LOADERBACKHOEMODELS
ThecompleterangeofLoaderBackhoemodelsdescribedinthismanualareidentifiedbelow:
Powershift
Powershuttle
Stabilizersideshift
Stabilizercentrepivot
Cab
Rops
2WD
4WD
4WS
Pilotcontrol
Mechanicalcontrol
EngineIveco71kW-95HPmodel
F4GE0454C*D660
EngineIveco82kW-110HPmodel
F4GE0484C*D660
EngineIveco82kW-110HP(4WS)model
F4GE0484C*D655
Shortdipper
Longdipper
SECTION17-TORQUECONVERTERS
SECTION21-TRANSMISSION
SECTION25-FRONTAXLES
SECTION27-REARAXLE
SECTION33-BRAKESSYSTEM
SECTION35-HYDRAULICSYSTEM
1HYDRAULICDIAGRAMS
1.1HYDRAULICDIAGRAM-2WSCENTREPIVOTMECHANICALMODELS.........................................3
1.2HYDRAULICDIAGRAM-2WSSIDESHIFTMECHANICALMODELS
1.5HYDRAULICDIAGRAM-4WSCENTREPIVOTMECHANICALMODELS
1.6HYDRAULICDIAGRAM-4WSSIDESHIFTMECHANICALMODELS...............................................15
1.7HYDRAULICDIAGRAM-4WSCENTREPIVOTPILOTMODELS
SECTION41-STEERINGSYSTEM
SECTION50-CABHEATINGANDAIRCONDITIONING
SECTION55-ELECTRICALSYSTEM
SECTION82-LOADER
SECTION84-BACKHOE
SECTIONSINDEX
Wheredisassemblyofaspecificcomponentisrequiredrefertotherelevantrepairmanualsection
SECTION17: TORQUECONVERTER
SECTION21: TRANSMISSION
SECTION25: FRONTAXLE
SECTION27: REARAXLE
SECTION33: BRAKESSYSTEM
SECTION35: HYDRAULICSYSTEM
SECTION39: CHASSIS
SECTION41: STEERINGSYSTEM
SECTION50: CABHEATINGANDAIRCONDITIONING
SECTION55: ELECTRICALSYSTEM
SECTION82: LOADER
SECTION84: BACKHOE
SECTION00-SAFETYPRECAUTIONS
Thiswarningsymbolpointsoutimportantmessages involvingpersonalsafety
Carefullyreadthesafetyrulescontainedhereinand followadvisedprecautionstoavoidpotentialhazardsandsafeguardyoursafetyandpersonalintegrity
Inthismanualyouwillfindthissymboltogetherwith thefollowingkey-words:
WARNING-itgiveswarningaboutimproperrepair operationsandderivingpotentialconsequencesaffectingtheservicetechnicianspersonalsafety
DANGER-itgivesspecificwarningaboutpotential dangersforpersonalsafetyoftheoperatororother personsdirectlyorindirectlyinvolved
TOPREVENTACCIDENTS
Mostaccidentsandpersonalinjuriesthatoccurintheworksiteorontheroad,arecausedbythefailureof someindividualtofollowsimpleandfundamentalsafetyrulesorprecautions
Forthisreason,MOSTACCIDENTSCANBEPREVENTEDbyrecognizingtherealcauseandtakingthenecessaryprecautions,beforetheaccidentoccurs
Regardlessofthecareusedindesignandconstructionofanytypeofequipment,theremaybeconditionsthat cannotbecompletelysafeguardedagainst,withoutinterferingwithreasonableaccessibilityandefficientoperation
AcarefuloperatorortechnicianisthebestprecautionagainstaccidentsThecompleteobservanceofonesimplerulewouldpreventmanythousandsofseriousinjurieseachyear.
Thisruleis:Neverattempttoclean,lubricateoradjustamachinewhileitisinmotion
SAFETYRULES
Carefullyfollowspecifiedrepairandmaintenance procedures
Donotwearrings,wristwatches,jewels,unbuttonedorflappingclothingsuchasties,torn clothes,scarves,openjacketsorshirtswithopen zipswhichcouldgetholdintomovingparts Weadvisetouseapprovedsafetyclothingsuchas anti-slippingfootwear,gloves,safetygoggles,helmets,etc
Nevercarryoutanyrepaironthemachineifsomeoneissittingontheoperatorsseat,exceptifthey arecertifiedoperatorstoassistintheoperationto becarriedout.
Neveroperatethemachineoruseattachments fromaplaceotherthansittingattheoperators seat.
Nevercarryoutanyoperationonthemachine whentheengineisrunning,exceptwhenspecificallyindicated
Stoptheengineandensurethatallpressureisrelievedfromhydrauliccircuitsbeforeremoving caps,covers,valves,etc
Allrepairandmaintenanceoperationsshouldbe carriedoutwiththegreatestcareandattention. Servicestairsandplatformsusedinaworkshopor inthefieldshouldbebuiltincompliancewiththe safetyrulesinforce
Disconnectthebatteriesandlabelallcontrolsto warnthattheMachineisbeingservicedBlockthe machineandallequipmentwhichshouldbe raised
Nevercheckorfillfueltanksandaccumulatorbatteries,norusestartingliquidifyouaresmokingor nearopenflamesassuchfluidsareflammable Brakesareinoperativewhentheyaremanuallyreleasedformaintenancepurposes.Insuchcases, themachineshouldbekeptconstantlyundercontrolusingblocksorsimilardevices
Thefuelfillinggunshouldremainalwaysincontact withthefillerneck
Maintainthiscontactuntilthefuelstopsflowing intothetanktoavoidpossiblesparksduetostatic electricitybuildup
Useexclusivelyspecifiedtowingpointsfortowing themachineConnectpartscarefully
Ensurethatforeseenpinsand/orlocksaresteadily fixedbeforeapplyingtraction
Donotstopneartowingbars,cablesorchains workingunderload.
Totransferafailedmachine,useatraileroralow loadingplatformtrolleyifavailable
Toloadandunloadthemachinefromthetransportationmean,selectaflatareaprovidingafirmsupporttothetrailerortruckwheelsFirmlytiethe machinetothetruckortrailerplatformandblock wheelsasrequiredbytheforwarder.
Forelectricalheaters,battery-chargersandsimilar equipmentuseexclusiveauxiliarypowersupplies withaefficientgroundtoavoidelectricalshock hazard
Alwaysuseliftingequipmentandsimilarofappropriatecapacitytoliftormoveheavycomponents
Payspecialattentiontobystanders
Neverpourgasolineordieseloilintoopen,wide andlowcontainers
Neverusegasoline,dieseloilorotherflammable liquidsascleaningagents Usenon-flammable non-toxicproprietarysolvents
Wearprotectiongoggleswithsideguardswhen cleaningpartsusingcompressedair.
Donotexceedapressureof2.1bar,inaccordance withlocalregulations
Donotruntheengineinaclosedbuildingwithout properventilation
Donotsmoke,useopenflames,causesparksin thenearbyareawhenfillingfuelorhandlinghighly flammableliquids
Donotuseflamesaslightsourceswhenworking onamachineorcheckingforleaks.
MovewithcautionwhenworkingunderaMachine, andalsoonornearaMachineWearpropersafety accessories: helmets,gogglesandspecialfootwear. Duringcheckswhichshouldbecarriedoutwiththe enginerunning,askanassistanttositattheoperatorsseatandkeeptheservicetechnicianunder visualcontrolatanymoment.
Incaseofoperationsoutsidetheworkshop,drive themachinetoaflatareaandblockit.Ifworking onaninclinecannotbeavoided,firstblocktheMachinecarefullyMoveittoaflatareaassoonas possiblewithacertainextentofsafety.
Ruinedorpliedcablesandchainsareunreliable
DonotusethemforliftingortrailingAlwayshandlethemwearingglovesofproperthickness
ChainsshouldalwaysbesafelyfastenedEnsure thatfasteningdeviceisstrongenoughtoholdthe loadforeseenNopersonsshouldstopnearthe fasteningpoint,trailingchainsorcables
TheworkingareashouldbealwayskeptCLEAN andDRY.Immediatelycleananyspillageofwater oroil
Donotpileupgreaseoroilsoakedrags,asthey constituteagreatfirehazardAlwaysplacethem intoametalcontainer.BeforestartingtheMachine oritsattachments,check,adjustandblocktheoperatorsseat.AlsoensurethattherearenopersonswithintheMachineorattachmentoperating range.
Donotkeepinyourpocketsanyobjectwhich mightfallunobservedintotheMachinesinner compartments
Wheneverthereisthepossibilityofbeingreached byejectedmetalpartsorsimilar,useprotection eyemaskorgoggleswithsideguards,helmets, specialfootwearandheavygloves.Wearsuitable protectionsuchastintedeyeprotection,helmets, specialclothing,glovesandfootwearwheneverit isnecessarytocarryoutweldingproceduresAll personsstandinginthevicinityoftheweldingprocessshouldweartintedeyeprotectionNEVER LOOKATTHEWELDINGARCIFYOUREYES ARENOTSUITABLYPROTECTED.
Metalcableswiththeusegetfrayed.Alwayswear adequateprotections(heavygloves,eyeprotection,etc.).
HandleallpartswiththegreatestcautionKeep yourhandsandfingersfarfromgaps,moving gearsandsimilar.Alwaysuseapprovedprotective equipment,suchaseyeprotection,heavygloves andprotectivefootwear.
STARTUP
Neverruntheengineinconfinedspaceswhichare notequippedwithadequateventilationforexhaust gasextraction
Neverbringyourhead,body,arms,legs,feet, hands,fingersnearfansorrotatingbelts.
ENGINE
Alwaysloosentheradiatorcapveryslowlybefore removingittoallowpressureinthesystemtodissipateCoolantshouldbetoppeduponlywhenthe engineisstoppedoridleifhot.
Donotfillupfueltankwhentheengineisrunning, mainlyifitishot,toavoidignitionoffiresincaseof fuelspilling
Nevercheckoradjustthefanbelttensionwhenthe engineisrunningNeveradjustthefuelinjection pumpwhenthemachineismoving Neverlubricatethemachinewhentheengineis running.
ELECTRICALSYSTEMS
Ifitisnecessarytouseauxiliarybatteries,cables mustbeconnectedatbothsidesasfollows:(+)to (+)and(-)to(-).Avoidshort-circuitingtheterminals GASRELEASEDFROMBATTERIESIS HIGHLYFLAMMABLE.Duringcharging,leavethe batterycompartmentuncoveredtoimproveventilation Avoidcheckingthebatterychargeby meansofjumpersmadebyplacingmetallicobjectsacrosstheterminalsAvoidsparksorflames nearthebatteryareaDonotsmoketopreventexplosionhazards
Priortoanyservice,checkforfuelorcoolantleaks Removetheseleaksbeforegoingonwiththework DonotchargebatteriesinconfinedspacesEnsurethatventilationisappropriatetopreventacci-
dentalexplosionhazardduetobuild-upofgasses relievedduringcharging
Alwaysdisconnectthebatteriesbeforeperforming anytypeofserviceontheelectricalsystem
HYDRAULICSYSTEMS
Somefluidslowlycomingoutfromaverysmall portcanbealmostinvisibleandbestrongenough topenetratetheskin.Forthisreason,NEVERUSE YOURHANDSTOCHECKFORLEAKS,butuse apieceofcardboardorapieceofwoodforthis purposeIfanyfluidisinjectedintotheskin,seek medicalaidimmediatelyLackofimmediatemedicalattention,seriousinfectionsordermatitismay result.
Alwaystakesystempressurereadingsusingthe appropriategauges
WHEELSANDTYRES
Checkthatthetyresarecorrectlyinflatedatthe pressurespecifiedbythemanufacturer.Periodicallycheckpossibledamagestotherimsand tyres.
Keepoffandstayatthetyresidewhencorrecting theinflationpressure
Checkthepressureonlywhenthemachineisunloadedandtyresarecoldtoavoidwrongreadings duetoover-pressureDonotreusepartsofrecoveredwheelsasimproperwelding,brazingorheatingmayweakenthewheelandmakeitfail
Nevercut,norweldarimwiththeinflatedtyreassembled
Toremovethewheels,blockbothfrontandrear MachinewheelsRaisetheMachineandinstall safeandstablesupportsundertheMachineinaccordancewithregulationsinforce
Deflatethetyrebeforeremovinganyobjectcaught intothetyretread
Neverinflatetyresusingflammablegasesasthey mayoriginateexplosionsandcauseinjuriestobystanders
REMOVALANDINSTALLATION
Liftandhandleallheavycomponentsusinglifting equipmentofadequatecapacity.Ensurethatparts aresupportedbyappropriateslingsandhooks UseliftingeyesprovidedtothispurposeTake careofthepersonsneartheloadstobelifted
HandleallpartswithgreatcareDonotplaceyour handsorfingersbetweentwoparts Wearapprovedprotectiveclothingsuchassafetygoggles, glovesandfootwear.
DonottwistchainsormetalcablesAlwayswear protectionglovestohandlecablesorchains
IMPORTANTECOLOGICALCONSIDERATIONS
Thefollowingarerecommendationswhichmaybe ofassistance:
Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyour country
Wherenolegislationexists,obtaininformation fromsuppliersofoils,fuels,antifreeze,cleaning agents,etc.,withregardtotheireffectonmanand natureandhowtosafelystore,useanddisposeof thesesubstances
Helpfulhints
Avoidfillingtanksusingjerrycansorinappropriate pressurizedfueldeliverysystemswhichmay causeconsiderablespillage
Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc
Mostofthemcontainsubstanceswhichcanbe harmfultoyourhealth
ModernoilscontainadditivesDonotburncontaminatedfuelsand/orwasteoilsinordinaryheating systems
Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,transmissionandhydraulic oils,brakefluids,etc
DonotmixdrainedbrakefluidsorfuelswithlubricantsStorethemsafelyuntiltheycanbedisposed ofinaproperwaytocomplywithlocallegislation andavailableresources
Moderncoolantmixtures,i.e.antifreezeandother additives,shouldbereplacedeverytwoyears
Theyshouldnotbeallowedtogetintothesoilbut shouldbecollectedanddisposedofsafely DonotopentheAir-Conditioningsystemyourself. Itmaycontaingaseswhichshouldnotbereleased intotheatmosphereYourairconditioningspecialisthasspecialequipmentfordischargingand chargingthesystem.
Repairanyleaksordefectsintheenginecoolingor hydraulicsystemimmediately
Donotincreasethepressureinapressurizedcircuitasthismayleadtoacatastrophicfailureofthe systemcomponents
Protecthosesduringweldingaspenetratingweld chipsmayburnaholeorweakenthem,causing thelossofoils,coolant,etc.
LB90.B LB95.B
LB110.B LB115.B
SECTION01-MAINTENANCE
Allmaintenanceandrepairoperationsdescribedin thismanualshouldbecarriedoutexclusivelybyauthorizedworkshopsAllinstructionsdetailedshould becarefullyobservedandspecialequipmentindicatedshouldbeusedifnecessary
Everyonewhocarriesoutserviceoperationsdescribedwithoutcarefullyobservingtheseprescriptions will be directly responsible of deriving damages
GENERAL
Cleantheexteriorofallcomponentsbeforecarrying outanyformofrepair.Dirtanddustcanreducethe efficientworkinglifeofacomponentandleadto costlyreplacement.
Timespentonthepreparationandcleanlinessof workingsurfaceswillpaydividendsinmakingthe jobeasierandsaferandwillresultinoverhauled componentsbeingmorereliableandefficientinoperationUsecleaningfluidswhichareknowntobe safeCertaintypesoffluidcancausedamagetoOringsandcauseskinirritation.Solventsshouldbe checkedthattheyaresuitableforthecleaningof componentsandalsothattheydonotriskthepersonalsafetyoftheuser.
ReplaceO-rings,sealsorgasketswheneverthey aredisturbedNevermixnewandoldsealsorOrings,regardlessofconditionAlwayslubricatenew sealsandO-ringswithhydraulicoilbeforeinstallation.
Whenreplacingcomponentparts,usethecorrect toolforthejob
HOSESANDTUBES
Alwaysreplacehosesandtubesiftheconeendor theendconnectionsonthehosearedamaged
Wheninstallinganewhose,looselyconnecteach endandmakesurethehosetakesupthedesigned positionbeforetighteningtheconnectionClamps shouldbetightenedsufficientlytoholdthehose withoutcrushingandtopreventchafing
Afterhosereplacementtoamovingcomponent, checkthatthehosedoesnotfoulbymovingthe componentthroughthecompleterangeoftravel. Besureanyhosewhichhasbeeninstalledisnot kinkedortwisted
Hoseconnectionswhicharedamaged,dented, crushedorleaking,restrictoilflowandtheproductivityofthecomponentsbeingservedConnectors whichshowsignsofmovementfromtheoriginal swaggedpositionhavefailedandwillultimatelyseparatecompletely.
AhosewithachafedoutercoverwillallowwaterentryConcealedcorrosionofthewirereinforcement willsubsequentlyoccuralongthehoselengthwith resultanthosefailure.
Ballooningofthehoseindicatesaninternalleakage duetostructuralfailureThisconditionrapidlydeterioratesandtotalhosefailuresoonoccurs
Kinked,crushed,stretchedordeformedhosesgenerallysufferinternalstructuraldamagewhichcan resultinoilrestriction,areductioninthespeedof operationandultimatehosefailure
Free-moving,unsupportedhosesmustneverbeallowedtotoucheachotherorrelatedworkingsurfacesThiscauseschafingwhichreduceshoselife
O-RINGFLATFACESEALFITTINGS
WhenrepairingO-ringfacesealconnectors,thefollowingproceduresshouldbeobserved
WARNING
Neverdisconnectortightenahoseortubethatis underpressure,ifindoubt,actuatetheoperatingleversseveraltimeswiththeengineswitchedoffprior todisconnectingahoseortube
Releasethefittingsandseparatethehoseortube assembly,thenremoveanddiscardtheO-ringseal fromthefitting
DipanewO-ringsealintocleanhydraulicoilpriorto installation.InstallanewO-ringintothefittingand, ifnecessary,retaininpositionusingpetroleumjelly Assemblethenewhoseortubeassemblyandtightenthefittingfingertight,whileholdingthetubeor hoseassemblytopreventitfromturning.
Usetwosuitablewrenchesandtightenthefittingto thespecifiedtorqueaccordingtothesizeofthefitting
NOTE:toensurealeak-freejointisobtained,itis importantthatthefittingsarenotoverorunder torqued
SHIMMING
Ateachadjustment,selectadjustingshims,measurethemindividuallyusingamicrometreandthen sumuprecordedvalues
Donotrelyonmeasuringthewholeshimmingset, whichmaybeincorrect,oronratedvalueindicated foreachshim
ROTATINGSHAFTSEALS
Tocorrectlyinstallrotatingshaftseals,observethe followinginstructions: letthesealsoakintothesameoilasitwillsealfor atleasthalfanhourbeforemounting; thoroughlycleantheshaftandensurethatthe shaftworkingsurfaceisnotdamaged;
placethesealingliptowardsthefluidIncaseofa hydrodynamiclip,considertheshaftrotationdirectionandorientgroovesinorderthattheydeviate thefluidtowardstheinnersideoftheseal; coatthesealinglipwithathinlayeroflubricant(oil ratherthangrease)andfillwithgreasethegapbetweenthesealinglipandthedustlipofdoublelip seals; insertthesealintoitsseatandpressitdownusing aflatpunchDonottapthesealwithahammeror adrift; takecaretoinsertthesealperpendicularlytoits seatwhileyouarepressingit.Oncethesealissettled,ensurethatitcontactsthethrustelementifrequired; topreventdamagingthesealinglipagainstthe shaft,placeasuitableprotectionduringinstallation
O-RINGS
LubricatetheO-ringsbeforeinsertingthemintotheir seats.ThiswillpreventtheO-ringsfromrollingover andtwistingduringmountingwhichwilljeopardize sealing
BEARINGS
Itisadvisabletoheatthebearingsto80to90°Cbeforemountingthemontheirshaftsandcoolthem downbeforeinsertingthemintotheirseatswithexternaltapping
SPRINGPINS
Whenmountingsplitsocketspringpins,ensurethat thepinnotchisorientedinthedirectionoftheeffort tostressthepin Spiralspringpinsshouldnotbeorientedduringinstallation.
HARDWARETORQUEVALUES
Checkthetightnessofhardwareperiodically. Usethefollowingchartstodeterminethecorrect torquewhenchecking,adjustingorreplacinghardwareontheBackhoeloader.
IMPORTANT:Torquevalueslistedareforgeneral useonly.Makesurefastenerthreadsarecleanand notdamaged
NOTE:atorquewrenchisnecessarytoproperly torquehardware
NOTESFORSPAREPARTS
Onlygenuinepartsguaranteesamequality,life, safetyasoriginalcomponentsastheyarethesame asmountedinproduction.Onlythegenuinespare partscanofferthisguarantee Allsparepartsordersshouldbecompletewiththe followingdata: machinemodel(commercialname)andchassis number; enginetypeandnumber; partnumberoftheorderedpart,whichcanbe foundontheSparePartsCatalogue,whichisthe basefororderprocessing
NOTESFOREQUIPMENT
Equipmentwhichproposesandshowsinthismanualareasfollows: studiedanddesignedexpresslyforuseoncompanymachines; necessarytomakeareliablerepair; accuratelybuiltandstrictlytestedtoofferefficient andlong-lastingworkingmeans. Wealsoremindtherepairpersonnelthathaving theseequipmentmeans: workinoptimaltechnicalconditions; obtainbestresults; savetimeandeffort; workmoresafely
NOTICES
Wearlimitsindicatedforsomedetailsshouldbeintendedasadvised,butnotbindingvalues.The wordsfront,rear,righthand,andlefthandreferredtothedifferentpartsshouldbeintendedas seenfromtheoperatorsseatorientedtothenormal senseofmovementofthemachine.
HOWTOMOVETHEMACHINEWITHTHE BATTERYREMOVED
Cablesfromtheexternalpowersupplyshouldbe connectedexclusivelytotherespectiveterminalsof theMachinepositiveandnegativecablesusingpliersingoodconditionwhichallowproperandsteady contact.
Disconnectallservices(lights,wind-shieldwipers, etc.)beforestartingtheMachine Ifitisnecessarytocheckthemachineelectricalsystem,checkitonlywiththepowersupplyconnected Atcheckend,disconnectallservicesandswitchthe powersupplyoffbeforedisconnectingthecables
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