New Holland LB75.B User manual

CONSTRUCTION
CONSTRUCTION
SERVICE
MANUAL
LB75.B
LB90.B
LB95.B
LB110.B
LB115.B 4WS
BACKHOE LOADERS
6036702103

COMPANY POLICY
Company policy, which is one of continuous improvement, reserves the right to make changes in design and speci-
fication at any time without notice and without obligation to modify units previously built.
All data given in this book is subject to production variations. Dimensions and weights are approximate only and
the illustrations do not necessarily show tractors in standard condition. For exact information about any particular
machine please consult your Dealer.
PARTS AND ACCESSORIES
Genuine parts and accessories have been specifically designed for these machines.
We would like to point out that '' non-genuine" parts and accessories have NOT been examined and released by
the Company. The installation and or use of such products could have negative effects upon the design characte-
ristics of your machine and thereby affect its safety. The Company is not liable for any damage caused by the use
of "non-genuine" parts and accessories.
MODEL CODES
The complete range of Backhoe Loaders described in this manual are identified below :
EUR NA
FB
695
FB FB
LB
LB
100.2 200.2
LB
LB LB LB
580 590 SM 110.2
LB
95.B
LB
115.B
895
4WS 115.B
90.B 95.B 110.B 4WS SR SR -75.B -110.B 4WS
695
8200 LB
8100 8110
SR 4WS 90.B
Moteur 95HP X X X X X
FAGE0454C
Moteur 110HP X X X X X X X X X X
FAGE0484G
PowerShuttle X X X X X X X X X X
PowerShift X X X X X X X X X
Cab X X X X X X X X X X X X X
Euro. cab X X X X X
ROPS X X X X X
Central Pivot X X X X X X X X X
Side Shift X X X X X X X X X X X
2WD X X
4WD X X X X X X X X X X X X X X X
4WS X X X X
Mechanical X X X X X X X X X X X X X X X
control
Pilot control X X X X X X X X X X X X X X
The vehicles listed above may not be available in all countries or markets, therefore for the latest information con-
sult your local authorised dealer.
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CONTENTS
SECTION 00 -HEALTH, SAFETY, MAINTENANCE
CHAPTER 1 -General
Description Page
General Specifications ...................................................................... 1
SECTION 17 -TORQUE CONVERTOR
CHAPTER 1 -With Powershuttle Transmission
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 4
CHAPTER 2 -With Powershift Transmission
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 4
SECTION 21 -TRANSMISSIONS
CHAPTER 1 -4x4 Compact Shuttle
Description Page
General Specifications ...................................................................... 1
Description and Operation ................................................................... 5
Overhaul .................................................................................. 28
CHAPTER 2 -Powershift Introduction
Description Page
General Specifications ...................................................................... 1
Description and Operation ................................................................... 2
Removal .................................................................................. 35
CHAPTER 3 -Powershift Operating Lever
Description Page
General Specifications ...................................................................... 1
Fault Finding ............................................................................... 14
CHAPTER 4 -Powershift Overhaul (includes 4 Wheel Steer)
Description Page
General Specifications ...................................................................... 1
Fault Finding ............................................................................... 5
Overhaul .................................................................................. 8
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2 CONTENTS
SECTION 25 -FRONT AXLES
CHAPTER 1 -Front Axle for 2 and 4 Wheel Drive Only
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 1O
CHAPTER 2 -Front Axle for 4 Wheel Steer Only
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 3
CHAPTER 3 -Front Axle
Description Page
Identification ............................................................................... 1
Overhaul .................................................................................. 4
CHAPTER 7 -Front Axle
Description Page
Identification ............................................................................... 1
Overhaul .................................................................................. 4
CHAPTER 10- Front Axle
Description Page
Identification ............................................................................... 1
SECTION 27 -REAR AXLES
CHAPTER 1 -Rear Axle with Foot Operated Diff Lock for 2 and 4 Wheel Drive Only
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 6
CHAPTER 2 -Rear Axle with Electrically Operated Diff Lock for 2 and 4 Wheel Drive
Only
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 8
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CONTENTS
CHAPTER 3 -Rear Axle for 4 Wheel Steer Only
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 2
CHAPTER 4 -Rear Axle
Description Page
Identification ............................................................................... 1
SECTION 33 -BRAKE SYSTEMS
CHAPTER 1 -Brakes for 2 and 4 Wheel Drive Only
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 8
CHAPTER 2 -Brakes for 4 Wheel Steer Only
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 5
SECTION 35 -HYDRAULIC SYSTEMS
CHAPTER 1 -Hydraulic Circuits and Components for HUSCO Only
Description Page
General Specifications ...................................................................... 2
Hydraulic Valve Spool Seals ................................................................. 15
Stabliliser and Extendible Dipper Control Valves ................................................ 21
Loader Control Valve ........................................................................ 33
Backhoe Control Valve ...................................................................... 49
CHAPTER 2 -Fault Finding, Pressure and Flow Testing for HUSCO Only
Description Page
General Specifications ...................................................................... 2
Fault Finding ............................................................................... 6
Pressure Testing ........................................................................... 11
Flow Testing (Pump Performance Test) ........................................................ 21
3
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4 CONTENTS
CHAPTER 3 - Hydraulic Circuits and Components for REXROTH
Description Page
General Specifications ...................................................................... 1
Description and Operation ................................................................... 5
Hydraulic Circuits ........................................................................... 10
CHAPTER 4 - Fault Finding, Pressure and Flow Testing for REXROTH Only
Description Page
Specifications .............................................................................. 1
Preliminary Checks ......................................................................... 2
Fault Finding Charts ........................................................................ 3
Pressure Testing ........................................................................... 7
Steering Stndby ............................................................................ 7
Steering Circuit Relief Valve ................................................................. 7
System Pressure Relief Valve ................................................................ 8
Loader Bucket Relief Valve (Piston End) ....................................................... 9
Extendible Dipper Relief Valve (Piston End) .................................................... 8
Swing System Relief Valve .................................................................. 9
Dipperstick Bucket and Boom Relief Valves .................................................... 9
Flow Testing (Pump Performance Test) ........................................................ 10
CHAPTER 5 - Control Valves for REXROTH with Mechanical or Hydraulic Control
Description Page
General Specifications ...................................................................... 1
Loader Control Valve Overhaul ............................................................... 2
Backhoe Control Valve Overhaul ............................................................. 3
Control Valve Disassembly .................................................................. 4
Control Valve Section Disassembly ........................................................... 8
CHAPTER 6 - Swing System and Hydraulic Cylinders
Description Page
General Specifications ...................................................................... 1
Swing System Description and Operation ...................................................... 3
Hydraulic Cylinders Description and Operation ................................................. 6
Backhoe and Loader Cylinders -Removal and Installation ...................................... 9
Backhoe and Loader Cylinder Overhaul ....................................................... 18
Swing Cylinder Removal and Overhaul ........................................................ 22
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CHAPTER 7 -Hydraulic Pump
Description
CONTENTS
Page
General Specifications ...................................................................... 1
Tightening torques .......................................................................... 1
Description and Operation ................................................................... 2
Pump Overhaul ............................................................................ 5
Flow Divider Overhaul ...................................................................... 7
Rear Pump Overhaul ....................................................................... 8
Front Pump Overhaul ....................................................................... 11
CHAPTER 8 -Rexroth Control Blocks
Description Page
General Specifications ...................................................................... 1
Tightening torques .......................................................................... 1
Exploded Wiew of the Lever ................................................................. 2
Overhaul of the Control Block ............................................................... 5
SECTION 39 -VEHICLE CHASSIS
CHAPTER 1 -CHASSIS COMPONENTS
Description Page
General Specifications ...................................................................... 1
Overhaul ................................................................................. 6
SECTION 41 -STEERING SYSTEMS
CHAPTER 1 -Steering for 2 and 4 Wheel Drive Only
Description Page
General Specifications ...................................................................... 1
Fault Finding ............................................................................... 7
Overhaul ................................................................................. 8
CHAPTER 2 -Steering for 4 Wheel Steer Only
Description Page
General Specifications ...................................................................... 1
Fault Finding ............................................................................... 7
Overhaul ................................................................................. 1O
5
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6 CONTENTS
SECTION 50 -CAB HEATING AND AIR CONDITIONING
CHAPTER 1 -Cab Heating
Description Page
General Specifications ...................................................................... 1
Fault Finding ............................................................................... 5
Overhaul .................................................................................. 6
CHAPTER 2 -Cab Air Conditioning
Description Page
General Specifications ...................................................................... 1
Description & operation ..................................................................... 5
Fault Finding ............................................................................... 16
Overhaul .................................................................................. 38
SECTION 55 -ELECTRICAL SYSTEM
CHAPTER 1 -System General
Description Page
Electrical Equipment Specifications ........................................................... 1
Tempory wiring harness repair ............................................................... 2
Electrical System General Fault Finding ....................................................... 3
CHAPTER 2.1- Powershuttle Wiring Diagrams (N/A and Europeen Model)
Description Page
Fuses and Relays .......................................................................... 2
Components .............................................................................. 3
Connector ................................................................................. 4
Wiring Diagrams (N/A and Europeen Model) ................................................... 6
Connectors (Details) ........................................................................ 18
CHAPTER 2.2- Powershift Wiring Diagrams (N/A and Europeen Model)
Description Page
Fuses and Relays .......................................................................... 2
Components .............................................................................. 3
Connector ................................................................................. 4
Wiring Diagrams (N/A and Europeen Model) ................................................... 6
Connectors (Details) ........................................................................ 18
CHAPTER 2.3- Powershift 4 WS Wiring Diagrams (N/A and Europeen Model)
Description Page
Fuses and Relays .......................................................................... 2
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CONTENTS
Components .............................................................................. 3
Connector ................................................................................. 4
Wiring Diagrams (N/A and Eurpeen Model ..................................................... 6
Connectors (Details) ........................................................................ 18
CHAPTER 2.4- ROPS Wiring Diagrams (N/A and Europeen Model)
Description Page
Fuses and Relays .......................................................................... 2
Components .............................................................................. 3
Connector ................................................................................. 4
Wiring Diagrams (N/A and Europeen Model) ................................................... 6
Connectors (Details) ........................................................................ 19
CHAPTER 3 - Starter Motor 2,7kW
Description Page
General Specifications ...................................................................... 1
Fault Finding ............................................................................... 3
7
Exploded Wiew of the Starter ................................................................ 6HA
CHAPTER 4 - Alternator 90A
Description Page
General Specifications ...................................................................... 1
Fault Finding ............................................................................... 4
Exploded Wiew of the Alternator ............................................................. 6
CHAPTER 5 - Battery
Description Page
General Specifications ...................................................................... 1
Removal and Installation .................................................................... 2
Battery Maintenance and Tests ............................................................... 3
Battery Charging ........................................................................... 4
Common Causes of Battery Failure ........................................................... 6
CHAPTER 6 - Service Diagnostics, Calibration and Immobiliser
Description Page
Service Indicators .......................................................................... 1
Alarms and Diagnostics Signalling ............................................................ 2
Calibration of speedometer .................................................................. 4
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8
CHAPTER 7 -Component Testing
Description
CONTENTS
Page
General Introduction ........................................................................ 2
Component Testing ......................................................................... 3
Component Earth Points .................................................................... 4
SECTION 82 -LOADER
CHAPTER 1 -Loader Frame, Controls and Buckets for 2 and 4 Wheel Drive Only
Tightening Torques and Special Tools ......................................................... 1
General Specifications ...................................................................... 2
Description and Operation ................................................................... 5
Overhaul -Loader Controls .................................................................. 6
CHAPTER 2 -Loader Frame, Controls and Buckets for 4 Wheel Steer Only
General Specifications ...................................................................... 2
Description and Operation ................................................................... 4
Overhaul -Loader Controls .................................................................. 5
SECTION 84 -BACKHOE
CHAPTER 1 -Backhoe, Boom and Dipperstick assembly
Description Page
General Specifications ...................................................................... 1
Description and Operation ................................................................... 7
Backhoe Control Linkage Overhaul ........................................................... 15
Component Removal ....................................................................... 18
Dipperstick ................................................................................ 21
Extendible Dipperstick Overhaul .............................................................. 27
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SECTION 00 - MAINTENANCE - CHAPTER 1 1
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.
ROTATING SHAFT SEALS
To correctly install rotating shaft seals, observe the following instructions:
-Let the seal soak into the same oil as it will seal for at least half an hour before mounting;
-Thoroughly clean the shaft and ensure that the shaft working surface is not damaged;
-Place the sealing lip towards the fluid. In case ofa hydrodynamic lip, consider the shaft rotation direction and
orient grooves in order that they deviate the fluid towards the inner side of the seal;
-Coatthe sealing lip with a thin layer oflubricant (oil rather than grease) and fill with grease the gap between
the sealing lip and the dust lip of double lip seals;
-Insertthe seal into its seat and press it down using a flat punch. Do no tap the seal with a hammer or a drift;
-Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled,
ensure that it contacts the thrust element if required.;
- To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.
'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 willjeopardise 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 heatthe bearings to 80 to 90°C before mountingthem on their shafts and cool them down before
inserting them into their seats with external tapping.
SPRING PINS
When mounting splitsocketspring pins, ensure thatthe pin notch is oriented in the direction ofthe effortto stress
the pin.
Spiral spring pins should not be oriented during installation.
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2 SECTION 00 -MAINTENANCE -CHAPTER 1
NOTES FOR SPARE PARTS
USE EXCLUSIVELY GENUINE SPARE PARTS
Only genuine parts guarantee same quality, life, safety as original components as theyare 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.
NOTES FOR EQUIPMENT
Equipment which proposes and shows in this manual are as follows:
-studied and designed expressly for use on company machines;
-necessary to make a reliable repair;
-accurately built and strictly tested to offer efficient and long-lasting working means.
-we also remind the Repair Personnel that having these equipment means:
-work in optimal technical conditions;
-obtain best results;
-save time and effort;
-work more safely.
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 operator's
seat oriented to the normal sense of movement of the Machine.
HOW TO MOVE THE MACHINE WITH THE BATTERY REMOVED
Cables from the external power supply should be connected exclusively to the respective terminals of the Ma-
chine positive and negative cables using pliers in good condition which allow proper and steady contact.
Disconnect all services (lights, wind-shield wipers, etc.) before starting the Machine.
Ifit is necessary to checkthe Machine electrical system, check it onlywith the power supply connected. At check
end, disconnect all services and switch the power supply off before disconnecting the cables.
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SECTION 00 -MAINTENANCE -CHAPTER 1 3
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL
A This warning symbol points out important messages involving personal safety. A
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 key-words:
WARNING (ATTENZIONE) -it gives warning about improper repair operations and
deriving potential consequences affecting the service technician's personal safety.
DANGER (PERICOLO) -it gives specificwarning about potential dangersfor person-
al 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 non-observance of some
simple and essential prudential rule and safety pre-
cautions. For this reason, IN MOST CASES THEY
CAN BE AVOIDED. It suffices to foresee possible
causes and actconsequentlywith necessarycaution
and care.
The possibility that an accident might occur with any
type of machines should not be disregarded, no mat-
ter how well the machine in question was designed
and built.
A wise and careful service technician is the best pre-
cautions 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 run-
ning.
SAFETY RULES
• Carefully follow specified repair and mainte-
nance procedures.
• Do not wear rings, wristwatches, jewels, unbut-
toned or flapping clothing such as ties, torn
clothes, scarves, openjacketsor shirts with open
zips which could get hold into moving parts. We
advise to use approved safety clothing such as
anti-slipping footwear, gloves, safety goggles,
helmets, etc.
• Never carry out any repair on the machine if
someone is sitting on the operator's seat, except
if they are certified operators to assist in the op-
eration to be carried out.
• Never operate the machine or use attachments
from a place other than sitting at the operator's
seat.
• Never carry out any operation on the machine
whenthe engine is running, exceptwhen specifi-
cally indicated.
• Stop the engine and ensure that all pressure is
relieved from hydraulic circuits before removing
caps, covers, valves, etc.
• All repair and maintenance operations should be
carried out with the greatest care and attention.
• Service stairs and platforms used in a workshop
or in the field should be built in compliance with
the safety rules in force.
• Disconnect the batteries and label all controls to
warn that the Machine is being serviced. Block
the machine and all equipment which should be
raised.
• Never check or fill fuel tanks and accumulator
batteries, nor use starting liquid ifyou are smok-
ing or near open flames as such fluids are flam-
mable.
• Brakes are inoperative when they are manually
released for maintenance purposes. In such
cases, the machine should be kept constantly
under control using blocks or similar devices.
• The fuel filling gun should remain always in con-
tact with the filler neck. Maintain this contact until
the fuel stops flowing into the tank to avoid pos-
sible sparks due to static electricity buildup.
• Use exclusively specified towing points for tow-
ing the Machine. Connect parts carefully. Ensure
that foreseen pins and/or locks are steadily fixed
before applying traction. Do not stop neartowing
bars, cables or chains working under load.
• To transfer a failed Machine, use a trailer or a low
loading platform trolley if available.
• To load and unload the machine from the trans-
portation mean, selecta flat area providing a firm
support to the trailer or truck wheels. Firmly tie
the machine to the truck or trailer platform and
block wheels as required by the forwarder.
• Forelectrical heaters, battery-chargers and sim-
ilar equipment use exclusive auxiliary power
supplies with a efficientground to avoid electrical
shock hazard.
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4 SECTION 00 -MAINTENANCE -CHAPTER 1
• Always use lifting equipment and similar of ap-
propriate capacity to lift or move heavy compo-
nents.
• Pay special attention to bystanders.
• Never pour gasoline or diesel oil into open, wide
and low containers.
• Never use gasoline, diesel oil or otherflammable
liquids as cleaning agents. Use non-flammable
non-toxic proprietary solvents.
• Wear protection goggles with side guards when
cleaning parts using compressed air.
• Do not exceed a pressure of 2 .1 bar, in accor-
dance with local regulations.
• Do not run the engine in aclosed building without
proper ventilation.
• Do not smoke, use open flames, cause sparks in
the nearbyarea when filling fuel or handling high-
ly flammable liquids.
• Do not use flames as lightsources when working
on a machine or checking for leaks.
• Move with caution when working under a Ma-
chine, and also on ornearaMachine. Wear prop-
er safetyaccessories: helmets, goggles and spe-
cial footwear.
• During checks which should be carried out with
the enginerunning, askan assistantto seatatthe
operator's seat and keep the service technician
under visual control at any moment.
• In case ofoperations outsidethe workshop, drive
the Machine to a flat area and block it. Ifworking
on an incline cannot be avoided, first block the
Machine carefully. Move it to a flat area as soon
as possible with a certain extent of safety.
• Ruined or plied cables and chains are unreliable.
Do not use them for lifting ortrailing. Always han-
dle them wearing gloves of proper thickness.
• Chains should always be safely fastened. En-
sure that fastening device is strong enough to
hold the load foreseen. No persons should stop
nearthe fastening point, trailing chains or cables.
• The working area should be always kept CLEAN
and DRY. Immediately clean any spillage of wa-
ter or oil.
• Do not pile up grease or oil soaked rags, as they
constitute a greatfire hazard. Always place them
into a metal container.
Before starting the Machine or its attachments,
check, adjust and block the operator's seat. Also
05/2003
ensure that there are no persons within the Ma-
chine or attachment operating range.
• Do not keep into your pockets any object which
might fall unobserved into the Machine's inner
compartments.
• Whenever there is the possibility of being
reached by ejected metal parts or similar, use
protection eye maskor 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 ofthe welding process should weartinted
eye protection. NEVER LOOK AT THE WELD-
ING 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 protec-
tive equipment, such as eye protection, heavy
gloves and protective footwear.
START UP
• Never run the engine in confined spaces which
are not equipped with adequate ventilation for
exhaust gas extraction.
• Never bring your head, body, arms, legs, feet,
hands, fingers near fans or rotating belts.
ENGINE
• Always loosen the radiator cap very slowly be-
fore 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 notfill up fuel tankwhen the engine is running,
mainly ifit is hot, to avoid ignition offires 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.

SECTION 00 -MAINTENANCE -CHAPTER 1 5
ELECTRICAL SYSTEMS
• Ifit is necessary to use auxiliary batteries, cables
must be connected at both sides as follows: ( +)
to(+) and(-) to(-). Avoid short-circuiting theter-
minals. GAS RELEASED FROM BATTERIES IS
HIGHLY FLAMMABLE. During charging, leave
the battery compartment uncovered to improve
ventilation. Avoid checking the battery charge by
means of'Jumpers" made by placing metallic ob-
jects across the terminals. Avoid sparks or
flames near the battery area. Do no smoke to
prevent explosion hazards.
• Prior to any service, check for fuel or coolant
leaks. Remove these leaks before going on with
the work.
• Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent
accidental explosion hazard due to build-up of
gasses relieved during charging.
• Always disconnect the batteries before perform-
ing any type of service on the electrical system.
HYDRAULIC SYSTEMS
• Some fluid slowly coming out from a very small
port can be almost invisible and be strong
enough to penetrate the skin. For this reason,
NEVER USE YOUR HANDS TO CHECK FOR
LEAKS, but use a piece of cardboard or a piece
of wood to this purpose. If any fluid is injected
into the skin, seek medical aid immediately. Lack
of immediate medical attention, serious infec-
tions or dermatosis may result.
• Always take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
• Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi-
cally check possible damages to the rims and
tyres.
• Keep offand stay atthe tyre side when correcting
the inflation pressure.
• Checkthe pressure only when the Machine is un-
loaded and tyres are cold to avoid wrong read-
ings due to over-pressure. Do not reuse parts of
recovered wheels as improper welding, brazing
or heating may weaken the wheel and make it
fail.
• Nevercut, norweld a rim with the inflated tyre as-
sembled.
• To remove the wheels, block both front and rear
Machine wheels. Raise the Machine and install
safe and stable supports under the Machine in
accordance with regulations in force.
• Deflate the tyre before removing any object
caught into the tyre tread.
• Never inflate tyres using flammable gases as
they may originate explosions and cause injuries
to bystanders.
REMOVAL AND INSTALLATION
• Liftand handleall heavy components using lifting
equipment of adequate capacity. Ensure that
parts are supported by appropriate slings and
hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.
• Handle all parts with great care. Do not place
your hands or fingers between two parts. Wear
approved protective clothing such as safety
goggles, gloves and footwear.
• Do nottwine chains or metal cables. Always wear
protection gloves to handle cables or chains.
05/2003

6 SECTION 00 -MAINTENANCE -
CHAPTER 1
IMPORTANT ECOLOGICAL CONSIDERATIONS
The following are recommendations which may be of oils, brake fluids, etc. Do not mix drained brake
assistance: fluids or fuels with lubricants. Store them safely
• Become acquainted with and ensurethatyou un- until they can be disposed of in a proper way to
derstand the relative legislation applicable to comply with local legislation and available re-
your country. sources.
• Where no legislation exists, obtain information 5. Modern coolant mixtures, i.e. antifreeze and
from suppliers of oils, fuels, antifreeze, cleaning other additives, should be replaced every two
agents, etc., with regard to their effect on man years. They should not be allowed to get into the
and nature and how to safely store, use and dis- soil butshould be collected and disposed ofsafe-
pose ofthese substances. ly.
HELPFUL HINTS
1. Avoid filling tanks usingjerry cans or inappropri-
ate 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 sub-
stances which can be harmful to your health.
3. Modern oils contain additives. Do not burn con-
taminated fuels and/or waste oils in ordinary
heating systems.
4. Avoid spillage when draining off used engine
coolant mixtures, engine, gearbox and hydraulic
05/2003
6. Do not open the Air-Conditioning system your-
self. It maycontain gasses which should not be re-
leased into the atmosphere. Your air conditioning
specialist has aspecial equipment for discharging
and charging the system.
7. Repair any leaks or defects in the engine cooling
or hydraulic system immediately.
8. Do not increase the pressure in apressurised cir-
cuit as this may lead to a catastrophic failure of
the system components.
9. Protect hoses during welding as penetrating
weld splatter may burn a hole or weaken them,
causing the loss ofoils, coolant, etc.

SECTION 00 -MAINTENANCE -CHAPTER 1 7
SERVICE TECHNIQUES
GENERAL
Clean the exterior of all components before carrying
out any form of repair. Dirt and abrasive dust can re-
duce 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 saferand will result in overhauled compo-
nents being more reliable and efficient in operation.
Use cleaning fluids which are known to be safe. Cer-
tain types offluid can cause damage to 'O' rings and
cause skin irritation. Solvents should be checked that
they are suitable for the cleaning ofcomponents 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 installa-
tion.
When replacing component parts, use the correct
tool for thejob.
HOSES AND TUBES
Always replace hoses and tubes if the cone end or
the end connections on the hose are damaged.
When installing a new hose, loosely connect each
end and make sure the hose takes up the designed
position before tightening the connection. Clamps
should be tightened sufficiently to hold the hose with-
out crushing and to prevent chafing.
After hose replacement to a moving component,
checkthatthe hosedoes notfoul by moving the com-
ponent through the complete range of travel.
Be sure any hose which has been installed is not
kinked or twisted.
Hose connections which are damaged, dented,
crushed or leaking, restrict oil flow and the productiv-
ity of the components being served. Connectors
which show signs of movement from the original
swagged position have failed and will ultimately sep-
arate completely.
A hose with a chafed outer cover will allow water
entry. Concealed corrosion ofthe wire reinforcement
will subsequently occur along the hose length with
resultant hose failure.
Ballooning of the hose indicates an internal leakage
due to structural failure. This condition rapidly de-
teriorates and total hose failure soon occurs.
Kinked, crushed, stretched or deformed hoses gen-
erally suffer internal structural damagewhich can re-
sult in oil restriction, a reduction in the speed of oper-
ation and ultimate hose failure.
Free-moving, unsupported hoses must never be al-
lowed to touch each other or related working sur-
faces. This causes chafing which reduces hose life.
'O' RING FLAT FACE SEAL FITTINGS
When repairing 'O' ring face seal connectors, the fol-
lowing procedures should be observed.
A WARNING A
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
petroleumjelly.
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 accordingto the size ofthe
fitting. Refer to the following torque chart.
NOTE: To ensure aleak-freejointis obtained, it is im-
portantthat the fittings are not overor undertorqued.
05/2003

8 SECTION 00 -MAINTENANCE -
CHAPTER 1
'O' RING FLAT FACE SEAL FITTING TORQUE VALUES
Nominal Thread Swivel Nut
O.D Tube Dash Size Torque
(in.) (mm) Size In. lbf. Ft Nm
0.250 6.35
-4 9/16-18 12
16
0.375 9.52 -6 11/16-16 18 24
0.500 12.70 -8 13/16-16 37 50
0.625 15.88 -10 1-14 51
69
0.750 19.05 -12 1 3/16-12 75 102
0.875 22.22 -14 1 3/16-12 75 102
1.000 25.40 -16 1 7/16-12 105 142
1.250 31.75 -20 1 11/16-12 140 190
1.500 38.10 -24 2-12 160 217
SEALER SPECIFICATIONS
The following sealers should be used as directed in the manual:
SEALERS PART NUMBER
Anaerobic sealer 82995770/1
RTV silicone sealer 82995775/6
Pipe sealant 82995768
Thread-locking compound 82995773
HARDWARE TORQUE VALUES
Check the tightness of hardware periodically.
Use the following charts to determine the correct
torque when checking, adjusting or replacing hard-
ware on the Backhoe Loader.
IMPORTANT: DO NOT use the values listed in the
charts if a different torque value or tightening pro-
05/2003
TRADE DESCRIPTION
LOCTITE GASKET ELIMINATOR 518
LOCTITE SUPERFLEX 593, 595 or 596
LOCTITE ULTRA BLUE 587 DOW CORNING
SILASTIC 732 GENERAL ELECTRIC RTV 103
OR 108
PST 592 PIPE SEALANT WITH TEFLON
LOCTITE 271 THREADLOCKER/SEALANT (red)
cedure is specified in this manual for a specific ap-
plication. Torque values listed are for general use
only.
Make sure fastener threads are clean and not dam-
aged.
NOTE: A torque wrench is necessary to properly
torque hardware.

NOMINAL
SIZE
M4
M6
MS
M10
M12
M16
M20
M24
SECTION 00 -MAINTENANCE - CHAPTER 1
MINIMUM HARDWARE TIGHTENING TORQUES
IN FOOT POUNDS -LBF. FT (NEWTON-METRES -Nm)
FOR NORMAL ASSEMBLY APPLICATIONS
METRIC HARDWARE AND LOCKNUTS
CLASS 5.8 CLASS 8.8 CLASS 10.9
UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED
W/ZnCr W/ZnCr W/ZnCr
15*(1.7} 19* (2.2} 23* (2.6} 30* (3.4} 33* (3.7} 42* (4.8}
51 * (5.8) 67* (7.6) 79* (8.9) 102* (12) 115* (13) 150* (17)
124* (14} 159* (18) 195* (22} 248* (28} 274* (31) 354* (40}
21 (28) 27 (36) 32 (43) 41 (56) 45 (61) 58 (79)
36 (49) 46 (63) 55 (75) 72 (97) 79 (107) 102 (138)
89 (121) 117 (158) 137 (186} 177 (240} 196 (266} 254 (344}
175 (237) 226 (307) 277 (375) 358 (485) 383 (519) 495 (671)
303 (411) 392 (531) 478 (648} 619 (839} 662 (897} 855 (1160}
NOTE: Torque values shown with* are inch pounds.
IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
MANUFACTURER'S IDENTIFICATION
,,
/
HEX NUTS AND LOCKNUTS
CLASSES 05 AND UP
PROPERTY CLASS CLOCK MARKING
9
LOCKNUT
CL.8
W/CL8.8
BOLT
16* (1.8)
56* (6.3)
133* (15)
22 (30)
39 (53)
97 (131}
195 (265)
338 (458)
05/2003