New holland b100 b backhoe loader service repair manual

Information about New holland b100 b backhoe loader service repair manual

Published on January 24, 2020

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1. B90B / B90BLR / B100B / B100BLR / B100BTC B110B / B110BTC / B115B B90B B90BLR B100B B100BLR B100BTC B110B B110BTC B115B SERVICE MANUALSERVICE MANUAL Backhoe Loaders Print No. 84428663BPrint No. 84428663B Backhoe Loaders

2. INDEX SECTION 00 - SAFETY RULES FOREWORD..................................................................................................................................................... 4 SAFETY INSTRUCTIONS ................................................................................................................................ 6 PREVENTION OF FIRE OR EXPLOSIONS..................................................................................................... 8 PREVENTION OF BURNS ............................................................................................................................... 9 PRECAUTIONS FOR WASTE DISPOSAL..................................................................................................... 10 SECTION 01 - MAINTENANCE SECTION 02 - TECHNICAL SPECIFICATIONS MODELS........................................................................................................................................................... 3 IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4 TECHNICAL SPECIFICATIONS....................................................................................................................... 7 DIESEL ENGINE ......................................................................................................................................... 7 TRANSMISSION........................................................................................................................................ 10 AXLES ....................................................................................................................................................... 11 BRAKES .................................................................................................................................................... 11 STEERING................................................................................................................................................. 12 HYDRAULIC SYSTEM .............................................................................................................................. 12 FRONT COUNTERWEIGHT ..................................................................................................................... 13 NOISE AND VIBRATION LEVELS ............................................................................................................ 13 BUCKETS.................................................................................................................................................. 13 TYRES....................................................................................................................................................... 14 DIMENSIONS AND PERFORMANCE............................................................................................................ 15 DIMENSIONS - 2WS SIDESHIFT ............................................................................................................. 15 DIMENSIONS - 2WS CENTER PIVOT...................................................................................................... 16 DIMENSIONS - 2WS TC - SIDESHIFT ..................................................................................................... 17 DIMENSIONS - 4WS SIDESHIFT ............................................................................................................. 18 DIMENSIONS - 4WS CENTER PIVOT...................................................................................................... 19 LOADER ATTACHMENT PERFORMANCE.............................................................................................. 20 PERFORMANCE OF LOADER ATTACHMENT WITH FORKS................................................................ 30 BACKHOE ATTACHMENT PERFORMANCE........................................................................................... 35 BACKHOE ATTACHMENT LIFTING CAPACITY ........................................................................................... 55 MAXIMUM LIFTING LOADS........................................................................................................................... 61 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE .................................................................. 61 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................... 62 SUPPLY SUMMARY TABLE.......................................................................................................................... 63

3. INDEX SECTION 21 - TRANSMISSION POWERSHUTTLE TRANSMISSION................................................................................................................ 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 4 HYDRAULIC DIAGRAM............................................................................................................................... 7 CONTROLS ............................................................................................................................................... 13 LUBRICATION........................................................................................................................................... 17 GREASING ................................................................................................................................................ 20 REMOVAL FROM MACHINE .................................................................................................................... 22 DISASSEMBLY AND ASSEMBLY............................................................................................................. 23 TROUBLESHOOTING............................................................................................................................. 148 REPAIR TIMES........................................................................................................................................ 152 SPECIAL TOOLS..................................................................................................................................... 153 POWERSHIFT TRANSMISSION.................................................................................................................. 154 TECHNICAL SPECIFICATIONS.............................................................................................................. 154 CONTROLS ............................................................................................................................................. 165 LUBRICATION......................................................................................................................................... 167 GREASING .............................................................................................................................................. 169 REMOVAL FROM MACHINE .................................................................................................................. 170 DISASSEMBLY AND ASSEMBLY........................................................................................................... 171 TROUBLESHOOTING............................................................................................................................. 335 REPAIR TIMES........................................................................................................................................ 339 SPECIAL TOOLS..................................................................................................................................... 340 SECTION 25 - FRONT AXLES 2WD - 2WS FRONT AXLE................................................................................................................................ 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 LUBRICATION AND GREASING ................................................................................................................ 4 REMOVAL FROM MACHINE ...................................................................................................................... 6 DISASSEMBLY AND ASSEMBLY............................................................................................................... 7 TROUBLESHOOTING................................................................................................................................. 7 4WD - 2WS FRONT AXLE.............................................................................................................................. 10 TECHNICAL SPECIFICATIONS................................................................................................................ 10 LUBRICATION AND GREASING .............................................................................................................. 11 REMOVAL FROM MACHINE .................................................................................................................... 13 DISASSEMBLY AND ASSEMBLY............................................................................................................. 14 TROUBLESHOOTING............................................................................................................................... 57 SPECIAL TOOLS....................................................................................................................................... 61 4WS FRONT AXLE......................................................................................................................................... 62 TECHNICAL SPECIFICATIONS................................................................................................................ 62 LUBRICATION AND GREASING .............................................................................................................. 63 REMOVAL FROM MACHINE .................................................................................................................... 65 DISASSEMBLY AND ASSEMBLY............................................................................................................. 66 TROUBLESHOOTING............................................................................................................................. 131 REPAIR TIMES........................................................................................................................................ 137 SPECIAL TOOLS..................................................................................................................................... 138

4. INDEX SECTION 27 - REAR AXLE 2WS REAR AXLE (B90B - B100B - B100BTC).............................................................................................................................. 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 LUBRICATION AND GREASING ................................................................................................................ 5 REMOVAL FROM MACHINE ...................................................................................................................... 7 DISASSEMBLY AND ASSEMBLY............................................................................................................... 8 TROUBLESHOOTING............................................................................................................................... 61 REPAIR TIMES.......................................................................................................................................... 67 SPECIAL TOOLS....................................................................................................................................... 68 2WS REAR AXLE (B110B - B110BTC)........................................................................................................................................ 69 TECHNICAL SPECIFICATIONS................................................................................................................ 69 LUBRICATION AND GREASING .............................................................................................................. 71 REMOVAL FROM MACHINE .................................................................................................................... 73 DISASSEMBLY AND ASSEMBLY............................................................................................................. 74 TROUBLESHOOTING............................................................................................................................. 127 REPAIR TIMES........................................................................................................................................ 133 SPECIAL TOOLS..................................................................................................................................... 134 4WS REAR AXLE (B115B)......................................................................................................................................................... 135 TECHNICAL SPECIFICATIONS.............................................................................................................. 135 LUBRICATION AND GREASING ............................................................................................................ 138 REMOVAL FROM MACHINE .................................................................................................................. 140 DISASSEMBLY AND ASSEMBLY........................................................................................................... 141 TROUBLESHOOTING............................................................................................................................. 219 REPAIR TIMES........................................................................................................................................ 225 SPECIAL TOOLS..................................................................................................................................... 227 SECTION 33 - BRAKE SYSTEM PARKING BRAKE............................................................................................................................................. 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 OPERATION................................................................................................................................................ 3 ADJUSTMENT............................................................................................................................................. 4 DISASSEMBLY AND ASSEMBLY............................................................................................................... 5 SERVICE BRAKE........................................................................................................................................... 14 TECHNICAL SPECIFICATIONS................................................................................................................ 14 OPERATION.............................................................................................................................................. 14 SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS ................................................................................................................................. 3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS....................................................... 3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS.................................................................... 5 HYDRAULIC DIAGRAM - 2WS CENTER PIVOT PILOT MODELS ............................................................ 7 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS....................................................... 9 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS.................................................................. 11 HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .......................................................... 13

5. INDEX HYDRAULIC PUMP........................................................................................................................................ 15 HYDRAULIC FIXED-FLOW-RATE GEAR PUMP...................................................................................... 15 HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP............................................................................ 26 CONTROL VALVES........................................................................................................................................ 40 LOADER CONTROL VALVE ..................................................................................................................... 49 BACKHOE ATTACHMENT CONTROL VALVE......................................................................................... 53 RELIEF VALVES........................................................................................................................................ 65 BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE .................................................. 74 ACCUMULATOR “GLIDE RIDE” PARKER..................................................................................................... 77 TECHNICAL SPECIFICATIONS................................................................................................................ 77 MAINTENANCE......................................................................................................................................... 77 SAFETY ..................................................................................................................................................... 77 CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ............................................................. 78 HYDRAULIC SWING SYSTEM ...................................................................................................................... 80 OPERATION.............................................................................................................................................. 80 HYDRAULIC CYLINDERS.............................................................................................................................. 83 LOADER ATTACHMENT BOOM CYLINDER............................................................................................ 84 LOADER BUCKET CYLINDER.................................................................................................................. 91 4X1 LOADER BUCKET CYLINDER .......................................................................................................... 97 BACKHOE BOOM CYLINDER ................................................................................................................ 100 BACKHOE ATTACHMENT DIPPER CYLINDER .................................................................................... 104 BACKHOE BUCKET CYLINDER............................................................................................................. 108 TELESCOPIC CYLINDER ....................................................................................................................... 112 STABILIZER CYLINDER - CENTER PIVOT............................................................................................ 116 STABILIZER CYLINDER - SIDESHIFT ................................................................................................... 120 SWING CYLINDER.................................................................................................................................. 124 BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT.................................................................. 128 SPECIAL TOOLS..................................................................................................................................... 129 HYDRAULIC CONTROL LEVERS................................................................................................................ 130 TECHNICAL SPECIFICATIONS.............................................................................................................. 130 CONTROLS AND OPERATION .............................................................................................................. 131 COMPONENTS ....................................................................................................................................... 132 DISASSEMBLY AND ASSEMBLY........................................................................................................... 134 CONTROL LEVER VALVE ...................................................................................................................... 137 TROUBLESHOOTING.................................................................................................................................. 139 PRELIMINARY CHECKS......................................................................................................................... 139 TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES).......................................................... 140 SWING..................................................................................................................................................... 142 HYDRAULIC PUMP................................................................................................................................. 143 SECTION 39 - CHASSIS DESCRIPTION.................................................................................................................................................. 3 REMOVAL AND INSTALLATION OF COMPONENTS..................................................................................... 6 COMPONENTS WITHIN THE CHASSIS..................................................................................................... 6 COMPONENTS OF THE LOWER PART OF THE CHASSIS ..................................................................... 7 COMPONENTS ATTACHED OUTSIDE THE CHASSIS........................................................................... 11

6. INDEX COMPONENTS OF THE UPPER PART................................................................................................... 12 SECTION 41 - STEERING SYSTEM DESCRIPTION ................................................................................................................................................. 3 2WS STEERING SYSTEM ............................................................................................................................... 4 4WS STEERING SYSTEM ............................................................................................................................... 7 POWER STEERING....................................................................................................................................... 11 TECHNICAL SPECIFICATIONS................................................................................................................ 11 COMPONENTS ......................................................................................................................................... 13 DISASSEMBLY.......................................................................................................................................... 15 ASSEMBLY................................................................................................................................................ 18 SECTION 50 - CAB HEATING AND AIR CONDITIONING TECHNICAL SPECIFICATIONS....................................................................................................................... 3 GENERAL.................................................................................................................................................... 3 CAB HEATING.................................................................................................................................................. 5 CONTROLS................................................................................................................................................. 5 OPERATION................................................................................................................................................ 6 OVERHAUL ................................................................................................................................................. 9 TROUBLESHOOTING............................................................................................................................... 11 AIR CONDITIONING ...................................................................................................................................... 12 PRINCIPLES OF AIR CONDITIONING..................................................................................................... 12 CONTROLS............................................................................................................................................... 17 OPERATION.............................................................................................................................................. 18 TROUBLESHOOTING AND TESTING...................................................................................................... 25 FLUSHING THE SYSTEM......................................................................................................................... 44 DRAINING THE SYSTEM ......................................................................................................................... 46 CHARGING THE SYSTEM........................................................................................................................ 47 OVERHAUL ............................................................................................................................................... 48 COMPRESSOR.............................................................................................................................................. 53 TECHNICAL SPECIFICATIONS................................................................................................................ 53 REMOVAL AND INSTALLATION .............................................................................................................. 54 DISASSEMBLY AND ASSEMBLY............................................................................................................. 57 TROUBLESHOOTING............................................................................................................................... 66 SECTION 55 - ELECTRIC SYSTEM ELECTRIC DIAGRAMS .................................................................................................................................... 3 ELECTRIC DIAGRAMS - POWERSHUTTLE ROPS (B90B) ...................................................................... 3 ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (B90B) ....................................................................... 19 ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (B100B - B100BTC - B110B - B110BTC) ....................................................................................................... 36 ELECTRIC DIAGRAMS - POWERSHIFT CAB (B110B - B110BTC) ........................................................ 52 ELECTRIC DIAGRAMS - 4WS POWERSHIFT CAB (B115B) .................................................................. 70 CONTROLS AND INSTRUMENTS ................................................................................................................ 88

7. INDEX FRONT INSTRUMENT PANEL ................................................................................................................. 88 SIDE INSTRUMENT CLUSTER PANEL (B90B) ....................................................................................... 91 SIDE INSTRUMENT CLUSTER PANEL (B100B - B100BTC - B110B - B110BTC - B115B).................... 93 SIDE INSTRUMENT CLUSTER (B90B) .................................................................................................... 95 SIDE INSTRUMENT CLUSTER (B100B - B100BTC - B110B - B110BTC - B115B)................................. 97 ANTI-START SYSTEM .............................................................................................................................. 99 DIAGNOSTIC DISPLAY (B100B - B100BTC - B110B - B110BTC - B115B)................................................ 100 SYMBOLS................................................................................................................................................ 102 SETUP MENU.......................................................................................................................................... 103 PROCEDURE ABOUT SELF TEST......................................................................................................... 104 ON BOARD ERROR CODE RETRIEVAL................................................................................................ 105 BACKLIGHTING AND DIMMING............................................................................................................. 106 WORK HOURS........................................................................................................................................ 107 OPERATION............................................................................................................................................ 108 WARNING SYSTEM................................................................................................................................ 112 MAINTENANCE....................................................................................................................................... 113 WARNING MESSAGES........................................................................................................................... 114 STARTING SYSTEM .................................................................................................................................... 121 OPERATION............................................................................................................................................ 121 STARTER MOTOR.................................................................................................................................. 124 TROUBLESHOOTING............................................................................................................................. 129 ALTERNATOR.............................................................................................................................................. 131 TECHNICAL SPECIFICATIONS.............................................................................................................. 131 OPERATION............................................................................................................................................ 131 COMPONENTS ....................................................................................................................................... 133 REMOVAL................................................................................................................................................ 134 PRELIMINARY CHECKS AND TESTS.................................................................................................... 135 TROUBLESHOOTING............................................................................................................................. 144 BATTERY...................................................................................................................................................... 145 TECHNICAL SPECIFICATIONS.............................................................................................................. 145 OPERATION............................................................................................................................................ 145 REPLACEMENT ...................................................................................................................................... 146 CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 147 CONNECTING A BOOSTER BATTERY ................................................................................................. 148 BATTERY MASTER SWITCH ................................................................................................................. 148 TROUBLESHOOTING.................................................................................................................................. 149 SECTION 82 - LOADER LOADER ATTACHMENT CONTROLS............................................................................................................. 4 LOADER ATTACHMENT OPERATION....................................................................................................... 4 4x1 LOADER BUCKET CONTROL (Optional)............................................................................................. 7 LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries)............................................................................................................................ 8 LOADER BUCKET SELF-LEVELLING............................................................................................................. 9 LOADER ATTACHMENT SAFETY STRUT.................................................................................................... 12 LOADER ATTACHMENT SAFETY STRUT

8. INDEX (B90B - B100B - B110B)................................................................................................................................. 12 LOADER ATTACHMENT SAFETY STRUT (B100BTC - B110BTC - B115B) ..................................................................................................................... 14 REMOVAL AND INSTALLATION OF LOADER BUCKET.............................................................................. 15 LOADER BUCKET (B90B - B100B - B110B) ............................................................................................ 15 LOADER BUCKET (B100BTC - B110BTC - B115B)................................................................................. 16 LOADER BUCKET WITH FORKS (Optional) ............................................................................................ 17 BUCKET TEETH REPLACEMENT............................................................................................................ 18 LOADER REMOVAL....................................................................................................................................... 19 LOADER ATTACHMENT (B90B - B100B - B110B) .................................................................................. 19 LOADER ATTACHMENT (B100BTC - B110BTC - B115B) ..................................................................................................................... 21 SECTION 84 - BACKHOE DESCRIPTION AND OPERATION................................................................................................................... 3 BACKHOE ATTACHMENT CONTROLS.......................................................................................................... 6 BACKHOE ATTACHMENT MECHANICAL CONTROLS ............................................................................ 7 BACKHOE ATTACHMENT HYDRAULIC CONTROLS............................................................................. 17 BACKHOE ATTACHMENT SIDESHIFT (Sideshift version) ...................................................................... 23 BACKHOE ATTACHMENT DISASSEMBLY .................................................................................................. 25 CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY.................................................................. 25 SIDESHIFT BACKHOE ATTACHMENT DISASSEMBLY.......................................................................... 28 BACKHOE BUCKET REPLACEMENT...................................................................................................... 30 BUCKET TEETH REPLACEMENT............................................................................................................ 31 DIPPER REMOVE..................................................................................................................................... 32 TELESCOPIC DIPPER REVISION................................................................................................................. 35 OVERHAUL ............................................................................................................................................... 35 BACKHOE ATTACHMENT HYDRAULIC HANDLING ................................................................................... 38 CONTROLS............................................................................................................................................... 38 HYDRAULIC DIAGRAM ............................................................................................................................ 38 HANDLING CYLINDER ............................................................................................................................. 39 DISASSEMBLY AND ASSEMBLY............................................................................................................. 40

9. B90B - B90BLR B100B - B100BLR - B100BTC B110B - B110BTC B115B SECTION 00 - SAFETY RULES

10. SECTION 00 - SAFETY RULES 3 SAFETY INSTRUCTIONS The non-compliance with the warnings preceded by the above-mentioned keywords (WARNING and DANGER) can cause serious accidents or even the death of the persons involved. Moreover, in the present Manual, some instructions are given with text in italics, preceded by the words NOTE and CAUTION. NOTA: it emphasizes and underlines to the operator the correct technique or correct procedure to follow. S WARNING S This warning symbol points out important mes- sages involving your safety. Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity. In this manual you will find this symbol together with the following keywords: S WARNING S This symbol warns about the possibility of potential damages to the machine that can involve the oper- ator’s safety. S WARNING S With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved. S WARNING S This symbol warns about the possibility of potential damages to the machine that can involve the oper- ator’s safety.

11. 4 SECTION 00 - SAFETY RULES FOREWORD Loader backhoes B90B - B90BLR - B100B - B100BLR - B100BTC - B110B - B110BTC - B115B have been designed to perform most earth-moving operations. If you use this machine for duties involving the use of attachments, accessories, or special tools, con- sult your Dealer to make sure that the adaptations or modifications carried out are in conformity with the machine’s technical specifications and with current regulations on safety. Any modifications or adaptations which are not approved by the manufacturer may invalidate the machine’s original conformity with safety require- ments. The machine must be used according to its intended use, respecting the safety and precautionary rules and strictly following the operating instructions. Any functional disorders, especially those affecting the safety of the machine, should therefore be recti- fied immediately. The manufacturer/supplier cannot be held responsi- ble for any damage resulting from unintended use. The risk involved in such misuse lies entirely with the user. The current Operator’s Manual is the user’s guide for correct run-in, use and maintenance of the machine. S DANGER S A different use of the excavator or of its working equipment: - for lifting or transporting persons; - as working platform; - for lifting loads without the attachment being approved for this purpose; - for pulling loads; - is considered unintended use. Unintended use may cause injury or life-threatening risks for the operator and for other persons. S DANGER S It is absolutely forbidden to tamper with and/or change the setting of any of the hydraulic system valves to avoid damaging machine components, with a consequent risk for personal safety. 1

12. SECTION 00 - SAFETY RULES 5 Carefully read this Operator’s Manual and store it in the cab for quick location and reference. Instructions concerning safety, operation and main- tenance have been developed to permit safe serv- ice and repair of this machine without any risk. In the event of queries or suggestions relevant to your machine do not hesitate to address to your Dealer. Dealers have qualified and trained personnel at dis- posal as well as Original Spares, means and equip- ment suitable to carry out all necessary maintenance. Any modifications or adaptations which are not ap- proved by the manufacturer may invalidate the ma- chine’s original conformity with safety requirements. IMPORTANTE: the engine and fuel system on your machine are designed and built to government emissions standards. Tampering by dealers, cus- tomers, operators and users is strictly prohibited by law. Failure to comply with this prohibition could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be carried out by a certified technician only. NOTA: each machine is supplied complete with a copy of this Manual. Descriptions and illustrations provided herein are not binding. The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change compo- nents, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improve- ment purposes or due to commercial or manufac- turing requirements. For exact information, please consult your Dealer or contact the Manufacturer’s Branch Offices, who remain at your disposal for fur- ther help. SPARE PARTS The “non-genuine” spare parts have not been checked and authorized by the Manufacturer. The assembly and/or use of such products may have negative effects on the machine design fea- tures and could impair its operation safety. The Manufacturer is not liable for any damage caused by “non-genuine” spare parts or accesso- ries. WARRANTY This machine is under warranty according to the regulations in force in Your Country and in compli- ance with the sales agreement drawn up with the Dealer. The warranty, however, expires if the operation and maintenance instruction for this machine and con- tained in this manual, have not been followed.

13. 6 SECTION 00 - SAFETY RULES SAFETY INSTRUCTIONS Carefully read the safety rules contained herein and follow advised precautions to avoid potential haz- ards and to safeguard your safety and personal integrity. Your safety and that of the people around you depends on you. It is essential that you understand this manual for a correct inspection, lubrication and repair of this machine. Read this manual carefully and check that: - you understand fully the symbols on the controls and the safety signs used in this manual and on the machine; - you understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your Dealer. The safety messages in this section concern situa- tions which may arise during normal machine opera- tion, servicing and repair. These safety messages also indicate the different ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers. The information given in this chapter is a summary of the basic rules to respect at all times and does not exempt you from observing traffic regulations or the requirements of insurance companies. The presence of grease, oil, mud or (in winter) ice on the steps and access handles can cause acci- dents. Make sure they are always clean. When mounting or dismounting from the machine always face the machine and use the steps and access handles on the left-hand side of the machine.

14. B90B - B90BLR B100B - B100BLR - B100BTC B110B - B110BTC B115B POWERSHUTTLE TRANSMISSION................................................................................................................ 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 4 CONTROLS................................................................................................................................................. 9 LUBRICATION........................................................................................................................................... 13 GREASING................................................................................................................................................ 16 REMOVAL FROM MACHINE .................................................................................................................... 18 DISASSEMBLY AND ASSEMBLY............................................................................................................. 19 TROUBLESHOOTING............................................................................................................................. 144 REPAIR TIMES........................................................................................................................................ 148 SPECIAL TOOLS..................................................................................................................................... 149 POWERSHIFT TRANSMISSION.................................................................................................................. 150 TECHNICAL SPECIFICATIONS.............................................................................................................. 150 CONTROLS............................................................................................................................................. 161 LUBRICATION......................................................................................................................................... 163 GREASING.............................................................................................................................................. 165 REMOVAL FROM MACHINE .................................................................................................................. 166 DISASSEMBLY AND ASSEMBLY........................................................................................................... 167 TROUBLESHOOTING............................................................................................................................. 331 REPAIR TIMES........................................................................................................................................ 335 SPECIAL TOOLS..................................................................................................................................... 336 SECTION 21 - TRANSMISSION

15. SECTION 21 - TRANSMISSION 3 POWERSHUTTLE TRANSMISSION This transmission is used on powershuttle loader backhoe models B90B-B90BLR-B100B-B100BLR- B100BTC-B110B-B110BTC.

16. 4 SECTION 21 - TRANSMISSION TECHNICAL SPECIFICATIONS 2WD/2WS TRANSMISSION - POWERSHUTTLE (B90B) Model .....................................................................................................................CARRARO TLB1 MPB 2WD Type (4x4)................................................................................................. 4 forward and 4 reverse travel gears Torque converter ratio.................................................................................................................................. 2.38 Transmission ratios: 1st gear .........................................................................forward travel 5.603:1 reverse travel 4.643:1 2nd gear........................................................................forward travel 3.481:1 reverse travel 2.884:1 3rd gear.........................................................................forward travel 1.585:1 reverse travel 1.313:1 4th gear.........................................................................forward travel 0.793:1 reverse travel 0.657:1 4WD/2WS TRANSMISSION - POWERSHUTTLE (B90B - B100B - B100BTC - B110B - B110BTC) Model .....................................................................................................................CARRARO TLB1 MPB 4WD Type (4x4)................................................................................................. 4 forward and 4 reverse travel gears Torque converter ratio.................................................................................................................................. 2.38 Transmission ratios: 1st gear .........................................................................forward travel 5.603:1 reverse travel 4.643:1 2nd gear........................................................................forward travel 3.481:1 reverse travel 2.884:1 3rd gear.........................................................................forward travel 1.585:1 reverse travel 1.313:1 4th gear.........................................................................forward travel 0.793:1 reverse travel 0.657:1

17. SECTION 21 - TRANSMISSION 7 HYDRAULIC DIAGRAM 2WD * located in the pump

18. 8 SECTION 21 - TRANSMISSION REF. DESCRIPTION NOTES 1 Suction filter 250 micron 2 Pump 36 cm3 /rev (2.19 in3 /rev) 3 Filter 15 micron 4 Pressure regulator 5 Oil filter relief valve 23 bar (334 psi) 6 Differential lock engagement/release 7 Hydraulic differential lock valve 8 Torque converter relief valve 3.5 ÷ 5.5 bar (51 ÷ 80 psi) 9 Torque converter 10 Oil cooler 11 Temperature thermostat port 12 Flow divider 13 Forward/reverse travel modulation valve 14 Modulation relief valve 15 Forward/reverse travel selector valve 16 Forward gear clutch 17 Reverse gear clutch 18 Forward/reverse travel shaft lubrication 19 1st, 2nd, 3rd, 4th gear shaft lubrication 20 Check port for torque converter pressure 21 Pressure check port of lubrication return from cooler 22 Forward/reverse/HDL gear main pressure check port 23 Forward gear pressure check port 24 Reverse gear pressure check port

19. SECTION 21 - TRANSMISSION 9 4WD * located in the pump

20. 10 SECTION 21 - TRANSMISSION REF. DESCRIPTION NOTES 1 Suction filter 250 micron 2 Pump 36 cm3 /rev (2.19 in3 /rev) 3 Filter 15 micron 4 Pressure regulator 5 Oil filter relief valve 23 bar (334 psi) 6 Valve for 4WD engagement/release 7 “Easy” 4WD engagement/release 8 Torque converter relief valve 3.5 ÷ 5.5 bar (51 ÷ 80 psi) 9 Torque converter 10 Oil cooler 11 Temperature thermostat port 12 Flow divider 13 Forward/reverse travel modulation valve 14 Modulation relief valve 15 Forward/reverse travel selector valve 16 Forward gear clutch 17 Reverse gear clutch 18 Forward/reverse travel shaft lubrication 19 1st, 2nd, 3rd, 4th gear shaft lubrication 20 4WD pressure check port 21 Check port for torque converter pressure 22 Pressure check port of lubrication return from cooler 23 Forward/reverse/HDL gear main pressure check port 24 Forward gear pressure check port 25 Reverse gear pressure check port 26 Hydraulic differential lock engagement/release 27 Hydraulic differential lock valve

21. SECTION 21 - TRANSMISSION 11 PORTS 2WD Ref. Dimension Use Notes - Miscellaneous 1 7/8” - 14 UNF Oil inlet from cooler 2 7/8” - 14 UNF Oil outlet to cooler 3 1/2” - 14 NPTF Transmission temperature switch 4 1/2” Oil drain plug 5 1/8” - 28 BSP ISO 228 Oil cooler return pressure check port 0.5 + 3.5 bar (7.3 + 50 psi) ON = forward / reverse travel 0.5 + 5 bar (7.3 + 72.5 psi) ON = neutral position 6 1/8” - 28 BSP ISO 228 Forward gear pressure check port 11 + 13 bar (159 + 188 psi) 0.3 bar (4.3 psi) = maximum pressure in neutral position 7 1/8” - 28 BSP ISO 228 Reverse gear pressure check port 11 + 13 bar (159 + 188 psi) 0.3 bar (4.3 psi) = maximum pressure in neutral position 8 1/8” - 28 BSP ISO 228 Forward / reverse gear pressure check port 11 + 13 bar (159 + 188 psi) 0.3 bar (4.3 psi) = maximum pressure in neutral position 9 1/8” - 28 BSP ISO 228 Converter pressure check port 0.5 + 9 bar (7.3 + 130.5 psi) 10 9/16” - 18 UNF Oil inlet / outlet for hydraulic differential lock 11 9/16” - 18 UNF Oil outlet to brake 13 bar (188 psi) at 900 rpm 14.5 bar (210 psi) at 2200 rpm 12 9/16” - 18 UNF Oil inlet from the brake 13 9/16” - 18 UNF Oil inlet from “transport lock”

22. 12 SECTION 21 - TRANSMISSION 4WD Ref. Dimension Use Notes - Miscellaneous 1 7/8” - 14 UNF Oil inlet from cooler 2 7/8” - 14 UNF Oil outlet to cooler 3 1/2” - 14 NPTF Transmission temperature switch 4 1/2” Oil drain plug 5 1/8” - 28 BSP ISO 228 Oil cooler return pressure check port 0.5 + 3.5 bar (7.3 + 50 psi) ON = forward / reverse travel 0.5 + 5 bar (7.3 + 72.5 psi) ON = neutral position 6 1/8” - 28 BSP ISO 228 Forward gear pressure check port 11 + 13 bar (159 + 188 psi) 0.3 bar (4.3 psi) = maximum pressure in neutral position 7 1/8” - 28 BSP ISO 228 Reverse gear pressure check port 11 + 13 bar (159 + 188 psi) 0.3 bar (4.3 psi) = maximum pressure in neutral position 8 1/8” - 28 BSP ISO 228 Forward / reverse gear pressure check port 11 + 13 bar (159 + 188 psi) 0.3 bar (4.3 psi) = maximum pressure in neutral position 9 1/8” - 28 BSP ISO 228 Converter pressure check port 0.5 + 9 bar (7.3 + 130.5 psi) 10 9/16” - 18 UNF Oil inlet / outlet for hydraulic differential lock 11 9/16” - 18 UNF Oil outlet to brake 13 bar (188 psi) at 900 rpm 14.5 bar (210 psi) at 2200 rpm 12 9/16” - 18 UNF Oil inlet from the brake 13 9/16” - 18 UNF Oil inlet from “transport lock” 14 4WD pressure check port 13 bar (188 psi) at 900 rpm 16 bar (232 psi) at 2200 rpm 15 1/8” - 28 BSP ISO 228 Main line pressure check port 13 bar (188 psi) at 900 rpm 16 bar (232 psi) at 2200 rpm

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24. SECTION 21 - TRANSMISSION 13 CONTROLS 1. GEARSHIFT LEVER: it is possible to select four forward and four rearward travel gears. 2. TRANSMISSION DISCONNECT BUTTON (on gearshift level): prior to gearshifting, press and hold the disconnect switch; select the desired gear with the gearshift lever and release the switch to re-engage transmission. 3. POWERSHUTTLE TRANSMISSION DIREC- TION LEVER: the movement of this lever from the neutral position will engage the forward or reverse travel. NOTE: the warning horn activates in reverse travel. 4. HORN BUTTON 5. TRANSMISSION DISCONNECT BUTTON (on loader attachment control lever)

25. 14 SECTION 21 - TRANSMISSION The transmission is fully synchronised providing 4 forward and 4 reverse speeds allowing gear ratio changes on the move. A torque converter is used to connect the engine to the transmission and the column mounted power- shuttle lever (3) enables shifts between forward and reverse travel without disengaging gear ratios. A device for “transmission disconnection” is acti- vated by pushing button (2), placed on the gearshift lever (1) or by pushing button (5), placed on the loader attachment control lever. GEARSHIFT LEVER The single gearshift lever (1) is used to select any of the four gear ratios. The transmission disconnect button (2) is depressed and held as the lever is shifted from one gear to another and then released to re-connect transmission drive. FORWARD/REVERSE POWERSHUTTLE LEVER (TRAVEL DIRECTION CHANGE) To select the forward travel, engage the required gear ratio with the gearshift lever; then, with the engine idling, lift the powershuttle lever from the neutral lock position (1) and move it to the forward position (2). Use the accelerator pedal to control the engine rpm and the ground speed. To reverse the direction of travel, reduce engine speed and move the power reversing from neutral lock position (1) and rearwards (3) for reverse travel an audible alarm device sounds. S WARNING S Always apply the parking brake whenever the machine is parked as the machine is free to roll even though the transmission gearshift lever and power reversing lever may be “In Gear” and the engine is turned OFF.

26. SECTION 21 - TRANSMISSION 15 IMPORTANT: the powershuttle lever is equipped with a neutral lock to prevent an accidental engage- ment of the transmission. With this design, the pow- ershuttle lever moves through a “T” slot to the forward or reverse positions. IMPORTANT: when operating at low environmental temperatures with cold transmission oil, allow the oil to warm up before attempting to shift the powershut- tle lever. The transmission can be shifted normally after the oil warms up. IMPORTANT: the horn will sound if the powershuttle lever is operated with the parking brake engaged. IMPORTANT: the powershuttle lever can be shifted at any engine speed; however, as a safety and pre- cautionary measure, the engine must run at approx- imately 1200 rpm. This action is easily controlled by means of the foot accelerator to control engine and ground speed. TRANSMISSION DISCONNECTION The 4x4 transmission provides for easy upward and downward gear ratio changes on the move. However, as a clutch is not used between the engine and transmission, the power flow from the engine to the transmission must be interrupted to shift from one gear ratio to another. This is accom- plished by means of a transmission disconnect (dump) button. The finger operated button (2) on the main gearshift lever knob (1) is easy to operate. To make upward gear ratio changes simply depress and hold the button (2) on the gearshift lever (1), while moving the lever from one gear ratio to another. When the desired gear ratio has been selected release the button and allow the unit to gain engine speed and ground speed. If another higher ratio is required repeat the proce- dure. S WARNING S To avoid personal injury do not use the disconnect switch control to coast down hill. Excessive speed may cause loss of control, personal injury to a bystander or failure of the transmission.

27. 16 SECTION 21 - TRANSMISSION IMPORTANT: to prevent possible damage to the transmission hydraulic clutches, never use the dis- connect switch for inching the machine forward. Inching the machine forward with the button will cause the clutches to slip excessively and overheat. To make downward gear ratio changes or reduce ground speed, simply lower the engine speed, depress and hold the gearshift lever button and downshift the transmission. When the desired gear ratio has been selected release the button and adjust the engine speed to suit ground speed required. Operating the machine in a too high gear or under a too heavy load will cause the torque converter to slip excessively and overheat. If the machine is over- loaded, the engine speed will not exceed a range of 1800-2200 rpm at maximum accelerator and the torque converter will “stall” bringing the machine to a complete stop. If “stall” does occur, there is still sufficient engine power to operate the loader attachment; however, to prevent the transmission from overheating, either reduce the load on the machine or select a lower gear ratio. IMPORTANT: operating at a “stall” for more than 20 seconds can cause the transmission to overheat and can possibly damage the transmission. If the transmission overheats, the needle (3) reaches the red field. Shift both the powershuttle lever and the gearshift lever to neutral. Let the engine run idle (1000 rpm) until transmission oil cools down enough to have the needle (3) return to correct position. Once the needle is returned to its position, all opera- tions can be resumed.

28. SECTION 21 - TRANSMISSION 17 LUBRICATION 2WD 4WD 1. Oil filler tube interface 2. Oil drain plug 3. Breather

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