Inner Bearing
61
Drive Pinion Re-assembly
1.
2.
3.
4.
5.
6.
7.
62
Differential Adjustments Pinion Bearing Preload
To check the preload of the bearing, it will be necessary to fabricate a bracket to the dimensions shown.
Weld a nut of a size suitable to match a socket available to you in the centre of the bracket.
NOTE: The adjustment can only be carried out with
a new collapsible spacer fitted to the pinion.
110 mm
95 mm
65 mm
45 mm
5 mm
10 mm (x4)
63
2
64
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LB 75110 / FH 90.2110.2
25
Dial Indicator
Crown Wheel
Adjuster Ring
Pry Bars
65
Installed Differential
Spring Balance
Pinion
66
Example:
Turn the torque meter slowly:
A. Pinion and differential:
2.98 Nm (26.5 lbs in)
B. Pinion only:
2.0 Nm (18.02 lbs in)
Differential bearing preload:
0.9 Nm (8.22 lbs in)
Resultant preload is within specification.
Install adjusting ring locking tabs.
Recheck differential bearing preload and crown
wheel to pinion backlash.
Finally, tighten bearing cap nuts to 266 Nm
(196 lbf ft).
LB 75110 / FH 90.2110.2
26
Differential Disassembly
Whilst all dimensions and teardown operations remain the same for both front axles, it must be remembered that on the the Powershuttle Front Axle the differential is mounted to left of the front axle:
POWERSHUTTLE SHOWN, Figure 67.
67
On Powershift Front Axles the differential is mounted
to the right of the front axle:
POWERSHIFT SHOWN, Figure 68.
68
LB 75110 / FH 90.2110.2
Description
Page
25 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
Component
Axle Type
Planetary Reduction
Overall Ratio
Number of Planetary Gears
Load Carrying Capacity Dynamic
Overall Width
Oil Capacity
Oil Change Period
Lubricants
Modular
6.923 : 1
18.5 : 1
3
8000 kg (17636 lb) at 1890 mm track width
2304 mm
11 Litres (2.9 US. gals)
1 year or 1200 hours
MultiG API GL4 ISO32/46
LB 115 / FH 200.2
9.213.7 Nm
1.5mm 1.6mm
Torque Specification
SPECIAL TOOLS
Pinion setting tool
Pinion nut tool
Slide hammer
297132 or 4775
297511
297111
LB 115 / FH 200.2
Axle Disassembly
Hub Disassembly
1. Remove the hub oil drain plug and drain the hub
oil. Remove the differential plug and drain the oil
from the centre housing.
2
2. Remove the hub outer casing allen screws
3
3. Remove the hub outer casing.
4
4. Remove the sun gear airclip and 3 spacers.
5
LB 115 / FH 200.2
6
6. Using two of the fixing bolts, fit these to the outer
threaded holes and tighten to push the ring gear
away from the hub.
7
7. With a soft faced mallet hammer off the hub
centre housing and also the outer conical bearing.
8
8. Then remove the inner conical bearing by hand.
9
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LB 115 / FH 200.2
10
10. Use a set of bearing pullers to press the tapered
shaft from the hub assembly
11
11. Undo the bolts holding the top and bottom pivot
pins. Then remove the pivot pins and also the
belleville washers and spacers.
12
12. Remove the remainder of the hub assembly.
13
LB 115 / FH 200.2
14
Centre Housing Disassembly.
14. Remove the input shaft coupler fixing bolts and
remove the coupler.
15
15. By hand slide off the pivot bearing and housing
assembly.
16
16. Remove the pivot spacer ring.
17
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LB 115 / FH 200.2
18
18. Steering Cylinder Removal.
Remove the track rod ends from the steering cylinder rods.
19
19. Undo and remove the 6 steering cylinder fixing
bolts and remove the steering angle sensor.
20
20. Lift off the steering cylinder assembly.
21
LB 115 / FH 200.2
22
22. Swivel hub seal and bush removal.
Remove the shaft seal and bush using a suitable
puller or drift.
23
23. Axle shaft seal and bush removal.
Use an internal puller and slide hammer to remove the seal and bush.
24
24. Pivot bush removal.
Remove the upper and lower pivot bushes using
an internal puller and slide hammer.
25
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LB 115 / FH 200.2
26
26. Steering Cylinder Disassembly
The gland ends of the steering cylinder are not
retained by any circlips, bolts, etc. Therefore to
remove the gland ends simply stroke the rod and
piston to the end of its travel in both directions
and this action will knock out the glands.
27
27. The gland consists of a number of seals.
1.
2.
3.
4.
5.
6.
7.
Dust Seal
Friction Ring
Oil Seal
Backup Oil Seal
Friction Seal
Gland Block
Gland Block to Cylinder Seal
28
28. The Piston contains 3 seals, 2 outer slip seals
and the central main seal.
29
LB 115 / FH 200.2
10
30
30. Lock the differential and bend back the locking
tabs on the pinion nut. Then using tool number
297511 and a 3/4 drive socket, undo the pinion
nut.
31
Pinion Assembly
32
1.
2.
3.
4.
Pinion Nut
Washer
Bearing
Washer
5.
6.
7.
Collapsable Bush
Pinion
Bearing
LB 115 / FH 200.2
11
33
1.
2.
3.
4.
Differential Housing
Thrust Washer
Planet Gears
Shaft
5.
6.
7.
8.
Crown Wheel
Fixing Bolts
Thrust Washer
Side Gears
LB 115 / FH 200.2
12
Pinion Reassembly
If any new components have been fitted then the following setup procedure must be followed.
Measure the differential housing bearing bore diameter. This is dimension A.
Install the new pinion bearings into the housing and
clamp into position using tool number 297132. Ensure the bearings can still be turned by hand after
clamping.
34
Dimension C is the valve required, to find this use the
following equation.
C = B Bar + 1/2 A.
NOTE: Bar (297132) = 25mm.
1.
2.
3.
4.
5.
Depth Gauge.
Bar Gauge tool 297132.
Pinion Shaft Bearing.
Pinion Bearing Clamp 297132.
Differential Support Housing.
35
Example of Calculation
Dimension A = 90mm
Dimension B = 90.3mm
C = B Bar + 1/2 A
C = 90.3 25 + 45
C = 110.3mm
Calculation of Shim Requirement
Pinion Dimension = 107.00
(See end of pinion).
36
LB 115 / FH 200.2
13
Press
Protector
Pinion
Shim
Inner Bearing
37
Fit the Pinion with the two new washers and a new
collapsable bush.
Position the pinion into its housing and place the
other bearing over the pinion shaft. Using a suitable
drift and hammer fit the bearing or alternatively use
a press.
38
Fit a new washer and ring nut on to the pinion.
39
Pinion Preload
Tighten the ring nut (using tool no. 297511) in incremental steps to eliminate any bearing end freeplay.
Using a spring torque meter with a piece of string
wrapped around the pinion shaft, ensure the preload
is within 9.2 13.7N.
Adjustment is carried out by gradually increasing the
tightening torque of the ring nut.
40
LB 115 / FH 200.2
14
41
Crown Wheel Backlash
Position a magenticbase dial gauge on the differential carrier and record the backlash. Ensure the stylus
touches the crown wheel teeth at 90 angle.
Backlash should be 0.18mm 0.23mm.
42
If the backlash is too small, loosen the locknut on the
same side as the crown wheel and tighten the locknut
on the opposite side by the same amount.
If the backlash is too big, loosen the locknut on the
opposite side to the crown wheel and tighten the
locknut on the same side as the crown wheel.
To check the combined differential and pinion preload perform the same test as before using the spring
balance and string on the pinion shaft.
The combined preload should be Pinion Preload +
(1.53 2.29N).
43
LB 115 / FH 200.2
Description
Page
27 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
Component
Axle Type
Differential Lock
Crown Wheel & Pinion Ratio
Planetary Reduction
Overall Ratio
Brake Operation
Brakes
Brake Discs (per side)
Brake Disc Total Friction Area
Number of Planetary Gears
Load Carrying Capacity Dynamic
Modular
Mechanical
4.11 : 1
4.5 : 1
18.5 : 1
Hydraulic
Wet Disc, Piston Operated
4
2735 cm2
3
9250 kg (20400 lb) at 1696 1727 mm track width
SPECIFICATIONS
Overall width
Oil capacity
Oil change period
Lubricants
Thread sealant
LB 75110 / FH 90.2110.2
TORQUE VALUES
LB 75110 / FH 90.2110.2
SPECIAL TOOLS
Splitting Tool 297471
Half axle lifting bracket
Sliding Hammer
Ratchet Tool 297457
Puller Tool No 297101
Pulling Attachment Tool No 297504
APPLICATION
Axle removal
Half shaft removal
Axle bearing cup removal
Axle housing bearing/seal
Axle housing bearing/seal
Axle housing bearing/seal
SEALANTS
Code
82995768
82995776
82995774
82995773
Number
Sealer
Sealer
Sealer
Sealer
Name
Anaerobic Low strength
Silicone
Polyester Urethane
Anaerobic
LB 75110 / FH 90.2110.2
DESCRIPTION
The rear axle (1) is of modular design and is fixed by
4 bolts to the chassis with a torque value of 1000 Nm
(737lbf ft). It incorporates the following features:
Mechanically operated diff-lock
Hydraulically operated oil immersed foot brakes
fitted with four disc brakes
Three planetary reduction carrier
3
Operation, Figure 4.
Power from the transmission output shaft is transmitted to the rear axle through (1) the brake disc (2)
and onto the half shaft (3).
The spiral bevel pinion is located in preloaded taper
roller bearings.
The differential is located on two taper roller bearings, the right hand bearing supported by an internal
web of the axle centre housing.
The crown wheel is rivetted to the differential housing. Drive from the housing is transmitted through a
conventional four pinion differential to sun gear
shafts which are splined into the differential side
gears.
NOTE: If repaired in service the rivets are replaced
by grade 8 bolts and must be torqued to: 115 Nm (85
lbf ft)
LB 75110 / FH 90.2110.2
5
The rear axle shaft is supported on taper roller bearings (1). Preload is adjusted by means of selective
shims held under the retaining plate and bolts.
FAULT FINDING
Differential Lock not engaging
(mechanically engaged)
LB 75110 / FH 90.2110.2
1. Replace/repair as required.
OVERHAUL
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 26 litres
(6.86 US. gals) and drain the oil from the plug at the
base of the axle (1).
Disconnect the differential Lock lever(2)
2
8
LB 75110 / FH 90.2110.2
10
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 stabilisers must
be lowered to the ground and the front wheels
chocked.
IMPORTANT: Do not rely on the stabilisers, install
axle stands to support the unit.
With the axle (1) supported using a suitable support
plate (2) and attached to splitting stand (3), Tool No
297471. Remove the retaining bolts and gently lower
the axle to the ground.
Place the axle onto a suitable axle stand to facilitate
repairs
11
Differential Removal
NOTE: Remove the left hand axle housing using lifting tool 297413 and the differential will be removed
with the axle housing.
12
1.
2.
3.
4.
Centre Housing
Differential Assembly
Lifting Tool
Half Shaft Axle Housing
13
LB 75110 / FH 90.2110.2
Pinion Shaft
Differential Lock Actuator
Half Shaft
14
Loosen the pinion nut using a pre fabricated tool, the
dimensions being:
1. 46mm (1.811in)
2. 65mm (2.559in)
3. 9mm (0.354)
4. 40mm (1.575in)
5. 220mm (8.66in)
6. 140mm (5.51in)
7. 95mm (3.74in)
8. 10mm (0.394in)
9. 110mm (4.33in)
15
Using the special tool (1) hold the coupling steady
while loosening the coupling retaining nut. Loosen
the pinion housing bolts.
16
Leave 2 bolts in the position shown removing the remaining bolts and jack the pinion out evenly.
17
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LB 75110 / FH 90.2110.2
18
1.
2.
3.
4.
5.
6.
7.
8.
Pinion Housing
Seal
Retainer
Nut
Lock Pin
Washer
Seal
Flange
19
LB 75110 / FH 90.2110.2
10
20
1.
2.
3.
4.
5.
6.
7.
Lock Ring
Washer
Dog Gear
Spring
Dog Gear
Bearing
Crown Wheel
Differential lock.
Prior to separating the differential, mark the two half
housings (1) to ensure correct re-assembly.
Replace the differential lock coupling and adaptor if
worn or damaged.
The crown wheel is rivetted to the differential housing
in production.
Replacement crown wheels are secured with nuts
and bolts for easier field service.
21
LB 75110 / FH 90.2110.2
11
23
Axle Shaft Component Removal
Remove the fork and shaft (right hand side housing
only). With either of the left or right brake housings
(1) exposed remove the attaching nuts and lift the
outer housing over the axle half shaft (2).
Inspect the housing scoring damage or distortion, repair as required.
24
Lift the brake discs (3) over the half shaft (2) to expose the inner brake housing (1).
Inspect the steel separator plates and rotating brake
discs for wear or distortion. Replace the brake discs
if worn to a thickness of less than 4.23 mm (0.170in).
Maximum allowable warpage is 0.08mm (0.003in)
Reassemble in reverse order to disassembly.
25
LB 75110 / FH 90.2110.2
12
The brake pipe fitting (1) can be removed by loosening and removal of the attaching Allen screws (2).
Before reassembly fit a new O ring (1) to the fitting
and new O rings (3) that seal the oil galleries. On re
assembly torque the attaching bolts to 813.5Nm
(610lbs ft).
3
26
Remove the brake housing (3) and brake piston (1)
and inspect all moving parts for wear or scoring. If in
any doubt replace suspect parts with new.
27
To remove the planetary gear (2) from the carrier (1)
remove the lock washer (3) and retaining bolt (4).
28
Remove the planetary gear carrier.
29
604.56.061.00 / 604.13.028.00 09/2000
LB 75110 / FH 90.2110.2
13
Planetary Gear
Retaining Ring
Thrust Washer
Roller Bearings
Thrust Washer
Roller Bearings
Thrust Washer
8.
9.
30
31
Refitting the ring gear (1) is the reverse procedure
but using Tool (2) the ring gear is pressed back into
the axle (3) from the brake side. If fitting a new ring
gear ensure the gear is seated equally in the axle by
placing a feeler gauge between the gear and housing.
IMPORTANT: If a new ring gear has been fitted in the
left hand axle housing, the differential bearing preload must be checked.
32
Axle housing bearing cup removal.
1.
2.
3.
4.
33
LB 75110 / FH 90.2110.2
14
34
To remove the bearing, stand the half axle (4) upright
and attach the bearing removal tool as shown.
1.
2.
3.
4.
5.
6.
7.
35
Applying gradual pressure to the puller tool the bearing will separate from the half axle.
Inspect the bearing for wear, scoring or damage and
replace if in any doubt.
IMPORTANT: Always fit a new axle seal if the axle
bearing is removed for any reason.
Reassembly of the seal and bearing is the reverse
procedure. Locate the seal and using an induction
heater, heat the bearing sufficiently to expand it
enough to allow it to easily seat onto the half shaft.
36
LB 75110 / FH 90.2110.2
15
37
1.
2.
3.
4.
5.
6.
7.
8.
9.
Axle Housing
Brake Fitting
Bearing
Seal
Half Shaft
Bearing
Planetary Reduction Assembly
Shim
Washer
LB 75110 / FH 90.2110.2
16
ADJUSTMENTS
Drive pinion preload
Axle shaft bearing preload
Differential bearing preload
NOTE: Crown wheel to pinion backlash is preset by
manufacturing tolerances in production.
The pinion bearing preload is set by selecting the correct shim (spacer) which is placed between the bearings.
Reassemble the pinion assembly, attach the fabricated spanner (1) to the assembly (2) and torque to
271813 Nm (200600 lbf ft) with spanner (4) to the
locknut.
Shims Available:
' 31.852/31.864
'31.902/31.915
' 31.953/31.966
'32.004/32.017
' 32.055/32.068
'32.106/32.32.118
'32.156/32.169
'32.207/32.220
'32.258/32.271
'32.309/32.322
'32.360/32.372
'32.410/32.423
'32.461/32.474
'32.512/32.525
'32.563/32.576
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 (1040 lb in)
Leave pinion retainer bolts loose for this check.
If under specification, fit a smaller shim
If over specification, fit a larger shim
NOTE: Make sure both bearings are well lubricated
and, once preload is set, lock nut to pinion.
38
39
Axle shaft bearing preload
Adjustable shims (1) are located between the inner
end of the axle shaft and carrier retainer.
40
LB 75110 / FH 90.2110.2
17
Adjustment procedure
To achieve the correct preload proceed through
steps 1 to 7
1. Fit a shim 2.06mm (0.081in) thus reducing end
float and possible damage to the seal.
2. Replace the planetary gear assembly.
3. Tighten the retaining bolt to 217745 Nm
(160550 lb ft).
4. Position the dial gauge and measure end float
eg. 0.562mm (0.022in).
5. To ensure correct preload, subtract endfloat from
shims already fitted for example
2.06 0.562mm=1.498mm.
6. Select shim from table to provide specified
preload of 1.72mm (0.067in).
IMPORTANT: Increasing shim thickness will reduce
preload.
Decreasing shim thickness will increase preload.
7. Fit selected shim and re-tighten retained bolt to
correct torque and allow lock plate to locate.
41
Shim to be Installed
1.24 1.32mm
(0.049 0.052in)
A13 81803491
1.14mm (0.045in)
1.35 1.42mm
(0.053 0.056in)
A13 81803502
1.24mm (0.049in)
1.45 1.54mm
(0.057 0.060in)
A13 81803503
1.35mm (0.053in)
1.55 1.64mm
(0.061 0.064in)
A13 81803504
1.45mm (0.057in)
1.65 1.74mm
(0.065 0.068in)
A13 81803505
1.55mm (0.061in)
1.75 1.84mm
(0.069 0.072in)
A13 81803506
1.65mm (0.065in)
1.85 1.94mm
(0.073 0.076in)
A13 81803507
1.75mm (0.069in)
1.96 2.04mm
(0.0770.080in)
A13 81803508
1.85mm (0.073in)
2.06 2.14mm
(0.081 0.084in)
A13 81803509
1.96mm (0.077in)
2.16 2.24mm
(0.085 0.088in)
A13 81803510
2.06mm (0.081in)
2.26 2.34mm
(0.089 0.092in)
A13 81803511
2.16mm (0.085in)
LB 75110 / FH 90.2110.2
18
42
Fit bridging bar (1) across the rear axle housing
flange and use a torque meter (2) to check rolling resistance which should be 2.310 Nm (2080 lb in).
NOTE: The brake housing, brake discs and 1/4 shaft
should not be installed but all bearings well lubricated.
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 cone using two methods:
If the left hand axle housing, ring gear or brake housing are replaced the following checks should be
made:
Method 1
Remove the differential bearing cone and shim from
the outer brake housing.
Place the gauge ring of tool 297146 (1) into the vacant bearing location.
Bolt bridge tool 297146 (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 following table to determine the correct
size shim which should be installed between the
brake housing and bearing cone, thus preloading the
bearing back to specifications.
43
44
LB 75110 / FH 90.2110.2
19
Method 2
When the differential bearings are not changed the
differential rolling resistance must be checked.
Remove the right hand axle bearing.
Remove the left hand axle housing and differential
Remove pinion.
Compress the differential Lock Spring and install
shim stock to constantly engaged differential lock.
Refit differential and left hand axle housing but less
the 1/4 shaft and brake discs.
Fit the 1/4 shaft in from the right hand side and fit
adaptor tool onto shaft.
Differential Lock
1/4 Shaft
Adapter Tool
Torque Meter
Right Hand Brake Housing
Check rolling resistance is between 2.310 Nm
(2090 lb in)
If out of specification the shim should be adjusted
and bearing preload rechecked.
1.
2.
3.
4.
5.
45
Differential Bearing Preload Adjustment Shims
Gap Reading
Shim Thickness
0.86 0.99mm
0.034 0.039in
1803515
0.097 10.2mm
0.038 0.040in
1.02 1.14mm
0.040 0.045in
1803516
1.12 1.18mm
0.044 0.046in
1.17 1.13mm
0.046 0.051in
1803517
1.28 1.33mm
0.050 0.052in
1.32 1.45mm
0.052 0.057in
1803518
1.43 1.48mm
0.056 0.058in
1.47 1.60mm
0.058 0.063in
1803519
1.59 1.64mm
0.062 0.064in
1.63 1.75mm
0.064 0.069in
1803520
1.74 1.79mm
0.068 0.070in
1.78 1.90mm
0.070 0.075in
1803521
1.89 1.95mm
0.074 0.076in
1.93 2.06mm
0.076 0.081in
1803522
2.05 2.10mm
0.080 0.082in
LB 75110 / FH 90.2110.2
20
NOTES
LB 75110 / FH 90.2110.2
Description
Page
27 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
Component
Axle Type
Differential Lock
Crown Wheel & Pinion Ratio
Planetary Reduction
Overall Ratio
Brake Operation
Brakes
Brake Discs (per side)
Brake Disc Total Friction Area
Number pf Planetary Gears
Load Carrying Capacity Dynamic
LB 75115 / FH 90.2200.2
Modular
Mechanical Electrically Operated
4.11 : 1
4.5 : 1
18.5 : 1
Hydraulic
Wet Disc, Piston Operated
4
2735 cm2
3
9250 kg (20400 lb) at 1696 1727 mm track width
TORQUE VALUES
LB 75115 / FH 90.2200.2
SPECIAL TOOLS
Splitting Tool No 297471
Half axle lifting bracket
Sliding Hammer
Ratchet Tool 297457
Puller Tool No 297101
Pulling Attachment Tool No 297504
APPLICATION
Axle removal
Half shaft removal
Axle bearing cup removal
Axle housing bearing/seal
Axle housing bearing/seal
Axle housing bearing/seal
SEALANTS
Code
82995768
82995776
82995774
82995773
Number
Sealer
Sealer
Sealer
Sealer
Name
Anaerobic Low strength
Silicone
Polyester Urethane
Anaerobic
LB 75115 / FH 90.2200.2
WARNING
Never use the differential lock at speeds above
8 km/h (5 miles/h) or when turning the machine.
When engaged the lock will prevent the machine
turning and personal injury could result.
The differential lock fitted to this machine is operated
by oil pressure and controlled by an electrically operated solenoid. The solenoid is energised when the
switch (1) mounted in the front console is depressed.
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
and the lock will engage giving direct drive to both
rear wheels.
The lock will remain engaged until traction at the rear
wheels equalises or until either of the foot brakes are
applied and the vehicle stops. The warning light on
the instrument panel will go out when the differential
lock has disengaged.
Operating System
When the instrument panel switch is selected the differential is operated by the pressure of the oil it receives from the transmission, acting on the differential operating piston.
This oil pressure 13 14 bar (188 203 psi) which
is constantly available when the engine is running is
controlled by a solenoid operated valve. When the
switch is deselected (differential lock not required)
the oil is diverted back to the dipstick tube (dump)
and the differential piston spring releases the lock.
LB 75115 / FH 90.2200.2
3
6
4
5
5
1.
2.
3.
Powershift Transmission
Dipstick Tube
Return Line to Sump
1
3
6
1.
2.
Actuating Valve
Differential Assembly
LB 75115 / FH 90.2200.2
LB 75115 / FH 90.2200.2
The rear axle shaft is supported on taper roller bearings (1). Preload is adjusted by means of selective
shims held under the retaining plate and bolts.
FAULT FINDING
Differential Lock
Not Engaging
Differential Lock
Not Disengaging
LB 75115 / FH 90.2200.2
6. 3. Replace/repair as required.
7. 4. Replace/repair as required.
10
OVERHAUL
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 26 litres
(6.86 US. gals) and drain the oil from the plug at the
base of the axle (1).
Disconnect the differential Lock hydraulic hose
11
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.
12
LB 75115 / FH 90.2200.2
13
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 stabilisers must
be lowered to the ground and the front wheels
chocked.
14
IMPORTANT: Do not rely on the stabilisers, install
axle stands to support the unit.
With the axle (1) supported using a suitable support
plate (2) and attached to splitting stand (3), Tool No
297471. Remove the retaining bolts and gently lower
the axle to the ground.
Place the axle onto a suitable axle stand to facilitate
repairs
15
Differential Removal
NOTE: Remove the right hand axle housing using
lifting tool 297413 and the differential will be removed
with the axle housing.
1.
2.
3.
4.
Centre Housing
Differential Assembly
Lifting Tool
Half Shaft Axle Housing
16
LB 75115 / FH 90.2200.2
17
Loosen the pinion nut using a pre fabricated tool, the
dimensions being:
1. 46mm (1.811in)
2. 65mm (2.559in)
3. 9mm (0.354)
4. 40mm (1.575in)
5. 220mm (8.66in)
6. 140mm (5.51in)
7. 95mm (3.74in)
8. 10mm (0.394in)
9. 110mm (4.33in)
18
Using the special tool (1) hold the coupling steady
while loosening the coupling retaining nut. Loosen
the pinion housing bolts.
19
Leave 2 bolts in the position shown removing the remaining bolts and jack the pinion out evenly.
20
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FH 90.2200.2
21
1.
2.
3.
4.
5.
6.
7.
8.
Pinion Housing
Seal
Retainer
Nut
Lock Pin
Washer
Seal
Flange
22
LB 75115 / FH 90.2200.2
23
1.
2.
3.
4.
5.
6.
7.
Lock Ring
Washer
Dog Gear
Spring
Dog Gear
Bearing
Crown Wheel
Differential lock.
Prior to separating the differential, mark the two half
housings (1) to ensure correct re-assembly.
Replace the differential lock coupling and adaptor if
worn or damaged.
The crown wheel is rivetted to the differential housing
in production.
Replacement crown wheels are secured with nuts
and bolts for easier field service.
24
LB 75115 / FH 90.2200.2
26
Lift the brake discs (3) over the half shaft (2) to expose the inner brake housing (1).
Inspect the steel separator plates and rotating brake
discs for wear or distortion. Replace the brake discs
if worn to a thickness of less than 4.23 mm (0.170in).
Maximum allowable warpage is 0.08mm (0.003in)
Reassemble in reverse order to disassembly.
27
The brake pipe fitting (1) can be removed by loosening and removal of the attaching Allen screws (2).
Before reassembly fit a new O ring (1) to the fitting
and new O rings (3) that seal the oil galleries. On re
assembly torque the attaching bolts to 813.5Nm
(610lbs ft).
3
28
LB 75115 / FH 90.2200.2
29
To remove the planetary gear (2) from the carrier (1)
remove the lock washer (3) and retaining bolt (4).
30
Remove the planetary gear carrier.
31
LB 75115 / FH 90.2200.2
Planetary Gear
Retaining Ring
Thrust Washer
Roller Bearings
Thrust Washer
Roller Bearings
Thrust Washer
8.
9.
32
34
Axle housing bearing cup removal.
1. Puller Tool No 297101
2. Slide Hammer Tool No 297504
3. Axle Housing
4. Bearing Cup
35
LB 75115 / FH 90.2200.2
36
To remove the bearing, stand the half axle (4) upright
and attach the bearing removal tool as shown.
1.
2.
3.
4.
5.
6.
7.
37
Applying gradual pressure to the puller tool the bearing will separate from the half axle.
Inspect the bearing for wear, scoring or damage and
replace if in any doubt.
IMPORTANT: Always fit a new axle seal if the axle
bearing is removed for any reason.
Reassembly of the seal and bearing is the reverse
procedure. Locate the seal and using an induction
heater, heat the bearing sufficiently to expand it
enough to allow it to easily seat onto the half shaft.
38
LB 75115 / FH 90.2200.2
39
1.
2.
3.
4.
5.
6.
7.
8.
9.
Axle Housing
Brake Fitting
Bearing
Seal
Half Shaft
Bearing
Planetary Reduction Assembly
Shim
Washer
LB 75115 / FH 90.2200.2
40
41
Axle shaft bearing preload
Adjustable shims (1) are located between the inner
end of the axle shaft and carrier retainer.
42
LB 75115 / FH 90.2200.2
Shim to be Installed
1.24 1.32mm
(0.049 0.052in)
A13 81803491
1.14mm (0.045in)
1.35 1.42mm
(0.053 0.056in)
A13 81803502
1.24mm (0.049in)
1.45 1.54mm
(0.057 0.060in)
A13 81803503
1.35mm (0.053in)
1.55 1.64mm
(0.061 0.064in)
A13 81803504
1.45mm (0.057in)
1.65 1.74mm
(0.065 0.068in)
A13 81803505
1.55mm (0.061in)
1.75 1.84mm
(0.069 0.072in)
A13 81803506
1.65mm (0.065in)
1.85 1.94mm
(0.073 0.076in)
A13 81803507
1.75mm (0.069in)
1.96 2.04mm
(0.0770.080in)
A13 81803508
1.85mm (0.073in)
2.06 2.14mm
(0.081 0.084in)
A13 81803509
1.96mm (0.077in)
2.16 2.24mm
(0.085 0.088in)
A13 81803510
2.06mm (0.081in)
2.26 2.34mm
(0.089 0.092in)
A13 81803511
2.16mm (0.085in)
LB 75115 / FH 90.2200.2
44
Fit bridging bar (1) across the rear axle housing
flange and use a torque meter (2) to check rolling resistance which should be 2.310 Nm (2080 lb in).
NOTE: The brake housing, brake discs and 1/4 shaft
should not be installed but all bearings well lubricated.
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 cone using two methods:
If the right hand axle housing, ring gear or brake
housing are replaced the following checks should be
made:
Method 1
Remove the differential bearing cone and shim from
the outer brake housing.
Place the gauge ring of tool 297146 (1) into the vacant bearing location.
Bolt bridge tool 297146 (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 following table to determine the correct
size shim which should be installed between the
brake housing and bearing cone, thus preloading the
bearing back to specifications.
45
46
LB 75115 / FH 90.2200.2
47
Shim Thickness
0.86 0.99mm
0.034 0.039in
1803515
0.097 10.2mm
0.038 0.040in
1.02 1.14mm
0.040 0.045in
1803516
1.12 1.18mm
0.044 0.046in
1.17 1.13mm
0.046 0.051in
1803517
1.28 1.33mm
0.050 0.052in
1.32 1.45mm
0.052 0.057in
1803518
1.43 1.48mm
0.056 0.058in
1.47 1.60mm
0.058 0.063in
1803519
1.59 1.64mm
0.062 0.064in
1.63 1.75mm
0.064 0.069in
1803520
1.74 1.79mm
0.068 0.070in
1.78 1.90mm
0.070 0.075in
1803521
1.89 1.95mm
0.074 0.076in
1.93 2.06mm
0.076 0.081in
1803522
2.05 2.10mm
0.080 0.082in
LB 75115 / FH 90.2200.2
48
Disconnect and plug the attaching hydraulic pipes
and remove the valve from the machine.
Clean and flush the manifold block ports with a suitable cleaning fluid.
49
Remove the solenoid coil attaching knob and clean
the parts with lint free cloth.
1.
2.
3.
4.
5.
Spool
O ring
Solenoid Coil
O ring
Plastic Retainer
2
Upon reassembly apply 12 volts to the solenoid and
observe its function if in any doubt replace with new
parts.
4
5
50
LB 75115 / FH 90.2200.2
Description
Page
27 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS
Component
Axle Type
Planetary Reduction
Overall Ratio
Brake Operation
Brakes
Brake Discs (per side)
Brake Disc Total Friction Area
Number of Planetary Gears
Load Carrying Capacity Dynamic
Overall Width
Oil Capacity
Oil Change Period
Lubricants
Modular
6.923 : 1
18.5 : 1
Hydraulic
Wet Disc, Piston Operated
3
2735 cm2
3
10000 kg (22000 lb) at 1890 mm track width
2304 mm
11 Litres (2.9 US. gals)
1 year or 1200 hours
MultiG API GL4 ISO32/46
LB 115 / FH 200.2
9.213.8 N
1.5mm 1.6mm
Axle Disassembly
Hub Disassembly
1. Remove the hub oil drain plug and drain the hub
oil. Remove the differential plug and drain the oil
from the centre housing.
1
2. Remove the hub outer casing allen screws
2
3. Remove the hub outer casing.
3
4. Remove the sun gear circlip and 3 spacers.
4
604.56.061.00 / 604.13.028.00 09/2000
LB 115 / FH 200.2
5
6. Using two of the fixing bolts, fit these to the outer
threaded holes and tighten to push the ring gear
away from the hub.
6
7. With a soft faced mallet hammer off the hub
centre housing and also the outer conical bearing.
7
8. Then remove the inner conical bearing by hand.
8
LB 115 / FH 200.2
9
10. Use a set of bearing pullers to press the tapered
shaft from the hub assembly
10
11. Undo the bolts holding the top and bottom pivot
pins. Then remove the pivot pins and also the
belleville washers and spacers.
11
12. Remove the remainder of the hub assembly.
12
604.56.061.00 / 604.13.028.00 09/2000
LB 115 / FH 200.2
13
14. Disassembly of the planetary housing.
Remove the bolt from each of the planet gears.
Then remove the Upper (1) and Lower (2)
washer. The gear can then be removed and also
the individual needle bearings.
14
15. Swivel hub seal and bush removal.
Remove the shaft seal and bush using a suitable
puller or drift.
15
16. Axle shaft seal and bush removal.
Use an internal puller and slide hammer to remove the seal and bush.
16
LB 115 / FH 200.2
17
18
Using a slide hammer with threaded end M18, remove the upper and lower bushes (1) on the left side.
19
Lift off the complete assembly.
To disassemble the cylinder remove the circlip from
each end then slide the piston to one end and tap out
one gland, then slide it to the other end to remove the
remaining gland block.
LB 115 / FH 200.2
20
Remove the brake discs and central hub.
21
To disassemble the brake housing, remove the abler
bolts which secure it to the central housing. Remove
the complete brake housing.
22
Remove the three piston retaining bolts.
To assist in removing the brake piston from the housing, undo the brake bleed nipple and blow compressed air down to eject the piston.
1.
2.
3.
4.
Brake Piston
Return Belleville Washers
Piston Retaining Nuts
Piston Seals
23
LB 115 / FH 200.2
24
25
1.
2.
3.
4.
Differential Housing
Thrust Washer
Planet Gears
Shaft
5.
6.
7.
8.
Crown Wheel
Fixing Bolts
Thrust Washer
Side Gear
LB 115 / FH 200.2
PINION DISASSEMBLY
Remove the coupler retaining ring using suitable circlip pliers.
26
Then remove the coupler and O ring.
Lever out the oil seal and dispose of it. Then slide off
the steel ring, O ring and washer.
27
Using tool no. 297511 lock the shaft and undo the
pinion nut.
Withdraw the pinion shaft and bearings.
28
LB 115 / FH 200.2
10
29
1.
2.
3.
4.
5.
6.
7.
Ring
Inner seal
Outer Seal
Ring
Washer
Adjusting Nut
Tab Washer
heading
8.
9.
10.
11.
12.
13.
14.
Shaft
Washer
Bearing
Washer
Shaft Guide
Circlip
Coupling
LB 115 / FH 200.2
11
30
Then fit the false differential (297414) with the housing complete with side brake housing.
31
Record the A dimension using a depth gauge.
X is the dimension needed to calculate the pinion
shams.
Carry out the following calculation:
X = (A + C) B
Example: A = 164.9
therefore X = (164.9 + 45) 100
X = 109.9
B = 100 mm
C = 45 mm
SHK35013
32
LB 115 / FH 200.2
12
To determine the shims required, check the pinion dimension on the end of the pinion (V).
Shim thickness = X V
Example:
Shim thickness = 109.9 107.00
= 2.9
Shim are available from 2.5 mm to 3.4 mm in 0.1 increments.
33
Remove the false pinion and differentials and also
the side brake housings.
Reassemble the pinion with the calculated shim between the pinion head and conical bearing.
Ensure the chamfered side of the shim is toward the
pinion head. Press on the first bearing.
34
Replace the pinion, shim and bearing into the housing complete with new collapsible bush and washers.
Fit the other bearing onto the end of the shaft and
using a suitable drift hammer on the bearing. Oppose
hammer force by holding a heavy hammer against
the pinion head.
35
Fit the rest of the components to the shaft and tighten
the pinion nut in incremented steps until the correct
rolling pull is achieved:
9.2 13.8 N
36
604.56.061.00 / 604.13.028.00 09/2000
LB 115 / FH 200.2
13
37
Measure the crown wheel to pinion backlash by placing the magnetic base of a dial gauge on the housing
and placing the stylus of the dial gauge on to the flat
surface of the tool. The stylus of the tool should be
approximately 39mm from the pinions centre radius.
The backlash should be 0.17 0.22 mm.
If the measured backlash is too large, tighten the adjuster ring nearest the crown wheel and loosen the
ring on the opposite side equal amounts.
If the backlash is too small, loosen the adjuster ring
on the same side as the crown wheel and tighten the
ring on the opposite side.
38
Recheck the rolling resistance of the pinion with the
differential fitted.
The valve should now be the original pinion valve
plus
(2.59 3.88) N.
If the rolling resistance is too high then loosen each
of the adjuster rings by equal amounts.
If the rolling resistance is too low then tighten both
adjuster rings by equal amounts until the desired resistance is achieved.
39
LB 115 / FH 200.2
14
40
LB 115 / FH 200.2
SECTION 33 BRAKES
Chapter 1 Brake Overhaul
CONTENT
Section
33 000
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
Brake Operation
Brakes
Brake Oil
Brake Discs (per side)
Brake Disc Total Friction Area
Hydraulic
Wet Disc, Piston Operated
NH 610
4
1440 cm2
LB 75110 / FH 90.2110.2
10 40 lb in
1.72mm (0.067 in)
0.09 0.11 mm (0.0035 0.044in)
1
TOOL
Splitting Tool No MS 2700 C
Half axle lifting bracket
Sliding Hammer
Ratchet Tool P61
Puller Tool No 938
Pulling Attachment Tool No 952
APPLICATION
Axle removal
Half shaft removal
Axle bearing cup removal
Axle housing bearing/seal
Axle housing bearing/seal
Axle housing bearing/seal
SEALANTS
Code
82995768
82995776
82995774
82995773
Number
Sealer
Sealer
Sealer
Sealer
Name
Anaerobic Low strength
Silicone
Polyester Urethane
Anaerobic
LB 75110 / FH 90.2110.2
2
1.
2.
3.
4.
Braking System
5. Master Cylinders
6. Hand Brake
7. Trumpet Housing
LB 75110 / FH 90.2110.2
Brake Reservoir
1.
2.
Brake Reservoir
Low Level Test Switch
3
The brake cylinders are linked by a balance pipe (1)
situated below the cylinders to maintain equal oil
pressure between the two cylinders
1
5
1.
2.
3.
4.
5.
6.
Fitting
Pressure Switch
Reservoir Adapter
Body
Main Spool
End Cap
LB 75110 / FH 90.2110.2
6
Master Cylinder With Brakes Released
Trapped Oil
1.
2.
3.
4.
5.
LB 75110 / FH 90.2110.2
7
Master Cylinder With Brake Pedals Depressed
LB 75110 / FH 90.2110.2
8
Master Cylinder With One Brake Pedal Depressed
LB 75110 / FH 90.2110.2
Steel Plates
Outer Brake Housing
Seals
Brake Piston
Friction Plates
Outer Brake Housing
9
Brake Piston and Seals
1.
2.
3.
Brake Piston
Brake Pipe fitting
Outer Brake Housing
10
The brakes hydraulically operated are supplied oil
from the brake pedal reservoir and into the axle by
tubes into each half axle (1) through the mounted
brake pipe fitting (2) which is sealed to the piston by
two O rings.
1
2
11
When the brake pipe fitting (1) is removed ensure the
O rings (2) are replaced with new
12
604.56.061.00 / 604.13.028.00 09/2000
LB 75110 / FH 90.2110.2
13
2. Open left hand brake bleed valve (2)
2
14
3.
4.
5.
6.
7.
8.
9.
15
NOTE: When the brake pedals are operated, both together, the electrical supply to the front wheel drive
switch is cut allowing the clutch to denergise thus engaging the front wheel drive, providing four wheel
braking.
LB 75110 / FH 90.2110.2
10
16
17
1.
2.
3.
4.
5.
6.
7.
Lever
Cover
Fixing Bolts
Outer Caliper
Bolt
Inner Caliper
Inner Friction Pad
Component Layout
8. Fixing Spring
9. Outer Friction Pad
10. Spacer
11. Actuator Plate
12. Balls and Retainer Plate
13. Actuator Plate
14. Adjusting Nuts
LB 75110 / FH 90.2110.2
11
18
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. Ensure that the tubes
can move.
19
Adjust the clearance between the brake pads and
disc to 0.5mm using the nut and lock nut (1).
20
Adjust the cable clevis and lock the nut to get 5 to 7
clicks on the hand brake lever.
21
LB 75110 / FH 90.2110.2
12
NOTES PAGE
LB 75110 / FH 90.2110.2
SECTION 33 BRAKES
Chapter 2
CONTENT
Section
33 000
Description
Page
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hand brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
Brake operation
Brakes
Brake oil
Brake discs, per side
LB 115 / FB 200.2
Hydraulic
Wet disc, piston operated
Ambra LHM
3
1
1.
2.
3.
4.
Braking System
5. Master Cylinder
6. Hand Brake
7. Trumpet Housing
LB 115 / FB 200.2
NOTES
LB 115 / FB 200.2
10
Y
X
14
13
12
11
SHK33001
2
Brake Cylinder in Neutral
Return to Reservoir
Neutral
With the brake pedal released oil in the Y and Z gallery is free to go to the reservoir. Oil from gallery X
also is free to flow to the reservoir past the O ring (2)
into gallery Y.
Braking (1st Phase)
Oil is compressed in galleries X and Y, the oil from
gallery Y passing through the central part of the
sleeve (12) and past seal (3). As the sleeve moves
to the left it also opens up the one way valve (13) allowing the balancing system to operate if the other
8.
9.
10.
11.
12.
13.
14.
Actuator
Seal
Seal
Switch Over Pin
Brake Sleeve
One Way Valve
Piston Return Spring
LB 115 / FB 200.2
Y
X
SHK33002
3
Braking (1st Phase)
SHK33003
4
Braking (2nd Phase)
LB 115 / FB 200.2
Overhaul
Brake Reservoir
1.
2.
Brake Reservoir
Low Level Test Switch
5
Brake master cylinders are accessible from the engine compartment.
The brake cylinders are linked by a balance pipe
which supplies equal pressure to both brake pistons
when both pedals are pressed.
6
1
2
3
4
12
11
10
SHK33005
7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Seal Retainer
Sleeve to Piston Retaining Ring
Sleeve
One Way Valve
Relief Valve Actuator
Balancer One Way Valve
LB 115 / FB 200.2
Brake Piston
Steel Seperator Plates
Steel Back Plate
Sleeve
Brake Housing
8
Brake Piston
1.
2.
3.
4.
Brake Piston
Return Belleville Washers
Piston Retaining Nuts
Piston Seals
9
NOTE: The belleville washers must always be fitted
in pairs as shown.
10
The brakes are operated by supply oil from the
master cylinder which enters at fitting (1) on each
side of the axle.
11
LB 115 / FB 200.2
12
11. Open the left hand brake bleed valve (2).
13
12. Pump both brakes to purge the system (3), ensuring the reservoir is kept topped up.
14
14. Release the pedals and repeat procedure items
1 to 4 for the right hand brake bleed valve.
15. Test the brakes and repeat if necessary.
LB 115 / FB 200.2
15
16
1.
2.
3.
4.
5.
6.
7.
Lever
Cover
Fixing Bolts
Outer Caliper
Bolt
Inner Caliper
Inner Friction Pad
LB 115 / FB 200.2
Component Layout
8. Fixing Spring
9. Outer Friction Pad
10. Spacer
11. Actuator Plate
12. Balls and Retainer Plate
13. Actuator Plate
14. Adjusting Nuts
10
17
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 heads flats, and then
torque the locknuts to 150 Nm. Ensure that the tubes
can move.
18
Adjust the clearance between the brake pads and
disc to 0.5mm using the nut and lock nut (1).
19
Adjust the cable clevis and lock the nut to get 5 to 7
clicks on the hand brake lever.
20
604.56.061.00 / 604.13.028.00 09/2000
LB 115 / FB 200.2
CONTENT
Section
35 000
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Load Sensing Flow Sharing Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
35 701
LB 85115 / FB 90.2200.2
HYDRAULIC OIL
Specification
Capacity Total System
Reservoir Capacity
Change Interval
Oil Filter Change
PUMP
Tandem Gear Pump Operating Steering and Hydraulic Circuits
Rear Pump (Steering Pump)
Output
N/ASP New Pump
75.5 L/min (20 US. gals/min)
@ 2200 rev/min @175 bar (2500 psi)
Worn Pump (minimum)
63 L/min (16.6 US. gals/min)
@ 2200 rev/min @175 bar (2500 psi)
Turbo
New Pump
79.5 L/min (21 US. gals/min)
@ 2070 rev/min @175 bar (2500 psi)
Worn Pump (minimum)
67 L/min (17.7 US. gals/min)
@ 2070 rev/min @175 bar (2500 psi)
Steering Circuit Relief Valve Not 4WS
136.5 150 bar (1980 2175 psi)
Steering Circuit Relief Valve 4WS
177 190 bar (2566 2755 psi)
Steering Circuit Standby Pressure
7 bar (101.5 psi)
Rear Pump Relief Valve Pressure
(Located in Stabiliser Valve Section)
196 202 bar (2842 2929 psi)
Front Pump
Output
N/ASP New Pump
75.5 L/min (20 US. gals/min)
@ 2200 rev/min @175 bar (2500 psi)
Worn Pump (minimum)
63 L/min (16.6 US. gals/min)
@ 2200 rev/min @175 bar (2500 psi)
Turbo
New Pump
79.5 L/min (21 US. gals/min)
@ 2070 rev/min @175 bar (2500 psi)
Worn Pump (minimum)
67 L/min (17.7 US. gals/min)
@ 2070 rev/min @175 bar (2500 psi)
Combined Output (minimum)
N/ASP
151 L/min (40 US. gals/min) @ 2200 rev/min
Turbo
159 L/min (42 US. gals/min) @ 2070 rev/min
Loader Control Valve
Type
LB 85115 / FB 90.2200.2
1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
LB 85115 / FB 90.2200.2
1.
2.
3.
4.
5.
6.
7.
TIGHTENING TORQUES
LB 85115 / FB 90.2200.2
mm
4
Steel Tube Outside Diameter
(mm)
Nm
lbf ft
10
36
27
12
54
40
1416
85
63
1820
122
90
2225
162
120
SPECIAL TOOLS
Quick Release Coupler
Universal Pressure Test Kit
or
Pressure Test Kit PT 10045
or
0300 bar Pressure Gauge
Flowmeter 0200 Litres/min
LB 85115 / FB 90.2200.2
5
1.
2.
3.
4.
5.
hydrostatic steering system with remaining flow supplementing the output from the front pump to the
loader and backhoe hydraulic circuits.
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.
LB 85115 / FB 90.2200.2
Located within the inlet cover (3) of the backhoe control valve are the load sense limiter (system pressure
relief valve) (2) and load sense return to reservoir orifice (1) which allows load sense pressure to vent to
reservoir when hydraulic circuits are in neutral or
load sense pressure exceeds the 210 bar maximum
value due to a malfunction in the system.
The pump flow balancer valve, items (48) controls
the flow of oil from the hydraulic pump and diverts ex-
LB 85115 / FB 90.2200.2
7
cess flow back to reservoir. The valve also maintains
a back pressure of 17 bar in the circuit when all valve
sections are in neutral and engine speed is 1000 rev/
min.
Back pressure will increase to 23 bar at an engine
speed of 2200 rev/min
HYDRAULIC CIRCUIT
The hydraulic circuit is a load sensing flow sharing
system working in conjunction with a fixed displacement 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 control valves is load independent and it is therefore
possible to satisfactorily operate two or more spools
at the same time.
The principal components of the load sensing flow
sharing system are the pressure compensator
valves in each control valve section, refer to Figure 15, together with the load sense line which connects all the spool sections 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 reservoir and
flow from the front pump is directed to the centre gal-
LB 85115 / FB 90.2200.2
8
Hydraulic Circuit Schematic
Suction Oil
Return to Reservoir
Hydraulic Reservoir
Hydraulic Pump
Steering Motor
Hand Hammer Control Valve
Hand Hammer
Loader Control Valve
Backhoe Hammer Control Valve
LB 85115 / FB 90.2200.2
8.
9.
10.
11.
12.
13.
Backhoe Hammer
Backhoe Control Valve
Return Line Distributor Block
Filter
Oil Cooler ByPass Valve
Oil Cooler
10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Front Axle
Boom
Crowd
Boom
Swing
Bucket
Dipper
LH Stabiliser
RH Stabiliser
Clamps
Pump Output
38+38 for Machine with Turbo Engine
34+34 for Machine with Normally Aspirated Engine
LB 85115 / FB 90.2200.2
11
2
1
P2
P
L
R
200 bar
(2900 PSI)
LS
200 bar
(2900 PSI)
LS
15 bar
T2
P2
210 bar
T1
T3
230
bar
T2
315 bar
160
bar
4
240 bar
T1
205 bar
LS
T
205 bar
220 bar
240 bar
EF
LS
8
7 BAR
(101.5 PSI)
140+/3.5 BAR
(1050+/50.75 PSI)
11
10
T3
5 bar
(72.5 PSI)
3.5 bar
(51 PSI)
9
Main Hydraulic System 2 and 4 Wheel Drive (LESS options) Outside North America
LB 85115 / FB 90.2200.2
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
LB 85115 / FB 90.2200.2
Front Axle
Boom
Crowd
Bucket 4x16x1
Glide Ride
Telescopic
Boom
Swing
Bucket
Dipper
LH Stabiliser
RH Stabiliser
Clamps
Backhoe Hammer
Hand Hammer
Pump Output
38+38 for Machine with Turbo Engine
34+34 for Machine with Normally Aspirated Engine
13
PT
5
Y
X2
B
1
T
MX MA A
P2
P
LS
L OSPC125LS R
200 bar
(2900 PSI)
200 bar
(2900 PSI)
LS
15 bar
T3
230
bar
T2
160
bar
240 bar
P2
T2
T1
210 bar
T1
LS
165 bar
315 bar
B A
10 bar
(145 PSI)
240 bar
205 bar
B A
205 bar
T
220 bar
B
15
240 bar
16
14
LS
10
EF P
7 bar
(101.5 PSI)
140+/ 3.5 bar
(1050+/50.75 PSI)
11
12
5 bar
(72.5 PSI)
3.5 bar
(51 PSI)
13
T3
10
Main Hydraulic System 2 and 4 Wheel Drive (with options) Outside North America
LB 85115 / FB 90.2200.2
14
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
LB 85115 / FB 90.2200.2
Rear Axle
Boom
Crowd
Boom
Swing
Bucket
Dipper
Stabiliser
Stabiliser
Clamps
Pump38.5cc+38.5cc
Front Axle
15
1
A
12
P
T
P2
P
R
L
240 bar
(3480 PSI)
240 bar
(3480 PSI)
LS
15 bar
LS
P2
T2
210 bar
T1
T
T3
230
bar
T2
315 bar
160
bar
T1
240 bar
205 bar
LS
5
205 bar
220 bar
240 bar
EF
11
LS
7 bar
(101.5 PSI)
180+/3.5 bar
(2610+/50.75 PSI)
10
T3
5 bar
(72.5 PSI)
3.5 bar
(51 PSI)
13
Main Hydraulic System 4 Wheel Steer (LESS Options) Outside North America
LB 85115 / FB 90.2200.2
16
LB 85115 / FB 90.2200.2
Rear Axle
Boom
Crowd
Bucket 4x1 6x1
Glide Ride
Telescopic
Boom
Swing
Bucket
Dipper
Stabiliser
Stabiliser
Clamps
Backhoe Hammer
Hand Hammer
Pump38.5cc+38.5cc
Front Axle
17
1
A
5
Y
X2
B
MX MA A
P2
P
17
A
OSPC160LS
240 bar
(3480 PSI)
LS
240 bar
(3480 PSI)
LS
15 bar
T3
230
bar
T2
160
bar
240
bar
P2
T2
210 bar
T1
T1
6
P
LS
165 bar
315 bar
7
B
B
10 bar
(145 PSI)
240 bar
205 bar
T
205 bar
T
220 bar
9
15
204 bar
14
EF
16
10
LS
7 bar
(101.5 PSI)
180+/3.5 bar
(2610+/50.75 PSI)
11
12
5 bar
(72.5 PSI)
3.5 bar
(51 PSI)
13
T3
14
Main Hydraulic System 4 Wheel Steer (With Options) Outside North America
LB 85115 / FB 90.2200.2
18
LB 85115 / FB 90.2200.2
19
15
1.
2.
3.
4.
5.
6.
7.
Spool Cap
Centralising Spring
Spool
Plug
Spring
Check Valve
Wiper
LB 85115 / FB 90.2200.2
20
16
Flow Balancer Valve Operation All Spools In Neutral
Return to Reservoir
1.
2.
3.
LB 85115 / FB 90.2200.2
21
17
Load Sensing Flow Sharing All Spools in Neutral
Pump Pressure
Return to Reservoir
Trapped Oil
1.
2.
LB 85115 / FB 90.2200.2
3.
4.
22
18
Flow Balancer Valve Operation Hydraulic Circuits Operating
Return to Reservoir
Pump Pressure
1.
2.
3.
4.
5.
6.
7.
LB 85115 / FB 90.2200.2
23
19
Load Sensing Flow Sharing One Spool Operating
Pump Pressure
Return to Reservoir
Trapped Oil
1.
2.
LB 85115 / FB 90.2200.2
3.
4.
24
20
Load Sense Relief Valve Operating
Return to Reservoir
4.
5.
6.
7.
LB 85115 / FB 90.2200.2
25
21
Load Sensing Flow Sharing Two Spools Operating
1.
2.
Trapped Oil
Return to Reservoir
LB 85115 / FB 90.2200.2
3.
4.
26
NOTES PAGE
LB 85115 / FB 90.2200.2
27
22
2. Stop the engine and relieve any residual pressure in the backhoe and loader circuits by moving
the loader and backhoe control levers through all
operating positions.
23
3. Disconnect the battery
24
LB 85115 / FB 90.2200.2
28
25
1.
2.
3.
4.
5.
26
7. Installation is removal procedure in reverse.
LB 85115 / FB 90.2200.2
29
27
6. Stop the engine and relieve any residual pressure in the backhoe and loader circuits by moving
the loader and backhoe control levers through all
operating positions.
28
7. Disconnect the battery
29
LB 85115 / FB 90.2200.2
30
8.
9.
10.
11.
12.
30
13. Support the weight of the valve using a suitable
lift.
31
14. Remove valve retaining bolts which are located
on the rear of the control valve mounting plate
and carefully withdraw and lower valve from machine.
15. Installation is removal procedure in reverse.
32
Control Valve Disassembly
Disassembly of the loader and backhoe control valve
assemblies are similar.
For reference the individual valve sections and relief
valves are identified as follows.
1.
2.
3.
4.
5.
6.
7.
33
604.56.061.00 / 604.13.028 09/2000
LB 85115 / FB 90.2200.2
31
1. Prior to disassembly the valves should be thoroughly cleaned using an approved degreaser.
2. Scribe a diagonal line across the valve sections
to aid reassembly.
3. Remove tie rod nuts and separate components.
34
35
1.
2.
3.
4.
5.
6.
7.
Spool Cap
Centralising Spring
Spool
Plug
Spring
Check Valve
Wiper
LB 85115 / FB 90.2200.2
32
36
1.
2.
3.
4.
37
LB 85115 / FB 90.2200.2
Description
Page
35 000
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader Bucket Relief Valve (Piston End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Extendible Dipper Relief Valve (Piston End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Swing System Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dipperstick Bucket and Boom Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flow Testing (Pump Performance Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LB 75115 / FB 90.2200.2
EXAMPLE:
Backhoe lift circuit slow to raise, all other circuits appear to work normally.
Listed in the column under Malfunction in the Fault
Finding Chart, the description would be lift fails to
operate, is slow or has loss of power.
The column headed Malfunction lists the observed malfunctions when the backhoe or loader
is operated.
The column headed Possible Cause lists all the
items in the circuit which could cause the observed malfunction.
The column headed Test/Repair lists the test
which should be used to determine the item
causing the observed malfunction.
Refer to Test/Repair column and perform the recommended tests. Systematic and logical testing will
reduce the time required in locating the cause of the
malfunction and provide a more accurate indication
of the malfunction. If adequate test equipment is not
available, disassembly and inspection of the items
listed under Possible Causes must be undertaken.
Before pressure testing the machine ensure the hydraulic oil is at normal operating temperature of
75C.
Pressure testing is performed using the two pressure
test ports on the left hand side of the machine.
The upper port tests the hydraulic system and the
lower port the steering system.
Install 0200 bar (03000 psi) pressure gauge in
this port using quick release coupler, Part No
291924, when pressure testing the steering system.
38
LB 75115 / FB 90.2200.2
POSSIBLE CAUSES
CORRECTION
Pump worn.
POSSIBLE CAUSES
CORRECTION
LB 75115 / FB 90.2200.2
Refer to the following backhoe fault finding chart after first considering the preceding charts. The backhoe chart
should only be referred to if the supply circuit is performing normally, thereby confirming that the pump and hydraulic supply circuits are functioning to specification. See also Fault Finding Hydraulic Pump.
PROBLEM
Lift fails to operate, is slow, has
loss of power or is not holding.
POSSIBLE CAUSES
CORRECTION
Examine/overhaul stabiliser
lock valve.
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
POSSIBLE CAUSES
CORRECTION
POSSIBLE CAUSES
CORRECTION
Visual.
Tubing vibration.
Visual.
Reservoir overfilled.
Fill reservoir.
Contaminated oil.
Foaming oil.
Fill reservoir.
Oil heating.
LB 75115 / FB 90.2200.2
PRESSURE TESTING
Steering Standby
3. install 040 bar (0600 psi) pressure gauge into
the lower test port on left hand side of machine.
4. Set engine speed to 1000 rev/min
39
5. Ensure no turning force is being applied to the
steering wheel and observe pressure on gauge.
The pressure gauge should read approximately
17 bar (250 psi) and is the steering standby pressure.
6. If pressure incorrect remove and examine flow
divider spool on end of pump
40
Steering Circuit Relief Valve
1. install 0200 bar (03000 psi) pressure gauge
into the lower test port on left hand side of machine.
2. Set engine speed to 2000 rev/min and fully turn
and hold steering on either full left or right hand
turn and observe pressure gauge. The gauge reading
should
rise
to
175183 bar
(25602660 psi) and is the steering circuit relief
valve setting.
41
3. If reading is not to specification stop engine, remove blanking plug on pump flow divider and
using screwdriver turn relief valve adjusting
screw to increase or decrease setting.
4. Retest steering and when pressure correct peen
end of adjuster to prevent movement and reinstall blanking plug.
42
LB 75115 / FB 90.2200.2
43
4. Hold the loader bucket control lever to the left
causing the bucket to roll back.
44
5. Observe the reading on the upper gauge which
will display the system pressure relief valve setting.
Pressure reading should be
210 bar
(3040 psi)
6. If relief valve is away from specification adjust to
Specification.
45
LB 75115 / FB 90.2200.2
46
3. Observe the upper gauge which should read
160 bar (2300 psi) minimum and is the operating
pressure of the loader bucket, piston end, relief
valve. Values up to 190 bar are acceptable
4. Adjust valve if not to specification.
5. To test rod end circuit relief valve hold lever to the
left and curl in the bucket. If pressure reading is
210 bar the system relief valve is operating and
it is an indication that relief valve which is set at
230 bar is set correctly.
47
Extendible Dipper Relief Valve (Piston End)
1. Set engine speed to 2200 rev/min
2. Fully extend the extendible dipper and continue
to depress the control pedal.
48
3. Observe the reading on the gauge in the lower
test port (3).
4. Pressure recorded is the extendible dipper relief
valve setting and should read 165 bar (2375 psi)
minimum. Values up to 200 bar are acceptable
5. Adjust valve if not to specification.
49
LB 75115 / FB 90.2200.2
10
50
6. Observe the reading on the gauge in the lower
test port (3).
7. Pressure recorded is the extendible dipper relief
valve setting and should read 165 bar (2375 psi)
minimum. Values up to 200 bar are acceptable
8. Adjust valve if not to specification.
51
Dipperstick Bucket and Boom Relief Valves
Valves
These relief valve are set to a higher pressure than
the main system relief valve setting of 210 bar.
To test these circuit relief valves operate each service until the corresponding relief valve operates.
If pressure reading in each incidence is 210 bar the
system relief valve is operating and it is an indication
that relief valves are set correctly.
Dipperstick bucket circuit relief valve (rod end) secification is 220 bar.
Dipperstick boom circuit relief valve setting (piston
end) is 240 bar.
To accurately test the dipperstick bucket (rod end)
and boom (piston end) relief valves the main system
pressure can be temporarly increased to 240 bar.
Do Not increase pressure setting to higher than 240
bar and reset system relief valve to 210 bar on
completion of test.
NOTE: Dipperstick boom circuit relief valve setting
(rod end) is 315 bar and can not be checked using
this system. Replace this valve if considred faulty.
LB 75115 / FB 90.2200.2
11
Flow Testing
Pump Performance Test
The following pump performance test must be performed after pressure testing the system and rear
pump relief valves and when the hydraulic oil is at
normal operating temperature of 75 C.
1. Disconnect inlet and outlet hoses to backhoe
control valve and install 0200L/min flowmeter
2. Open flowmeter valve.
3. Slowly turn flow control valve and increase pressure to 175 bar (2550 psi) Measure pump flow
which should be 6981 Litres/min.
Analysis
If flow recorded in step 3 is less than 69 Litres/min
the pump is worn and requires overhaul.
NOTE: If the machine has a history of poor service
intervals replace the hydraulic system filter and clean
pump intake filter in the reservoir.
52
LB 75115 / FB 90.2200.2
12
NOTES
LB 75115 / FB 90.2200.2
Description
Page
35 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Swing System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Cylinders
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Backhoe and Loader Cylinders Removal and Installation
35 702
35 702
35 701
35 701
35 703
35 703
35 703
35 701
35 702
SPECIFICATIONS
Grease
Thread Sealant
TORQUES
Cylinder
Gland Torque
Nm
lbf. ft
Nm
lbf. ft
705855
520630
670830
500600
705855
520630
Wired Gland
Wired Gland
19302075
14251530
670830
500600
19302075
14251530
670830
500600
14301570
10501150
670830
500600
705855
520630
Wired Gland
Wired Gland
705855
520630
Wired Gland
Wired Gland
14301570
10501150
670830
500600
Swing Cylinder
14301575
10501150
670830
500600
LB 75115 / FH 90.2200.2
TORQUES Continued
Tool No.
SPECIAL TOOLS
Application
297188 (C wrench)
297185 (C wrench)
297185 (C wrench)
LB 75115 / FH 90.2200.2
SWING SYSTEM
DESCRIPTION AND OPERATION
The backhoe boom and digging elements can be
moved in an arc about the mainframe of 180 degrees.
3
This movement is obtained by the use of two interconnected hydraulic cylinders coupled between the
mainframe and swing post.
The cylinders act directly on the swing post, without
the use of any connecting links or bellcranks.
4
Each cylinder incorporates a headstock consisting of
two large trunnions (1) 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.
5
LB 75115 / FH 90.2200.2
LB 75115 / FH 90.2200.2
6
Swing Cylinder Operation Right Hand Swing
1.
2.
3.
4.
LB 75115 / FH 90.2200.2
5.
6.
7.
HYDRAULIC CYLINDERS
DESCRIPTION AND OPERATION
1.
2.
3.
4.
Decelerator*
Piston
Rod
Gland Assembly
LB 75115 / FH 90.2200.2
9
1.
2.
3.
4.
5.
6.
7.
LB 75115 / FH 90.2200.2
Gland
Wiper Seal
U Seal
Locking Wire
Back-up Ring
O Ring Seal
Buffer Seal
Cylinder Pistons
11
1.
2.
3.
Decelerator Ring
Piston Seals
Washer
Figure 161 illustrates the various pistons used together with the appropriate method of attaching the
piston to the cylinder rod.
Piston Design Cylinder
A
Backhoe Lift
B
Backhoe Crowd
C
Backhoe Bucket
D
Loader Bucket
Loader Lift
Extendible Dipper
Sideshift Stabiliser
Centre Pivot Stabiliser
E
Backhoe Swing
LB 75115 / FH 90.2200.2
12
WARNING
Always support the structural members so that they
will be stable and safe to work around.
2. If the bucket cylinder is to be removed ensure the
bucket is firmly positioned on the ground.
13
3. Stop the engine and move the backhoe control
levers through all operating positions to relieve
all residual pressures in the system.
14
4. If the cylinder is to be disassembled following removal loosen the cylinder gland approximately
1/4 of a turn using the special peg wrench listed
under special tools on Page 1. DO Not completely unscrew the gland. This operation will assist in
removing the gland during subsequent cylinder
disassembly.
If necessary gently heat the gland carrier to
soften the thread sealant applied during manufacture.
15
LB 75115 / FH 90.2200.2
10
16
NOTE: The rod end of the crowd cylinder and piston
end of the lift cylinder use a common attaching pin.
When either cylinder is being removed, the other cylinder must be securely supported and the dipstick
positioned in such a way that no movement is possible.
17
7. Disconnect the hydraulic connections to the cylinder ports and cap or plug all openings.
8. Remove the cylinder pivot barrel pivot pin (1) and
remove the cylinder.
9. Drive the attaching pins from the cylinder using
a brass drift and hammer. Accurate positioning of
the cylinder prior to hose disconnection will aid
pin removal.
10. Remove the cylinder, drain the contained oil and
recap the openings.
18
11. Installation follows the removal procedure in reverse.
12. If necessary carefully use hydraulic power to extend or retract cylinder and align cylinder for pivot
pin installation.
13. During installation ensure the grease retention
seals are correctly fitted.
14. Grease the pivot points with the specified
grease.
19
604.56.061.00 / 604.13.028 09/2000
LB 75115 / FH 90.2200.2
11
WARNING
Always support the structural members so that they
will be stable and safe to work around.
20
2. Stop the engine and move the backhoe control
levers and extendible dipper control pedal
through all operating positions to relieve all residual pressures in the system.
21
3. Remove pivot pin (1) from dipper using a suitable
drift.
22
4. Disconnect hydraulic connections (1), at dipper
cylinder and support cylinder using suitable
hoist.
5. Remove pivot pin (2) at top of cylinder and carefully withdraw cylinder.
6. Installation follows removal procedure in reverse. Use an additional strap around the barrel
of the cylinder to hold the cylinder in position
when installing the lower pivot pin.
7. If necessary carefully extend or retract the cylinder using hydraulic power to align cylinder for
pivot pin installation.
23
LB 75115 / FH 90.2200.2
12
24
IMPORTANT: If the bucket cannot be safely supported it must be removed and the loader arms supported using a suitable stand or hoist.
WARNING
Always ensure loader is fully supported. Do Not work
under or near an unsupported loader or personal
injury may occur
25
3. Relieve the residual pressure in the system by
moving the loader control lever through all operating positions and recheck loader is fully supported.
26
4. If cylinder is to be overhauled use peg wrench
297191 to loosen cylinder gland by approximately 1/4 of a turn and break the thread seal. Do Not
completely unscrew the gland.
5. If necessary gently heat the gland carrier to
soften the thread sealant applied during manufacture.
27
604.56.061.00 / 604.13.028 09/2000
LB 75115 / FH 90.2200.2
13
28
Loader Bucket Cylinder
(Op No 35 701)
1. Position loader bucket firmly on the ground and
position a suitable support below the bucket cylinder tie rod (1).
2. Use a suitable block to support the cylinder remove idler (2) and tipping link (3).
29
3. Remove engine side cover and withdraw cylinder
barrel pivot pin (1).
4. Remove the cylinder.
5. Installation follows removal procedure in reverse. If necessary carefully use hydraulic power
to extend or retract cylinder to align cylinder for
pivot pin installation.
30
LB 75115 / FH 90.2200.2
14
31
2. Remove the stabiliser pad. Lower the stabiliser
to the ground and with the engine stopped, relieve residual pressures.
3. Disconnect the hydraulic feed tubes at the top of
the stabiliser leg
32
4. Remove the cylinder pin locking bolt (1).
5. Fit a 1/2 inch13 x 1.50 threaded eye bolt and
shackle in the threaded hole on the top of the cylinder. Ensure that the threaded portion of the eye
bolt does not screw into the waisted section of
the locating pin (2)
33
6. Drive out the locating pin and lift the cylinder from
the casing.
7. Installation follows removal procedure in reverse. Tighten locking bolt to a torque of
108130 Nm (8096 lbf ft).
34
604.56.061.00 / 604.13.028 09/2000
LB 75115 / FH 90.2200.2
15
35
3. If cylinder is to be overhauled after removal use
peg wrench 297192 to loosen cylinder gland nut.
4. Securely support the cylinder using a suitable
strap and hoist.
5. Remove the cylinder rod end pivot pin (1) and
using hydraulic power very slowly retract the cylinder.
6. With the engine stopped, relieve any residual
pressures by moving the stabiliser control levers.
36
7. Disconnect and cap the hydraulic hoses at the
lock valve (1).
8. Remove the cylinder barrel pivot pin (2) and remove cylinder.
37
LB 75115 / FH 90.2200.2
16
WARNING
Always support the structural members so that they
will be stable and safe to work around.
38
3. Position a trolley jack beneath the carriage.
39
4. Remove the 6 clamp bolts on the bottom of the
carriage followed by the 6 bolts (1) on top of the
carriage.
40
LB 75115 / FH 90.2200.2
17
WARNING
Before moving machine forward check that backhoe
is still fully supported by the hoist and remains stable.
41
6. Using an M10 bolt or adaptor and slide hammer
remove piston (1) from bore.
7. Replace piston seals (2) and examine cylinder
bore. The cylinder is spot welded to the carriage
but can be replaced if damaged.
8. Installation follows the disassembly procedure in
reverse. When installing carriage onto frame ensure piston cups (3) are fitted.
42
9. Torque all carriage clamp bolts to a torque of
1030 Nm (760 lbf ft).
43
LB 75115 / FH 90.2200.2
18
CYLINDER OVERHAUL
Backhoe and Loader Cylinders
(Op No 35 701 and 35 702)
1. Thoroughly drain oil from cylinder. Cap the ports
and thoroughly clean the exterior so that the internal parts will not become contaminated.
2. Using the correct wrench as detailed on Page 1
remove the cylinder gland.
NOTE: A high torque is required to loosen the
threaded type gland, It is therefore recommended
that the attaching points on the machine are used to
secure the cylinder when loosening the gland as described in cylinder removal
44
3. If the gland is the wired type rotate rotate the
gland and withdraw the locking wire.
45
4. Pull the cylinder rod gland and piston assembly
from the barrel.
5. Secure the cylinder rod trunnion in a vice or preferably secure to the cylinder anchor point on the
machine and using a high quality socket and
drive system unscrew the piston retaining bolt. A
considerable torque may be required to loosen
the bolt.
46
LB 75115 / FH 90.2200.2
19
47
1.
2.
3.
4.
Decelerator*
Piston
Rod
Gland Assembly
1.
2.
3.
4.
5.
6.
LB 75115 / FH 90.2200.2
48
20
8. Thoroughly clean all parts in an approved cleansing agent and inspect for damage.
9. Small nicks, burrs or other damage may be
hidden by oil film. It is therefore essential that a
thorough cleaning process be adopted.
10. Replace the gland seals.
1.
2.
3.
4.
5.
6.
7.
49
Wired Type Gland Assembly
1.
2.
3.
4.
5.
6.
7.
Gland
Wiper Seal
Buffer Seal
Locking Wire
Back-up Ring
O ring seal
U Seal
50
11. When reassembling the gland assemblies ensure that:
The concave face of the backup ring touches
the O ring.
The groove moulded in the face of the buffer seal
is positioned towards the cylinder barrel.
12. Inspect the piston wear rings. These rings are not
removable and if damaged a new piston assembly must be installed.
13. If damage on cylinder rods cannot be repaired by
buffing with a very fine abrasive a new rod should
be installed.
14. Inspect cylinder bushes (1) for wear and replace
seals (2).
51
LB 75115 / FH 90.2200.2
21
52
3. Wired Glands
On wire retained glands lightly coat the outer surface of the gland and lead in area of the cylinder
barrel with a lithium base high melting point type
grease and gently tap the gland into the barrel.
4. Slowly rotate the gland until the small hole in the
locking wire groove aligns with the hole in the
barrel. Install the short right angled bend of the
locking wire into the gland hole and rotate the
gland in a clockwise direction until the wire has
been installed . Ensure 8 mm of wire is exposed
for future disassembly.
5. Apply sealant New Holland Part No 82995776 to
the wire entry hole to prevent the ingress of wire.
LB 75115 / FH 90.2200.2
53
22
54
2. With the engine stopped, relieve residual pressures by moving all control levers in all directions.
55
3. Disconnect the feed and return hose to the cylinders and cap all exposed openings.
4. Remove the locking pin (3) and pivot pin (2).
5. Remove bolts securing the retaining plate (1).
56
6. Using a suitable sling lift the plate from the swing
cylinder trunnions. Retrieve and identify the
shims (2) used on each side of the plate to ensure correct reassembly.
7. Carefully lift the cylinder from the swing post.
57
604.56.061.00 / 604.13.028 09/2000
LB 75115 / FH 90.2200.2
23
Disassembly
1. Release locking tab on the headstock
2. Position the headstock/gland trunnion in a vice.
and using Tool 297191, unscrew barrel from the
headstock.
58
3. Remove Piston and rod assembly from barrel.
59
4. Secure end of cylinder rod in a vice and using
high quality deep welled socket and drive system
unscrew piston retaining bolt (1), taking care not
to damage the sliding restrictor (2).
5. Remove piston and withdraw rod from headstock.
60
6. Disassemble sliding restrictor.
1.
2.
3.
4.
5.
Sliding Restrictor
Bush
Piston Bolt
Retaining Pin
Spring
Sliding Restrictor
61
LB 75115 / FH 90.2200.2
24
62
63
Reassembly and Installation
Reassembly follows the disassembly procedure in
reverse while observing the following.
1. Tighten the piston retaining bolt to a torque of
14701570 Nm (10841157 lbf ft.)
2. Apply 6 drops of thread sealant New Holland Part
No 82995773 to the gland threads and tighten to
a torque of 670830 Nm (494612 lbf ft).
3. Bend locking tab into groove in the gland.
4. Tighten swing cylinder plate retaining bolts to a
torque of 607 Nm .
64
LB 75115 / FH 90.2200.2
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
Specifications are listed for the individual components at the beginning of each section of the Repair Manual for
your guidance.
TORQUES
Torque figures for individual components are listed at the beginning of each section of the Repair Manual.
This section specifies the torques of the attachment of components to the vehicle and interlinking parts hoses
and tubes. Below are general torque figures for hydraulic hoses, tubes and ORS Connections that you may find
on your machine.
Thread Size:
9/
16 in 18
11/ in 16
16
13/ in 16
16
....................
....................
....................
1 in 14
....................
13/16 in 12 . . . . . . . . . . . . . . . . . . . .
17/16 in 12 . . . . . . . . . . . . . . . . . . . .
111/16 in 12 . . . . . . . . . . . . . . . . . . . .
2 in 12
....................
13.5 16.5 Nm . . . . . .
23 28 Nm . . . . . . . . .
45 53 Nm . . . . . . . . .
62 77 Nm . . . . . . . . .
86 107 Nm . . . . . . .
125 142 Nm . . . . . .
169 190 Nm . . . . . .
203 246 Nm . . . . . .
( 10 12 lbf ft)
(17 20 lbf ft)
(32 39 lbf ft)
(46 57 lbf ft)
(63 79 lbf ft)
(93 105 lbf ft)
(125 140 lbf ft)
(150 182 lbf ft)
SPECIAL TOOLS
Special Tools are listed in the Repair Manual introduction and at the beginning of each section of the Repair
Manual for your guidance.
LB 75115 / FB 90.2200.2
Description
Part No.
NH
82995773
82995778
FLEXIBLE 50ml
GASKET
SEALANT 300ml
THREAD SEAL
50ml
CLEAR
ADHESIVE 50ml
AND
SEALANT 310ml
GASKET DRESSING
60ml
Typical Applications
General locking and sealing of metallic
threadsmedium strength
Oil tolerant
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.
Bonds most materials including wood, rubber,
metals, most plastics
Not absorbed by porous materials
82995771
82995768
82995770
82995775
82995776
82995774
82995772
SOLVENT CLEANER
& DEGREASER 400ml 82995779
LB 75115 / FB 90.2200.2
MISCELLANEOUS
Description
Part No.
NH
STRIPPED THREAD
REPAIR KIT
82995777
GASKET REMOVER
300ml
82995782
CITRUS HAND
CLEANER 400ml
82995780
3 litre
82995781
PENETRATING OIL
330ml
LB 75115 / FB 90.2200.2
82995769
Typical Applications
Use for fast repair of most stripped or damaged
threaded metallic parts (see pack)
Complete kit, no additional special tools required
Withstands temperature to 150C
Spray on fast action foaming gasket remover
Removes old heat hardened gasket residue
without damaging metal surfaces
Removes all Loctite gaskets and gasket residue.
Removes carbon deposits from cylinder heads etc.
Natural hand cleaner made from citrus oil
Removes ground in dirt, grease, grime, paint,
glue oil and tar
Contains premium skin conditioners
Use with or without water
General purpose penetrating lubricant
Frees corroded fasteners, mechanisms etc.
Lubricates cables, locks, linkages etc.
Cleans, displaces moisture, prevents corrosion
LB 75115 / FB 90.2200.2
3
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
TORQUES
ENGINE
Engine / transmission retaining bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . 95 Nm (70 lbf ft)
Engine coolant expansion tank retaining bolts . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft)
Engine / transmission mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Nm (70 lbf ft)
Engine top panel to support bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (59 lbf ft)
Air cleaner retaining bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft)
Air cleaner bowl to pipe clamp connection . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft)
Coolant radiator bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Nm (70 lbf ft)
Radiator hose connections (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft)
Radiator hose connections (large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft)
Radiator retaining bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Nm (70 lbf ft)
Fuel tank connecting hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft)
Front support cowling to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Nm (158 lbf ft)
Front bonnet to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Nm (125 lbf ft)
Upper and front bonnet to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (59 lbf ft)
TRANSMISSION
Transmission gear lever clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm (66 lbf ft)
Hydraulic pump pipe connection (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm (26 lbf ft)
Hydraulic pump pipe connection (large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm (86 lbf ft)
Power steering outlet to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft)
Hydraulic oil cooler to coolant radiator bolts . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft)
Hose transport lock valve to gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 lbf ft)
Hose transport lock valve to gearbox dipstick pipe . . . . . . . . . . . . . . . . . . . 15 Nm (11 lbf ft)
Spicer universal couplings rear and front (when FWD fitted) . . . . . . . . . . 38 Nm (28 lbf ft)
LB 75115 / FB 90.2200.2
25 000 4WD Front Axle, 44 000 2WD Front Axle and 27 000 Rear Axle
REMOVE:
Rear Wheels
DISCONNECT:
Brake piston hoses (cap all exposed ports)
Spicer coupling
Differential Lock pedal
Axle attaching bolts
FRONT AXLE 2WD 44 000 Mounted below the
front of the chassis and held in position by the swivel
pin trunnion supports attached to the underside of
the chassis by 8 through bolts.
To remove the front axle it will be necessary to
disconnect or remove the following with the vehicle
suitably supported:
REMOVE:
Front Wheels
DISCONNECT:
Steering piston hoses
Axle swivel pin attaching bolts
LB 75115 / FB 90.2200.2
25 000 4WD, 44 000 2WD Front Axle and 27 000 Rear Axle
COMPONENTS
TORQUES
1. FRONT AXLE
Font axle retaining bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607 Nm (447 lbf ft)
Front Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 Nm (516 lbf ft)
Front axle power steering hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Nm (1.8 lbf ft)
Spicer coupling to transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 lbf ft)
2. REAR AXLE
Rear axle to frame retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 Nm (700 lbf ft)
Rear Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 Nm (516 lbf ft)
Front axle power steering hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Nm (1.8 lbf ft)
Spicer coupling to transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 lbf ft)
LB 75115 / FB 90.2200.2
10
35 000 Hydraulics
2
16
15
7
14
8
12
13
11
10
9
6
LB 75115 / FB 90.2200.2
11
35 000 Hydraulics
COMPONENTS
TORQUES
Pipes lockout valves to stabiliser cylinder (where fitted) . . . . . . . . . . . 55 Nm (41 lbf ft)
LB 75115 / FB 90.2200.2
12
Hoses backhoe control valve to swing cylinder retaining clamps . . . . 50 Nm (37 lbf ft)
Hoses backhoe control valve to swing post 5/8 . . . . . . . . . . . . . . . . . . 120 Nm (88 lbf ft)
Hoses backhoe control valve to swing post 1/2 . . . . . . . . . . . . . . . . . . 85 Nm (63 lbf ft)
LB 75115 / FB 90.2200.2
13
LB 75115 / FB 90.2200.2
14
TORQUES
BALLAST
Chin weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Nm (369 lbf ft)
LB 75115 / FB 90.2200.2
15
82 000 Loader
Loader
LOADER 82 000 Attached in position by pins and
retained by bolts the loader frame can be removed
as an assembly from the machine.
Removal of the loader is achieved by disconnection
or removal of the following with the loader fully
supported:
IMPORTANT: Before disconnecting any hoses or
cylinders relieve all pressure in the hydraulic system
and have ready suitable clean containers to drain the
oil into. Ensure all ports and hoses are plugged or
capped to prevent dirt ingress during overhaul.
LB 75115 / FB 90.2200.2
DISCONNECT:
Leveling Arm
Pivot Pins
Loader pivot cross shaft upper
Lift cylinder hoses
Bucket cylinder hoses
loader pivot support shafts lower
REMOVE:
Bucket
16
82 000 Loader
COMPONENTS
TORQUES
LB 75115 / FB 90.2200.2
17
10
Backhoe
BACKHOE 84 000 Disassembly of the backhoe is
similar for both sideshift and centre pivot models
upto the swing post.
IMPORTANT: Before disconnecting any hoses or
cylinders relieve all pressure in the hydraulic system
and have ready suitable clean containers to drain the
oil into. Ensure all ports and hoses are plugged or
capped to prevent dirt ingress during overhaul.
To remove the backhoe it will be necessary to
disconnect or remove the following with the backhoe
fully supported:
DISCONNECT;
Hoses (depressurise the system first)
Sideshift Backhoe
The backhoe on sideshift models is attached to a
frame that is attached to the vehicle and can traverse
the rear of the machine. For disassembly purposes
the backhoe and its support frame can be removed
from the machine.
Centre Pivot Backhoe
On centre pivot models the backhoe is connected
directly to the chassis and can be removed from the
machine at that point.
In the following pages are the torque figures for the
various assemblies that will may removed to affect
repairs
REMOVE:
Sideshift only Backhoe support frame to chassis
LB 75115 / FB 90.2200.2
18
84 000 Backhoe
COMPONENTS
TORQUES
BACKHOE
1. Backhoe sideshift to frame retaining bolts . . . . . . . . . . . . . . . . . . . . . . . 800 Nm (590 lbf ft)
2. Backhoe to frame hose retaining clamps . . . . . . . . . . . . . . . . . . . . . . . . 52 Nm (38 lbf ft)
Backhoe Clamp Valve Retaining Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (7 lbf ft)
Pipes lockout valves to stabiliser cylinder (where fitted) . . . . . . . . . . . 55 Nm (41 lbf ft)
Transport lock cylinder retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft)
BACKHOE HOSES
Hose transport lock valve to transmission . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 lbf ft)
Hose transport lock valve to transmission dipstick pipe . . . . . . . . . . . . 15 Nm (11 lbf ft)
Hoses backhoe control valve to boom (large) . . . . . . . . . . . . . . . . . . . . 120 Nm (88 lbf ft)
Hoses backhoe control valve to boom (small) . . . . . . . . . . . . . . . . . . . . 85 Nm (63 lbf ft)
Hoses backhoe control valve to swing cylinders retaining clamps . . . 50 Nm (37 lbf ft)
Hoses backhoe control valve to swing post 5/8in . . . . . . . . . . . . . . . . . 120 Nm (86 lbf ft)
Hoses backhoe control valve to swing post 1/2in . . . . . . . . . . . . . . . . . 85 Nm (63 lbf ft)
Hoses backhoe control valve to swing cylinders . . . . . . . . . . . . . . . . . . 54 Nm (40 lbf ft)
STABILISERS
3. Stabilisers Upper Pins Retaining Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (59 lbf ft)
Stabiliser elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Nm (60 lbf ft)
Hoses lockout valves (where fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft)
MISCELLANEOUS
4. Rear Shield to frame bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Nm (38 lbf ft)
LB 75115 / FB 90.2200.2
19
11
LB 75115 / FB 90.2200.2
20
TORQUES
CAB
Cab support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 Nm (332 lbf ft)
Front cab retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Nm (158 lbf ft)
Rear cab retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm (133 lbf ft)
SHEET METAL
Bonnet Front casting to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Nm (158 lbf ft)
Upper and front bonnet retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (59 lbf ft)
Front bonnet to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Nm (125 lbf ft)
NOTES
LB 75115 / FB 90.2200.2
SECTION 41 STEERING
Chapter 1 Control
CONTENT
Section
41 000
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
Pump
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi G API GL4, ISO 32/46
Output at 2200 revs/min @ Standby Pressure . . . . . 62.7 litres/min (16.6 US.gals/min )
Steering Motor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Turns Lock to Lock
Four-Wheel Drive Axle . . . . . . . . . . . . .
Two Wheel Drive . . . . . . . . . . . . . . . . . .
Steering Pressure Relief Valve . . . . . . . . . . . . . . . . . . . .
Standby Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LB 75110 / FH 90.2110.2
ft. lbs.
Nm
kgf.m
41.0
17.0
22.0
35.0
40.0
32.0
130.0
200.0
26.0
31.0
23.0
12.0
31.0
22.0
55.0
23.0
30.0
45.0
55.0
43.0
176.0
271.0
35.3
42.0
31.2
16.3
42.0
30.0
5.6
2.3
3.0
4.5
4.0
4.4
18.0
27.5
3.6
4.3
3.2
1.7
4.2
4.0
SPECIAL TOOLS
DESCRIPTION
Seal Installer
Part No 291924
LB 75115 / FH 90.2110.2
1
1.
2.
3.
LB 75110 / FH 90.2110.2
Steering pump located on the rear of the transmission which has a priority valve giving up to
62.7 L/min (16.6 US.gals) at 2200 rev/min.
Oil cooler and filter is an integral part of the hydraulic system.
A closed centre steering motor is used.
LB 75115 / FH 90.2110.2
Flow Divider
3
1.
2.
3.
4.
5.
6.
7.
Housing
Valve
O Ring
Spool
Adjuster
Spring Seat
Spring
The flow divider located on the rear of the pump comprises of a load sensed priority valve and steering
system pressure relief valve.
The load sense valve ensures that a priority oil flow
to the steering system is maintained while steering
the vehicle, with remaining flow directed to the stabiliser, loader and backhoe circuits.
NOTE: Flow from the rear pump on entering the
loader and backhoe circuits combines with the flow
from the front pump to provide increased flow.
Operation
Flow from the rear pump enters the flow divider at
inlet port (1).
The spring force on the end of the spool holds the
spool to the left enabling flow to pass into steering
port (3).
LB 75110 / FH 90.2110.2
10
2
3
4
13
11
14
5
6
12
9
4
1.
2.
3.
4.
5.
6.
7.
When the steering is in neutral the LS port is connected to the unload (through the steering) and the
steering inlet port (CF) is open.
LB 75115 / FH 90.2110.2
6
BRC0706B
5
Load Sensing Valve with Pump Running Steering in Neutral
Pressure Oil
Trapped Oil
1.
2.
3.
4.
Orifice
To steering priority flow
Filter
Spool
5.
6.
7.
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).
1
6
BRC0706C
6
1.
2.
3.
4.
POSSIBLE CAUSES
Steering wanders
Front wheels
steering
surge
when
Noisy pump
CORRECTION
2. Air in system
4. Worn pump
2. Air in system
3. Water in oil
4. Worn Pump
4. Replace Pump
LB 75115 / FH 90.2110.2
7
1.
2.
3.
4.
5.
Pump Body
O Ring Seal
Backup Seal
Pressure Seal (Rubber)
Bearing Block
OVERHAUL
Steering pump overhaul (rear pump), refer to the hydraulic pump section.
LB 75110 / FH 90.2110.2
10
9
Steering Motor Neutral
Pump Pressure
Trapped Oil
Standby Pressure
Return to Reservoir
LB 75115 / FH 90.2110.2
11
10
Steering Motor Turning Right
Pump Pressure
Trapped Oil
Metered Pressure
Return to Reservoir
LB 75110 / FH 90.2110.2
12
System Overhaul
To gain access to the steering motor the bonnet and
air cleaner should be removed.
11
Removing Steering Motor
Disconnect the four connectors and collect the O
ring seals, noting the connector positions.
12
Remove the four Allen screws from within the cab.
The motor can be removed from the front of the cab
through the engine compartment.
13
Steering motor ports.
1.
2.
3.
4.
14
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FH 90.2110.2
13
15
End plate removal
NOTE: The position of the pin bolt must remain the
same upon reassembly of the end cap.
1.
2.
End plate
Pump body
16
Metering unit removal
1.
2.
3.
4.
Steering motor
Driving link
Stator
Rotor
17
Drive link removal
1.
2.
18
LB 75110 / FH 90.2110.2
14
Body
Valve Plate
19
Check valve removal
1.
2.
Retainer cap
Check valve
20
Suction and check valves
1.
2.
3.
4.
21
Cylinder Relief Valves
IMPORTANT: Before removal of the cylinder relief
for cleaning valves if necessary remove the end plug
and seal. Measure at, (x) using a depth gauge, the
distance from the outer body to the head of the adjuster (5) and record the results. Upon reassembly
reset the adjuster to the exact depth previously recorded.
1.
2.
3.
4.
5.
6.
Ball
Seat
End Plug
Seal
Adjuster
Spring
3
4
6
22
LB 75115 / FH 90.2110.2
15
Control valve
Housing
23
Control valve
1.
2.
3.
4.
5.
6.
7.
NOTE: The thick washer must be reinstated with internal diameter chamfer toward the valve sleeve.
24
Drive pin and centring springs
1.
2.
3.
4.
Control valve
Drive pin
Spool
Centring springs
25
Oil seal location
1.
2.
Seal seat
Seal
26
LB 75110 / FH 90.2110.2
16
27
1.
2.
3.
4.
5.
6.
7.
8.
Component Inspection
Check for signs of wear in the following areas:
Rotor and stator of metering unit move freely
Check the drive pin is not cracked or bent
Check the rollers in thrust bearing are free to rotate
LB 75115 / FH 90.2110.2
17
28
Oil seal installation
1.
2.
3.
Oil seal
Outer tool sleeve
Inner Tool shaft
29
Reassembly
NOTE: Great care should be taken during reassembly. Coat all components in hydraulic oil.
Ensure drive pin is horizontal before installation.
Ensure thick thrust washer internal diameter
chamfer is towards the valve sleeve.
Do not over torque end plate.
This motor does not have to be timed due to a
master spline.
Finally, check motor turns freely.
30
LB 75110 / FH 90.2110.2
18
1
7
3
5
31
Pressure Testing
Connect a suitable pressure gauge capable of reading up to 200 bar (2900 psi) to the centre connector
inside the left hand loader support.
Start engine. A standby pressure of 67 bar
(87101 psi) should be observed.
Turn steering to the left or right to the stop. A
maximum pressure of 140 bar (2030 psi) should
be seen.
NOTE: Engine speed should be set to 1000 rev/min.
For settings and adjustment procedure refer to the
pressure testing section.
32
LB 75115 / FH 90.2110.2
SECTION 41 STEERING
Chapter 2
CONTENT
Section
41 000
Description
Page
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
Pump
Oil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambra Multi G
Displacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 cm3/rev
Steering Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 bar +/ 3.5 bar (2610 +/ 50 psi)
Standby Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7bar (101.5 psi)
Shock Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 bar (3480 psi)
TIGHTENING TORQUES
Steering Wheel Nut
Steering Motor to Steering Column Bracket
Steering Motor End Cover
Steering Motor Pipe Connections
Steering Motor Pipe Adaptors
Steering Cylinder Balljoint Clamps
Steering Cylinder Balljoint Nuts
Steering Cylinder Extension Tube to Cylinder
Steering Pump Body Through Bolts
Steering Pump Drive Gear Nut
Steering Pump to Front Cover Bolt
Steering Pump Reservoir Bolt
Steering Pump Relief Valve
Check Valve Bolt
LB 115 / FB 200.2
ft.lbs
41.0
17.0
22.0
35.0
40.0
32.0
130.0
200.0
26.0
31.0
23.0
12.0
31.0
22.0
Nm
55.0
23.0
30.0
45.0
55.0
43.0
176.0
271.0
35.3
42.0
31.2
16.3
42.0
30.0
kgf.m
5.6
2.3
3.0
4.5
4.0
4.4
18.0
27.5
3.6
4.3
3.2
1.7
4.2
4.0
1
1.
2.
3.
Steering System
4. Hydraulic System Filter
5. Flow Divider
6. Hydraulic Oil Cooler
Oil flow from the steering motor to axles is electronically controlled using a 4 wheel steer valve
which diverts oil in various directions depending
on the choice selected by the operator.
LB 115 / FB 200.2
2
Steering Valve Schematic
3a
3b
2a
2b
2WS
4WS
4WS
TO
2WS
CRAB
CRAB
TO
2WS
X
3
LB 115 / FB 200.2
T
a
b
P
A
SHK41001
4
port T. Oil cannot exit at A or B, cutting off flow to the
rear steering cylinder, the spool is only in this position
in the standard front wheel steer mode.
The spool in valve 3 above was last moved by solenoid 3b, as can be seen oil flowing in from P flows
through the internal gallerys of the spool and exits at
Valve 2.
B
P
b
T
2
SHK41001
The spool in valve 2 above was last moved by solenoid 2b. Oil enters at port P and exits at port A. Oil
5
enters from valve 3 at port B and exits at port T which
enters the front steering cylinder.
LB 115 / FB 200.2
LB 115 / FB 200.2
Flow Divider
7
1.
2.
3.
4.
5.
6.
7.
Housing
Valve
O Ring
Spool
Adjuster
Spring Seat
Spring
The flow divider located on the rear of the pump comprises of a load sensed priority valve and steering
system pressure relief valve.
The load sense valve ensures that a priority oil flow
to the steering system is maintained while steering
the vehicle, with remaining flow directed to the stabiliser, loader and backhoe circuits.
NOTE: Flow from the rear pump on entering the
loader and backhoe circuits combines with the flow
from the front pump to provide increased flow.
Operation
Flow from the rear pump enters the flow divider at
inlet port (1).
The spring force on the end of the spool holds the
spool to the left enabling flow to pass into steering
port (3).
LB 115 / FB 200.2
10
2
3
4
13
11
14
5
6
12
9
8
1.
2.
3.
4.
5.
6.
7.
When the steering is in neutral the LS port is connected to the unload (through the steering) and the
steering inlet port (CF) is open.
LB 115 / FB 200.2
6
BRC0706B
9
Load Sensing Valve with Pump Running Steering in Neutral
Pressure Oil
Trapped Oil
1.
2.
3.
4.
Orifice
To steering priority flow
Filter
Spool
5.
6.
7.
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).
1
6
BRC0706C
10
1.
2.
3.
4.
LB 115 / FB 200.2
POSSIBLE CAUSES
Steering wanders
Front wheels
steering
Noisy pump
LB 115 / FB 200.2
surge
when
CORRECTION
2. Air in system
4. Worn pump
2. Air in system
3. Water in oil
4. Worn Pump
4. Replace Pump
10
11
Steering Motor Neutral
Pump Pressure
Trapped Oil
Standby Pressure
Return to Reservoir
LB 115 / FB 200.2
11
12
Steering Motor Turning Right
Pump Pressure
Trapped Oil
Metered Oil
Return to Reservoir
LB 115 / FB 200.2
12
The solenoids energised are shown in the table opposite. These are also the pins which need to be
pressed when changing steering mode manually in
an emergency.
X = Energised
O = Not Energised
3a
3b
2a
2b
2WS
4WS
4WS
TO
2WS
CRAB
CRAB
TO
2WS
X
13
LB 115 / FB 200.2
13
14
are only energised momentarily to move the spool.
On the end of each solenoid is an emergency hand
operating pin which moves the control spool without
energising the solenoid. The switching of the steering valve is normally controlled by a microprocessor
located underneath the right hand side console.
15
1.
2.
3.
4.
5.
LB 115 / FB 200.2
14
16
Removing Steering Motor
Disconnect the four connectors and collect the O ring
seals, noting the connector positions.
17
Remove the four Allen screws from within the cab.
The motor can be removed from the front of the cab
through the engine compartment.
18
1.
2.
3.
4.
19
604.56.061.00 / 604.13.028.00 09/2000
LB 115 / FB 200.2
15
20
End plate removal
NOTE: The position of the pin bolt must remain the
same upon reassembly of the end cap.
1.
2.
End plate
Pump body
21
Metering unit removal
1.
2.
3.
4.
Steering motor
Driving link
Stator
Rotor
22
Drive link removal
1.
2.
23
LB 115 / FB 200.2
16
Body
Valve plate
24
Check valve removal
1.
2.
Retainer cap
Check valve
25
Suction and check valves
1.
2.
3.
4.
26
Cylinder relief valves
IMPORTANT: Before removal of the cylinder relief
for cleaning valves if necessary remove the end plug
and seal. Measure at, (x) using a depth gauge, the
distance from the outer body to the head of the adjuster (5) and record the results. Upon reassembly
reset the adjuster to the exact depth previously recorded.
1.
2.
3.
4.
5.
6.
Ball
Seat
End Plug
Seal
Adjuster
Spring
3
4
6
27
LB 115 / FB 200.2
17
Control valve
Housing
28
Control valve
1.
2.
3.
4.
5.
6.
7.
NOTE: The thick washer must be reinstated with internal diameter chamfer toward the valve sleeve.
29
Drive pin and centring springs
1.
2.
3.
4.
Control valve
Drive pin
Spool
Centring springs
30
Oil seal location
1.
2.
Seal seat
Seal
31
LB 115 / FB 200.2
18
32
1.
2.
3.
4.
5.
6.
7.
8.
Component Inspection
LB 115 / FB 200.2
19
33
1
7
3
5
34
Pressure Testing
Connect a suitable pressure gauge capable of reading up to 200 bar (2900 psi) to the connector inside
the left hand loader support.
35
LB 115 / FB 200.2
20
NOTES
LB 115 / FB 200.2
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
Engine Radiator Coolant:
Antifreeze Ambra Agriflu
Water
System Type
Fan Belt Deflection:
Naturally Aspirated
Turbocharged
Thermostat:
Start to Open at
Fully Open at
Radiator Cap
TORQUE VALUES
Coolant/Hot water hose connections
Air hose ducting connections
Heater housing to floor mounting bolts
SEALANTS
Code Number
82995768
82995776
82995774
82995773
LB 75115 / FB 90.2200.2
Name
SealerAnaerobic Low strength
SealerSilicone
SealerPolyester Urethane
SealerAnaerobic
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 adequate ventilation as exhaust fumes can suffocate you.
Cab Air Filter
Before servicing the air filter situated under the drivers
seat, switch off the blower and close all windows and
one door. Forcibly close the other door. The resulting
back pressure will dislodge loose dirt from the underside of the filters.
To remove the filter (1) release the retaining straps (2)
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
prior to servicing the filters. Damp particles drawn
into the filter may solidify and prove difficult to remove without washing.
The filter elements are made of specially treated
paper with a sealing strip bonded to the outer face.
Clean all of the elements by blowing with compressed
air from the clean side through to the dirty side. The
compressed air should not exceed 2 bar (30 psi) and
the air line nozzle should be at least 300 mm (12 in)
from the element.
LB 75115 / FB 90.2200.2
3
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.
LB 75115 / FB 90.2200.2
3
4
5
1.
2.
3.
LB 75115 / FB 90.2200.2
FAULT FINDING
PROBLEM
Dust enters the cab
POSSIBLE CAUSE
CORRECTION
Defective filter
Replace filter
Excessive air leak (s) around doors Repair and Seal air leak (s)
and windows
Blower motor air flow low
Fuse blown
Replace fuse
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
LB 75115 / FB 90.2200.2
OVERHAUL
IMPORTANT: When overhauling the heating system
remember that with the engine running or shortly
after it is turned off that the system will be at engine
temperature 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
from the seat and remove seat from the heater housing.
6
Draining the System
Too drain the cooling system down disconnect either
hose at the T junction found at the rear of the engine
oil filter mounted to the right hand side of the engine.
1
7
Heater Radiator
With the system drained remove the heater radiator
hose connections, attaching bolts and remove from
the vehicle.
Inspect the Heater Radiator:
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 (100 psi) taking care not to damage
the radiator fins.
Ensure tbe radiator is not leaking under pressure, repair or replace as required.
Clean the chamber with a damp, cloth and reassemble the housing filter element with the seal facing
the inside of the cover.
LB 75115 / FB 90.2200.2
Blower Motor
The blower motor can be removed by removal of the
attaching hardware and disconnection of the wiring
connector.
Check the blower is working, if not check fuse and
continuity of blower motor. If defective replace the
blower unit as an assembly.
9
Heater Control Valve
To service the control valve disconnect the hoses
and the control cable and remove. Check the operation of the valve and if tight or worn replace.
10
Heater Control Panel
The blower motor is operated by a 3 position switch
which through a variable potentiometer increases 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.
11
Both of the above are mounted to the right of the
drivers seat and can be accessed by removal of the
control panel for repair or replacement.
12
LB 75115 / FB 90.2200.2
NOTES
LB 75115 / FB 90.2200.2
Description
Page
50 200
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Finding and System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Leak Testing, Charging, Discharging and System Flushing . . . . . . . . . . . . . . . . . . . . 33
Component Overhaul (excluding compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Compressor Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SPECIFICATIONS
Refrigerant Specification
R134a
Refrigerant Charge
LB 75115 / FB 90.2200.2
Sanden SD7H15
0.40.8 mm (0.0160.031in)
10 mm (0.4in) deflection with 1kg (2.2lb) force
applied midway between the pulleys
TORQUES COMPRESSOR
Cylinder Head Bolts
Clutch Front Plate Retaining Bolt
Armature Retaining Nut
Compressor Mounting Bolts
M6
M8
M5 x6
M8
ADJUSTMENT COMPRESSOR
Air Conditioning Compressor Assembly
(where fitted) 75 hp
A correctly tensioned belt can be deflected
1319mm (0.500.75 in) when hand pressure is applied midway between the alternator and crankshaft
pulley
Once adjusted retorque the tension arm bolt to
33.9Nm (25 lbf ft).
13
Air Conditioning Compressor Assembly
(where fitted) 92 to 108 hp
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 16mm
(3/8in).
Once adjusted retorque the tension arm bolt to
33.9Nm (25 lbf ft).
14
LB 75115 / FB 90.2200.2
SPECIAL TOOLS
Only Certified Refrigerant Recovery, Recycling and Recharge Equipment suitable for the type of refrigerant gas
R134a should be used on these vehicles when servicing the air conditioning system.
This special equipment is available through recognised suppliers of air conditioning equipment. Refer to the Tool
supplier for details on the latest equipment available for servicing the air conditioning system.
General Tools
Vacuum/charge Portable system
Recovery/recharge Portable System
Evaporator and Condenser Cleaner
Expansion Valve Tape
Electronic Gas Leak Detector
Manifold Gauge Set (Where required)
Tool No NH 294030
Tool No NH 294048
Tool No NH 293831
Tool No NH 293826
Tool No NH294036
OTC/V.L Churchill Ltd Part No NH00172
Compressor Tools
Sanden Compressor SD7H15
Tool No 297423
LB 75115 / FB 90.2200.2
SAFETY PRECAUTIONS
WARNING
Before overhauling an air conditioning system read
and observe the following Safety Precautions If a repair or replacement becomes necessary, ensure that
only certified Air Conditioning technicians are employed, using approved equipment to effect repairs.
Do not attempt to disassemble the air conditioning
system, It is possible to be severely frostbitten or injured by escaping refrigerant.
When charging and discharging the system always wear goggles and take suitable precautions to protect the face in general and the eyes
in particular, from accidental spillage of the refrigerant fluid.
Before loosening any connection, cover the fitting in question with a cloth and wear gloves and
goggles in order to prevent refrigerant from reaching the skin or eyes.
LB 75115 / FB 90.2200.2
WARNING
The air filter is designed to remove dust from the air
but may not exclude chemical vapour. Refer to
chemical manufacturers directions regarding protection from dangerous chemicals.
If the machine has been parked in the sun, quicken
the cooling by operating the airconditioning for 23
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 airconditioner to extract 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.
LB 75115 / FB 90.2200.2
REFRIGERANT R134a
WARNING
R134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
R134a has a boiling point of 10F (12C).
Never expose any part of the airconditioner 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.
WARNING
If refrigerant should contact the skin use the same
treatment as for frostbite.
Warm the area with your hand or lukewarm water
90F (32C), cover the area loosely with a bandage
to protect affected area against infection and consult
a doctor immediately.
If refrigerant should contact the eyes wash immediately in cold clean water for at least 5 minutes and
consult a doctor immediately.
LB 75115 / FB 90.2200.2
6050001
TI
6050002
TI
5
3. When a gas is cooled it will condense into a
liquid. In the air conditioning system a condenser
is used to cool the gas and the resulting liquid is
stored in a receiver dryer.
6050003
TI
6
4. When a liquid is atomized through an orifice, the
temperature of the resultant vapour will drop.
The low temperature of the atomized liquid will
then absorb heat from its surroundings. On air
conditioning systems the refrigerant is atomized
using an expansion valve.
C
6050004
TI
7
LB 75115 / FB 90.2200.2
8
1.
2.
3.
4.
LB 75115 / FB 90.2200.2
EXPANSION VALVE
LOW TEMPERATURE
HIGH PRESSURE LIQUID
FILTERED AND MOISTURE REMOVED
LOWER TEMPERATURE
LOW PRESSURE
ATOMIZED LIQUID
RECEIVER DRYER
LOWER TEMPERATURE
HIGH PRESSURE LIQUID
EVAPORATOR
CONDENSER
WARM
LOW PRESSURE VAPOUR
HIGH TEMPERATURE
HIGH PRESSURE VAPOUR
COMPRESSOR
HEAT FROM INSIDE CAB
MOVES TO REFRIGERANT
9
Air Conditioning Flow Diagram
LB 75115 / FB 90.2200.2
By giving off heat to the outside air, the vapour is condensed to a liquid which moves under high pressure
to the receiver dryer where it is stored until released
to the evaporator by the temperature sensing expansion valve.
As liquid refrigerant passes through the metered orifice in the expansion valve the refrigerant changes
from a high pressure liquid to a low pressure atomized liquid with a lower temperature.
This low pressure, low temperature, atomized liquid
enters the evaporator coils and absorbs heat from
the cab warm air blown across the coils and fins by
the cab blower motor. The refrigerant now changes
from a cold low pressure atomized liquid to a warm
low pressure vapour and leaves the evaporator
outlet, moving to the suction (low pressure) side of
the compressor to repeat the cycle.
As this heat loss is taking place, moisture (humidity)
in the cab air will condense on the outside of the
evaporator and drain off as water through the drain
hoses attached to the evaporator drain pan, thereby
reducing the humidity level of the cab.
10
WARNING
R134a refrigerant is not compatible with R12 refrigerant. Do not attempt to replace R134a refrigerant with R12 refrigerant or test the system using
gauges or equipment previously used with R12 as
damage to the system will result.
R-134a refrigerant is stable at all operating temperatures and able to absorb great quantities of heat.
The boiling point of R-134a is -22 C (-15 F) at atmospheric pressure.
If the pressure is increased, R-134a will readily vaporize to absorb heat at temperatures between
-11.7 C (11 F) at 1.9 bar (27.5 psi) and 0C (32
F) at 2.9 bar (42 psi) in the evaporator.
At higher pressures, R-134a will condense and give
off heat at temperatures between 48 C (118 F) at
12.4 bar (180 psi) and 58 C (136 F) at 15.85 bar
(230 psi) in the condenser.
LB 75115 / FB 90.2200.2
11
10
1.
2.
3.
4.
5.
Discharge Chamber
Pistons
Reed Valve Plate Assembly
Cylinder Head
Static Gear
Compressor Pump
The air conditioning compressor pump 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 pressure sides of the system and is basically a pump
which has two functions:
(1) To raise the refrigerant temperature by compression 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
wobble plate unit housed in a die cast aluminium
housing.
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 oscillates the wobble plate. The wobble plate is prevented
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.
LB 75115 / FB 90.2200.2
12
11
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 (2) attached to the
larger evaporator tube.
The temperature control switch compares the voltage 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 determines 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 the radiator behind the
battery.
The purpose of the switch is to shut off the compressor pump in the event of low pressure in the refrigerant system.
Low refrigerant pressure may occur due to a faulty
expansion valve, icing up of the expansion valve orifice 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.
12
13
LB 75115 / FB 90.2200.2
13
Condenser
The condenser, (1) located at the front of the
machine in front of the engine radiator consists of a
number of turns of continuous coil mounted in a
series 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 refrigerant vapour from the compressor. The hot vapour passes through the condenser coils and outside
air is drawn through the condenser by the engine
cooling fan.
14
LB 75115 / FB 90.2200.2
16
14
Expansion Valve
The expansion valve is located underneath the evaporator in the pressure line leading from the receiver/
dryer and performs the following functions:
1. METERING ACTION A metered orifice changes the liquid refrigerant
from a high pressure low temperature liquid to a
low pressure, lower temperature atomized liquid.
2. MODULATING ACTION A thermostatically controlled valve within the expansion 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 damage the compressor reed valves or freeze the
pistons.
3. CONTROLLING ACTION The valve responds to changes in the cooling requirements. When increased cooling is required,
the valve opens to increase the refrigerant flow
and when less cooling is required the valve
closes 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 purposes.
The refrigerant from the condenser and receiver
dryer 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
atomized liquid.
The atomized liquid now passes through the evaporator where it absorbs heat before returning via the
expansion valve to the compressor as a warm low
pressure vapour.
There are two refrigerant passages 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 valves temperature sensing element.
Liquid refrigerant flow from the condenser and
receiver 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.
17
6050014
TI
18
LB 75115 / FB 90.2200.2
15
When the system is started, the pressure on the bottom of the diaphragm drops rapidly, allowing the orifice 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 passes the temperature sensor.
The temperature sensor reacts to variations in refrigerant gas pressure returning from the evaporator.
When heat from the passenger compartment is absorbed by the refrigerant the pressure of the gas increases causing a differential pressure above and
below the temperature sensor diaphragm. The diaphragm 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 refrigerant 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 absorbs heat from the hotter air in the operators compartment, thereby cooling the air.
19
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.
20
LB 75115 / FB 90.2200.2
16
Filter General
The blower fan, draws warm air from outside the cab
through the intake filter (2) below the cab floor and already cooled dehumidified air through the recirculation 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 operators
feet.
21
Blower Fan
The blower motor is controlled by a three-speed
switch (2) the switch 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 evaporator for a longer period resulting in the warm air giving
up more heat to the cooler refrigerant. Therefore, the
coldest air temperature is obtained when the blower
fan is operated at the lowest speed.
WARNING
Before dismantling an air conditioning system for repair the gas within the system must be discharged
and recovered using a certified recovery unit designed for the type of refrigerant gas used in the system.
22
To prevent the entry of any foreign material, observe
the following points:
Ensure all tools, gauges, hoses and replacement
parts are kept clean and dry and are suitable for
the type of refrigerant gas used in the system.
Clean all hoses and fittings before disconnecting. Cap or plug all openings when disconnected.
When adding lubricating oil to the system always
uncap and re-cap the oil container immediately
before and after use. Always ensure the oil remains free of moisture.
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
5.
6.
7.
8.
9.
17
18
23
1.
2.
3.
4.
5.
manifold gauge set is connected into a system, pressure is registered on both gauges.
NEVER open the HIGH SIDE shut off valve when
the system is operating.
ALWAYS open the LOW SIDE shutoff valve
when adding refrigerant.
Attaching The Gauge Set To The Tractor
WARNING
To avoid personal injury, stop the tractor engine during connection of the manifold gauge set.
1. Check that the gauge set shut off valves are
closed (turned fully clockwise).
2. Connect the high side gauge hose (normally red)
to the high pressure (discharge) side service
valve and the low side gauge hose (normally
blue) to the low pressure (suction) side service
valve on the tractor. Ensure the hose connections are fully tightened.
LB 75115 / FB 90.2200.2
19
WARNING
A significant amount of refrigerant vapour may have
condensed to a liquid at the service fitting at the high
side of the compressor. Use a cloth or other protective material when disconnecting the manifold hose
from this fitting to prevent personal injury to hands
and face.
LB 75115 / FB 90.2200.2
27
29
32
35
38
41
43
10.3/11.8
11.4/12.9
12.5/14.0
13.6/15.5
14.8/17.0
16.3/18.6
17.7/20.3
lb/in2
147/168
162/184
179/200
194/221
210/242
231/265
252/289
20
PROBLEM
Evaporator air not cold
POSSIBLE CAUSES
CORRECTION
Perform leak tests and repair
Evacuate system
Charge system, retest system
Extremely
charge.
low
refrigerant
Expansion valve
sufficient flow.
Stuck valve
not
permitting
Check expansion
follows:
valve
as
LB 75115 / FB 90.2200.2
21
PROBLEM
POSSIBLE CAUSES
High
pressure
cutting out
Air in system
CORRECTION
Inspect for dirty condenser
restricting air flow and cooling
Check operation of condenser
cooling fans. Repair or replace
as needed.
Check for overcharge as follows:
Stop the engine. Recover and
recycle the charge using correct
recovery equipment.
Recharge the the system with
the
correct
quantity
of
refrigerant, replacing any lost
lubricant. Recheck performance
of air conditioning system.
LB 75115 / FB 90.2200.2
22
PROBLEM
POSSIBLE CAUSES
Insufficient cooling
CORRECTION
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
Retest
PROBLEM
POSSIBLE CAUSES
CORRECTION
Discharge the system
Replace the compressor
Evacuate the system
Charge the system
Retest
PROBLEM
POSSIBLE CAUSES
CORRECTION
Perform leak test
Discharge system
Repair leaks
Replace receiver/drier
Check oil level
Evacuate system
Charge the system
Retest
PROBLEM
Compressor cycles on
and off too frequently
POSSIBLE CAUSES
Defective temperature
(thermostatic) switch
control
CORRECTION
Stop engine and shut off A/C
Replace temperature control
switch
Retest system and check
compressor cycling
LB 75115 / FB 90.2200.2
23
6050019
24
1.
2.
3.
4.
PROBLEM:
Little or no cooling.
CAUSE:
Refrigerant slightly low.
CONDITIONS*
Low side pressure too low.
Gauge should read 12 bar (15-30 psi).
High side pressure too low.
Gauge should read 13.314.8 bar
(194215 psi).
Evaporator air not cold.
LB 75115 / FB 90.2200.2
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Repair leaks. (Discharge and recover the refrigerant from the system; replace lines or components).
3. Check compressor oil to ensure no loss.
4. Evacuate the system.
5. Charge the system.
6. Performance test the system.
DIAGNOSIS: System refrigerant is low. May be
caused by a small leak.
24
NOTE: * Test procedure based upon ambient temperature of 355C (955 F). For proper high side gauge
reading for other ambient temperatures, refer to the
pressure temperature chart.
6050020
25
1.
2.
3.
4.
PROBLEM:
Insufficient cooling.
CAUSE:
Refrigerant excessively low.
CONDITIONS*
Low side pressure very low.
Gauge should read 12 bar (15-30 psi)
High side pressure too low.
Gauge should read 13.314.8 bar
(194215 psi).
Evaporator air warm.
Low pressure switch cutting out
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Discharge and recover the refrigerant from the
system.
3. Repair leaks.
4. Check compressor oil to ensure no loss.
5. Evacuate the system.
6. Charge the system.
7. Performance test the system.
DIAGNOSIS: System refrigerant is extremely low. A
serious leak is indicated.
NOTE: * Test procedure based upon ambient temperature of 955 F. For proper high side gauge reading
for other ambient temperatures, refer to the pressure
temperature chart.
LB 75115 / FB 90.2200.2
25
6050021
26
1.
2.
3.
4.
PROBLEM:
Insufficient cooling.
CAUSE:
Air in system.
CONDITIONS*
Low side pressure reading does not change when
compressor cycles on and off.
High side pressure slightly high or slightly low. Gauge
should read 13.314.8 bar (194215 psi).
Evaporator air not cold.
LB 75115 / FB 90.2200.2
CORRECTIVE PROCEDURES
1. Leak test the system. Give special attention to
the compressor seal area.
2. Discharge and recover the refrigerant from the
system.
3. Repair leaks.
4. Replace the receiver/dryer.
5. Check compressor oil to ensure no loss.
6. Evacuate the system.
7. Charge the system.
8. Performance test the system.
DIAGNOSIS: Air or moisture in system. System not
fully charged.
NOTE: * Test procedure based upon ambient temperature of 355C (955 F). For proper high side gauge
reading for other ambient temperatures, refer to the
pressure temperature chart.
26
6050022
27
1.
2.
3.
4.
PROBLEM:
Insufficient cooling.
CORRECTIVE PROCEDURES
1. Replace the compressor.
CAUSE:
Compressor malfunction.
CONDITIONS*
Low side pressure too high. Gauge should read
12 bar (15-30 psi).
High side pressure too low. Gauge should read
13.314.8 bar (194215 psi).
Evaporator air not cold.
NOTE: * Test procedure based upon ambient temperature of 355C (955 F). For proper high side gauge
reading for other ambient temperatures, refer to the
pressure temperature chart.
LB 75115 / FB 90.2200.2
27
6050023
28
1.
2.
3.
4.
PROBLEM:
Insufficient or no cooling. Engine overheats in some
cases.
CAUSE:
Condenser not functioning properly.
CONDITIONS*
Low side pressure too high. Gauge should read
12 bar (15-30 psi).
High side pressure too high. Gauge should read
13.314.8 bar (194215 psi).
Liquid line hot.
Evaporator air warm.
High pressure switch cutting out.
CORRECTIVE PROCEDURES
1. Check belt. Loose or worn drive belts could
cause excessive pressures in the compressor
head.
2. Look for clogged passages between the condenser fins and coil, or other obstructions that
could reduce condenser airflow.
LB 75115 / FB 90.2200.2
28
6050024
29
1.
2.
3.
4.
PROBLEM:
Insufficient or no cooling.
CAUSE:
Large amount of air in system.
CONDITIONS*
Low side pressure too high. Gauge should read
12 bar (15-30 psi).
High side pressure too high. Gauge should read
13.314.8 bar (194215 psi).
Evaporator air not cool.
CORRECTIVE PROCEDURES
1. Discharge and recover the refrigerant from the
system.
2. Replace the receiver/dryer.
3. Evacuate the system.
4. Charge the system.
5. Performance test the system.
DIAGNOSIS: Air in system. This, and the moisture
in the air, is contaminating the refrigerant, causing
the system to operate improperly.
NOTE: * Test procedure based upon ambient temperature of 355C (955 F). For proper high side gauge
reading for other ambient temperatures, refer to the
pressure temperature chart.
LB 75115 / FB 90.2200.2
29
6050025
30
1.
2.
3.
4.
PROBLEM:
Insufficient or no cooling.
CAUSE:
Improper operation of thermostatic expansion valve
(stuck open)
CONDITIONS*
Low side pressure too high. gauge should read
12 bar (15-30 psi).
High side pressure too high. Gauge should read
13.314.8 bar (194215 psi).
Evaporator air warm.
Evaporator and suction hose (to compressor) surfaces show considerable moisture.
CORRECTIVE PROCEDURES
1. Check for sticking expansion valve as follows:
Operate the system at maximum cooling.
LB 75115 / FB 90.2200.2
30
6050026
31
1.
2.
3.
4.
PROBLEM:
Insufficient cooling.
CAUSE:
Improper operation of thermostatic expansion valve
(stuck closed).
CONDITIONS*
Low side pressure too low (zero or vacuum). Gauge
should read 12 bar (15-30 psi).
High side pressure low.
Gauge should read
13.314.8 bar (194215 psi).
Evaporator air cool, but not sufficiently cold.
Evaporator inlet pipe surface shows considerable
moisture or frost.
Low pressure switch cutting out.
CORRECTIVE PROCEDURES
1. Place finger on expansion valve to evaporator
tube. If too cold to touch, proceed as follows:
LB 75115 / FB 90.2200.2
31
6050027
32
1.
2.
3.
4.
PROBLEM:
Insufficient cooling.
CAUSE:
Restriction in high side of system.
CONDITIONS*
Low side pressure too low. Gauge should read
12 bar (15-30 psi).
High side pressure too low. Gauge should read
13.314.8 bar (194215 psi).
NOTE: A normal or high reading of the high side
pressure gauge under these conditions indicates the
system is overcharged or the condenser or receiver/
dryer is too small.
Evaporator only slightly cool.
Liquid line and receiver/dryer are cool to touch and
show frost or considerable moisture.
LB 75115 / FB 90.2200.2
CORRECTIVE PROCEDURES
1. Discharge and recover the refrigerant from the
system.
2. Replace the liquid lines, receiver/dryer, or other
obstructed components.
3. Evacuate the system.
4. Charge the system.
5. Performance test the system.
6.
DIAGNOSIS: Restriction in the liquid line and/or receiver/dryer resulting in a starved evaporator (compressor moving refrigerant from the evaporator
faster than it can enter).
NOTE: * Test procedure based upon ambient temperature of 955 F. For proper high side gauge reading
for other ambient temperatures, refer to the pressure
temperature chart.
32
6050028
33
1.
2.
3.
4.
PROBLEM:
Compressor cycles (cuts in and out) too rapidly.
CAUSE:
Thermostatic switch defective.
CONDITIONS*
Low side pressure readings too high during both on
and off compressor cycles and between cycles.
Readings should be:
0.81.0 bar (12-15 psi) - cycle off
2.52.7 bar (36-39 psi) - cycle on
1.71.9 bar (24-27 psi) - between
cycles
High side pressure normal. Gauge should read
13.314.8 bar (194215 psi).
CORRECTIVE PROCEDURES
1. Stop the engine and shut off A/C system.
2. Replace thermostatic switch with switch of same
type.
3. Make sure the switchs temperature sensor is installed in the same position and depth (in evaporator core) as previous.
4. Performance test the system.
DIAGNOSIS: Defective thermostatic switch.
NOTE: * Test procedure based upon ambient temperature of 355C (955 F). For proper high side gauge
reading for other ambient temperatures, refer to the
pressure temperature chart.
LB 75115 / FB 90.2200.2
33
6050029
TI
34
6050030
TI
35
LB 75115 / FB 90.2200.2
34
36
1.
2.
WARNING
Never discharge refrigerant gas into the atmosphere. Always wear safety goggles and gloves when
working with refrigerant. Only use authorised refrigerant tanks.
IMPORTANT: Always follow the manufactures instructions when operating recovery equipment.
1. Run the vehicles air conditioning system for a
few minutes.
2. Set up the recovery unit following manufacturers
instructions. Ensure that the units red (high side)
hose is connected to the high side (discharge) fitting and the blue (low side) hose to the low side
(suction) fitting.
NOTE: If a unit requiring the manifold gauge set is
being used, the low and high sides of the manifold set
are connected to the low and high sides of the tractor
air conditioning system. The hose from the recovery
unit is then connected to the manifold centre port. .
3. To recover refrigerant, open both high and low
side valves on the control panel or the valves on
the manifold gauge set if being used.
4. Open the valves labelled gas and liquid on the
recovery unit refrigerant tank.
5. Plug in the units power cord
6. Operate the recovery system in accordance with
the manufacturers instructions.
The compressor will shut off automatically when the
recovery is complete.
LB 75115 / FB 90.2200.2
35
7
Air conditioning systems may occasionally become
contaminated with solid particles. This contamination 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
6
2
5
6050032
TI
37
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 disassembled and cleaned or replaced and the expansion
valve should be replaced. When flushing the system
always replace the receiver/drier.
1.
2.
3.
4.
5.
6.
7.
6050033
TI
38
LB 75115 / FB 90.2200.2
36
System Vacuum
In
Mercury
28.0
28.9
29.4
29.7
29.8
29.9
Temperature
Cm. of
Mercury
71.0
73.4
74.6
75.4
75.7
75.9
100
80
60
40
20
0
38
27
16
5
-7
-18
and high sides of the vehicle air conditioning system as described for discharging the system.
Connect the manifold centre hose to the vacuum
pump suction port as per the manufacturers instructions.
Fully open both the low and high side gauge shutoff valves.
2. If a combined recovery/evacuation unit is to be
used attach the unit to the air conditioning system in accordance with the manufacturers instructions. Be sure to read all installation and operating instructions carefully before starting the
unit.
3. After starting the evacuation cycle, note the low
side gauge to be sure the system pulls down into
a vacuum.
4. Time the evacuation for a minimum of 30 minutes
from the point when lowest vacuum is attained.
5. Thirty minutes later when the low side gauge attains the lowest steady vacuum, stop the evacuation process.
NOTE: The vacuum pump achieves ultimate vacuum with the vented exhaust valve closed. Do not
evacuate too quickly as oil may be drawn from the
system.
6. Check the system by closing the gauge shutoff
valves, turning the vacuum pump off and noting
the low side gauge reading. A loss of more than
2 (5 cm) of vacuum in 5 minutes indicates either
a leak or moisture in the system.
7. If the gauge needle remains stationary and the
vacuum is maintained for 3-5 minutes, close both
the high and low side manifold hand valves, turn
off and disconnect the center hose from the
pump. The system is now ready for charging.
8. If a leak is detected, charge the system with approximately 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
the refrigerant in the system, repair the leak, then
repeat the evacuation procedure.
LB 75115 / FB 90.2200.2
37
39
1.
2.
LB 75115 / FB 90.2200.2
38
WARNING
Before disconnecting components in the air conditioning system the refrigerant gas must be discharged and recovered using a certified recovery
system. Refer to Discharging the system on Page
31. 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 removed from the replaced component must then be
added to the new item before being installed onto the
tractor.
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 refrigerant oil prior to installing the valve using disassembly procedure in reverse.
6. Evacuate, leak test and recharge the system.
40
LB 75115 / FB 90.2200.2
39
41
42
LB 75115 / FB 90.2200.2
40
43
BLOWER MOTOR ASSEMBLY
The blower motor 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 disconnect the hoses.
2. Disconnect the motor wiring connector block.
3. Remove the remaining motor securing screws
and withdraw motor.
4. Reassembly follows the disassembly procedure in reverse.
RECEIVER DRYER
The receiver/dryer cannot be overhauled and must
be replaced as an assembly. The receiver/dryer assembly should be replaced if it is suspected that
moisture is in the system.
The receiver dryer must also be replaced if the system has been discharged and the air conditioning
joints disconnected.
1. Discharge and reclaim refrigerant gas using
certified recovery systems.
2. Disconnect the hoses and switch and remove the
dryer from the tractor.
3. Drain the refrigerant oil from the receiver dryer
into a clean calibrated container. Measure the
quantity of oil obtained and add the same quantity of new refrigerant oil directly into the new
item.
4. Cap and plug all fittings to prevent any dirt entering the system.
5. Install a new receiver dryer.
44
45
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
41
46
47
42
COMPRESSOR OVERHAUL
Compressor Removal
1. Discharge and reclaim refrigerant gas using
certified recovery systems. Record the amount
of oil discharged into the collector as (X).
2. Disconnect tubing to compressor.
3. Disconnect wiring to compressor clutch.
4. Disconnect drive belt, remove the four mounting
bolts and remove compressor from tractor.
5. Drain the refrigerant oil from the old compressor
into a clean calibrated container. Measure and
record the quantity of oil as (Y). This information
is required during installation of the new or overhauled unit.
NOTE: It is necessary to rotate the compressor drive
shaft several times to completely expel all the oil.
CC
X=
48
Compressor Installation
6. Installation is the reversal of the removal but the
following points should be noted:
Torque the mounting bolts to 4051Nm
(2938lbf.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.
49
50
After charging a system use the following start up
procedure to ensure the lubricating oil is properly
dispersed around the system:
Ensure air conditioning is switched OFF.
Start the engine and bring speed down to idle.
Turn the air conditioning ON and allow system to
operate for at least five minutes before increasing engine speed.
LB 75115 / FB 90.2200.2
43
cc
Compressor
57
Evaporator
1.15
33
Condenser
0.5
14
Receiver / drier
0.25
Hoses
0.14
Preliminary Inspection
1. Rotate the compressor shaft. Use a suitable
socket on the hub centre bolt or by hand using
the rubber dampers.
If severe roughness is felt while rotating the hub,
the compressor should be disassembled.
2. Using a 12 volt battery check current drawn by
the field coil which should be between 3.6 4.2
Amps.
Very high current readings indicate a short circuit
in the field coil and no current reading indicate an
open circuit. Replace coil with either fault. Resistance of the coil using an ohmmeter should be
approximately 3.0 at 20C.
A poor earth (ground) connection of the field coil
will result 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.
51
52
LB 75115 / FB 90.2200.2
44
53
3. Using the front plate tool, insert tool number
JD166/3 into 297423 and place a tommy bar
through both hold the clutch plate stationary.
4. Place the bolt into the tool JD166/3 and by
tightening the bolt onto the end of the shaft the
front plate will be extracted from the shaft.
54
5. Remove the pulley bearing external snap ring (1)
and lift the pulley assembly from the compressor.
1
TA605064
55
6. Inspect the pulley bearing assembly for wear and
replace the assembly as necessary.
1
56
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
45
TA605067
57
8. Remove the field coil retaining snap ring.
TA605068
58
9. Lift the coil from the housing and replace as required.
TA605071
59
Clutch Reassembly
1. Install the field coil, ensuring that the wire is located back at cable clip on the outside of the
body and snap ring is placed in the groove.
TA605067
60
LB 75115 / FB 90.2200.2
46
2. Position the pulley on the housing hub and carefully slide the pulley down the shaft.
61
3. Install the bearing snap ring.
TA605064
62
4. Replace the front plate and retaining nut and
tighten to a torque of 18Nm (13lbf.ft).
63
5. Check the clearance between the clutch front
plate and pulley. This should be consistent
around the circumference and be between
0.40.8mm (0.0160.031in.)
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.
64
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
47
65
Shaft Seal Replacement
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior
to replacing the shaft seal.
Removal
1. Remove the clutch front plate, as detailed in the
steps of clutch disassembly.
2. Remove the woodruff key, shims and felt lubrication ring to expose the snap ring.
3. Remove the shaft seal retaining snap ring.
TA605075
66
4. Insert the seal remover/installer tool 297423.
Twist the tool to engage the slots in the seal. Pull
up to remove and discard the seal.
6050095TAG
67
Installation
1. Thoroughly clean the seal cavity in the hub. Use
lint free cloth only.
2. 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.
TA605079
68
LB 75115 / FB 90.2200.2
48
6050095TAG
69
4. Install the seal snap ring. If the snap ring has a
bevelled edge this should face outwards.
TA605075
70
5. Install a new felt seal and push into position.
1
71
6. Position the shims over the shaft and refit the
woodruff key.
7. Reinstall the clutch front plate as described in
clutch reassembly.
72
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
49
TA605085
74
Reassembly
1. Coat the top of the valve plate with clean refrigerant oil and reassemble the cylinder head using
the reverse of the disassembly procedure.
2. When installing the gaskets and valve plate ensure they are correctly positioned over the locating pins in the cylinder block.
TA605086
75
3. Install the cylinder head bolts and tighten using
the sequence shown. Torque initially to 20Nm
(14lbf.ft) then finally to 32Nm (24 lbf.ft).
4. When the overhaul is complete add to the compressor a volume of oil equivalent to that drained
prior to disassembly, or as the reclaim measured
fill.
TA605087
76
LB 75115 / FB 90.2200.2
50
NOTES
LB 75115 / FB 90.2200.2
Description
Page
55 000
55 100
55 512
55 514
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
55 000
55 000
55 100
55 000
LB 75115 / FB 90.2200.2
1
The battery is located behind the front radiator grille.
The battery type is 12volt , 95 amp. hr (12V/960
CCA) SAE. There is an isolator switch located on the
negative cable to provide a battery disconnect facility.
1
2
The alternator is a 70 amp. unit for all models.
LB 75115 / FB 90.2200.2
4
Fuses and Relays
The fuse panel is situated in the side console and can
be accessed through a small panel after removal of
the attaching cover screws. The fuses are numbered
and reference to the diagram and the following table
will permit rapid identification of the circuits they
protect.
IMPORTANT: Do not replace a blown fuse with
another of a different rating. Certain optional items of
equipment may not be installed on your machine.
However, the fuses are still installed and may be
used as spares.
5
In addition to the fuses some circuits are protected
or controlled by the items listed below, these are
mounted on the left hand front cab face behind the
engine and consist of the following:
3
1. FUSIBLE LINK: Main Circuit Protection between
the battery and the machine electrical system
2. RELAY: Starter Motor Circuit
3. RELAY: Air Conditioning (Where fitted)
6
Blower Motor Fuse
Where air conditioning is fitted a 25 ampere fuse has
been fitted inline for the 3rd speed on the blower
motor.
This fuse is located beneath the seat pod and can be
accessed once the seat is removed.
7
LB 75115 / FB 90.2200.2
Rating
Colour
Circuit
F1/A
F1/B
7.5A
Brown
F1/C
F2/A
10A
15A
Red
Blue
F2/B
F2/C
F3/A
20A
3A
Yellow
Violet
F3/B
3A
Violet
F3/C
10A
Red
K7
K8
K9
K10
K11
K12
BUZZER
BZ1
CONNECTORS
CN
F4/A
5A
Orange
F4/B
10A
Red
F4/C
F5/A
10A
15A
Red
Blue
F5/B
F5/C
10A
15A
Red
Blue
F6/A
F6/B
F6/C
7.5A
7.5A
7.5A
Brown
Brown
Brown
Rotating Beacon
Flashers
Hand Hammer Valve, 4WD
F7/A
10A
Red
F7/B
F7/C
F8/A
15A
Blue
F8/B
F8/C
15A
15A
Blue
Blue
K10
K12
CN/1 CN/2
K11
+BZ1
K1
K2
F1/C F2/C
F1/B F2/B
CN/3 F1/A F2/A
F3/C F4/C
CN/6
K3
F3/B F4/B
K4
F3/A F4/A
F5/C
CN/4
CN/5
K5
F5/B
F5/A
K6
K7
K8
RELAYS
F6/A F7/A
K9
K1
K2
K3
K4
K5
K6
+15V
TA424497
F8/A
+30V
GND
Powershuttle
10
LB 75115 / FB 90.2200.2
Rating
15A
Colour
Blue
Circuit
Rear Windshield Motor
and Washer Motor
F1/B
7.5A
Brown
F1/C
F2/A
10A
15A
Red
Blue
F2/B
15A
Blue
F2/C
F3/A
20A
3A
Yellow
Violet
F3/B
3A
Violet
F3/C
10A
Red
F4/A
5A
Orange
F4/B
10A
Red
K7
K8
K9
K10
K11
K12
BUZZER
BZ1
CONNECTORS
CN
K10
CN/1 CN/2
F4/C
F5/A
10A
15A
Red
Blue
F5/B
F5/C
F6/A
10A
15A
7.5A
Red
Blue
Brown
F6/B
F6/C
F7/A
7.5A
7.5A
10A
Brown
Brown
Red
F7/B
10A
Red
Flashers
Hand Hammer Valve, 4WD
+ 30 Warning and Horn
Fuse
Auxiliary 12v socket, Radio,
Cab interior light
F7/C
F8/A
F8/B
F8/C
6A
15A
15A
15A
Black*
Blue
Blue
Blue
K12
K2
K3
K4
K5
K6
LB 75115 / FB 90.2200.2
K1
K2
F1/B F2/B
CN/3 F1/A F2/A
F3/C F4/C
CN/6
K3
F3/B F4/B
K4
F3/A F4/A
F5/C
CN/4
CN/5
K5
F5/B
F5/A
K6
K7
K8
F6/A F7/A
K9
+15V
Transmission Forward / Reverse
+BZ1
F1/C F2/C
RELAYS
K1
K11
TA424497
F8/A
+30V
GND
Powershuttle
11
Rating
Colour
Circuit
F1/A
15A
Blue
F1/B
7.5A
Brown
F1/C
F2/A
10A
15A
Red
Blue
F2/B
F2/C
F3/A
15A
20A
3A
Blue
Yellow
Violet
F3/B
3A
Violet
F3/C
10A
Red
F4/A
5A
Orange
F4/B
10A
Red
Blower Motor
Engine Glow Plug
Rear right / Front Left side
light, Instrument, Air
Conditioning light
Rear left / Front right side,
licence plate light
Rapid connect, Glide Ride,
Hand Hammer, Cold Start
EGS Shift Lever, 4WD
Transmission disconnect
Backhoe Hammer Valve,
Loader Self Levelling
F4/C
10A
Red
F5/A
15A
Blue
F5/B
F5/C
10A
15A
Red
Blue
F6/A
F6/B
F6/C
7.5A
7.5A
7.5A
Brown
Brown
Brown
Rotating Beacon
Flashers
Hand Hammer Valve, 4WD,
Differential Lock
F7/A
10A
Red
F7/B
10A
Red
F7/C
F8/A
6A
15A
Black*
Blue
F8/B
F8/C
15A
15A
Blue
Blue
K7
K8
K9
K10
K11
K12
not used
Flashers
BUZZER
BZ1
CONNECTORS
CN
K10
K12
CN/1 CN/2
K11
+BZ1
K2
F1/C F2/C
F1/B F2/B
CN/3 F1/A F2/A
F3/C F4/C
CN/6
K3
F3/B F4/B
K4
F3/A F4/A
F5/C
CN/4
CN/5
K5
F5/B
F5/A
K6
K7
K8
F6/A F7/A
K9
F8/A
RELAYS
K1
K2
K3
Not used
Handbrake on Alarm / Speed Alarm
Starting Relay
K4
K5
K6
TA424497
+30V
GND
Powershift
12
LB 75115 / FB 90.2200.2
Rating
15A
Colour
Blue
F1/B
7.5A
Brown
F1/C
10A
Red
F2/A
15A
Blue
Circuit
Rear Windshield Motor
and Washer Motor
Fuel Shut Off, Anti Theft,
Fuel Pump, Thermostart
All Wheel Steer
Stop Light Instruments,
Switches, Brake Oil, Seat,
Buzzer
F2/B
F2/C
15A
20A
Blue
Yellow
Blower Motor
Engine Glow Plug
F3/A
3A
Violet
F3/B
3A
Violet
F3/C
10A
Red
F4/A
5A
Orange
F4/B
10A
Red
F4/C
10A
Red
F5/A
15A
Blue
F5/B
10A
Red
F5/C
F6/A
F6/B
F6/C
15A
7.5A
7.5A
7.5A
Blue
Brown
Brown
Brown
F7/A
10A
Red
F7/B
10A
Red
F7/C
6A
Black*
F8/A
F8/B
F8/C
15A
15A
15A
Blue
Blue
Blue
K7
K8
K9
K10
K11
K12
not used
Flashers
BUZZER
BZ1
CONNECTORS
CN
K10
K12
CN/1 CN/2
K11
+BZ1
K2
F1/C F2/C
F1/B F2/B
CN/3 F1/A F2/A
F3/C F4/C
CN/6
K3
F3/B F4/B
K4
F3/A F4/A
F5/C
CN/4
CN/5
K5
F5/B
F5/A
K6
K7
K8
F6/A F7/A
K9
F8/A
+30V
GND
RELAYS
K1
K2
K3
Not Used
Handbrake on Alarm / Speed Alarm
Starting Relay
K4
K5
K6
LB 75115 / FB 90.2200.2
TA424497
Powershift
13
WARNING
WARNING
Operate the starting motor only from the operators
seat. If the neutral start switch is bypassed the engine may be started inadvertently with the transmission in gear.
Wear eye protection when charging the battery or starting the machine engine with a slave battery.
If it is necessary to use jump leads from an external
battery to start the machine, proceed as follows:
Connect one end of the jump lead to the machine
12 volt battery positive (+) terminal and the other
to the auxiliary 12 volt battery positive (+) terminal.
Connect one end of the second jump lead to the
auxiliary 12 volt battery negative () terminal and
the other end to the machine engine block, following this procedure will prevent sparks occurring
near the batteries. Follow the starting procedure
previously described.
NOTE: When using a slave battery to start the engine ensure that the polarity is correct otherwise the
alternator may be damaged.
When the engine starts allow it to run at idle speed,
turn on all electrical equipment (lights, etc.) then
disconnect the jump leads in reverse order to the
connecting procedure. This will help protect the alternator from damage due to extreme load
changes.
NOTE: Your machine has an electromagnetic fuel
shutoff, it is therefore not possible to operate the
machine without a battery installed. The machine will
shut down when the power supply to the fuel shutoff
solenoid is disconnected (battery removed).
LB 75115 / FB 90.2200.2
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
33.
34.
35.
36.
37.
Parking Brake
Hand Throttle Lever
Stabiliser Leg Operating Levers
Air Flow Direction Outlet
Hydraulically Extendible Dipper, H.E.D Operating
Pedal (Optional Equipment)
38. Backhoe Control Lever Patterns
Standard:
2 Lever Cross Pattern with Horn Button
Optional:
2 Lever Cross Pattern ISO
2 Lever Diagonal Pattern
LB 75115 / FB 90.2200.2
WARNING
10
14
LB 75115 / FB 90.2200.2
11
15
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
LB 75115 / FB 90.2200.2
12
16
WARNING
WARNING: Do not attempt to connect or disconnect
the hammer with the switch on with engine running
as the couplers and hoses will be pressurised
When selected the external couplings mounted to
the left of the machine are hydraulically pressurised
to power Company Recommended hand hammers.
5. Four Wheel Drive Switch
This switch engages and disengages four wheel
drive. When the four wheel drive switch is in the Off
position and both brake pedals are operated together
the four wheel drive, will automatically be engaged
(above 3 Km/h) to give four wheel drive braking and
disengage with brake pedals released.
17
LB 75115 / FB 90.2200.2
13
18
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
LB 75115 / FB 90.2200.2
14
19
Tachometer and Hour Meter
The Tachometer (1) graduated to 3000 rev/min is
driven from the alternator and reflects true engine
speed.
The hourmeter (2) situated in the lower half of the
tachometer reflects hours of engine operation and is
driven from the alternator when running.
20
Engine Coolant Temperature Warning Gauge
with Warning alarm
The engine coolant temperature indicator responds
to a sensor fitted in the engine. During normal
operations the indicator will tend to rise from the low
point of the green segment to the centre of the
gauge. When operating under heavy load conditions
the indicator may continue to rise to just below the
red segment and return to a lower position when
normal machine operation is resumed.
Should the indicator rise into the red segment a
warning alarm will sound. Stop the engine
immediately and investigate the cause. Normal
operations can be resumed once the engine has
cooled sufficiently or the cause corrected.
21
LB 75115 / FB 90.2200.2
15
WARNING LIGHTS
1. Alternator Charge Warning Light:
The alternator charge warning light illuminates when
the key start is turned on and will remain on until the
engine is started. Once started the battery is being
charged by the alternator and the lamp will be
extinguished.
2. Engine Oil Pressure Warning Light with Warning
alarm:
Indicates low oil pressure and should extinguish
immediately after the engine starts. Should the oil
pressure drop the warning light will illuminate and an
audible alarm will sound.
22
WARNING
WARNING: Corrective action must be taken
immediately when this lamp illuminates. If not failure
of the engine system could occur
LB 75115 / FB 90.2200.2
23
16
WARNING
WARNING: If the light stays on stop the engine as
soon as possible and investigate the cause. Do not
continue to drive the machine as failure of the
transmission could occur and result in serious injury
to you or bystanders.
24
2. Transmission Oil Pressure Warning Light with
alarm:
Should the transmission oil pressure drop to a
predetermined level the warning light will illuminate
and the alarm will sound.
If the warning light illuminates, place the
transmission in neutral and stop the engine
immediately. Check that the oil level is correct and
adjust as required. If the transmission oil is lost or
extremely low DO NOT ATTEMPT TO DRIVE THE
MACHINE. Contact your Dealer to investigate the
cause and consult the manual as for towing the
machine as necessary.
3. Park Brake Warning Light:
The warning light is illuminated when the parking
brake is applied and the ignition is switched ON.
An alarm will sound when the ignition is ON and the
parking brake applied.
WARNING
WARNING: Do not attempt to disconnect the
warning apparatus in any way. Do not attempt to
drive the machine with the parking brake applied, as
serious damage to the machine brakes with possible
failure will occur. This could result in serious injury to
you and other people.
LB 75115 / FB 90.2200.2
17
25
26
27
SWITCH 2. Hydraulic Speed Control (where
fitted)
When the hydraulic speed control switch (2) is
selected a percentage of hydraulic oil is diverted from
the system and into the reservoir reducing the flow
and hence speed of the loader and backhoe. When
the tortoise is selected, slow precise hydraulic
operation for delicate work is possible.
Selection of the tortoise can also be utilised for
travelling on the road and allow more engine power
to the driving wheels.
28
LB 75115 / FB 90.2200.2
18
29
SWITCH 4. Cold Start (optional)
Where a cold start facility is required this switch
activates this (optional system).
30
SWITCH 5. Glide Ride Control (optional)
The function of Glide control when actuated is to
absorb the vibration normally felt from the loader
when driving along a road. It is not recommended for
use during loader operations
WARNING
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF. If the switch is ON upon engine start up the
vehicle will fall to the ground without any control.
31
SWITCH 6. Rear Worklamp Switch
The switch (5) when actuated the rear worklamps will
operate independently of the side or headlights.
NOTE:Do not use the rear worklamps when
travelling on the public highway.
32
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
19
WARNING
WARNING: Ensure the carriage clamp switch is
OFF whenever the machine is driven on the road.
Failure to observe this action could result in injury or
accident to bystanders or yourself.
SWITCH 8. Backhoe Transport Lock
When driving the machine on the highway the
backhoe must be locked in the transport position.
This is achieved by fully crowding the dipper to the
boom and fully raising the boom to allow the plate
using switch (7) to engage onto the boom pins.
NOTE:On sideshift machines swing the backhoe to
the cab where the bucket can be chained to the right
hand stabiliser leg, Refer to Section 1, On Road
Requirements.
With the transport lock applied and the warning light
(1) illuminated slew the boom around to the transport
position when an additional pin (2) where fitted, can
be placed through the lock plate to frame to prevent
the boom from swinging during machine
transportation.
To release the lock for normal operation activate
switch (7) to off the boom lock plate (1) will release.
34
WARNING
WARNING: Do not attempt to operate the backhoe
with the lock plate engaged.
35
LB 75115 / FB 90.2200.2
20
36
SWITCH 10. Loader Lock Valve (optional)
The loader lock when actuated is designed to
prevent movement of the front loader during
transport.
37
55 514 BULB REPLACEMENT
Work lamp Bulb Replacement, Front and Rear,
To gain access to the bulb, extract the securing
screws (1) gently remove the lens cover and remove
the bulb. Replacement of the bulb follows the
removal procedure in reverse.
NOTE:Modern headlights and worklamps tend to
have halogen bulbs fitted. Never touch a halogen
bulb with the fingers. Natural moisture in the skin will
cause the bulb to burn out when the lamp is switched
on. Always use a clean cloth or tissue when handling
halogen bulbs.
38
39
LB 75115 / FB 90.2200.2
21
40
42
Rocker Switch Bulb Replacement
The rocker switches are internally illuminated by a
bulb which can be removed from the rear of the
switch assembly.
22
IMMOBILISER
44
A.
B.
C.
D.
M38 Immobiliser
Electronic key socket with LED
2 piece electronic key
+50 to ignition
Immobiliser Connections
E. Starter motor
F. Engine control wire
G. Plug connecting electronic key socket to immobiliser
Wire
No.
Function
Connection
7, 8,
9
LB 75115 / FB 90.2200.2
23
45
46
4. Twist two bare leads together for each damaged
lead, being careful to match wire colours, then
solder the leads using resin cored solder. Tape
each repaired lead with vinyl insulation tape, Figure 46.
5. 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 47, then apply silicon rubber compound (non hardening sealant)
over the repaired section up to the cover ends.
Sufficient sealant must be used to fill the ends of
the cut away area.
47
6. 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,
Figure 48.
7. Check to ensure the repair is satisfactory and secure 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.
48
LB 75115 / FB 90.2200.2
24
POSSIBLE CAUSE
Loose
or
connections
corroded
CORRECTION
battery Clean and tighten connections
Sulphated batteries
Starter inoperative
Charge
indicating
voltage
indicator
excessive
tighten
loose
Clean
and
connections
Dead batteries
oil
tighten
for
loose
Loose belt
Malfunctioning battery
Malfunctioning alternator
Check alternator
Loose or
connections
corroded
sulphated batteries
Clean
and
connections
Check alternator
LB 75115 / FB 90.2200.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
How to use the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Circuit Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Universal Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wiring Diagrams and Connectors ROPS Powershuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Circuit 1 System from key start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Circuit 2 Electric solenoid valve systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Circuit 3 Electric solenoid valve systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit 4 Front lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Circuit 5 Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Circuit 6 Working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Circuit 7 Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Circuit 8 Miscellaneous items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Circuit 9 Instrument panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
LB 85110 / FB 90.2110.2
S20
1.5
A
X4
X5
S24
S25
R3
R2
N1
2
X5
N1
B
X4
N1
R2 R3
S21
N1
N1
31
2.1
2
1
1.4
1.5
C/N1
RN1
S1
1
1
3.1
10
B1.5
M1.5
B1.5
X65
2
At the 3rd diagram at box reference 3.1, you can
identify the wires by their colour and see they enter
into switch S4.
1.5
1.5
3.2
RN1
C/N1
1
1
S4
S4
5
10
N1
LG1
3.1
LB 85110 / FB 90.2110.2
3.1
1.5
1.5
3.2
RN1
C/N1
1
1
S4
10
LG1
S4
N1
4
When tracing wire paths on the diagrams and you
see a number with an X number (1) this denotes that:
Pin 6 located in connector X15 is in the path you are
tracing.
3.1
1.5
1.5
3.2
RN1
C/N1
1
1
S4
10
LG1
S4
1
6
X15
5
Key Start
Pin functions of the key start switch as viewed from
the rear of the switch
30 58 . . . . .
30 15/54 . . .
30 19 . . . . .
30 17 . . . . . .
30 50a . . . .
No connection
OFF
Accessories
Preheat & Engine run
Engine start
6
In the following circuit diagrams the key start is
shown as opposite with an input at terminal 30 and
outputs as shown above.
15/54
P
19
17
50a
58
01 2
3
30
7
LB 85110 / FB 90.2110.2
Alternator
Buzzer
Starter
Motor
Pressure Switch
Wiper
Motor
Washer
Motor
86
87a
12Vcc
87
Sender Unit
Fluid Level
Switch
Horn
Connector
Buzzer
Solenoid Valve
Diode
Momentary
Switch
Battery
Relay
85
Lamp
30
Radio
Cam Operated
Switch
Speaker
Roof
Beacon
86
87
Relay
Connector
85
1
1
30
Switch
5
10
LB 85110 / FB 90.2110.2
UNIVERSAL SYMBOLS
Thermostart
starting aid
Turn signals
Alternator
charge
Front windscreen
wipe
Fuel level
Front windscreen
wash
Engine speed
(rev/min x 100)
Hours recorded
Engine oil
pressure
Transmission
Oil temperature
Engine coolant
temperature
Coolant
level
Rear windscreen
wash/wipe
Heater
temperature
control
Heater fan
Horn
Air filter
blocked
Parking brake
Machine
lights
Transport lock
Headlamp
main beam
Roof
Beacon
Work lights
Licence plate
Light
Interior light
LB 85110 / FB 90.2110.2
Sideshift
Lock
Accessory
socket
Manual Hammer
External tools
connection
Tools Rapid
Disconnect
2 Wheel Steer
Engaged
Slow or
low setting
4 Wheel Steer
Engaged
Ground
speed
Rear axle
oil temperature
Hydraulic and
transmission
filters
Transmission
oil pressure
Air conditioner
Stop lamps
Headlamp
dipped beam
Side lamps
Crab Steer
Engaged
Hazard
warning lights
Malfunction!
See Operators
Manual
Manual
Override
FWD
engaged
Brake reservoir
oil level
Differential
Lock
Warning!
Read Operators
Manual
Variable
control
Pressurised!
Open carefully
Warning!
Corrosive
substance
Transmission
in neutral
Hammer
Attachment
Transmission
in Forward
Glide Ride
Control
Transmission
in Reverse
Loader Level
Transmission
Disconnect
Speedo
Sensor
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
1
2
3
4
5
6
7
8
9
10
11
12
13
C/N1
RN1
S1
20
3.1
3.1
25
1
1
30
RPM x 100
electronic
10
00000 00 h
10 11 12 13 14 15 16 17 18 19
1
X65
20
X22
M1.5
B1.5
M/N1
ZB1
GR1
VB1
R1
G/R1
9
X71
X75 1
2
3
4
5
VB1
Z1
GR1
AG1
LB1
BG1
S18
3
X14
7
X14
19
X16
VB1
7
X16
B1
20
X16
R1.5
5
X14
7
X15
6
X16
8
X16
9
X16
4
X15
17
X16
5
XC6
A2.5
A2.5
A2.5
G/R1
RN1.5
G/N1
G/R1
M/N1.5
M/N1.5
4
X71
2
X71
15
10
M/N1
1 7
X71 X71
5
6
X71 X71
1.5
ST1
B/N1
30
1.4
RN1.5
G/N1
50a
Z1
17
SN1
0 1 2
19
VN1
15/54
B/N1
58
X76
B1
S17
1.3
S1
1.1
6
X14
18
X16
8.1
8.4
21
X16
2
XC6
+15
3
R6
2.5
+30
LN1.5
N1.5
N1.5
R1.5
LN1
86
87a
85
K3
87
2.3
4.3
30
+15
8
10
11
X17
F2C
20A
F1B
7,5A
K13
KC
GR1
Z1
ZB1
3
X1
5
X1
GR1
B1
14
X1
2
X1
ZB1
B1
15
X1
10
X1
Z1
MN1.5
L1.5
7
X1
16
X1
M1.5
B/N1
R1.5
9
X1
7
10
9
XC6 XC6 XC6
L1.5
12
X1
1
X64
M1.5
SN1
S1
B/N1
R10
11
X1
R10
1
X1
3
XC6
B1.5
13
XC6
6
XC6
VN1
VN1
BG1
BG1
N1.5
N1.5
l
XD
86
87
K01
30
XD
R2.5
85
S19
X2
X11
N1.5
N2.5
N1
N1
EV7
31
M1
AR1
3
X3
S20
p
M2
S21
R2
R3
S25
S24
EV13
2
X5
B
X4
N1
N1
N1
30
3
1
X5
A
X4
N1
G2
l
X2
N1
N1
R1
D+
N50
50
30
12Vcc
LN1
S1
1
XA
G1
LN1
R50
SN1
R10
R10
AG1
B2.5
FG2
70A
FG1
80A
31
LB 85110 / FB 90.2110.2
2.1
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
10
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
11
2.3
2.4
2.5
R/N1
4.1
C1
N1
4.4
4.1
5.1
R/N1
2.1
MV1
10
1
1
II
NO
F
II
0
R
5
6
X62
MN1
MB1
L/G1
N1
N1
M/B1
RN1
NI
S40
S3
MV1
C1
S2
10
RN1
5
XC1
11
XC4
9
XC1
C1
MN1
MB1
L/G1
2
6
XC2 XC2
7
XC4
HN1
MV1
M/B1
1
X9
3
XC1
1
XC1
3
1.4
F6C
7,5A
+15
+15
K1
86
+15
F4B
10A
87a
85
K4
87
86
30
1.4
87a
85
F4A
5A
K10
87
86
30
87a
85
K11
87
K2
86
30
87a
85
87
86
30
85
87a
87
30
KC
6
XC3
1
XC3
9
XC3
19
XC3
16
XC3
8
XC3
8
XC6
5
XC3
1
XC6
11
XC3
RV1
1
X35
B
X26
1
X7
CN1
MN1
2
X19
2
X7
CN1
MN1
MB1
MB1
MB1
2
X29
8
X10
17
X1
MB1
1
X29
CN1
MN1
MB1
HR1
HR1
HR1
AG1
RV1
4
X1
22
X10
RV1
AG1
AG1
2
X23
12
X10
RV1
AR1
AR1
AR1
BR1
2
X28
10
X10
13
X10
AR1
BR1
1
X28
2
X35
17
X10
4
X10
3.5
1
X6
2
X6
2
X27
S29
1
X8
AR1
HN1
HN1
MV1
2
X8
BR1
23
X10
20
X10
BR1
BR1
HN1
MV1
6
X1
MV1
18
X1
AR1
RV1
BR1
1.5
31
LB 85110 / FB 90.2110.2
1
X19
EV10
N1
EV9
N1
EV6
N1
S27
N1
S26
N1
EV2
N1
N2.5
N2.5
N1
EV8
N1
HA1
S28
1
X27
31
3.1
12
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
13
14
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
15
1.5
1.5
3.2
3.3
RN1
3.4
3.5
RN1
RN1
6.1
6.1
6.2
C/N1
C/N1
C/N1
C/N1
C/B1
H1
9
10
S4
10
1
1
10
10
10
S8
S7
V1
AN1
N1
1
1
S6
S5
LG1
BN1
1
1
N1
L/G1
CB1
CB1
BN1
V1
LG1
6
X15
15
X16
8
X14
L/G1
5
X15
9
X14
AN1
6
X15
2.5
15
X10
11
X10
1
X10
RV1
21
X10
14
X10
RV1
9
X10
6.1
2
X36
CB1
BN1
V1
LG1
AN1
S30
RV1
1
X36
2
X34
2
X31
1
X31
1
X24
1
X25
2
X24
2
X25
N1
EV4
EV5
2
X32
N1
LB 85110 / FB 90.2110.2
N1
N1
2.5
EV12
N1
EV11
EV1
31
1
X32
EV3
N1
1
X34
2
X30
1
X30
31
4.1
16
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
17
18
FRONT LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
19
4.1
2.5
4.2
4.3
R/N1
4.4
4.5
R/N1
ST2
S10
20
15
30
10
R/N1
7.4
S9
20
40
10
5
25
0
15/1
30/3
49/4
30b/2
R/7
1 2
30
50
10 11 12
X70
10
G1.5
R2.5
R1.5
HN1.5
RV1
5 6
L/N1
L1
GR1
G1
V1
GN1
2
AB1
L/6
L1
L/N1
Km/h
electronic
49a/5
A1
MPH
A1
G/R1
2.5
G/R1
N1
VN1.5
7.1
7.1
7.1
7.1
7.1
21
XC4
11
10
3
XC4
5.1
F3A
3A
H/R1
R/N1
R1.5
R2.5
4
XC1
4
XC4
13
XC4
2
XC5
+15
+30 +15
F2A
15A
F5C
15A
+15
F7A
10A
L1
A1
5.1
5.1
+30
K5
K12
F3B
3A
16 20 5
F5B
10A
F6B
7,5A
5.1
HN1.5
9
XC4
H1
10
XC4
VN1.5
10
XC1
HR1
L/N1
HL1
18
3
XC2
RV1
G1.5
S31
+
86
L
87a
87
51
8.3
C
85
30
BZ1
KC
1.4
50
7.5
10
XC3
A1
V1
H1
N1
V1
A1
56a
N1
H1
56b
L1
G1
L1
G1
58
H1
V1
2 3
X60
V1
56a
N1
H1
3
X59
AB1
C1
7
N1
3
X10
56b
C1
H/R1
C1
AB1
2.5
1
X33
H2
3.5
31
LB 85110 / FB 90.2110.2
58
HA2
31
S42
31
N1
2
X33
H3
31
5.1
20
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
21
22
REAR LIGHTS
All Models Except North America
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
23
5.1
2.5
5.2
5.3
4.5
5.5
RN1
S32
4.5
5.4
S33
L1
A1
19
XC4
17
XC4
B/R1
9
XC5
8
XC1
6
XC5
RN1
R1
7
8
XC5 XC5
7
XC1
2
XC1
17
XC5
F1C
10A
+15
4.2
4.2
11
52
10
8.4
KC
13
XC3
20
XC3
12
XC3
21
XC3
31
LB 85110 / FB 90.2110.2
RN1
1
X18
N1
RN1
59c
10
1
X63
31
H5
H6
N1
H4
4.5
G1
A1
N1
59c
31
58
2
X63
8
A1
GN1
N1
GN1
G1
58
GN1
RN1
6
N1
L1
2
GN1
RN1
L1
GN1
RN1
2
XC3
31
6.1
24
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
25
26
WORKING LIGHTS
All Models Except North America
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
27
6.1
6.3
6.5
RN1
C/N1
RN1
C/N1
1 2
9
0
1 2
10
S11
10
S12
N1
F8B
15A
C/B1
ZN1
13
XC5
14
XC3
7.1
C/B1
15
XC3
F8C
15A
11
XC5
14
X16
18
XC3
F4C
10A
F8A
15A
VN1
F5A
15A
12
XC5
5
X16
HN1
11
XC5
3
X16
V1
14
XC5
3
XC3
1
X15
AV1
SG1
3
X15
ZN1
SG1
AV1
N1
GV1
GV1
7.1
7.1
C/B1
3.5
3.5
6.4
H1
3.5
3.5
6.2
+15
+30
K6
+30
K8
+30
K7
+30
K9
K7
86
85
87a
87
86
30
87a
85
87
86
30
87a
85
87
86
30
87a
85
87
30
4
X51
H19
4
X50
H12
4
X44
H20
4
X45
H13
4
X47
H21
4
X46
H14
VN1
N1
HN1
N1
VN1
N1
HN1
N1
V1
N1
H1
N1
V1
4
X38
4
X40
H22
N1
H11
N1
N1
H1
KC
5.5
31
LB 85110 / FB 90.2110.2
31
7.1
28
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
29
30
MISCELLANEOUS ITEMS
Serial number from 031026803
Beacon Lamp
X80 = 2 Pin
Beacon Lamp
X81 = 2 Pin
Fuse and Relay Board
XC2 = 7 Pin
XC3 = 21 Pin
XC4 = 21 Pin
XC5 = 17 Pin
Beacon Lamp Switch
Lights Switch
X61 = 12 Pin
Solenoid Valves Connector 24 Pin
Side Dashboard Connector 21 Pin
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
31
7.3
RN1
RN1
C/N1
7.4
8.1
R/N1
4.5
S41
S15
57/58
0
7.5
56b
56a
54S
54D
53
31b
R
0
1
1
L
NOT CONNECTED SW
56
30
15
AV1.5
X80
l
X80
l
X81 X81
C/N1
10 11 12
X61
AG1.5
L/N1
8
L1
A/B1
12
X16
4
1
3 14 15 12
XC5 XC5 XC5 XC4 XC4 XC4
C/N1
4
X16
Z1
1
X16
AG1.5
2
X16
5 6
10
AG1.5
13
X16
A/R1
L/B1
A/N1
N1
A1
L/N1
L1
G/R1
VN1.5
A1
3
G/R1
VN1.5
31
5
6.5
4.5
4.5
4.5
4.5
4.5
H16
H15
49
1 2
Z1
6.5
6.5
7.2
AV1.5
7.1
7
XC3
4
1
1 16 5
7
XC4 XC2 XC5 XC2 XC2 XC2
F7C
6A
A.R
F6A
7,5A
+15
F3C
10A
+15
+15
+15
F1A
15A
4.4
KC
50
17
XC3
6.5
N1.5
N1.5
N1.5
N1
6
16 X10
X10
31
LB 85110 / FB 90.2110.2
31
8.1
32
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
33
34
MISCELLANEOUS ITEMS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
7.2
1.5
8.2
8.3
8.4
RN1
8.5
1.5
RN1.5
2
X14
G/N1
4
X14
12
XC6
RN1
N1
G/N1
1
X14
RN1.5
35
11
XC6
10
XC5
4
XC6
4
X21
F2B
15A
F7B
10A
S44
+30
4.4
51
+15
5.2
52
7.5
N1.5
N1.5
KC
31
LB 85110 / FB 90.2110.2
36
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
37
38
INSTRUMENT PANELS
All Models Except North America
Serial number from 031026803
Pos
Pin
Function
Signal
Pos
Pin
Function
L3
+12
Positive (+12V)
L2
Gnd 2
Negative
L1
Generator Lamp
S1
Speedometer
Hz
S4
L4
S1
ohm
L3
S2
Tachometer
Hz
+ILL 6
Instrument Lighting
+Luci
+ILL 6
Instrument Lighting
+Luci
L8
NC
Gnd 8
Negative
L7
NC
+15
Positive
L6
NC
10
NC
L5
10
NC
L1
11
Direction Lamp
L2
12
L10
Service Lamp
Int.
11
NC
+30
12
L7
13
Handbrake Lamp
14
NC
15
L8
16
+/
L8
17
+/
L6
18
L5
19
L4
20
Int.
L12
Signal
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
39
S2
L10
L12
20
11
+15
15
10
20
S2
S1
S1
L1 L2 L3 L4
S4
S4
5
25
17
L10
RPM x 100
30
S3
Gnd
electronic
L12
8
00000 00 h
NC
L8
L5 L6 L7
+ILL
15
19
18
13
14
16
10
12
+30
L1
L2
L3
L4
S3
L5
L6
L7
L8
S1
11
12
+12
1
L1
20 15 30
L2
10
25
L3
30
MPH
Km/h
electronic
50
Gnd
L5 L6 L7 L8
2
+ILL
6
LB 85110 / FB 90.2110.2
L1 L2 L3 L4
40
10
5
L4
S1
20
10
40
NOTES
LB 85110 / FB 90.2110.2
41
LB 85110 / FB 90.2110.2
42
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
43
1
1
RN1.5
G/N1
8.1
8.4
10
B1.5
00000 00
12
3
X14
7
X14
13
14
15
16
8
X16
19
X16
18
1920
X22
17
X16
S18
1
X65
6
X14
4
X15
9
X16
21
X16
18
X16
2
XC6
5
XC6
A2.5
A2.5
A2.5
17
M1.5
B1.5
10 11
M/N1
ZB1
GR1
G/R1
7
X16
VB1
VB1
R1
G/R1
25
R1.5
5
X14
7
X15
20
X16
6
X16
3.1
3.1
30
RPM x 100
electronic
G/R1
9
X71
B/N1
4
X71
2
X71
C/N1
RN1
S1
20
RN1.5
7
X71
BG1
1
X71
MN1.5
5
6
X71 X71
X75 1
2
3
4
5
VB1
Z1
GR1
AG1
LB1
G/N1
30
1.5
15
10
Z1
S17
1.4
ST1
SN1
S1
50a
B/N1
17
MN1.5
0 1 2
19
M/N1
15/54
B1
58
VN1
X76
1.3
B1
1.1
+15
R6
2.5
2.3
4.3
+30
K13
LN1.5
N1.5
BN1.5
BN1.5
N1.5
LN1
R1.5
86
87a
85
K3
87
30
+15
8
10 11
X17
F1B
7,5A
F2C
20A
3
XC6
9
XC6
14
X1
3
X1
GR1
ZB1
5
X1
Z1
VN1
2
X1
GR1
Z1
VN1
B1
BG1
15
X1
ZB1
B1.5
10
X1
7
X1
BG1
LN1.5
16
X1
B1
9
X1
7
XC6
10
XC6
L1.5
M1.5
S1
12
X1
1
X64
M1.5
R10
B/N1
R1.5
11
X1
SN1
B/N1
R10
1
X1
13
XC6
MN1.5
KC
6
XC6
l
XD
86
87
KO1
30
R2.5
85
X2
XD
S19
t
S25
N1
B
X4
M2
N1
N1.5
N2.5
N1
EV7
S24
R3
1 - X11
N50
LN1
AG1
1
X5
R2
31
LB 85110 / FB 90.2110.2
A
X4
2
X5
N1
S21
N1
G2
S20
N1
M1
D+
30
EV13
N1
12Vcc
R1
50
3
2 X3
X3
N1
G1
1
X3
l
X2
AR1
1
XA
30
LN1
R50
SN1
R10
R10
S1
FG2
70A
B2.5
FG1
80A
31
2.1
44
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
45
46
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
47
MV1
1
1
2.3
R/N1
S3
S2
2
2.2
2.4
2.5
R/N1
4.1
C1
N1
RN1
4.4
4.1
5.1
S40
I
II
NO
F
II
0
R
4
10
10
NI
M/B1
5 6
X62
MN1
C1
3
MB1
2
N1
L/G1
N1
MV1
RN1
7
XC4
2
XC2
11
XC4
6
XC2
5
XC1
9
XC1
C1
MN1
MB1
L/G1
HN1
M/B1
MV1
3
X9
1
XC1
3
XC1
1.4
F6C
7,5A
+15
+15
+15
F4B
10A
K1
86
87a
85
K4
87
86
30
1.4
87a
85
F4A
5A
K10
87
86
30
87a
85
K2
K11
87
86
30
87a
85
87
86
30
85
87a
87
30
KC
6
XC3
1
XC3
19
XC3
9
XC3
16
XC3
8
XC3
5
XC3
1
XC6
8
XC6
11
XC3
1
X8
B
X26
2
X29
CN1
MN1
CN1
8
X10
MN1
MB1
1
X7
2
X19
2
X7
CN1
MN1
MB1
1
X29
1
X6
2
X6
1
X19
EV9
1
X27
EV10
N1
EV6
N1
S28
N1
S27
N1
S26
N1
N2.5
N2.5
LB 85110 / FB 90.2110.2
S29
N1
31
EV2
2
X27
HA1
1.5
N1
EV8
3.5
MB1
MB1
HR1
HR1
RV1
17
X1
A
X26
C
X26
2
X28
MB1
HR1
RV1
AG1
AG1
RV1
AR1
AR1
AG1
BR1
BR1
AR1
1
X28
2
X35
2
X23
4
X1
22
X10
2
X8
12
13 X10
X10
10
17 X10
X10
1
X23
RV1
N1
1
X35
AR1
BR1
AR1
BR1
HN1
MV1
4
X10
23
X10
20
X10
AR1
6
X1
HN1
18
X1
BR1
MV1
HN1
BR1
RV1
31
3.1
48
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
49
50
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
51
3.2
RN1
C/N1
3.3
3.4
3.5
RN1
C/N1
C/N1
C/B1
RN1
C/N1
C/B1
6.1
6.1
6.2
N1
6.1
31
4.1
H1
9
10
10
1
1
10
10
S7
V1
10
S8
CB1
L/G1
N1
AN1
LG1
1
1
S6
S5
S4
BN1
1
1
16
X16
8
X14
CB1
L/G1
V1
AN1
LG1
15
X16
5
X15
9
X14
BN1
6
X15
RV1
RV1
2.5
15
X10
11
X10
1
X10
14
X10
21
X10
RV1
9
X10
2
X36
CB1
BN1
V1
AN1
LG1
S30
2
X34
2
X31
1
X31
1
X24
2
X24
1
X25
2
X25
LB 85110 / FB 90.2110.2
EV4
N1
EV12
EV5
2
X32
N1
2.5
EV11
N1
EV1
31
1
X32
EV3
N1
1
X34
2
X30
1
X30
RV1
1
X36
52
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
53
54
FRONT LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
55
4.1
2.5
4.2
4.3
4.4
R/N1
4.5
R/N1
R/N1
7.4
ST2
20
40
25
0
15/1
30/3
49/4
30b/2
R/7
49a/5
N1
6 7
10 11
12 13
X58
AV1
N1
N1
N1
G1.5
R2.5
L/R1
1112
X70
LN1
RV1
10
HL1
10
LG1
HN1.5
S9
HR1
GR1
5
G1
V1
4
GN1
3
AB1
L/6
S10
electronic
1 2
30
50
L/B1
MPH
Km/h
A/V1
SN1
AG1
R1.5
20 15 30
10
10
5
AV1
LN1
LG1
G/R1
G/R1
2.5
N1
VN1.5
7.1
7.1
7.1
7.1
7.1
F3B
3A
F3A
3A
21
XC4
10
XC1
11
5.1
10
5.1
F6B
7,5A
2 4
XC4
F5C
15A
+30 +15
R/N1
13
2
XC4 XC5
4
XC1
+15
F2A
15A
F5B
10A
+15
H/R1
HN1.5
VN1.5
3
XC4
16 20
H1
L/R1
9
XC4
HR1
HL1
10
XC4
R2.5
18
R1.5
3
XC2
RV1
G1.5
S31
F7A
10A
L1
5.1
A1
5.1
+30
+
86
L
87a
87
51
C
85
8.3
30
K12
K5
BZ1
KC
1.4
50
7.5
10
XC3
A1
V1
V1
56a
3
X59
A1
H1
4
H1
N1
G1
G1
58
56b
L1
V1
2 3
X60
L1
V1
56a
H1
56b
HA2
58
2
X33
N1
1
X33
AB1
C1
7
N1
3
X10
H1
H/R1
AB1
C1
C1
H/R1
2.5
31
31
S42
H2
3.5
31
LB 85110 / FB 90.2110.2
H3
31
5.1
56
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
57
58
REAR LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
59
5.1
5.3
5.4
5.5
RN1
17
XC4
S33
A1
G1
6
XC5
9
XC5
8
XC5
B/R1
R1
RN1
19
XC4
L1
A1
GN1
4.5
A1
L1
L1
S32
4.5
RN1
2.5
5.2
7
XC1
17
XC5
F1C
10A
+15
4.2
11
4.2
10
52
8.4
KC
RN1
4
X48
4
X42
8.3
N1
RN1
A1
G1
N1
A1
N1
RN1
L1
4
X52
GN1
N1
L1
RN1
RN1
7 1
X18
N1
10
G1
4
X37
31
59c
1
X63
R
21
XC3
G1
A1
A1
G1
N1
N1
2
X63
9
A1
GN1
GN1
G1
GN1
RN1
N1
RN1
59c
L1
GN1
L1
31
58
L1
GN1
20
XC3
12
XC3
13
XC3
58
2
XC3
H4
H6
31
LB 85110 / FB 90.2110.2
N1
4.5
N1
H5
31
6.1
60
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
61
62
WORKING LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
63
6.1
6.3
RN1
C/N1
1 2
9
0
1 2
10
RN1
C/N1
RN1
C/N1
7.1
7.1
N1
N1
7.1
10
S12
C/B1
5
X16
11
XC5
15
XC3
F8C
15A
14
X16
18
XC3
F4C
10A
F8A
15A
HN1
13
XC5
F8B
15A
F5A
15A
ZN1
14
XC3
C/B1
ZN1
AV1
12
XC5
4
XC3
3
X16
V1
14
XC5
1
X15
AV1
SG1
3
X15
SG1
GV1
GV1
N1
+15
+30
K6
86
85
87a
+30
K8
87
86
30
87a
85
+30
K7
87
86
30
87a
85
+30
K9
87
VN1
S11
3
XC3
6.5
C/B1
3.5
0
3.5
6.4
H1
3.5
3.5
6.2
86
30
87a
85
87
30
5.5
31
N1
H11
LB 85110 / FB 90.2110.2
3 4
X51
H19
4
X50
H12
4
X44
H20
4
X45
H13
3 4
X47
H21
4
X46
H14
VN1
HN1
N1
HN1
N1
H1
N1
V1
H1
N1
KC
4
X38
4
X40
H22
31
7.1
64
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
65
66
Beacon Lamp
X80 = 2 Pin
Beacon Lamp
X81 = 2 Pin
Fuse & Relay Board
XC2 = 7 Pin
XC3 = 21 Pin
XC4 = 21 Pin
XC5 = 17 Pin
Rear Windshield Wiper Motor
X39 = 4 Pin
Front Windshield Wiper Motor
X49 = 6 Pin
Rear Windshield Washer Motor
X57 = 2 Pin
Front Windshield Washer Motor
X56 = 2 Pin
Optional Blower Motor
X41 = 2 Pin
Windshield Wiper Switch
Beacon Lamp Switch
Windshield Wiper Lights Switch
X61 = 12 Pin
Front Dashboard Connector 13 Pin
Solenoid Valves Connector 24 Pin
Cabin Connector 5 Pin
Side Dashboard Connector 21 Pin
Beacon Lamp Connector 4 Pin
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
67
7.1
7.2
7.3
RN1
RN1
57/58
0
2
56b
56a
54S
53
31b
H15
S15
49
R
1
H16
L
30
15
31
5
10
11 12
X61
LN1
AV1
A/R1
G/R1
X80
l
X80
X81
M1
N1
AV1
LN1
LG1
G/R1
VN1.5
10
AV1.5
10
VN1.5
l
X81
4
X43
1
X9
F7C
6A
A.R.
Z1
Z1
7
F6A
7,5A
+15
16 5
C/N1
14 15 12
AV1.5
AG1.5
A/N1
A/N1
4
A/B1
4
X16
A/R1
12
X16
C/N1
LB1
A/B1
1
X16
A/B1
2
X16
R/N1
13
X16
A/R1
A/N1
L/B1
AG1.5
AG1.5
L1
56
3
6.5
4.5
4.5
4.5
4.5
4.5
54D
LG1
7.5
R/N1
4.5
S41
S14
II
7.4
8.1
A/B1
RN1
C/N1
A/N1
6.5
6.5
7
XC3
F3C
10A
+15
+15
+15
F1A
15A
4.4
l
X41
3
X39
53a
M9
53
LB1
53b
X56
l
X56
53
31b
1
X49
53b
31b
M5
N1
M7
N1
M6
N1
N1
N1
N1.5
N1.5
N1.5
N1
LB 85110 / FB 90.2110.2
31
M4
31
3
53a
31
6.5
17
XC3
A/B1
A/N1
LB1
l
X57
X57
50
3
X12
R/N1
L/B1
A/B1
A/B1
A/R1
A/N1
X41
2
X12
1
X12
4
X12
L/B1
5
X12
6
X10
A/N1
16
A/R1
A/N1
A/N1
KC
31
8.1
68
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
69
70
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
71
8.3
8.4
S43
H17
G1
5.5
BS2
S46
8.5
H18
G1
8.1
S45
BS1
1
X14
RN1.5
RN1
RN1.5
RN1
N1
1
4
X13
Z2.5
1
X77
G/N1
4
X14
12
XC6
G/N1
G/N1
2
X14
R1.5
1.5
R2.5
RN1
RN1.5
X20
C2.5
l
X20
l
X55 X55
G1.5
7 8
X54
N1
N2.5
G/N1
MN1
B/R1
N1
N1
RN1
RN1
7 8
X53
N0.5
R0.5
N0.5
R0.5
RN1
N1
RN1.5
RN1
7.2
1.5
3
N1
2
RN1
M8
S34 S35
10
XC5
4
XC6
11
XC6
4
X21
F2B
15A
F7B
10A
S44
+30
4.4
51
+15
5.2
+30
52
KC
7.5
N1.5
N1.5
13
X1
31
LB 85110 / FB 90.2110.2
72
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
73
74
INSTRUMENT PANELS
Serial number from 031026803
Pos
Pin
Function
Signal
Pos
Pin
Function
L3
+12
Positive (+12V)
L2
Gnd 2
Negative
L1
Generator Lamp
S1
Speedometer
Hz
S4
L4
S1
ohm
L3
S2
Tachometer
Hz
+ILL 6
Instrument Lighting
+Lights
+ILL 6
Instrument Lighting
+Lights
L8
NC
Gnd 8
Negative
L7
NC
+15
Positive
L6
NC
10
NC
L5
10
NC
L1
11
Direction Lamp
L2
12
L10
Service Lamp
Int.
11
NC
+30
12
L7
13
Handbrake Lamp
14
NC
15
L8
16
+/
L8
17
+/
L6
18
L5
19
L4
20
Int.
L12
Signal
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
75
S2
L10
L12
20
11
+15
15
10
20
S2
S1
S1
L1 L2 L3 L4
S4
S4
5
25
17
L10
RPM x 100
30
S3
Gnd
electronic
L12
8
00000 00 h
NC
L8
L5 L6 L7
+ILL
15
19
18
13
14
16
10
12
+30
L1
L2
L3
L4
S3
L5
L6
L7
L8
S1
11
12
+12
1
L1
20 15 30
L2
10
25
L3
30
MPH
Km/h
electronic
50
Gnd
L5 L6 L7 L8
2
+ILL
6
LB 85110 / FB 90.2110.2
L1 L2 L3 L4
40
10
5
L4
S1
20
10
76
NOTES
LB 85110 / FB 90.2110.2
77
LB 85110 / FB 90.2110.2
78
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
79
1
1
RN1.5
G/N1
8.1
8.4
10
B1.5
00000 00
12
3
X14
7
X14
13
14
15
16
8
X16
19
X16
17
18
1920
X22
M1.5
B1.5
10 11
M/N1
ZB1
GR1
G/R1
7
X16
VB1
17
X16
S18
1
X65
6
X14
4
X15
9
X16
VB1
R1
G/R1
25
R1.5
5
X14
7
X15
20
X16
6
X16
3.1
3.1
30
RPM x 100
electronic
G/R1
9
X71
B/N1
4
X71
2
X71
C/N1
RN1
S1
20
RN1.5
7
X71
BG1
1
X71
MN1.5
5
6
X71 X71
X75 1
2
3
4
5
VB1
Z1
GR1
AG1
LB1
G/N1
30
1.5
15
10
Z1
S17
1.4
ST1
SN1
S1
50a
B/N1
17
MN1.5
0 1 2
19
M/N1
15/54
B1
58
VN1
X76
1.3
B1
1.1
21
X16
18
X16
4.1
2
XC6
5
XC6
A2.5
A2.5
A2.5
+15
R6
2.5
2.3
4.3
+30
K13
LN1.5
N1.5
BN1.5
BN1.5
N1.5
LN1
R1.5
86
87a
85
K3
87
30
+15
8
10 11
X17
F1B
7,5A
F2C
20A
3
XC6
9
XC6
14
X1
3
X1
GR1
ZB1
5
X1
Z1
VN1
2
X1
GR1
Z1
VN1
B1
BG1
15
X1
ZB1
B1.5
10
X1
7
X1
BG1
LN1.5
16
X1
B1
9
X1
7
XC6
10
XC6
L1.5
M1.5
S1
12
X1
1
X64
M1.5
R10
B/N1
R1.5
11
X1
SN1
B/N1
R10
1
X1
13
XC6
MN1.5
KC
6
XC6
l
XD
86
87
K01
30
R2.5
85
X2
XD
S19
t
S25
N1
B
X4
M2
N1
N1.5
N2.5
N1
EV0
S24
R3
1 - X11
N50
LN1
AG1
1
X5
R2
31
LB 85110 / FB 90.2110.2
A
X4
2
X5
N1
S21
N1
G2
S20
N1
M1
D+
30
EV13
N1
12Vcc
R1
50
3
2 X3
X3
N1
30
1
X3
l
X2
AR1
1
XA
G1
LN1
R50
SN1
R10
R10
S1
FG2
70A
B2.5
FG1
80A
31
2.1
80
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
81
82
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
83
2.2
2.3
2.4
2.5
RN1
R/N1
N1
C1
R/N1
M/B1
Z/N1
5.1
4.1
4.1
4.4
MV1
1
10
1
1
1
1
S3
S2
10
S47
10
10
EGS
S50
S48
A
M N
V
X83
B0.5
BM0.5
V0.5
G0.5
H0.5
M0.5
LB0.5
HB0.5
L0.5
R0.5
BG0.5
9
XC1
3
XC1
5.2
1
1.4
3
1.4
K10
K4
85
C1
4.1
1
XC1
70
87a
Z/N1
AB1
+15
+15
F4A
F4B
5A
10A
+15
8
X82
11
5
XC1 XC1
F6C
7,5A
N0.5
S0.5
6
MN1
BR1
6
XC1
86
Z0.5
11
XC4
BS0.5
7
2
6
XC4 XC2 XC2
CL1
HN1
M/B1
BR1
AB1
6
X9
2
X9
MB1
MV1
CB1
RN1
BV0.5
N1
87
86
30
87a
85
K2
87
86
30
87a
85
87
30
KC
11
XC3
8
XC3
1
X28
B
X26
12 13
X84
G0.5
BV0.5
MB0.5
Z0.5
N0.5
R0.5
L0.5
H
A
X85
GEAR BOX
HR1
AR1
RV1
C
2
X28
AG1
BR1
1
2
X35 X35
1
X8
10 11
8
X10
2
X8
S0.5
HR1
CL1
24
X10
B0.5
22
X10
H0.5
14
X10
CN1
HR1
RV1
AR1
10 13
X10 X10
HN1
23
X10
V0.5
6
X1
20
X10
1
XC6
3.5
CN1
19
X10
AG1
CL1
HN1
BR1
RV1
8
XC6
M0.5
5
XC3
MB1
16
XC3
19
XC3
CN1
6
9
XC3 XC3
CN1
1
XC3
2
X27
1
2
X29 X29
S27
2
X19
4 3
X28 X28
1.5
LB 85110 / FB 90.2110.2
S29
N1
1
X27
EV6
N1
S28
N1
N2.5
S26
N1
31
N2.5
EV2
N1
EV7
N1
HA1
1
X19
31
3.1
84
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
85
86
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
87
3.2
RN1
C/N1
3.3
3.4
3.5
RN1
C/N1
C/N1
C/B1
RN1
C/N1
C/B1
6.1
6.1
6.2
N1
6.1
31
4.1
H1
9
10
10
1
1
10
10
S7
V1
10
S8
CB1
L/G1
N1
AN1
LG1
1
1
S6
S5
S4
BN1
1
1
16
X16
8
X14
CB1
L/G1
V1
AN1
LG1
15
X16
5
X15
9
X14
BN1
6
X15
RV1
RV1
2.3
15
X10
11
X10
1
X10
12
X10
21
X10
RV1
9
X10
2
X36
CB1
BN1
V1
AN1
LG1
S30
2
X34
2
X31
1
X31
1
X24
2
X24
1
X25
2
X25
LB 85110 / FB 90.2110.2
EV4
N1
EV12
EV5
2
X32
N1
2.5
EV11
N1
EV1
31
1
X32
EV3
N1
1
X34
2
X30
1
X30
RV1
1
X36
88
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
89
90
FRONT LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
91
4.1
2.5
4.2
4.3
4.4
R/N1
4.5
R/N1
R/N1
7.4
ST2
20
40
25
0
15/1
30/3
49/4
30b/2
R/7
49a/5
N1
6 7
10 11
12 13
X58
AV1
N1
N1
N1
G1.5
R2.5
L/R1
1112
X70
LN1
RV1
10
HL1
10
LG1
HN1.5
S9
HR1
GR1
5
G1
V1
4
GN1
3
AB1
L/6
S10
electronic
1 2
30
50
L/B1
MPH
Km/h
A/V1
SN1
AG1
R1.5
20 15 30
10
10
5
AV1
LN1
LG1
G/R1
G/R1
2.5
N1
VN1.5
7.1
7.1
7.1
7.1
7.1
F3B
3A
F3A
3A
21
XC4
10
XC1
11
5.1
10
5.1
F6B
7,5A
2 4
XC4
F5C
15A
+30 +15
R/N1
13
2
XC4 XC5
4
XC1
+15
F2A
15A
F5B
10A
+15
H/R1
HN1.5
VN1.5
3
XC4
16 20
H1
L/R1
9
XC4
HR1
HL1
10
XC4
R2.5
18
R1.5
3
XC2
RV1
G1.5
S31
F7A
10A
L1
5.1
A1
5.1
+30
+
86
L
87a
87
51
C
85
8.3
30
K12
K5
BZ1
KC
1.4
50
7.5
10
XC3
31
LB 85110 / FB 90.2110.2
58
V1
A1
3
X59
A1
V1
31
56a
H1
4
H1
N1
G1
G1
58
H2
3.5
56b
L1
V1
2 3
X60
L1
V1
31
56a
H/R1
1
H1
C1
7
H/R1
HA2
H1
C1
56b
2.5
N1
AB1
C1
2.5
H3
31
5.1
92
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
93
94
REAR LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
95
5.1
5.3
5.4
5.5
RN1
17
XC4
S33
A1
G1
6
XC5
9
XC5
8
XC5
B/R1
R1
RN1
19
XC4
L1
A1
GN1
4.5
A1
L1
L1
S32
4.5
RN1
2.5
5.2
7
XC1
17
XC5
F1C
10A
4.2
11
+15
70
2.2
71
7.5
K11
4.2
52
10
8.4
KC
RN1
4
X48
4
X42
8.3
N1
RN1
A1
G1
N1
A1
N1
RN1
L1
4
X52
GN1
N1
L1
RN1
RN1
7 1
X18
N1
10
G1
4
X37
31
59c
1
X63
R
21
XC3
G1
A1
A1
G1
N1
N1
2
X63
9
A1
GN1
GN1
G1
GN1
RN1
N1
RN1
59c
L1
GN1
L1
31
58
L1
GN1
20
XC3
12
XC3
13
XC3
58
2
XC3
H4
H6
31
LB 85110 / FB 90.2110.2
N1
4.5
N1
H5
31
6.1
96
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
97
98
WORKING LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
99
6.1
6.3
RN1
C/N1
1 2
9
0
1 2
10
RN1
C/N1
RN1
C/N1
7.1
7.1
N1
N1
7.1
10
S12
C/B1
5
X16
11
XC5
15
XC3
F8C
15A
14
X16
18
XC3
F4C
10A
F8A
15A
HN1
13
XC5
F8B
15A
F5A
15A
ZN1
14
XC3
C/B1
ZN1
AV1
12
XC5
4
XC3
3
X16
V1
14
XC5
1
X15
AV1
SG1
3
X15
SG1
GV1
GV1
N1
+15
+30
K6
86
85
87a
+30
K8
87
86
30
87a
85
+30
K7
87
86
30
87a
85
+30
K9
87
VN1
S11
3
XC3
6.5
C/B1
3.5
0
3.5
6.4
H1
3.5
3.5
6.2
86
30
87a
85
87
30
5.5
31
N1
H11
LB 85110 / FB 90.2110.2
3 4
X51
H19
4
X50
H12
4
X44
H20
4
X45
H13
3 4
X47
H21
4
X46
H14
VN1
HN1
N1
HN1
N1
H1
N1
V1
H1
N1
KC
4
X38
4
X40
H22
31
7.1
100
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
101
102
Beacon Lamp
X80 = 2 Pin
Beacon Lamp
X81 = 2 Pin
Fuse and Relay Board
XC2 = 7 Pin
XC3 = 21 Pin
XC4 = 21 Pin
XC5 = 17 Pin
Rear Windshield Wiper Motor
X39 = 4 Pin
Front Windshield Wiper Motor
X49 = 6 Pin
Rear Windshield Washer
X57 = 2 Pin
Front Windshield Washer
X56 = 2 Pin
Optional Blower Motor
X41 = 2 Pin
Windshield Wiper Switch
Beacon Lamp Switch
Windshield Wiper/Lights Switch
X61 = 12 Pin
Front Dashboard Connector 13 Pin
Solenoid Valves Connector 24 Pin
Cabin Cable Connector 5 Pin
Side Dashboard Connector 21 Pin
Beacon Lamp Connector 4 Pin
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
103
7.1
7.2
7.3
RN1
RN1
57/58
0
2
56b
56a
54S
53
31b
H15
S15
49
R
1
H16
L
30
15
31
5
10
11 12
X61
LN1
AV1
A/R1
G/R1
X80
l
X80
X81
M1
N1
AV1
LN1
LG1
G/R1
VN1.5
10
AV1.5
10
VN1.5
l
X81
4
X43
1
X9
F7C
6A
A.R.
Z1
Z1
7
F6A
7,5A
+15
16 5
C/N1
14 15 12
AV1.5
AG1.5
A/N1
A/N1
4
A/B1
4
X16
A/R1
12
X16
C/N1
LB1
A/B1
1
X16
A/B1
2
X16
R/N1
13
X16
A/R1
A/N1
L/B1
AG1.5
AG1.5
L1
56
3
6.5
4.5
4.5
4.5
4.5
4.5
54D
LG1
7.5
R/N1
4.5
S41
S14
II
7.4
8.1
A/B1
RN1
C/N1
A/N1
6.5
6.5
7
XC3
F3C
10A
+15
+15
71
5.3
+15
F1A
15A
4.4
l
X41
3
X39
53a
M9
53
LB1
53b
X56
l
X56
53
31b
1
X49
53b
31b
M5
N1
M7
N1
M6
N1
N1
N1
N1.5
N1.5
N1.5
N1
LB 85110 / FB 90.2110.2
31
M4
31
3
53a
31
6.5
17
XC3
A/B1
A/N1
LB1
l
X57
X57
50
3
X12
R/N1
L/B1
A/B1
A/B1
A/R1
A/N1
X41
2
X12
1
X12
4
X12
L/B1
5
X12
6
X10
A/N1
16
A/R1
A/N1
A/N1
KC
31
8.1
104
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
105
106
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
107
8.3
8.4
S43
H17
G1
5.5
BS2
S46
8.5
H18
G1
8.1
S45
BS1
1
X14
RN1.5
RN1.5
RN1
N1
1
4
X13
Z2.5
1
X77
G/N1
4
X14
12
XC6
G/N1
G/N1
2
X14
R1.5
1.5
R2.5
RN1
RN1.5
X20
C2.5
l
X20
l
X55 X55
G1.5
7 8
X54
N1
N2.5
G/N1
MN1
B/R1
N1
N1
RN1
RN1
7 8
X53
N0.5
R0.5
N0.5
R0.5
RN1
N1
RN1.5
RN1
7.2
1.5
3
N1
2
RN1
M8
S34 S35
10
XC5
4
XC6
11
XC6
4
X21
F2B
15A
F7B
10A
S44
+30
4.4
51
+15
5.2
+30
52
7.5
N1.5
N1.5
KC
31
LB 85110 / FB 90.2110.2
108
LB 85110 / FB 90.2110.2
LB 85110 / FB 90.2110.2
109
110
INSTRUMENT PANELS
Serial number from 031026803
Pos
Pin
Function
Signal
Pos
Pin
Function
L3
+12
Positive (+12V)
L2
Gnd 2
Negative
L1
Generator Lamp
S1
Speedometer
Hz
S4
L4
S1
ohm
L3
S2
Tachometer
Hz
+ILL 6
Instrument Lighting
+Lights
+ILL 6
Instrument Lighting
+Lights
L8
NC
Gnd 8
Negative
L7
NC
+15
Positive
L6
NC
10
NC
L5
10
NC
L1
11
Direction Lamp
L2
12
L10
Service Lamp
Int.
11
NC
+30
12
L7
13
Handbrake Lamp
14
NC
15
L8
16
+/
L8
17
+/
L6
18
L5
19
L4
20
Int.
L12
Signal
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 85110 / FB 90.2110.2
111
S2
L10
L12
20
11
+15
15
10
20
S2
S1
S1
L1 L2 L3 L4
S4
S4
5
25
17
L10
RPM x 100
30
S3
Gnd
electronic
L12
8
00000 00 h
NC
L8
L5 L6 L7
+ILL
15
19
18
13
14
16
10
12
+30
L1
L2
L3
L4
S3
L5
L6
L7
L8
S1
11
12
+12
1
L1
20 15 30
L2
10
25
L3
30
MPH
Km/h
electronic
50
Gnd
L5 L6 L7 L8
2
+ILL
6
LB 85110 / FB 90.2110.2
L1 L2 L3 L4
40
10
5
L4
S1
20
10
112
NOTES
LB 85110 / FB 90.2110.2
113
LB 115 / FB 200.2
114
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
115
1
1
RN1.5
G/N1
8.1
8.4
10
B1.5
00000 00
12
3
X14
7
X14
13
14
15
16
8
X16
19
X16
17
18
1920
X22
M1.5
B1.5
10 11
M/N1
ZB1
GR1
G/R1
7
X16
VB1
17
X16
S18
1
X65
6
X14
4
X15
9
X16
VB1
R1
G/R1
25
R1.5
5
X14
7
X15
20
X16
6
X16
3.1
3.1
30
RPM x 100
electronic
G/R1
9
X71
B/N1
4
X71
2
X71
C/N1
RN1
S1
20
RN1.5
7
X71
BG1
1
X71
MN1.5
5
6
X71 X71
X75 1
2
3
4
5
VB1
Z1
GR1
AG1
LB1
G/N1
30
1.5
15
10
Z1
S17
1.4
ST1
SN1
S1
50a
B/N1
17
MN1.5
0 1 2
19
M/N1
15/54
B1
58
VN1
X76
1.3
B1
1.1
21
X16
18
X16
4.1
2
XC6
5
XC6
A2.5
A2.5
A2.5
+15
R6
2.5
2.3
4.3
+30
K13
LN1.5
N1.5
BN1.5
BN1.5
N1.5
LN1
R1.5
86
87a
85
K3
87
30
+15
8
10 11
X17
F1B
7,5A
F2C
20A
3
XC6
9
XC6
14
X1
3
X1
GR1
ZB1
5
X1
Z1
VN1
2
X1
GR1
Z1
VN1
B1
BG1
15
X1
ZB1
B1.5
10
X1
7
X1
BG1
LN1.5
16
X1
B1
9
X1
7
XC6
10
XC6
L1.5
M1.5
S1
12
X1
1
X64
M1.5
R10
B/N1
R1.5
11
X1
SN1
B/N1
R10
1
X1
13
XC6
MN1.5
KC
6
XC6
l
XD
86
87
K01
30
R2.5
85
X2
XD
S19
t
S25
N1
B
X4
M2
N1
N1.5
N2.5
N1
EV0
S24
R3
1 - X11
N50
LN1
AG1
1
X5
R2
31
LB 115 / FB 200.2
A
X4
2
X5
N1
S21
N1
G2
S20
N1
M1
D+
30
EV13
N1
12Vcc
R1
50
3
2 X3
X3
N1
30
1
X3
l
X2
AR1
1
XA
G1
LN1
R50
SN1
R10
R10
S1
FG2
70A
B2.5
FG1
80A
31
2.1
116
LB 115 / FB 200.2
LB 115 / FB 200.2
117
118
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
119
2.2
2.3
2.4
2.5
RN1
R/N1
N1
C1
R/N1
Z/N1
5.1
4.1
4.1
4.4
MV1
1
10
1
1
1
1
S3
S2
10
10
EGS
S50
S48
A
M N
V
X83
B0.5
BM0.5
V0.5
H0.5
M0.5
G0.5
N0.5
LB0.5
HB0.5
L0.5
R0.5
3
XC1
1.4
1.4
K4
85
9
XC1
5.2
K10
87a
S0.5
4.1
1
XC1
70
+15
C1
AB1
+15
+15
F4A
F4B
5A
10A
86
8
X82
11
5
XC1 XC1
F6C
7,5A
Z0.5
6
XC1
BS0.5
11
XC4
Z/N1
MN1
BR1
HN1
7
2
6
XC4 XC2 XC2
AB1
BR1
MB1
6
X9
1
X9
M/B1
MV1
RN1
BG0.5
BV0.5
N1
87
86
30
87a
85
K2
87
86
30
87a
85
87
30
KC
CN1
10 11
12 13
X84
G0.5
BV0.5
MB0.5
Z0.5
N0.5
R0.5
L0.5
S0.5
B0.5
H0.5
8
X10
V0.5
24
X10
HR1
1
XC6
M0.5
22
X10
8
XC6
MB1
14
X10
CN1
HR1
RV1
10 13
X10 X10
HN1
23
X10
11
XC3
8
XC3
CN1
6
X1
20
X10
5
XC3
CN1
12
X10
16
XC3
19
XC3
AR1
BR1
HN1
RV1
RV1
6
9
XC3 XC3
AG1
1
XC3
2
X36
S30
1
X36
1
2
X35 X35
1
X28
B
X26
A
X85
GEAR BOX
HR1
RV1
AR1
2
X28
2
X32
1
X32
AG1
RV1
BR1
2
X27
1
2
X29 X29
S27
2
X19
4 3
X28 X28
1.5
LB 115 / FB 200.2
S29
N1
1
X27
EV6
N1
S28
N1
S26
N1
N2.5
N2.5
31
EV2
N1
EV3
N1
HA1
1
X19
31
3.1
120
LB 115 / FB 200.2
LB 115 / FB 200.2
121
122
SOLENOID VALVES
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
123
3.2
RN1
C/N1
1.5
1.5
3.3
3.4
3.5
RN1
C/N1
RN1
C/N1
C/B1
C/N1
C/B1
6.1
6.1
6.2
H1
1
10
S7
10
10
S8
S47
8
X9
V/N1
4.1
4.2
4.2
H/N1
4.2
M/B1
4.3
M/B1
H/N1
2
1
N1
EVA3
1
X94
EVB2
L/R1
S/N1
M/B1
H/N1
S/N1
2
EVA2
N1
EV5
N1
N1
N1
LB 115 / FB 200.2
EV4
EV12
N1
2.5
EV11
N1
EV1
31
1
X93
1
2
X92
2
1
1
X91
N1
1
X25
4.1
V/N1
5
X10
4
X10
S/N1
L/R1
CB1
1
X24
AR1
9
X9
L/G1
CB1
L/R1
1
X31
17
X10
1
X34
7
X10
1
X30
6.1
8
X14
21
X10
1
X10
V1
11
X10
AN1
LG1
19
X10
BN1
9
X10
4.1
N1
AR1
L/G1
CB1
16
X16
15
X16
BN1
AN1
LG1
5
X15
V1
9
X14
6
X15
RG1
EVB3
N1
S6
N1
LG1
10
1
1
V/N1
S5
LR1
10
S4
1
1
V1
RG1
1
1
BN1
AN1
1
1
31
4.1
124
LB 115 / FB 200.2
LB 115 / FB 200.2
125
126
FRONT LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
4.1
4.2
4.3
4.4
R/N1
2.5
127
4.5
R/N1
R/N1
7.4
ST2
20
40
25
0
R/7
0
49a/5
1 2
L/6
10
N1
5
10 11
HL1
LG1
12 13
X58
AV1
X70
LN1
N1
N1
N1
HN1.5
R2.5
L/B1
A/V1
SN1
AG1
R1.5
12
S9
HR1
10 11
AN1
GR1
8
M1
V/B1
30b/2
S10
Z/B1
5
G1
V1
4
GN1
AB1
30/3
49/4
G1.5
electronic
15/1
1
30
50
MPH
Km/h
L/R1
20 15 30
10
10
5
AV1
LN1
7.1
7.1
LG1
G/R1
7.1
7.1
VN1.5
7.1
B/R1
5.1
L1
5.1
A1
5.1
N1
2.5
G/R1
S31
3
XC2
18
10
XC1
21
XC4
10
XC4
3
XC4
16 20 5
11
5.1
10
5.1
+15
F5B
10A
+15
H/R1
R/N1
B/R1
4
XC1
4
XC4
13
2
XC4 XC5
+15
F7A
10A
F2A
15A
F5C
15A
+30
K5
K12
F3B F3A
3A 3A
+30 +15
F6B
7,5A
F1C
10A
R2.5
R1.5
VN1.5
H1
HR1
HL1
2
XC1
8
XC1
L/R1
12 11
X9
G1.5
10
RG1
RG1
HN1.5
RG1
3.5
+
86
L
87a
87
51
C
85
8.3
30
BZ1
KC
A1
V1
V1
3
X59
A1
H1
1
H1
3
X60
N1
G1
2
18
X10
L/N1
R/N1
HL1
A
X98
31
STEERING UNIT
31
LB 115 / FB 200.2
S40
S42
N1
H2
KS
58
A
X97
56a
31
8
X96
56b
58
56a
56b
M/B1
A/V1
R/N1
LN1
10 11 12 1
X95
H/N1
L/R1
S/N1
M1
V/B1
L/N1
N1
AB1
V/N1
RG1
VB1
HL1
2
AR1
C1
Z/B1
1
3.5
G1
L1
V1
H/R1
AR1
A/V1
3.5
3
X10
15
X10
H/R1
C1
2
X10
L1
C1
V1
V/N1
H1
3.5
C1
2.5
H/N1
S/N1
L/R1
3.5
3.5
3.5
H1
VB1
3.5
1
X33
7.5
M/B1
N1
1.4
50
C1
AB1
10
XC3
AB1
2.3
1.4
H3
HA2
31
5.1
128
LB 115 / FB 200.2
LB 115 / FB 200.2
129
130
REAR LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
131
5.1
5.3
5.5
RN1
4.5
B/R1
4.5
L1
4.5
A1
19
XC4
6
XC5
9
XC5
8
XC5
RN1
A1
G1
L1
17
XC4
S33
R1
GN1
L1
A1
S32
4.2
5.4
RN1
2.5
5.2
7
XC1
11
17
XC5
70
2.2
71
7.5
K11
4.2
52
10
8.4
KC
RN1
4
X48
4
X42
8.3
N1
RN1
A1
G1
N1
A1
N1
RN1
L1
4
X52
GN1
N1
L1
RN1
RN1
7 1
X18
N1
10
G1
4
X37
31
59c
1
X63
R
21
XC3
G1
A1
A1
G1
N1
2
X63
9
A1
GN1
N1
GN1
G1
GN1
RN1
N1
RN1
59c
L1
GN1
L1
31
58
L1
GN1
20
XC3
12
XC3
13
XC3
58
2
XC3
H4
H6
31
LB 115 / FB 200.2
N1
4.5
N1
H5
31
6.1
132
LB 115 / FB 200.2
LB 115 / FB 200.2
133
134
WORKING LIGHTS
Serial number from 031026803
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
135
6.1
6.3
RN1
C/N1
1 2
9
0
1 2
10
RN1
C/N1
RN1
C/N1
7.1
7.1
N1
N1
7.1
10
S12
C/B1
5
X16
11
XC5
15
XC3
F8C
15A
14
X16
18
XC3
F4C
10A
F8A
15A
HN1
13
XC5
F8B
15A
F5A
15A
ZN1
14
XC3
C/B1
ZN1
AV1
12
XC5
4
XC3
3
X16
V1
14
XC5
1
X15
AV1
SG1
3
X15
SG1
GV1
GV1
N1
+15
+30
K6
86
85
87a
+30
K8
87
86
30
87a
85
+30
K7
87
86
30
87a
85
+30
K9
87
VN1
S11
3
XC3
6.5
C/B1
3.5
0
3.5
6.4
H1
3.5
3.5
6.2
86
30
87a
85
87
30
5.5
31
LB 115 / FB 200.2
N1
H11
3 4
X51
H19
4
X50
H12
4
X44
H20
4
X45
H13
3 4
X47
H21
4
X46
H14
VN1
HN1
N1
HN1
N1
H1
N1
V1
H1
N1
KC
4
X38
4
X40
H22
31
7.1
136
LB 115 / FB 200.2
LB 115 / FB 200.2
137
138
Beacon Lamp
X80 = 2 Pin
Beacon Lamp
X81 = 2 Pin
Fuse and Relay Board
XC2 = 7 Pin
XC3 = 21 Pin
XC4 = 21 Pin
XC5 = 17 Pin
Rear Windshield Wiper Motor
X39 = 4 Pin
Front Windshield Wiper Motor
X49 = 6 Pin
Rear Windshield Washer
X57 = 2 Pin
Front Windshield Washer
X56 = 2 Pin
Optional Blower Motor
X41 = 2 Pin
Windshield Wiper Switch
Beacon Lamp Switch
Windshield Wiper/Lights Switch
X61 = 12 Pin
Front Dashboard Connector 9 Pin
Solenoid Valves Connector 24 Pin
Cabin Cable Connector 5 Pin
Side Dashboard Connector 21 Pin
Beacon Lamp Connector 4 Pin
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
139
7.1
7.2
7.3
RN1
RN1
57/58
0
2
56b
56a
54S
53
31b
H15
S15
49
R
1
H16
L
30
15
31
5
10
11 12
X61
LN1
AV1
A/R1
G/R1
X80
l
X80
X81
M1
N1
AV1
LN1
LG1
G/R1
VN1.5
10
AV1.5
10
VN1.5
l
X81
4
X43
5
X9
F7C
6A
A.R.
Z1
Z1
7
F6A
7,5A
+15
16 5
C/N1
14 15 12
AV1.5
AG1.5
A/N1
A/N1
4
A/B1
4
X16
A/R1
12
X16
C/N1
LB1
A/B1
1
X16
A/B1
2
X16
R/N1
13
X16
A/R1
A/N1
L/B1
AG1.5
AG1.5
L1
56
3
6.5
4.5
4.5
4.5
4.5
4.5
54D
LG1
7.5
R/N1
4.5
S41
S14
II
7.4
8.1
A/B1
RN1
C/N1
A/N1
6.5
6.5
7
XC3
F3C
10A
+15
+15
71
5.3
+15
F1A
15A
4.4
l
X41
3
X39
53a
M9
53
LB1
53b
X56
l
X56
53
31b
1
X49
53b
31b
M5
N1
M7
N1
M6
N1
N1
N1
N1.5
N1.5
N1.5
N1
LB 115 / FB 200.2
31
M4
31
3
53a
31
6.5
17
XC3
A/B1
A/N1
LB1
l
X57
X57
50
3
X12
R/N1
L/B1
A/B1
A/B1
A/R1
A/N1
X41
2
X12
1
X12
4
X12
L/B1
5
X12
6
X10
A/N1
16
A/R1
A/N1
A/N1
KC
31
8.1
140
LB 115 / FB 200.2
LB 115 / FB 200.2
141
142
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
143
8.3
8.4
S43
H17
G1
5.5
BS2
S46
8.5
H18
G1
8.1
S45
BS1
1
X14
RN1.5
RN1.5
RN1
N1
1
4
X13
Z2.5
1
X77
G/N1
4
X14
12
XC6
G/N1
G/N1
2
X14
R1.5
1.5
R2.5
RN1
RN1.5
X20
C2.5
l
X20
l
X55 X55
G1.5
7 8
X54
N1
N2.5
G/N1
MN1
B/R1
N1
N1
RN1
RN1
7 8
X53
N0.5
R0.5
N0.5
R0.5
RN1
N1
RN1.5
RN1
7.2
1.5
3
N1
2
RN1
M8
S34 S35
10
XC5
4
XC6
11
XC6
4
X21
F2B
15A
F7B
10A
S44
+30
4.4
51
+15
5.2
+30
52
7.5
N1.5
N1.5
KC
31
LB 115 / FB 200.2
144
LB 115 / FB 200.2
LB 115 / FB 200.2
145
146
INSTRUMENT PANELS
Serial number from 031026803
Pos
Pin
Function
Signal
Pos
Pin
Function
L3
+12
Positive (+12V)
L2
Gnd 2
Negative
L1
Generator Lamp
S1
Speedometer
Hz
S4
L4
S1
ohm
L3
S2
Tachometer
Hz
+ILL 6
Instrument Lighting
+Lights
+ILL 6
Instrument Lighting
+Lights
L8
Gnd 8
Negative
L7
+15
Positive
L6
10
NC
L5
10
L1
11
Direction Lamp
L2
12
L10
Service Lamp
Int.
11
NC
+30
12
L7
13
Handbrake Lamp
14
NC
15
L8
16
+/
L8
17
+/
L6
18
L5
19
L4
20
Int.
L12
Signal
WIRE COLOURS:
A = LIGHT BLUE . . . . . . . . . . M = BROWN
B = WHITE . . . . . . . . . . . . . . . N = BLACK
C= ORANGE . . . . . . . . . . . . . R = RED
G = YELLOW . . . . . . . . . . . . . S = PINK
H = GREY . . . . . . . . . . . . . . . . V = GREEN
L = BLUE . . . . . . . . . . . . . . . . . Z = VIOLET
LB 115 / FB 200.2
147
S2
L10
L12
20
11
+15
15
10
20
S2
S1
S1
L1 L2 L3 L4
S4
S4
5
25
17
L10
RPM x 100
30
S3
Gnd
electronic
L12
8
00000 00 h
NC
L8
L5 L6 L7
+ILL
15
19
18
13
14
16
10
12
+30
L1
L2
L3
L4
S3
L5
L6
L7
L8
S1
11
12
+12
1
L1
20 15 30
L2
10
40
10
S1
L3
30
MPH
Km/h
electronic
L6
L7
50
L8
Gnd
L5 L6 L7 L8
2
+ILL
6
LB 115 / FB 200.2
L1 L2 L3 L4
25
L4
L5
20
10
148
NOTES
LB 115 / FB 200.2
Description
Page
55 201
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
160 amps
7.00 mm (0.28 in)
42.5 mm
0.4 mm (0.015 in)
TORQUE SPECIFICATIONS
LB 75115 / FB 90.2200.2
lbf.ft
25
5
7
4
Nm
34
7
10
5
OPERATION
The system consists of a key start switch, heavy duty
wiring, starter motor, relay and solenoid assembly.
The starting motor is a four pole four brush type with
integral solenoid and positive engagement drive assembly.
The integral solenoid incorporates two windings connected in parallel. One winding is the low resistance
pullin coil, grounded through the motor, while the
other is the high resistance holdin coil grounded
via the solenoid body.
When the key start switch is operated with the transmission forward/reverse shuttle lever in neutral the
solenoid coils are energised and the solenoid
plunger is magnetically attracted into the solenoid
core.
This movement, transmitted through a pivoted linkage mechanism forces the drive pinion into mesh
with the flywheel ring gear. At ring gear to pinion engagement, the solenoid plunger closes a set of contacts to give a direct feed from the battery to all four
field coils, providing full power to the starting motor.
At this point one end of the pullin coil is connected
to battery positive through the starter switch while the
other end is connected to positive through the solenoid contacts. The pullin coil is thus bypassed,
drawing no current and the holdin coil alone keeps
the solenoid plunger engaged.
The starter incorporates a single set of contacts and
a two piece solenoid plunger which completely
closes the contacts even if the pinion and ring gear
teeth are misaligned. When this happens, an engagement spring is compressed which forces the
pinion into full engagement as soon as the starter begins to turn.
When the key start switch is released, power to the
solenoid and motor is removed. The solenoid return
spring acting through the pivoted linkage mechanism
pulls the drive pinion out of mesh and reopens the
solenoid contacts.
Incorporated in the drive pinion assembly is a roller
clutch device. This device prevents the armature
from rotating excessively if the pinion remains in
mesh with the flywheel ring gear after the engine has
started.
LB 75115 / FB 90.2200.2
FAULT FINDING
Engine Does Not Turn Over When Key Start Is Operated, Transmission In Neutral
Is the battery
fully charged?
Charge or replace
battery. Does engine
turn over OK?
NO
Investigate
engine failure
Replace
relay
Replace relay
Replace relay
Replace relay
Reconnect wiring
to switch
NO
Can the
solenoid be
heard
clicking?
Repair wiring
as required
NO
NO
Replace switch
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
6055002 mm
10
Starting Motor Ground Connections:
1. Connect the voltmeter positive lead to the starting motor frame.
2. Connect the voltmeter negative lead to the engine block.
3. Crank the engine while observing the voltmeter
reading. If the voltmeter reading exceeds 0.2
volts check the ground connections between the
starting motor flange and the chassis.
6055003 mm
11
Battery Ground Cable:
1. Connect the voltmeter positive lead to the engine
block.
2. Connect the voltmeter negative lead to the battery negative terminal.
3. Crank the engine while observing the voltmeter
reading. If the reading exceeds 0.2 volts, check
and tighten the ground cable connections. Recheck the voltage, if it is still excessive install a
new ground cable.
6055004 mm
12
LB 75115 / FB 90.2200.2
14
LB 75115 / FB 90.2200.2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
DISASSEMBLY
With reference to Figure 14.
1. Support the starting motor in a soft jawed vice.
2. Disconnect the thick braided wire from the field
coil housing to the solenoid assembly.
3. Remove the three screws from the front housing
assembly and withdraw the solenoid assembly.
Note that the plunger will remain in the drive engagement lever.
4. Remove the solenoid plunger from the drive engagement lever by gripping the plunger and lifting up the front end and releasing it from the drive
engagement lever.
5. Remove the two end housing nuts and the two
screws retaining the end cap and brush plate to
the end housing. Remove the C clip and armature shaft end play shims and withdraw the end
housing, leaving the brush gear on the commutator. Remove the thin metal washer from the
commutator end of the armature.
6. At this stage of disassembly inspect the brushes
and commutator. Check for sticking brushes. If
necessary, clean brushes and brush channels
with a petrol moistened cloth. Check brushes for
wear. If worn below the minimum length specified, of 7.00mm, it will be necessary to replace
the complete starter motor.
NOTE: The brushes are not serviced separately..
They are spot welded into position and not intended
to be replaced during the starter motors service life.
7. Withdraw the motor casing from the armature
and drive end bracket.
8. Withdraw the drive engagement lever pivot pin
from the drive end housing.
9. Remove the drive assembly and inner plate retaining snap ring from the armature shaft by driving the securing thrust collar squarely off the
snap ring with a suitable diameter tube and then
levering the snap ring from the groove.
10. Withdraw the armature and drive assembly.
LB 75115 / FB 90.2200.2
REASSEMBLY
1. Reassembly of the starting motor follows the
disassembly procedure in reverse.
Prior to installation, the armature end play must be
checked and the starting motor no load function must
be tested.
16
Armature
1. The commutator face should be clean and free
from burnt spots. If necessary remove any burnt
spots using fine glass paper, not emery cloth. Finally clean the commutator with a petrol
moistened cloth.
2. If it is necessary to skim the commutator ensure
the diameter is not reduced below the minimum
specified diameter of 42.5mm. Following skimming the commutator should be polished with a
fine glass paper and then wiped clean with a petrol moistened cloth.
LB 75115 / FB 90.2200.2
17
Field Coils
1. To test the insulation of the field coils connect an
ohmmeter in turn between each of the field winding brushes and a clean unpainted part of the
housing. There should be no reading, i.e, no
continuity.
2. To test the field winding continuity connect an
ohmmeter in turn between each of the field winding brushes and the main feed terminal (thick
braided wire). A reading of 1 M should be indicated.
3. If a fault is indicated in the field windings it will be
necessary to replace the complete field coils and
housing assembly.
18
Bearing Bushes
1. Inspect the bushes in the brush end plate assembly and pinion drive end housing for wear. Install
the armature shaft and observe
2. the free play, replace bushes where free play appears excessive. Inspect the field poles for signs
of rubbing by the armature which may also have
been caused by worn bushes.
LB 75115 / FB 90.2200.2
10
NOTES
LB 75115 / FB 90.2200.2
Description
Page
55 301
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal, Installation and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
Polarity
Nominal Voltage
Maximum Rev/Min.
Maximum Output
Regulator Controlled Voltage
Rotor Field Winding Resistance
Stator Field Winding Resistance
New Brush Length
Minimum Brush Length
Brush Spring Pressure
LB 75115 / FB 90.2200.2
A12770
Negative Ground
12.0 v
15,00018000
70 Amps
13.6 14.4 v
2.9
0.2
20.0 mm
5.0 mm
1.32.7 N (4.79.8 oz)
TORQUE SPECIFICATIONS
lbf.ft
4.0
52.0
3.0
2.0
2.0
Nm
5.5
70
4.0
2.7
2.7
70 Amp Alternator
Earth (Ground) Connection
Engine Speed Sensor Connection (W Terminal)
Warning Lamp (D+ terminal)
Output Connection (B+ Terminal)
Protective Terminal Sleeve
1
1
Alternator Operation
With reference to Figure 2.
When the key start switch is turned on a small current
flows from the battery through the rotor field wiring.
The circuit is made via the charge indicator warning
lamp, alternator terminal D+ the rotor field winding,
the alternator regulator and ground.
At this stage the warning light is illuminated and the
rotor partially magnetised.
When the engine is started and the partially magnetised rotor revolves within the stator windings a
3phase alternating current is generated. A constant
portion of the generated current is converted to direct
current by the three field diodes incorporated in the
rectifier pack.
This direct current is fed back to supplement the current flowing through the rotor field winding.
This action results in an ever increasing magnetic influence of the rotor along with an associated rapid
rise in generated output current and voltage.
During the rise in generated output voltage (reflected
at the D+ terminal) the brilliance of the warning lamp
is reduced and when the voltage at the D+ terminal
equates to that at the battery side of the warning light
the lamp is extinquished.
The voltage continues to rise until the predetermined
regulated voltage level is reached.
In the event of drive belt breakage the voltage will not
build up within the alternator and so the charge indicator light will remain on to indicate failure.
LB 75115 / FB 90.2200.2
1
7
B+
D+
W
3
5
4
2
A.
B.
C.
1.
2.
3.
To Starter Motor
To Starter Relay
Speed Sensor
Starter Solenoid
Battery
Rotor Field Winding
LB 75115 / FB 90.2200.2
Service Precautions
To avoid damage to the components of the alternator
charging system, service precautions must be observed as follows:
NEVER make or break any of the charging circuit
connections, including the battery, when the engine is running.
NEVER short any of the charging components to
ground.
ALWAYS disconnect the battery ground cable
(negative) when charging the battery on the tractor using a battery charger.
ALWAYS observe correct polarity when installing the battery or using a slave battery to start
the engine.
CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE
Preliminary Checks
Prior to electrical testing thoroughly inspect the
charging and electrical system.
Check all leads and connections for continuity and
tightness.
1. Check the battery
Using a hydrometer check the individual battery
cells. The battery should be at least 70% charged
and in good condition.
2. Check the drive belt
Inspect the alternator drive belt and pulley, ensuring
that both are clean, free from oil and grease and in
good condition.
Fan Belt
1. The fan belt should be removed in the following
manner.
2. Loosen the alternator 3 attaching bolts, twist the
alternator towards the engine and remove the
fan belt from the pulley.
Inspection and Repair
1. Check the fan belt for evidence of fraying or wear
and replace if in any doubt.
ReAssembly
1. Refitment of the fan belt is the reverse of the removal procedure, but ensure the V belt, is positioned correctly onto all of the pulleys twist out
the alternator to achieve a 10mm (0.39in) freeplay on the belt at its longest length and tighten
the bolts to 5 Nm (4.4 lbf ft).
Check the Warning Lamp
Turn on the key start switch and check that the warning lamp is fully illuminated.
If the warning lamp is not fully illuminated check the
bulb. If the bulb is not the cause of the fault carry out
the Alternator wiring connections test as detailed
under initial tests in this section.
If the warning lamp is illuminated start the engine and
run above idling speed. The lamp should go out.
If the lamp does not go out, stop the engine and remove the wire from the D+ terminal. If the lamp now
goes out a faulty alternator component is indicated.
Conduct the Alternator components tests as detailed in this section.
If the warning lamp remains illuminated, check for a
short circuit to earth (ground) between the D+ cable
end and the warning lamp.
INITIAL TESTS
The initial tests may be performed without removing
any of the charging circuit components from the tractor and enable the following items to be checked:
Alternator wire connections
Alternator charging current and controlled voltage
Alternator charging circuit volt drops
Alternator maximum output performance
Test equipment required:
Voltmeter (030 volts moving coil type
Millivoltmeter (01 volt)
Ammeter (0110 Amperes moving coil type)
1.5 Ohm 110 Amperes variable load resistor
NOTE: Most commercial test equipment incorporates several testing devices within a single unit . Use
such equipment in accordance with the manufacturers instructions.
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
4
+
2
3
4
3
1
+
+
A
4
4
(a) InsulatedSide Volt Drop Tests
Ensure the key start switch is in the off position.
1. Disconnect the battery negative cable and disconnect the B+ cable(1) from the alternator
2. Connect a milli voltmeter(4) between the battery
positive terminal and the B+ cable(5). (Positive
side to cable).
3. Securely connect an ammeter(2) between the
B+ terminal of the alternator and the B+ cable
(negative side to cable)
4. Reconnect the battery negative cable and connect a variable load resistor(3), with the slider in
the minimum current draw position (maximum
resistance), across the battery terminals.
5. Start the engine and increase the speed to 2000
rev/min.
6. Slowly increase the current loading of the resistor (decrease resistance) until the ammeter registers 70 Amperes.
7. Observe the millivoltmeter reading which should
not exceed 400 millivolts.
If the reading is in excess of 400 millivolts, a high resistance fault is indicated in the external circuitry.
If the required alternator output cannot be achieved
and the millivoltmeter reading is less than 400 millivolts, then a faulty alternator component is indicated. Conduct the alternator component tests as
detailed in this section.
8. Stop the engine.
(b) GroundSide Volt Drop Test
1. Ensure the key start switch is in the off position.
2. The circuit is the same as that used in the previous test except for the millivoltmeter(4) which is
now connected between the battery negative terminal and the alternator frame (negative side to
frame).
NOTE: Ensure the variable load resistor(3) is in the
minimum current draw position (maximum resistance).
3. Start the engine and increase the speed to
2000rev/min.
4. Slowly increase the current loading of the resistor (decrease resistance) until the ammeter(2)
registers 70 Amperes.
5. Observe the voltmeter reading which should not
exceed 200 millivolts.
If the reading is in excess of 200 millivolts a high resistance fault is indicated in the external circuitry.
Figure 1
5
4
3
6
LB 75115 / FB 90.2200.2
1
+
3
7
LB 75115 / FB 90.2200.2
1
8
9
BrushesandSprings and Rotor Slip Rings
1. Remove the regulator and brushbox assembly
as described in this Chapter.
2. Ensure the brushes and slip rings are clean and
check for freedom of movement of the brushes
in the brushbox moulding.
3. Check the brush spring pressure with a push
type spring gauge and record the spring pressure when the brush end face is flush with the
moulding. Install a new regulator and brushbox
assembly if the pressure is less than specified.
If the visible length of the brushes(1) in the free position is less than 0.25 in. (5mm) this is a probable
cause of open circuit in the field circuit and the regulator and brushbox assembly should be renewed.
NOTE: The brushes are an integral part of the regulator and brushbox assembly and cannot be replaced
as individual items.
5 mm
10
LB 75115 / FB 90.2200.2
1
1
2
2
4
3
3
TA424049
11
A. Fan Belt Less Air Conditioning
1.
2.
3.
4.
Alternator
Adjusting Bolts
Drive Belt
Drive Belt Freeplay 10mm
LB 75115 / FB 90.2200.2
Alternator
Adjusting Bolts
Drive Belt
Drive Belt Freeplay 10mm
10
12
1.
2.
3.
4.
5.
Rectifier Assembly
Pulley Retaining Nut
V Pulley
Cooling Fan
Front End Housing
LB 75115 / FB 90.2200.2
11
13
A
B
C
15
Stator Test Insulation
70 Amp Alternators
1. Check the insulation of each winding to the alternator casing. There should be no continuity between the winding and the casing. If any ohmmeter(2) reading other than open circuit is indicated
it will be necessary to replace the stator(1) assembly.
Figure 2
A
B
C
2
16
LB 75115 / FB 90.2200.2
12
Rotor Test
Prior to performing component tests on the rotor the
following slip ring inspection should be carried out.
1. Ensure the slip rings are clean and smooth. If
necessary the slip rings may be cleaned with a
petrol moistened cloth. If the slip rings are burnt
and require refinishing use very fine glass paper
(not emery cloth) and wipe clean.
NOTE: Ensure the refinishing glass paper is sufficiently fine to produce a highly polished slip ring surface otherwise excessive brush wear will occur.
2. If the slip rings are excessively worn a new rotor
must be installed.
Rotor Field winding Continuity
1. Connect an ohmmeter(3) between the two slip
rings(2). The resistance should read 2.6 ohms at
20C.
If the resistance is outside of the specification renew
the rotor(1).
17
Rotor Field Winding Insulation
1. Using an ohmmeter(3) test between each of the
slip rings(2) and the rotor poles(1). An infinity
reading should be indicated in each case. If any
resistance reading is indicated the rotor assembly must be replaced.
18
INSPECTION AND REPAIR
1. Inspect the rotor poles and stator for signs of rubbing. Areas of rubbing indicates possible worn
bearings, misaligned housings or a bent rotor assembly shaft.
NOTE: Bearings of the 70 Amp alternator are not
serviced separately. It will be necessary to either obtain a new rectifier and housing or stator assembly to
renew worn bearings.
19
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
13
2. Inspect the roller bearing(1) of the 70 Amp alternator located in the rear (slip ring) end bracket(2)
for wear and damage
3. If bearing replacement is necessary support the
housing (rear end bracket) and using a suitable
size mandrel carefully drive out the bearing, Figure 19.
4. Clean and examine all components.
5. Press the new bearing(2) into the housing(1).
The bearing should be positioned .020.028in
(0.500.70mm) proud of the inner face of the
bearing boss as shown at item (3), Figure 20.
20
REASSEMBLY
1. Reassembly of the alternator follows the disassembly procedure in reverse.
On reassembly of the 70 Amp alternators observe
the following:
To avoid misalignment of the end brackets, install the stator assembly in the drive end bracket
then assemble the slip ring end bracket to the
stator laminations.
INSTALLATION
1. Installation of the alternator is the removal procedure in reverse.
On installation observe the following:
Ensure the battery ground (negative) cable is
disconnected from the battery when installing the
alternator.
Adjust the alternator drive belt as previously described in this Chapter.
LB 75115 / FB 90.2200.2
14
NOTES
LB 75115 / FB 90.2200.2
Description
Page
55 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 300
55 000 SPECIFICATIONS
Standard
Capacity
Cold Cranking Ampere Rating
Voltage
Cells
Ground Terminal
95
960
12
6
Negative
LB 75115 / FB 90.2200.2
Removal
1. Tilt the side panel up on its support gas struts.
2. Remove the negative lead and then the positive
lead from the battery.
3. Remove battery securing bracket.
4. Using the lifting handles, remove the battery.
1
Installation
5. Installation of the battery, (1), is the removal procedure in reverse, observing the following points:
Ensure that the battery is clean and dry and that
the vent caps are fully installed. Smear the terminals with petroleum jelly (vaseline or equivalent),
do not use conventional lubricating greases as
these can promote electrolytic corrosion.
Ensure the battery tray and clamps are clean and
free from stones or small objects which may
puncture the battery casing.
Ensure that the battery terminal polarity is correct and that the terminal connections are sufficiently tight, but not overtightened.
The radio, if fitted, will lose its stored information
and will require reprogramming.
1
2
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
100%
82%
64%
58%
50%
40%
33%
WARNING
Batteries contain sulphuric acid and during charging
generate a highly explosive mixture of hydrogen and
oxygen gases.
Never use equipment that generates flames or
sparks in order to control electrolyte level
Do not remove the battery cover plugs without
protection for eyes and hands.
When servicing a battery the following steps should
be observed:
1. Maintain the electrolyte to the recommended
level of 6 mm (0.25 in.) above the plates. If this
is not observed the acid will reach a high concentration that will damage the separators and
impair the performance of the plates.
2. Use only distilled or demineralised water, do not
overfill and never use tap water or water from a
rain barrel or other source.
3. Always keep the battery at least 75% charged
otherwise the plates will become sulphated and
loss of efficiency will result with possible damage
from freezing at low temperatures.
4. Avoid overcharging the battery as excessive
charging will create high internal heat that will
cause plate grid deterioration and produce water
loss.
5. When fast charging ensure the battery temperature does not exceed 50C.
6. Do not add sulphuric acid to a cell unless the
electrolyte has been lost through spilling. Before
replenishing ensure the solution is at the correct
specific gravity. A slow charge is the only method
to be employed to fully charge a battery. A high
rate charger can be used to quickly boost the battery capacity but this must be followed by a slow
charge rate to bring the battery to full capacity.
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 disconnecting to avoid sparks which could ignite the gas.
18hrs at 5A
9hrs at 10A
5hrs at 18A
LB 75115 / FB 90.2200.2
1.2
1.2
0.0
State of
Charge
Corrected
Specific
Gravity
@15C
Corrected
Specific
Gravity
@25C
Average
Battery
Voltage
100%
75%
50%
25%
Discharged
1.295
1.253
1.217
1.177
1.137
1.287
1.246
1.210
1.170
1.130
12.76
12.52
12.30
12.06
11.84
LB 75115 / FB 90.2200.2
CAUTION
Do not leave the high discharge load on the battery
for periods longer than 15 seconds.
Test Charging:
This test is designed only for batteries that have
failed the previous capacity test.
1. Attach the battery starter (high rate discharge
tester) positive leads to the battery positive terminal and the negative leads to the battery negative terminal.
2. Connect the battery charger positive lead to the
battery positive terminal and the negative lead to
the battery negative terminal.
3. Turn the charger timer past a 3 minutes charge
indication and then back to the 3 minutes mark.
4. Set the charging rate as close as possible to 40
amperes.
5. After 3 minutes at this fast charge take the voltmeter reading.
If the total voltage is over 15.5 volts the battery
is unsatisfactory and is probably sulphated or
worn out and should be replaced.
NOTE: A mildly sulphated battery can be recovered
by using a multiple battery type charger, with an open
circuit upper voltage limit of 50 volts. Owing to the
high resistance of a sulphated battery, it will primarily
require a high voltage setting to overcome the resistance of the sulphation. initially there may be no visible acceptance of the charge. After a few minutes of
inactivity a small charge will be apparent, followed by
a rapid increase in the charge rate. The charge rate
must not exceed 14.0 amperes or the electrolyte
temperature 505C. When the ampere rate has stabilised, reset the volts until the charge rate is a steady
5 amperes. Continue at this rate until the electrolyte
specific gravity stops rising at approximately
1.2751.280 at 205C (685F), this can take up to 48
hours of charging. Stand the battery for 24 hours and
then conduct the capacity test detailed previously.
If the total voltage is under 15.5 volts, test the
specific gravity of each cell and recharge the
battery to the following scale:
Specific Gravity
Fast charge up to:
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 system
should be checked.
LB 75115 / FB 90.2200.2
Description
Page
55 000
Service Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 100
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1
2
LB 75115 / FB 90.2200.2
OFF
LAPTOP
ON
+15v
U
3
LB 75115 / FB 90.2200.2
TOTAL HOURS
0.0h
Trans Oil
Pressure
* Filter
Engine Oil
Pressure
Engine Oil
Temperature
Last Record
0h
0h
0h
0h
0h
Penultimate
0h
0h
0h
0h
0h
3rd Record
0h
0h
0h
0h
0h
1st Record
0h
0h
0h
0h
0h
SAVE
START
Engine Cool
Temperature
ERROR
MENU
CANCEL
Time Out
Error Out
MALFUNCTION EXAMPLE
* FILTER
1ST
2ND
3RD
4TH
10 h
20 h
30 h
40 h
1ST
2ND
3RD
4TH
10 h
10 h
10 h
10 h
10 h
10 h
4
FUNCTION
Check
Air Filter
yes
yes
yes
yes
yes
yes
yes
yes
Service 1
yes
Battery
Autocheck
Autocheck
Autocheck
Brake
yes
Buzzer
yes
LB 75115 / FB 90.2200.2
Service
Diagnostics
Note
yes
yes
Only on Iveco
CALIBRATION OF SPEEDOMETER
8
7
6
5
4
3
2
1
6
POWER SHUTTLE
AXLE RATIO
TYRE ROLLING
CIRCUMFERENCE
FREQUENCY AT
50 Km/hr
SWITCH POSITIONS
12345678
18.5
4065 4335
2055
11110100
18.5
3810 3911
2245
11101010
20.8
4065 4335
2310
11101110
20.8
3810 3911
2522
11000001
EGS FREQUENCY
TYRE ROLLING
CIRCUMFERENCE
FREQUENCY AT
50 Km/hr
SWITCH POSITIONS
12345678
6.53 6.13
4065 4335
315 Hz
00000000
6.97 6.79
3810 3911
345 Hz
01000100
POWER SHIFT
LB 75115 / FB 90.2200.2
IMMOBILISER CIRCUIT
7
C.
D.
E.
F.
M38 Immobiliser
Electronic key socket with LED
2 piece electronic key
+50 to ignition
Immobiliser Connections
G. Starter motor
H. Engine control wire
I. Plug connecting electronic key socket to immobiliser
Wire
No.
Function
Connection
7, 8,
9
LB 75115 / FB 90.2200.2
NOTES
LB 75115 / FB 90.2200.2
Description
Page
General introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Batteries and Isolater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Key Start and Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Earthing points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Key Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alternater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
BATTERY
WARNING
Battery gasses can be corrosive and explosive
handle with care
1
2
Battery Type
BATTERY
CHARGING
95Ah
18hrs at 5A
9hrs at 10A
Slow Charge
Programs
Fast charge
Program
(emergencies only)
5hrs at 18A
BATTERY ISOLATER
The battery isolater is found on the negative side of
the battery and can be used to islolate all circuits of
the machine (no earth no circuits).
LB 75115 / FB 90.2200.2
4
Earth Point B Right hand Console (front console harness)
This is also linked to earth points A, C, and D.
5
Earth Point C Rear of Chassis (Chassis harness)
This is also linked to Earth point E.
6
Earth Point D Fuse board
XC5
Air Seat
This is also a back-up earth point for Location E.
F5/B
F5/A
R5
R6
R7
R8
R9
15v
30v
GND
1
7
LB 75115 / FB 90.2200.2
8
Earth Point F Top right hand B pillar (roof
harness)
This is also linked to earth point G.
9
Earth Point G Interior lamp
This is also linked to earth point F.
10
LB 75115 / FB 90.2200.2
11
SWITCH X71
Test Procedure
Voltage:
Key Switch Position
Pin
No.
OFF
Pos. I
Pos. II
Pos.III
0v
0v
12v
12v
0v
0v
0v
12v
0v
0v
12v
12v
5&
6
0v
12v
12v
12v
12v
12v
12v
12v
12
Continuity:
Pin
No.
Pos. I
Pos. II
Pos.III
n
n
7
4
5&
6
LB 75115 / FB 90.2200.2
STARTER MOTOR M1
Test Procedure
Key Switch Position
OFF
AUX
ON
START
0v
0v
0v
12v
13
AUX
ON
START
0v
0v
0v
12v
0v
0v
0v
0v
12v
12v
12v
12v
0v
0v
0v
12v
14
FUSES 70 amp and 80 amp R10
The main fuses have been designed to protect the
whole electrical system. Fuses fitted are dependant
on models
Test Procedure
Battery voltage should be found both sides of fuse at
all times.
15
LB 75115 / FB 90.2200.2
Pin
No.
OFF
Pos. I
Pos. II
Pos.III
0v
0v
12v
12v
0v
0v
0v
12v
0v
0v
12v
12v
5&
6
0v
12v
12v
12v
12v
12v
12v
12v
K10
K12
CN/1 CN/2
K11
+BZ1
K2
F1/C F2/C
F1/B F2/B
Pin
No.
K1
CN/6
Pos. I
Pos. II
Pos.III
n
n
7
4
5&
6
K3
F3/B F4/B
K4
16
LB 75115 / FB 90.2200.2
ALTERNATOR G2
Frequency
(Hz)
65 amp 75hp
580
70 amp 92 to 108hp
780
18
LB 75115 / FB 90.2200.2
10
ENGINE 92 TO 108 HP
THERMOSTART R1
The Thermostart which is efficient at ambient temperature of 18C, comprises a heating element
fitted in the intake manifold. When the Thermostart
is switched on it heats/ignites fuel in the manifold,
thus heating the air before it enters the combustion
chamber. The thermostart is activated when the key
is turned to start and is enabled for 15 seconds.
29
Test Procedure
Pin
No.
Thermostart
Resistance
0V
Cold 1.2
12V
30
FUEL LIFT PUMP M2
31
Test Procedure
Pin
No.
Lift Pump
Resistance
0V
32
LB 75115 / FB 90.2200.2
11
ENGINE 92 TO 108 HP
FUEL PUMP TEMPERATURE SWITCH / WAX
MOTOR EV13
EV13
The temperature switch is normally open when cold
and closed when hot. Supply voltage of 12v at the
light blue / red wire
33
Test Procedure
Pin
No.
Sender
Resistance
0V
Cold 6
12V
34
SHUT-OFF SOLENOID EV0
EV0
X
The solenoid opens at 12 volts and closes at key off
35
Test Procedure
Pin
No.
Shut off
resistance
0V
1.6
36
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
12
ENGINE 92 TO 108 HP
ENGINE OIL PRESSURE SENDER S20
The resistance of the oil pressure sensor varies proportionally with the engine oil pressure, which makes
it possible to change the current flow to ground.
37
Test Procedure
Pin
No.
Sender
Resistance
0V
Cold 1
12V
at low pressure 96
12V
Upto 163
38
ENGINE COOLANT TEMPERATURE SENSOR
R2
39
Test Procedure
Pin
No.
Sender
Resistance
0V
12V
Hot <650
40
LB 75115 / FB 90.2200.2
13
ENGINE 92 TO 108 HP
AIR FILTER RESTRICTION SWITCH 92 TO 108
HP S21
41
Test Procedure
Pin
No.
Switch
Resistance
12V
42
LB 75115 / FB 90.2200.2
14
TRANSMISSIONS
POWERSHUTLE DISCONNECT X23 / X28
43
Test Procedure
Continuity should be found between Pin 1 and Pin 2
when switch is operated.
44
LB 75115 / FB 90.2200.2
15
46
Description
Pin
No.
27.5
27.5
27.5
27.5
27.5
27.5
14
31
* A
B
C
D
E
F
G
K
L
M
47
LB 75115 / FB 90.2200.2
16
Disconnect from control valve and fit the 12 pin connector from special tool. Connect the power socket
into the 12volt power socket . Install the probes from
a Multimeter into the tool. Raise the unit off the
ground and observe voltage (V1). Turn the rear
wheel which inturn rotates the transmission output
shaft, observe the second voltage (V2).
48
Test Procedure
Pin
No.
V1
V2
0.60.8
1.31.5
49
Description
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Speed sensor +
FWD request
Disconnect request input
Speedometer output
Diagnostic link input
Analogue Input 1
Analogue Input 0
LB 75115 / FB 90.2200.2
50
17
51
Test Procedure
Continuity should be found between Pin 1 and Pin 2
when switch is operated.
52
OIL PRESSURE SWITCH POWERSHIFT
53
Test procedure
The voltage measured between Pin 1 and Pin 2
should be 12V.
With Transmission oil pressure continuity should be
found.
Pin
No.
Sender
Resistance
12V
54
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
18
55
Test procedure
The voltage measured between Pin 1 and Pin 2
should be 12V.
With Transmission oil pressure continuity should be
found.
Pin
No.
Sender
Resistance
12V
56
PARKING BRAKE SWITCH
57
Test Procedure
Brake Engaged:
switch closed warning light illuminated
18
Brake Disengaged:
switch open warning light off
N
58
LB 75115 / FB 90.2200.2
19
59
SIDE INSTRUMENT PANEL X22 20 PIN
Receives signal from sensors to display, hours, engine RPM, oil pressure, fuel level and signals to
warning and indicator lights.
60
CLUSTERS
Side panel
Compact
without
Diagnostics
ENGINE
P 424
(BSD engine)
75 HP
(Iveco engine)
Front panel
Standard
Front panel
Optional
POWER SHIFT
FEATURES
Tacho 8,1 imp/g
770 Hz end of scale
Tacho 11,46 imp/g
585 Hz end of scale
4 w/l + Logo
4 w/l + Speedo
(Turner sensor)
Side panel
Compact with
Diagnostics
P 424
(BSD engine)
Front panel
Optional
P 424
(BSD engine)
4 w/l + Speedo
(EGS sensor)
Side panel
Compact with
Diagnostics
P 424
(BSD engine)
Front panel
Plus
P 424
(BSD engine)
8 w/l + Speedo
(EGS sensor)
LB 75115 / FB 90.2200.2
20
LB 75115 / FB 90.2200.2
5
1
12
6
61
21
9
1
20
10
62
LB 75115 / FB 90.2200.2
22
LB 75115 / FB 90.2200.2
5
1
12
6
63
23
9
1
20
10
64
LB 75115 / FB 90.2200.2
24
CAB
4WD SWITCH
65
Test Procedure
Continuity
Switch OFF
Position 1
Position 2
Pin 7 to Pin 5
Pin 5 to Pin 3
Pin 1 to Pin 3
Pin 6 to Pin 8
Pin 4 to Pin 6
Pin 2 to Pin 4
Voltage:
Ignition ON:
Pin 3 = 12v
Pin 6 = 9v
66
BRAKE PEDAL SWITCHES S32 / S33
Test Procedure
Continuity:
Brakes not applied: no continuity.
Brakes applied: continuity, between the two centre
pins of each switch.
Both brake pedals must be applied to allow 12V to
relay.
67
Voltage:
Left Switch:
White/Red wire 12V Continuous with Ignition ON
Red Wire
12V Pedal depressed,
0V pedal released.
Right Switch:
Red wire
12V Pedal depressed
0V Pedal released
RedBlack wire 12V Pedal depressed
0V Pedal released
68
LB 75115 / FB 90.2200.2
25
69
Test procedure:
Continuity:
With the fluid level correct there should be no continuity 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 12V at the Red/
Black terminal.
70
MAIN LIGHT SWITCH
12 volts should be found at the switch at all times irrepsective of keystart position
71
Test Procedure
(Switch Off)
Continuity should not be found between any pins
(Switch Side)
Continuity should be found between pins 1 and 3.
(Switch Main)
Continuity should be found between pins 2 and 8.
72
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
26
73
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.
74
HAZARD SWITCH
12 volts should be found at this switch at all times regardless of key start position
75
Test Procedure
Pin No.
Switch OFF
Switch ON
to Pin 4
to Pins 5/6/7
to PIn 1
to Pins 2/3/6/7
to Pins 2/3/5/7
to Pins 2/3/5/6
76
LB 75115 / FB 90.2200.2
27
K1
R10
XC1 XC2
R11
+BZ1
R2
F1/C F2/C
77
CONTINUITY
Pin No.
Hazard/Indicator
Switch OFF
Switch ON
CL
12v
12v
12v0v12v0v
31
12v0v12v0v
PR
78
MULTI FUNCTION SWITCH
Switch Continuity.
Pin
No.
All
Switc
hes
OFF
windscree
n
washer
Indicator
Left
Right
Beam
Low
High
Wiper
On
1
2
Pin7
Pin4
Pin5 Pin3
Pin4
Pin8
7
8
9
Pin2
Pin8
Pin6
Pin7
Pin
11
Pin
11
10
11
79
Pin9
Pin
10
12
80
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
28
81
Test Procedure
Pin No.
Continuity
Continuity
Pin 3
Pin 5 2.
Pin 5 2.
82
83
Test Procedure
With Ignition ON
Pin
2WS
4WS
CRAB
12v
12v
12v
12v
12v
B
C
A
84
LB 75115 / FB 90.2200.2
29
85
Connector Pin Out Description
12 pin connector X95:
Pin Function
1
Crab steering warning light
2
Buzzer configuration
3
Front alignment sensor input
4
Crab steering control
5
Buzzer output
6
Rod iron steering control
7
Control unit supply
8
Ground
9
Speed sensor input
10
Rear alignment sensor input
11
2WS warning light
12
4WS warning light
Signal
+12
+12
+12
+12
+12
Signal
+12
+12
+12
+12
+12
+12
+12
86
87
LB 75115 / FB 90.2200.2
30
Speed Pulses
Speed pulses are drawn from EGSCLARK control
unit. Output reference values of Clark gearbox are;
7 Hz for 1 km
14 Hz for 2 km
35 Hz for 5 km
values in volts 8 and +8.
The speed calculation has been determined with a
tyre having a circumference of 4.165m.
Buzzer Operation
Buzzer operation depends on setting of pin 2 of the
12 way connector:
Pin 2 not connected (North America only) If 12
km/h is exceeded in crab mode, the buzzer
sounds.
pin 2 grounded (Outside of N/America). If 12
km/h is exceeded in crab or 4WS mode, the buzzer sounds.
Buzzer operation is intermittent, 250ms on and
250ms off.
The control unit is set at 9 km/h; steering mode
change is not possible when this speed is exceeded.
LB 75115 / FB 90.2200.2
Solenoid
2WS
4WS
EVA2
CRAB
X
EVA3
EVB2
EVB3
31
88
TEST PROCEDURE X98
Pin
2WS
4WS
CRAB
12v
12v
12v
89
4WS FRONT AXLE STEERING SENSOR S40
90
TEST PROCEDURE X97
Pin
2WS
4WS
CRAB
12v
12v
12v
91
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
32
STEERING SOLENOIDS
92
Solenoid connections, viewed from the top. Arrow
denotes front of tractor
Solenoid
2WS
4WS
CRAB
EVA2
0v
0v
12v
EVA3
0v
12v
12v
EVB2
12v
12v
0v
EVB3
12v
0v
0v
EVA2 X91
EVB2 X92
EVA3 X93
EVB3 X94
93
TEST PROCEDURE
Pin
No.
Solenoid
resistance
0V
5.0
94
TEST PROCEDURE
Pin
No.
Solenoid
resistance
0V
5.0
95
LB 75115 / FB 90.2200.2
33
96
Test Procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On)
Continuity should be found between pins 1 and 5
97
TEST PROCEDURE EV7
Pin
No.
Solenoid
resistance
0V
5.0
98
LB 75115 / FB 90.2200.2
34
36mm
100
Resistance:
Pin 1 to Pin 2 = 1.7 MW
Pin 1 to Pin 3 = 31.9 KW
101
TEST PROCEDURE
With the loader lifted and bucket tipped
Pin
No.
Solenoid
resistance
12V
19.6
102
LB 75115 / FB 90.2200.2
35
The return to dig system consists of an electromagnet mounted on the bucket spool, a sensor
mounted on top of the loader arm and a pointer attached to the tube of the bucket self levelling linkage.
Whenever the bucket is rolled forward to dump the
return to dig electrical circuit is completed and the
solenoid on the bucket spool is energised.
SM009LB110
103
88.5 mm
7.5 mm
6 mm
SM060LB110
104
TEST PROCEDURE
Pin
No.
Solenoid
resistance
0V
23
105
LB 75115 / FB 90.2200.2
36
WARNING
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF.
If the switch is ON, upon engine start up the vehicle
will fall to the ground without any control.
106
Test Procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On)
Continuity should be found between pins 1 and 5
107
TEST PROCEDURE EV11
Pin
No.
Solenoid
resistance
0V
5.0
108
LB 75115 / FB 90.2200.2
37
The loader lock when actuated is designed to prevent movement of the front loader.during road travel.
1
109
Continuity should be found between Pin 1 and 3.
110
TEST PROCEDURE
Pin
No.
Solenoid
resistance
0V
5.0
111
LB 75115 / FB 90.2200.2
38
112
Test Procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On)
Continuity should be found between pins 1 and 5
113
TEST PROCEDURE EV1
Pin
No.
Solenoid
resistance
0V
5.0
114
LB 75115 / FB 90.2200.2
39
1
115
Test Procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On)
Continuity should be found between pins 1 and 5
116
SIDE SHIFT LOCK SOLENOID LINK
TEST PROCEDURE EV4
Pin
No.
Solenoid
resistance
12V
9.7
117
LB 75115 / FB 90.2200.2
40
118
Test Procedure
(Switch Off) X25
Continuity should be found between pins 1 and 5.
(Switch On)
Continuity should be found between pins 5 and 7.
119
BOOM LOCK SOLENOID EV5
Pin
No.
Solenoid
resistance
12V
7.5
120
LB 75115 / FB 90.2200.2
41
121
When switch is operated 12V should be found at Pin
2. X36
122
BACKHOE HAMMER SOLENOID EV3
Pin
No.
Solenoid
resistance
12V
7.5
123
LB 75115 / FB 90.2200.2
42
124
When switch is operated 12V should be found at Pin
1. X35
125
HAND HAMMER SOLENOID VALVE EV2
Pin
No.
Solenoid
resistance
12V
7.5
126
LB 75115 / FB 90.2200.2
43
127
When switch is operated 12V should be found at Pin
5.
128
QUICK HITCH SOLENOID EV12
Positioned on the backhoe frame.
129
When switch is operated 12V should be found at Pin
1. X36
Solenoid resistance should be 9.7 W
130
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
44
REVERSING BUZZER
Activated by 12 volts at key start when reverse gear
is selected.
131
With reverse selected 12v should be found at pin
connector .
Resistance of the buzzer 162
132
FUEL LEVEL SENDER
The signal from the fuel sender potentiometer determining the fuel level displayed on the instrument
cluster gauge.
133
Test Procedure
Approximate Resistance:
Gauge Indication
Sensor Resistance
Full
Half
129
Empty
333
134
LB 75115 / FB 90.2200.2
SECTION 82 LOADER
Chapter 1 Loader Frame, Controls and Buckets
CONTENT
Section
Description
Page
00 000
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
00 000
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
82 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
00 000
00 000
OverhaulLoader Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
00 000
00 000
Return to Dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
00 000
00 000
TORQUES
Loader arm Pivot retaining bolt
500 Nm (368 lbf.ft)
SPECIAL TOOLS
Loader Pivot Shaft Bolt Retainer
LB 75115 / FB 90.2200.2
297189
3
(PER SAE J 732 C) WITH TYRES
With Two or Four wheel drive and 1.0m3 bucket.
LB 75115 / FB 90.2200.2
4
(PER SAE J 732 C) WITH TYRES
With Two or Four wheel drive & 1.0m3 bucket.
LB 75115 / FB 90.2200.2
5
A single lever controls the lowering and raising of the
lift arms, rollback and dumping of the bucket and
opening and closing of the multipurpose bucket
where fitted.
In addition to these movements a float and Return
to dig position is also available.
The float position enables the loader lift arms and
bucket to follow the contour of the ground and is obtained by moving the loader control lever fully forward into the detent position. The lever will remain in
the float position until it is moved manually towards
neutral.
6
LB 75115 / FB 90.2200.2
8
OVERHAULLOADER CONTROLS
1. Remove covers at base of control lever.
2. Disassemble and examine linkage with reference to Figures 3 and 4.
1.
2.
3.
4.
5.
6.
7.
8.
10
LB 75115 / FB 90.2200.2
4
11
1.
2.
3.
4.
LB 75115 / FB 90.2200.2
12
Self Levelling Linkage Adjustment
1. Lower the loader to the ground.
2. Disconnect vertical linkage (3) at upper bell
crank (1).
3. Raise loader arms so that the bottom pin is
800 mm (31.5in) above the ground and fully roll
back the bucket.
13
4. Rotate the bell crank (1) to touch the tube (2) on
the loader arm.
5. Adjust the length of the vertical rod (3) so that
when reconnected, the end of the loader arm
tube remains in contact with bell crank.
6. Securely tighten locknuts on vertical rod.
3
14
LB 75115 / FB 90.2200.2
RETURN TO DIG
The electrically activated Return to Dig feature enables the operator to automatically return the bucket
to a level digging position after dumping with one
simple movement of the loader control lever.
The return to dig system consists of an electromagnet mounted on the end of the loader bucket
control spool. a sensor (1) mounted on top of the
loader arm, and a pointer (2) attached to the tube of
the bucket self levelling linkage.
When the bucket is rolled forward to dump the pointer
(2) no longer aligns with the face of the sensor(1) and
causes the sensor to complete the return to dig electrical circuit and engergise the electromagnet.
The electro magnet remains energised until such
time as the bucket is returned to the level digging
position and the pointer realigns with the face of the
sensor.
Consequently when the loader bucket control lever
is moved either fully left to the return to dig position
or diagonally left to simultaneously lower the loader
arms using float the bucket spool is held in the roll
back position by the electromagnet. When the
bucket reaches the level digging position the pointer
aligns with the face of the sensor and deenergises
the solenoid allowing the spool to automatically
spring back to the neutral position.
15
16
Return To Dig Sensor Adjustment
1. Place the bucket on the ground in the preferred
digging position.
2. Adjust the position of the sensor so that when the
bucket is in digging position and loader arms are
lowered, 50% (half) of the sensor face is obscured by the self levelling linkage pointer.
3. Ensure the face of the sensor (1) is 36 mm from
the pointer (2) on the self levelling linkage.
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
levelling linkage, when the loader arms are lowered and the bucket is in the level digging position.
LB 75115 / FB 90.2200.2
36mm
17
WARNING
When it is necessary to remove pins from the loader
that require a hammer and drift use only a brass hammer and brass drift and wear safety glasses.
18
WARNING
To avoid personal injury, shut off the engine, relieve
all hydraulic pressure before any hydraulic
connection is disconnected.
3. Inspect all bushings for dirt and foreign matter
and clean before installing the pivot pins. Installation of a bucket follows the removal procedure in reverse.
LOADER ARM REMOVAL
1. Remove loader bucket
2. Disconnect self levelling linkage rod (3) from bellcrank (1).
3. Strap linkage rod (2) to loader arm.
3
19
4. Disconnect loader lift cylinder rod end retaining
pin.
5. Disconnect and cap hoses to bucket cylinder and
multipurpose bucket pipework where fitted.
IMPORTANT: Examine pipework to ensure that any
clamps securing the hoses to the loader arms have
also been released
20
LB 75115 / FB 90.2200.2
10
21
7. nstall loader pivot shaft bolt retainer V. L. Churchill Tool No 297189
22
8. Using heavy duty socket remove pivot bolt.
23
9. Ensure loader arms are properly supported and
remove pivot bar.
24
LB 75115 / FB 90.2200.2
11
25
11. Installation folllows removal procedure in reverse. When installing the pivot rod retaining
bolts tighten retaining retaining bolt to 500 Nm
(368 lbf.ft)
26
LB 75115 / FB 90.2200.2
12
LB 75115 / FB 90.2200.2
SECTION 82 LOADER
Chapter 2 Loader Frame, Controls and Buckets
CONTENT
Section
82 100
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul Loader Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Return to Dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Loader Bucket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LB 75115 / FB 90.2200.2
1
(PER SAE J 732 C)
With Bucket m3
1.15m3
1.15m3
(with clam)
Breakout Force
45
45
45
E. Dump Angle
45
45
45
H. Peel Depth
I. Centre line of axle to Bucket Lip
1.15m3
M. Overall Length
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
1.
2.
3.
4.
5.
6.
7.
6
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
7
1.
2.
3.
LB 75115 / FB 90.2200.2
SM009LB110
88.5 mm
7.5 mm
6 mm
SM060LB110
LB 75115 / FB 90.2200.2
WARNING
When it is necessary to remove pins from the loader
that require a hammer and drift use only a brass hammer and brass drift and wear safety glasses.
2. If a multi purpose bucket is installed disconnect
and plug hydraulic hoses prior to removal.
WARNING
10
11
4. Remove the retaining rings and the locking pins
and then drive out the pivot pins. Lower the lift
cylinders carefully onto the chassis.
12
LB 75115 / FB 90.2200.2
13
6. Disconnect and cap the lift cylinder hoses (1) at
the top of the loader arm on each side of the machine and disconnect the return to dig sensor
cable (3) on the right hand side. If the multi purpose bucket is fitted disconnect and cap hose (2)
on each side of the loader arm
14
7. Support loader arm using a suitable sling.
15
8. Remove the retaining ring and locking pin and
then pull out the pivot pin.
16
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
17
10. Installation follows removal procedure in reverse.
LB 75115 / FB 90.2200.2
10
NOTES
LB 75115 / FB 90.2200.2
SECTION 84 BACKHOE
Chapter 1 Backhoe, Boom and Dipperstick Assembly
CONTENT
Section
Description
Page
84 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Backhoe Control LinkageOverhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
84 100
Component Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dipperstick and BoomComplete Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
84 114
Swing Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
84 114
Carriage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
84 100
SPECIFICATIONS
Grease
Thread Sealant
Wear Pad Limits
LB 75115 / FB 90.2200.2
2
(PER SAE J 732 C) WITH TYRES
A. Loading Reach
B. Bucket Rotation
C. Operating Height, Fully Raised
D. Loading Height Maximum
E. Reach from swing post
E. Reach from rear axle centre line
G. Maximum Length of Surface Excavation
H. Maximum Digging Depth
To Achieve a 0.6m (2ft). Flat Bottom Trench
To Achieve a 2.43m (8ft). Flat Bottom Trench
J. Maximum Digging Depth
K. Stabilizer Spread Transport
L. Stabilizer Spread Working (pads reversed)
M. Stabiliser Pad Levelling Angle
Swing Arc
Maximum digging force (general purpose bucket)
crowd cylinder
bucket cylinder
Lift capacity through dipper arc
Lift capacity, dipper 3.66m (12ft) above ground
Lift capacity at 4.2m (14ft) above ground
Extendible dipper extension length
LB 75115 / FB 90.2200.2
H.E.D. (Extended)
2573mm (8ft 4in)
204
6290mm (20ft 7in)
4550mm (14ft.9in)
6675mm (21ft.9in)
8000mm (26ft 3in)
7092mm (23ft 3in)
3
(PER SAE J 732 C) WITH TYRES
A. Loading Reach
B. Bucket Rotation
C. Operating Height, Fully Raised
D. Loading Height Maximum
E. Reach from swing post
E. Reach from rear axle centre line
G. Maximum Length of Surface Excavation
H. Maximum Digging Depth
To Achieve a 0.6m (2ft). Flat Bottom Trench
To Achieve a 2.4m (8ft). Flat Bottom Trench
J. Maximum Digging Depth
K. Stabilizer Spread Transport
L. Stabilizer Spread Working (pads reversed)
M. Stabiliser Pad Levelling Angle
Swing Arc
Maximum digging force (general purpose bucket)
crowd cylinder
bucket cylinder
Lift capacity through dipper arc
Lift capacity, dipper 3.66m (12ft) above ground
Lift capacity at 4.2m (14ft) above ground
Extendible dipper extension length
H.E.D. (Extended)
2820mm (9ft 2in)
204
6467mm (21ft 0in)
4664mm (15ft.1in)
6953mm (22ft.6in)
8278mm (26ft 9in)
7380mm (23ft 10in)
LB 75115 / FB 90.2200.2
Backhoe
Standard Dipper
HED Extended
A.
Loading Reach
B.
Bucket Rotation
204
204
C.
D.
E.
F.
G.
H.
J.
4302mm (14ft 1)
K.
L.
M.
14
14
Swing Arc
180
180
LB 75115 / FB 90.2200.2
TORQUES
LB 75115 / FB 90.2200.2
8
On sideshift machines the backhoe is attached to a
carriage hydraulically clamped to a frame at the rear
of the machine. This allows the operator to repositioning the carriage on the frame and adjust the pivot
point of the backhoe to suit operating conditions.
The machine is raised using two vertical stabilisers
attached to each side of the machine.
9
Each stabiliser is independently operated using
levers (1) and (2).
10
The backhoe is locked in position during transportation using a hydraulically operated boom lock(1). The
lock is operated by a switch (3) which illuminates a
warning light (2) whenever the lock is activated.
11
LB 75115 / FB 90.2200.2
1
12
Machines may be fitted with an optional extendible
dipperstick which can be operated simultaneously
with other boom, dipperstick and bucket movements.
13
The extendible dipperstick is controlled using a foot
operated pedal at the rear of the cab.
14
LB 75115 / FB 90.2200.2
PATTERN), FIGURE 15
IMPORTANT: Ensure the Sideshift Carriage Clamp switch (3) is ON before operating the backhoe and the
backhoe boom plate is disengaged either by lever or switch (4)
RIGHT HAND BACKHOE Operating Lever (1), is with the operator seated in the cab facing rearward.
INDIVIDUAL OPERATION
Straight line movement of the backhoe
lever (1) operates dipstick and bucket.
DUAL OPERATION
Diagonal movement of the backhoe
lever (1) allows dual operation of
dipstick and bucket.
BUCKET CURLS IN
DIPSTICK CROWDS IN
LEFT HAND BACKHOE Operating Lever (2), is with the operator seated in the cab facing rearward.
INDIVIDUAL OPERATION
Straight line movement of the backhoe
lever (2) operates boom and swing.
DUAL OPERATION
Diagonal movement of the backhoe
lever (2) allows dual operation of
boom and swing.
BOOM LOWERS
BOOM LIFTS
LB 75115 / FB 90.2200.2
FEATHERING CAPABILITY
Operating both backhoe Levers and the H.E.D foot pedal (1)
together (when fitted) allows multiple feathering operations.
15
LB 75115 / FB 90.2200.2
10
PATTERN), FIGURE 16
IMPORTANT: Ensure the Sideshift Carriage Clamp switch (3) is ON before operating the backhoe and the
backhoe boom plate is disengaged either by lever or switch (4)
RIGHT HAND BACKHOE Operating Lever (1), is with the operator seated in the cab facing rearward.
INDIVIDUAL OPERATION
Straight line movement of the backhoe
lever (1) operates boom and bucket.
DUAL OPERATION
Diagonal movement of the backhoe
lever (1) allows dual operation of
boom and bucket.
BOOM LOWERS
BUCKET CURLS IN
BOOM LIFTS
LEFT HAND BACKHOE Operating Lever (2), is with the operator seated in the cab facing rearward.
INDIVIDUAL OPERATION
Straight line movement of the backhoe
lever (2) operates dipstick and boom.
DUAL OPERATION
Diagonal movement of the backhoe
lever (2) allows dual operation of
dipstick and boom.
DIPSTICK CROWDS IN
LB 75115 / FB 90.2200.2
FEATHERING CAPABILITY
Operating both backhoe Levers and the H.E.D foot pedal (1)
together (when fitted) allows multiple feathering operations.
11
16
LB 75115 / FB 90.2200.2
12
PATTERN), FIGURE 17
IMPORTANT: Ensure the Sideshift Carriage Clamp switch (3) is ON before operating the backhoe and the
backhoe boom plate is disengaged either by lever or switch (4)
RIGHT HAND BACKHOE Operating Lever (1), is with the operator seated in the cab facing rearward.
INDIVIDUAL OPERATION
Diagonal movement of the backhoe
lever (1) operates dipstick and bucket.
DUAL OPERATION
Straight line movement of the
backhoe lever (1) allows dual
operation of dipstick and bucket.
BUCKET CURLS IN
DIPSTICK CROWDS IN
LEFT HAND BACKHOE Operating Lever (2), is with the operator seated in the cab facing rearward.
INDIVIDUAL OPERATION
Diagonal movement of the backhoe
lever (2) operates boom and swing.
DUAL OPERATION
Straight line movement of the
backhoe lever (2) allows dual
operation of boom and swing.
BOOM LOWERS
BOOM LIFTS
LB 75115 / FB 90.2200.2
FEATHERING CAPABILITY
Operating both backhoe Levers and the H.E.D foot pedal (1)
together (when fitted) allows multiple feathering operations.
13
17
LB 75115 / FB 90.2200.2
14
18
1.
2.
3.
4.
19
Backhoe Control Levers
Standard
Pattern
LB 75115 / FB 90.2200.2
15
1.
2.
3.
4.
5.
6.
20
Backhoe Control Levers
Pattern
Optional ISO
LB 75115 / FB 90.2200.2
16
21
1.
2.
3.
4.
5.
Pattern
Bucket Control Rod (127mm)
Dipperstick Control Rod (297mm)
Bucket Control Rod (175mm)
Bracket and Bellcrank Assembly
Control rod lengths shown for this pattern are approximate and minor adjustment may be required
after installation.
LB 75115 / FB 90.2200.2
17
COMPONENT REMOVAL
Dipperstick and BoomComplete Assembly
WARNING
Always support the structural members so that they
will be stable and safe to work around.
1. Park the machine on a level surface and position
loader bucket on the ground
22
2. Lower stabilisers sufficiently to remove the
weight from the rear wheels.
IMPORTANT: The rear wheels must remain in contact with the ground.
23
3. Fully retract extendible dipperstick, where fitted.
24
LB 75115 / FB 90.2200.2
18
25
5. Fully retract dipperstick cylinder and lower boom
until bucket is firmly resting on the ground.
6. Support the backhoe using suitable stand and
hoist capable of carrying 1500 Kg.
26
7. Turn off engine, then move backhoe control levers through all operating positions to relieve
pressure in the system.
8. Recheck that backhoe elements are fully supported.
27
LB 75115 / FB 90.2200.2
19
28
1.
2.
Installation
Installation follows removal procedure in reverse.
During installation observe the following:
Tighten boom pivot pin retaining bolt (3) to torque
of 190Nm (140 lbf.ft).
Check all hoses for leaks.
Check hydraulic reservoir oil level and add
Ambra multi G 10W30 oil to specification
NH410B or Hydrosystem biodegradable oil to
NH Specification NH646 H if applicable.
Lubricate grease fittings.
LB 75115 / FB 90.2200.2
20
Dipperstick Removal
1. Park the machine on a level surface and position
loader bucket on the ground.
29
2. Lower stabilisers sufficiently to remove the
weight from the rear wheels.
IMPORTANT: The rear wheels must remain in contact with the ground.
30
BOOM LOCK MECHANICAL (where fitted)
3. Disengage the boom lock
31
BACKHOE TRANSPORT BOOM LOCK
ELECTRICALLY OPERATED (where fitted)
4. Disengage the boom lock
1
32
LB 75115 / FB 90.2200.2
21
5. Remove bucket.
33
6. Fully retract extendible dipperstick where fitted
and instal locking pin in transport hole (1).
34
7. Lower the backhoe to the ground and support using a suitable stand.
35
8. Turn off engine, then move backhoe control levers through all operating positions to relieve
pressure in the system.
36
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
22
37
38
10. Support dipperstick cylinder and remove pivot
pin (1). Lower cylinder onto boom. Use suitable
packing to ensure weight of cylinder does not
damage hydraulic tubes attached to dipperstick.
39
11. Support dipperstick using suitable hoist, remove
pivot pin and carefully lower dipperstick to the
ground.
40
LB 75115 / FB 90.2200.2
23
Installation
Installation follows removal procedure in reverse.
During installation observe the following:
Tighten pivot pin retaining bolts to torque of
288Nm (212 lbf.ft).
Check all hoses for leaks.
Check hydraulic reservoir oil level and add
Ambra multi G 10W30 oil to specification
NH410B or Hydrosystem biodegradable oil to
NH Specification NH646 H if applicable.
Lubricate grease fittings.
41
Swing Post Removal
1. Remove dipperstick and boom as described on
Pages 1315.
42
2. Disconnect control rod (1) and remove boom
lock (2).
43
3. Disconnect hoses (1) from each side of swing
post.
4. Remove swing post hose clamp (2).
5. Disconnect hose to boom lock valve (3)
or mechanical lock linkage (where fitted)
6. Cap all hoses to prevent ingress of dirt.
44
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
24
45
8. Support swing post with suitable hoist and remove pivot pins.
46
9. Remove swing post from frame and collect locking washers (1) and shim(s) (2) where fitted.
47
LB 75115 / FB 90.2200.2
25
Inspection
Examine swing post and seals for wear or damage
and replace as necessary.
Installation
Installation follows removal procedure in reverse. On
installation tighten pivot pin retaining bolt to a torque
of 190Nm (140 lbf.ft).
48
Carriage Removal
NOTE: If carriage is being removed for overhaul of
sideshift clamp cylinders refer to Section 35 Chapter
3 before proceeding.
1. Remove dipperstick and boom as described on
Page 15 of this Chapter and cap all hoses.
2. Disconnect control rod (1) and remove boom
lock (2).
49
3. Disconnect carriage hose clamps (2).
4. Disconnect supply to clamp cylinders (1).
50
LB 75115 / FB 90.2200.2
26
51
10. Attach suitable hoist to carriage as shown in Figure 52.
11. Remove the 6 clamp bolts (1) on the top of the
carriage.
52
12. Carefully remove carriage.
53
LB 75115 / FB 90.2200.2
27
54
Installation
Installation follows the disassembly procedure in
reverse.
Torque all carriage clamp bolts to a torque of
800 Nm (592 lbf ft).
Check that all hoses are correctly routed and
clamped.
55
LB 75115 / FB 90.2200.2
28
56
1.
2.
3.
4.
5.
Inner Section
Outer Section
Shims
Adjusting Bolt
Upper Wear Pad
Extendible Dipperstick
6. Lower Wear Pad
7. Threaded Insert
8. Wear Pad Installation
9. Cylinder Assembly
LB 75115 / FB 90.2200.2
29
57
4. 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.
5. If pads do not require replacement visually check
if the gap between the inner section of the dipperstick and upper wear pad is greater than
1.5mm.
6. If the gap is greater than 1.5mm the wear pads
must be adjusted as follows:
58
Adjustment of Wear Pads
1. Position the dipperstick in the vertical position.
59
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
30
60
Replacement of Wear Pads
To replace the wear pads it is necessary to separate
the inner and outer sections of the dipperstick using
either of the following procedures which are dependant on workshop facilities.
Procedure 1
1. Park the machine on level ground and lower
loader bucket.
2. Lower stabilisers sufficiently to remove the
weight from the rear wheels.
61
IMPORTANT: The rear wheels must remain in contact with the ground.
3. Position dipperstick on a suitable stand.
4. Attach hoist to inner section of dipperstick.
5. Disconnect hose connections to bucket and extendible dipperstick cylinders.
6. Remove extendible dipperstick cylinder retaining
pin and separate inner and outer sections of dipperstick.
7. Remove and replace wear pads as described on
Page 27.
62
LB 75115 / FB 90.2200.2
31
Procedure 2
This procedure requires the use of a loading bay or
service pit.
1. Park the machine with backhoe positioned over
loading bay or service pit.
2. Place the loader bucket on the ground and lower
stabilisers sufficiently to remove the weight from
the rear wheels.
3. Attach suitable hoist to top of inner section of
dipperstick and position boom so that dipperstick
is hanging vertically.
4. Disconnect hose connections at bucket and extendible dipperstick cylinders.
5. Remove extendible dipperstick cylinder retaining
pin.
6. Slowly lower hoist allowing inner and outer sections of dipperstick to separate.
7. Remove and replace wear pads as described on
Page 27.
63
LB 75115 / FB 90.2200.2
32
64
1.
2.
3.
4.
5.
Inner Section
Outer Section
Shims
Adjusting Bolt
Upper Wear Pad
Extendible Dipperstick
6. Lower Wear Pad
7. Threaded Insert
8. Wear Pad Installation
9. Cylinder Assembly
LB 75115 / FB 90.2200.2
SECTION 90 CAB
Chapter 3 Safety Cab and Roll Over Protection (ROPS)
CONTENT
Section
Description
Page
90 100
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cab Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TORQUES
Torque figures for individual components are listed at the beginning of each section of the Repair Manual and
can also be found in Section 39 Chapter 1.
Front cab retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Nm (158 lbf ft)
Rear cab retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm (133 lbf ft)
Cab support to Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 450 Nm (332 lbf ft)
Bonnet Front casting to frame . . . . . . . . . . . . . . . . . . . . . 214 Nm (158 lbf ft)
Upper and front bonnet retaining bolts . . . . . . . . . . . . . . 80 Nm (59 lbf ft)
Front bonnet to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Nm (125 lbf ft)
Below are general torque figures for hydraulic hoses, tubes and ORS Connections that you may find on your
machine.
9/
Thread Size:
16 in 18 . . . . . . . . . . . . . 13.5 16.5 Nm . . . . . . . . . . . . . . (10 12 lbf ft)
11/ in 16 . . . . . . . . . . . . . . . . 23 28 Nm . . . . . . . . . . . . . . (17 20 lbf ft)
16
13/ in 16 . . . . . . . . . . . . . . . . 45 53 Nm . . . . . . . . . . . . . . (32 39 lbf ft)
16
1 in 14 . . . . . . . . . . . . . . . . 62 77 Nm . . . . . . . . . . . . . . (46 57 lbf ft)
13/16 in 12 . . . . . . . . . . . . . . . 86 107 Nm . . . . . . . . . . . . . . (63 79 lbf ft)
17/16 in 12 . . . . . . . . . . . . . . 125 142 Nm . . . . . . . . . . . . . (93 105 lbf ft)
111/16 in 12 . . . . . . . . . . . . . . 169 190 Nm . . . . . . . . . . . . (125 140 lbf ft)
2 in 12 . . . . . . . . . . . . . . 203 246 Nm . . . . . . . . . . . . (150 182 lbf ft)
SPECIAL TOOLS
Special Tools are listed in the Repair Manual introduction and at the beginning of each section of the Repair Manual for your guidance.
LB 75115 / FB 90.2200.2
10
41
55
90
84
39
35
10
33
27
82
21
17
10
50
44
25
1
Repair Manual Sections by numbers
LB 75115 / FB 90.2200.2
LB 75115 / FB 90.2200.2
WARNING
Prior to removing the cab the refrigerant in the Air
Conditioning System ( if fitted) must be evacuated
into an Air Conditioning reclaim/recharge unit, refer
to Section 50 Part 2. Do not attempt to disassemble
the air conditioning system It is possible to be severely frostbitten or injured by escaping refrigerant. Do not allow refrigerant to escape into the atmosphere.
Listed are the components that may require removal
of the cab or platform to allow repairs, or would facilitate repair of components difficult to access.
LB 75115 / FB 90.2200.2
x4
4
Cab Attachment to the Chassis
5
View with Cab removed
LB 75115 / FB 90.2200.2
CAB (FRONT)
6. Power Assist Steering Pipes Disconnect and
tape back to avoid leakage and damage.
NOTE: To minimise leakage, plug all open pipes and
ports to prevent leaks and dirt ingress.
LB 75115 / FB 90.2200.2
9
2. Cab side valence
3. Cab Looms Disconnect at the harness connectors to the right of the cab below B pillar.
10
CAB REAR
1. Rear harness connector
1
11
2. Rear skirt
2
12
LB 75115 / FB 90.2200.2
VEHICLE UNDERSIDE
1. Brake Pipes Disconnect the rubber pipes at the
top of the rear axle (both half shafts) and plug
open ends to prevent dirt ingress.
NOTE: To minimise leakage, plug all open pipes and
ports to prevent leaks or dirt ingress.
2. Cab Earth Strap Loosen and detach from the
chassis.
1
2
13
3. Air Conditioning (when fitted). After evacuation
of the refrigerant gas disconnect the Air Conditioning Expansion Valve which is mounted below
and at the rear of the cab heater pod .
14
4. Disconnect the heater control cable
15
5. Disconnect the handbrake at the caliper.
5
16
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
17
3. Rear Mounting With the nuts removed, the cab
through bolts can remain in position as the cab
is lifted
4. Front Mounting Bolts With the nuts removed,
the cab through bolts can remain in position as
the cab is lifted
18
1
NOTE: When lifting the cab ensure the hydraulic
brake reservoirs are not caught and damaged on the
loader support frame.
5. Slowly raise the cab from the chassis ensuring
that all cables, rods and hoses etc, are free moving.
6. With the cab safely clear of the chassis the vehicle can be repaired as required.
19
Reassembly Of Cab To Chassis
1. After completion of repairs reassemble in reverse order of disassembly, ensuring all torque
values are to specification, refer to relevant repair manual chapters.
LB 75115 / FB 90.2200.2
10
20
LB 75115 / FB 90.2200.2
11
GLASS REPLACEMENT
The following instructions detail the procedure for the
replacement of any direct glazed (bonded) glass.
The bonding kit, Figure 25, available from the Parts
Depot should be used when replacing any direct
glazed glass. If the bonding kit is not available use
only a reputable auto glazing company to perform repairs.
WARNING
Always wear gloves and eye protectors to avoid injury from small fragments of glass.
TA6090018
21
22
6. Anchor end of tool in adhesive and pull handle,
see Figure 23 (A), guiding wire close to glass
edge. Pull end of tool (1) from the adhesive bead
(2) and reposition further along the bead, Figure
23 (B). Use long cutting strokes on straight
edges to reduce risk of wire breakage and short
cutting strokes at corners to avoid breaking glass
(two man operation).
7. Using suction cups, lift out glass. Place outer surface of glass face down on a protected surface.
8. Taking care not to damage the frame, cut away
adhesive (1) to leave a smooth bevel of approximately 2.0 mm, see Figure 24.
NOTE: It is not necessary to remove all residual material from the frame.
9. Repeat Number 8, above, for glass clean up procedure.
LB 75115 / FB 90.2200.2
TA6090020
23
12
24
TA6090022
25
1. Apply the activator to the edge of the glass (adhesive contact area) with the clean tissue provided. Allow to dry.
2. Shake the bottle of glass primer for 60 seconds.
Pour into applicator bottle.
3. Trim the applicator to dimension C in Figure 26,
and insert the felt pad.
TA6090023
26
4. Screw the applicator to the applicator bottle.
5. Apply the primer (2) to the previously prepared
area of glass (1), Figure 27.
6. Allow 15 mins to dry.
TA6090024
27
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
13
7. Using a sharp knife, cut off the end of the adhesive applicator (1) and cut a V (2) in the end of the
nozzle, as shown in Figure 28. All dimensions
shown in millimetres.
8. Apply a smooth continuous bead of adhesive to
the glass (or Frame)
NOTE: It is difficult to fill in spaces to the correct profile. Ensure that joints are formed correctly to avoid
water leaks.
65
7.0
3.0
TA6090025
28
9.
10.
11.
12.
LB 75115 / FB 90.2200.2
14
CAB TRIM
CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
Parking Brake
Hand Throttle Lever
Stabiliser Leg Operating Levers
Air Flow Direction Outlet
Hydraulically Extendible Dipper, H.E.D Operating
Pedal (Optional Equipment)
14. Backhoe Control Lever Patterns
Standard:
2 Lever Cross Pattern with Horn Button
Optional:
2 Lever Cross Pattern ISO
2 Lever Diagonal Pattern
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
WARNING
When travelling on the road the brake pedals must
be latched together for straight line braking.
If the pedals are not latched pressure applied to one
pedal only, could result in the machine veering severely to the left or right hand side.
25. Hazard Flasher Button
26. POWER SHIFT 4X4 Transmission Forward / Reverse Lever with Integral Horn Button
27. Air Flow Direction Outlet
28. Front Instrument Panel
29. Speedometer Optional
30. Key Operated Steering Selection Switch:
1= Standard Steering
2= Double steering
3= Crab Steering
LB 75115 / FB 90.2200.2
15
29
Power Shuttle Machines with Analogue Instruments, Figure 29
LB 75115 / FB 90.2200.2
16
OVERHAUL SEATS
Seats Retained to the floor mount with bolts.
30
1.Seat Assembly with ROPS frame fitted As depicted many parts are serviceable and assembled
with standard hardware. Serviceable parts include
rails, sliders, supports and levers.
IMPORTANT: Be very careful when dissembling
sprung seats (when fitted), releasing hardware without releasing spring pressure could result in sudden
movement of the mechanism injuring yourself or
others
31
2.Seat Assembly (Standard Type) with Cab Fitted
As depicted many parts are serviceable and assembled with standard hardware. Serviceable parts
include rails, sliders, supports, levers and skirt.
IMPORTANT: Be very careful when disassembling
sprung seats, releasing hardware without releasing
spring pressure could result in sudden movement of
the mechanism injuring yourself or others
32
604.56.061.00 / 604.13.028.00 09/2000
LB 75115 / FB 90.2200.2
17
33
34
IMPORTANT: Before removal of the following components disconnect the battery by use of the isolator
switch mounted below the engine fuel pump.
Key Start Fitted in the right B Pillar and retained
by a locking nut. Take off B Pillar, disconnect harness connector and locknut and remove.
Courtesy Light Mounted in the roof panel and retained by screws inside the lens cover. Remove lens
and attaching screws to disassemble
12 Volt Auxiliary Socket Fitted in the left hand trim
panel and which can be removed by the loosening of
the locknut and detachment of cable connector
35
LB 75115 / FB 90.2200.2
18
36
Upper Front Console Attached to the machine by
attaching screws. Dependant upon the type of repair
required, switches, indicator lamps and gauges can
all be removed independently or retained in the console when removing the console but ensure the harness connectors are detached.
37
Lower Front Console Retained by attaching screws
to support brackets. Removal of this part will require
detachment of the upper console and related harness connectors, steering column gaiter, Steering
wheel, Power Shift/Shuttle lever and Direction Indicator stalk.
38
LB 75115 / FB 90.2200.2
19
39
40
Steering Column Assembly Standard Type Removal of this part will require all attaching parts to be
removed prior to removing from the machine. The
column to chassis is retained by 4 bolts.
41
LB 75115 / FB 90.2200.2
20
Steering Column Assembly Adjustable Type Removal of this part will require all attaching parts to be
removed prior to removing from the machine. The
column to chassis is retained by 4 bolts.
42
43
Side Mounted Console Attached to the machine by
attaching screws. Dependant upon the type of repair
required, switches, indicator lamps and gauges can
all be removed independently or retained in the console when removing the console but ensure the harness connectors are detached.
44
LB 75115 / FB 90.2200.2
21
Right Hand Side Mounted Console Retained by attaching screws to support brackets. Removal of this
part will require detachment of the upper console and
related harness connectors.
45
Right Hand Lower Side Mounted Trim.
46
Rear Mounted Trim As with the trim in general
these are attached by mounting screws to support
brackets and can be easily removed as required providing attaching parts and trim are removed.
47
LB 75115 / FB 90.2200.2
22
48
49
Outer Roof Panel Attached to the cab frame by
bolts and concealed by plugs
50
LB 75115 / FB 90.2200.2
23
51
Rear Windscreen Wiper Mounted on the c Pillar
by attaching bolts can be removed easily once the
bolts are removed.
52
Cab External Trim Panels These trim panels are attached by screws to support brackets and when removed expose the gap between cab and chassis.
53
LB 75115 / FB 90.2200.2
24
NOTES
LB 75115 / FB 90.2200.2