SM w110tc en

Copyright New Holland
W110/W110TC
WHEEL LOADER
Workshop Manual
Print N 604.13.487.00 English
II - 2005
THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.
Read and heed carefully the safety instructions listed and follow the precautions recommended to
avoid potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING
Cautions directed to avoid improper repair interventions involving potential consequences for the
operators safety.
DANGER
These warnings qualify specifically potential dangers for the safety of the operator or other per-
sons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service
Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the
recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own, for
the damages that may result.
Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional
or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts
and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or
merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or mer-
chandized by the Factory, when failures are caused by the use of parts and/or components not approved by the
Factory.
AVOID ACCIDENTS
Most accidents and injuries occurring in industry, on

the farm, at home or on the road, are caused by the
failure of some individual to follow simple and funda-
mental safety rules or precautions. For this reason,
MOST ACCIDENTS CAN BE PREVENTED by recog-
nizing the real cause and taking the necessary pre-
cautions, before the accident occurs.
Regardless of the care used in design and construc-
tion of any type of equipment, there may be conditions
that cannot be completely safeguarded against with-
out interfering with reasonable accessibility and effi-
cient operation.
A careful operator is the best insurance against acci-
dents. The complete observance of one simple rule
would prevent many thousands serious injuries each
year.
This rule is: Never attempt to clean, lubricate or adjust
a machine while it is in motion.
WARNING
On machines having hydraulically, mechanically and/or cable
controlled equipment (such as showels, loaders, dozers,
scrapers etc.) be certain the equipment is lowered to the
ground before servicing, adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suit-
ably supported by means other than the hydraulic lift cylin-
ders, cable and/or mechanical device used for controlling the
equipment.
SUMMARY
GENERALITIES .................................................... Section 0

ENGINE ................................................................ Section 1
TRANSMISSION ................................................... Section 2
BRAKE SYSTEM .................................................. Section 3
STEERING SYSTEM ............................................ Section 4
BUCKET BOOMS AND FRAME .......................... Section 5
EQUIPMENT HYDRAULIC SYSTEM ................... Section 6
ELECTRICAL SYSTEM ........................................ Section 7
CAB ...................................................................... Section 8
SECTION 0
GENERALITIES
INDEX
SUBJECT PAGE
SAFETY RULES ........................................................................................................................................... 0-1
SPECIFICATIONS ........................................................................................................................................ 0-8
DIMENSIONS AND WEIGHT ....................................................................................................................... 0-19
TABLE OF FLUID CAPACITIES ...................................................................................................................0-20
UNITS OF MEASURE ................................................................................................................................. 0-21
STANDARD TORQUE SPECIFICATION .......................................................................................................0-23
LOCTITE PRODUCT CHART ....................................................................................................................... 0-27

W110/W110TC GENERALITIES 0-1
SAFETY RULES
GENERALITIES Ensure that nobody is in the machine operating range
before moving off or operating the attachment. WALK
Read this Manual carefully before starting, operating,
COMPLETELY AROUND the machine before mounting.
maintaining, fuelling or servicing the machine.
Sound the horn.
Read and comply with all safety precautions before any
Before starting machine, check, adjust and lock the driver's
intervention.
seat for maximum comfort and control of the machine.
Do not allow unauthorised personnel to operate or serv-
Fasten your seat belts(when fitted).
ice this machine.
Obey all flag signals and signs.
Do not wear rings, wrist watches, jewellery, loose or hang-
ing garments, such as ties, torn clothing, scarves, unbut- Due to the presence of flammable fluids on the machine,
toned or unzipped jackets that can get caught in moving never check or fill fuel tanks or accumulator batteries near
parts. Wear certified safety clothes such as: hard hat, no- fires, open flames, or sparks.
slip footwear, heavy gloves, ear protection, safety glasses, REMEMBER THAT SPECIAL STARTING FLUIDS ARE
reflector vests, respirators. Ask your employer about spe- FLAMMABLE. Scrupolously follow recommendations
cific safety equipment requirements. printed on the containers and in this Manual.
Keep the operators compartment, step plates, grab-rails DO NOT PUNCTURE OR BURN CONTAINERS.
and handles clean and clear of foreign objects, oil, grease,
mud or snow to minimize the danger of slipping or stum- Containers must be stored in fresh, well ventilated places
bling. Remove mud or grease from your shoes before and out of the reach of unauthorised persons. Strictly
attempting to mount or operate the machine. follow the instructions provided by the Manufacturer.
Do not jump on or off the machine. Always keep both hands Never use these products near fires, open flames, or
and one foot, or both feet and one hand in contact with sparks.
steps and grab rails.
Do not use controls or hoses as hand holds when climbing
on or off the machine. Hoses and controls are movable
parts and do not provide solid support. Besides, controls
OPERATING
may be inadvertently moved and cause unexpected
movement of the machine or its attachments. Check wheel and rim retainers before each working shift.
If necessary, tighten to the torque specified.
Never operate the machine or its attachments from any
position other than sitting in the drivers seat. Do not run the engine of this machine in closed buildings
without proper ventilation capable to remove harmful
Keep head, body, limbs, hands and feet inside the opera-
exhaust gases.
tors compartment at all times to reduce exposure to
external hazards . Roll Over Protective Structures (ROPS) are required on
wheel or crawler loaders, dozers, or graders. NEVER
Be careful of possible slippery conditions of the steps and
OPERATE the machine if such protective structure is
hand rails as well as of the ground around the machine.
removed.
Do not leave the machine until it is has come to a complete
Keep the operators compartment free of foreign objects,
stop.
especially if not firmly secured. Never use the machine to
Check the seat safety belt at least twice per year and transport objects, unless proper securing points are pro-
replace it if it shows signs of wear, fraying or other vided.
weakness that could lead to failure.
DO NOT CARRY RIDERS ON THE MACHINE
Study and familiarize with escape routes alternate to
normal exit routes.
According to law provisions, seat belts must be fitted with
STARTING Roll Over Protection Structures or cabs. Keep safety belts
NEVER START OR OPERATE A FAILED MACHINE. Be- fastened during operation.
fore operating the machine, always ensure that any unsafe For your personal safety, do not climb on or off the machine
condition has been satisfactorily corrected. while it is in motion.
Check brakes, steering and attachment controls before Make sure that bystanders are clear of the machine oper-
moving off. Report any malfuctioning part or system to the ating range before starting the engine and operating the
maintenance managers for proper action. attachment. Sound the horn. Obey all indications provided
Ensure all protective guards and panels as well as all by flags, signs and signals.
safety devices provided are in place and in good operating DO NOT COAST OR FREEWHEEL down hills. Engage the
condition. most suitable gear speed to keep the machine under control.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-2 GENERALITIES W110/W110TC
SAFETY RULES
Do not operate the machine if you are extremely tired or feel When working on slopes or near sudden level drops in the
ill. Be especially careful towards the end of the working shift. terrain, avoid areas where ground is loose or soft since
Do not operate a machine with misadjusted brakes. overturn or loss of machine control could result.
Operate the machine at low speed which can ensure If noise level is high and continuosly exceeds 90 dBA over
complete control at all times. 8 hours at the operator's ear, wear approved ear protection
in compliance with local regulations.
Travel slowly over very rough terrain, slopes or near drop-
offs, in congested areas or on frozen or slippery surfaces. Where counterweights are provided, do not operate the
machine if they have been removed.
When backing, always look to where the machine is to be
moved. Be alert of the position of bystanders. Should When transporting a loaded bucket, keept it as rolled-back
someone enter the work area, STOP THE MACHINE. and low as possible for maximum visibility, stability and
safety of there machine. Ground speed should be ad-
Maintain a safe distance from other machines or obstacles equate to the load and ground conditions.
to ensure required visibility conditions. Give way to loaded
machines. The load must always be properly arranged in the bucket;
move with extreme care when transporting oversize loads.
Maintain a clear vision of the surroundings of the travel or
work area at all times. Keep cab windows clean and Use only the type of bucket recommended for the machine
repaired. and the materials to be handled. Follow the recommenda-
tions concerning loading capacity, arrangement of the
When machines are operating in tandem, the pusher (rear) materials, characteristics of the ground and job to be
must be equipped with the appropriate deflectors to protect performed.
the front unit driver against the air stream coming from the
blower fan. Do not lift and move loads overhead where persons are
standing or working, nor downhill when working crosswise
When pulling or towing through a cable or chain, do not on slopes. In this case, the bucket should be unloaded on
start suddenly at full throttle. Take-up slack carefully. the uphill side, whenever possible.
Carefuly inspect the towing items for flaws or problems
Start and stop the machine carefully when the bucket is full.
before proceedig. Do not move off without first reducing engine speed.
Avoid kinking or twisting chains or cables. Do not pull
Overtaking manoeuvres should be performed only when
through a kinked chain or cable as the high stresses
absolutely necessary and unavoidable. Beware possible
existing in this condition may induce failures. Always wear
uneven terrains, poor visibility, presence of other machin-
heavy gloves when handling chains or cables.
ery or persons out of sight.
Chains and cables should be securely anchored. Anchor
Operate the machine at a speed adequate to the working
points should be strong enough to withstand the expected
site conditions and in any case slow enough to ensure
load. Keep anyone clear of anchor points and cables or
complete control at all times.
chains.
Check instruments at start-up and frequently during
DO NOT PULL UNLESS THE OPERATORS COMPART-
operation. Stop the machine immediately should any
MENTS OF THE MACHINES INVOLVED ARE PROP-
malfunction be signalled.
ERLY PROTECTED AGAINST POSSIBLE BACKLAS IN
CASE OF CABLE OR CHAIN FAILURE OR DETACH- Never use the bucket as a man lift or to carry riders.
MENT. Never use the machine as a work platform or scaffolding,
Be alert of soft ground conditions close to newly con- nor for other improper use (such as pushing railway cars,
structed walls. The fill material and machine weight may trucks or other machines).
cause the wall to collapse.
Pay attetion to people within the machine operating range.
In darkness, check area of operation carefully before Load trucks from the drivers side whenever possible.
moving in with the machine. Use all lights provided. Do not
Prior to operating the machine, check which obstacles
move into low visibility areas.
and/or difficulties you will encounter, such as narrow
If the engine tends to stall for whatever reason under load streets, overhead doors, cables, piping, as well as ground,
or at idle, immediately report this problem to the mainte- bridges, paving and ramps bearing load limitations.
nance managers for proper action. Do not operate the
In case of road transfers, find out beforehand what condi-
machine until this condition has been corrected.
tions are likely to be encountered, such as size restrictions,
On machines fitted with suction radiator fans, regularly heavy traffic, paving type, etc.. Beware fog, smoke or dust
check the engine exhaust system for leaks, as exhaust that obscure visibility.
fumes expelled towards the operator are toxic.
When crossing gullies or ditches, move at an angle with
Operators must know thoroughly the performances of the reduced speed after ensuring ground conditions will per-
machine they are driving. mit a safe traverse.
SAFETY RULES
Always inspect the working area to identify potential risks Always remember to move the gearshift lever to the neutral
such as: inclines, overhangs, trees, demolition rubble, position and engage the control lever lock for safety
fires, ravines, steep slopes, rough terrain, ditches, crowns, purposes.
ridge trenches, heavy traffic, crowded parking and service Apply the parking brake (if fitted).
areas, closed ambients. In such conditions, proceed with
extreme care. NEVER LEAVE THE MACHINE UNATTENDED with the
engine running.
Whenever possible, avoid going over obstacles such as
very rough terrain, rocks, logs, steps, ditches, railroad Prior to leaving the operators seat,and after making sure
tracks. When obstructions must be crossed, do so with that all people are clear of the machine, always slowly
extreme care and at an angle, if possible. Slow down and lower the attachment until resting it safely to the ground
select a lower gear. Ease up to the break-over point, pass Park the machine in a non-operating and no-traffic area.
the balance point slowly and ease down the other side. Park on firm level ground. If this is not possible, position the
In steep down-hill operation, do not allow the engine to machine at a right angle to the slope, making sure there is
over-speed. Select the proper gear before starting down no danger of uncontrolled sliding. Apply the parking brake.
grade. If parking in traffic lanes cannot be avoided, provide
Avoid crosswise hill travel, whenever possible. Drive up appropriate flags, barriers, flares and signals as required
and down the slope. Should the machine start slipping to adequately warn the oncoming drivers.
sideways when going uphill, steer and turn machine front Keep head, body, limbs, hands and feet clear of the dozer,
immediately downhill. arms, bucket or ripper when raised.
The gradient you may attempt to overcome is limited by Always switch off the battery isolator switch before serv-
factors such as ground conditions, load being handled, icing the machine in whatever manner (i.e., cleaning,
machine type and speed, and visibility. repairing, maintaining, etc.). Do the same when the
There is no substitute for good judgement and experience machine is to remain parked for prolonged periods of time
when working on slopes. to avoid accidental or unauthorized starting.
Avoid operating the attachment too close to an overhang Never lower the attachments other than sitting in the
or high wall, either above or below the machine. Beware operators seat. Sound the horn. Make sure that nobody is
of caving edges, falling objects and landslips. Remember within the machine operating range. Lower the attachment
that such hazards are likely to be concealed by bushes, slowly. DO NOT USE FLOAT POSITION in case of hydrau-
undergrowth and such. lic controls.
When pushing-over trees, the machine must be equipped Securely block the machine and lock it every time you
with proper overhead guards. Never drive a machine up leave it unattended. Return keys to authorized security.
the roots, particularly while the tree is being felled. Use Perform all necessary operations as detailed in the Opera-
extreme care when pushing over any tree with dead tion and Maintenance Instruction Manual. Apply the park-
branches. ing brake (if fitted) every time you leave the machine.
Avoid faggots, bushes, logs and rocks.
NEVER DRIVE OVER THEM, nor over any other surface
irregularities that discontinue adherence or traction with MAINTENANCE
the ground, especially near slopes or drop-offs.
Be alert to avoid changes in traction conditions that could GENERALITIES
cause loss of control. AVOID driving on ice or frozen Before operating or performing any intervention on the
ground when working on steep slopes or near drop-offs. machine:
Working in virgin rough terrains is characterized by the - carefully read all the norms contained in this Manual;
presence of all the perils and risks listed above. In these
- read and observe all safety plates and instructions
conditions, it is emphasised the danger represented by
located on the machine.
large tree limbs (possibly falling on the machine), large
roots (which may act as a leverage under the machine Do not allow unauthorized personnel to service the ma-
when up-rooted and cause the unit to overturn), etc. chine. Do not carry out any maintenance work without prior
authorization. Follow all recommended maintenance and
service procedures.
Keep the operators compartment free of loose objects that
STOPPING are not properly secured.
When the machine is to be stopped for whatever reason, Do not wear rings, wrist watches, jewellery, loose or
do so following the instructions given in chapters Stop- hanging garments, such as ties, torn clothing,
ping the machine and Shutting off the engine" in the scarves,unbuttoned or unzipped jackets that can get
Operation and Maintenance Instruction Manual. caught in moving parts.
SAFETY RULES
Wear certified safety clothes such as: hard hat, no-slip The fuel filler pipe nozzle must be constantly kept in contact
footwear, heavy gloves, ear protection, safety glasses, with the filler neck. Keep this contact from the beginning to
reflector vests, respirators. Ask your employer about spe- the end of the fuelling operation to avoid possible genera-
cific safety equipment requirements. tion of sparks due to static electricity.
Never service the machine with someone sitting in the Tow the machine only from the attaching points provided.
driver's seat, unless this person is an authorized operator Use care in making connections and ensure pins and/or
assisting in the maintenance being carried out. bolt are firmly secured before pulling. Stay clear of draw-
bars, cables or chains under load.
Keep the operators compartment, step plates, grab rails
and handles clear of foreign objects, oil, grease, mud or To move a failed machine, use a trailer or a low platform
snow to minimize the danger of slipping or stumbling. truck, if available. In case towing is needed, use all neces-
sary signals required by local regulations, and follow
Clean mud or grease from your shoes before climbing on
directions provided in this Manual.
the machine or driving it.
Load/unload the machine from transporter on firm level
Never attempt to operate the machine or its attachments
ground providing safe support to the wheels of the truck or
from any position other than sitting in the operators seat.
trailer. Use strong access ramps, with adequate height and
Never stand under the boom. angle. Keep the loading platform free of mud, oil or slippery
Should it be necessary to move the attachment through the materials.
hydraulic controls for maintenance purposes, remember Tie the machine securely to the platform of the truck or
that this should be done while sitting in the operators seat. trailer and opportunely wedge machine wheels or tracks
Before starting the machine or moving its attachment, as required.
apply the brakes, sound the horn and call that you are
about to manoeuvre. Raise the attachment slowly. Never align holes or slots using your fingers; always use
appropriate aligning tools.
Always lock machine arms or any other parts that must be
lifted for maintenance purposes using adequate external Remove all sharp edges and burrs from re-worked parts.
means. Do not allow anyone to pass near or even below Use only approved and effectively grounded auxiliary
a raised yet unlocked attachment. If you are not absolutely power sources for heaters, battery chargers, pumps and
sure about your safety, do not stay under a raised attach- similar equipment to reduce electrical shock hazard.
ment, even if it is locked.
Lift and handle heavy components using hoisting devices
Do not place body, limbs, or fingers near articulated cutting of appropriate capacity. Ensure the sling has been cor-
edges of uncontrolled machine parts or deprived of the rectly applied. Use lifting eyes if provided. Pay attention to
necessary guards, unless they are suitably and safely bystanders.
locked.
Never pour gasoline or diesel fuel into open, wide and low
Never perform any work on the machine with the engine containers. Never use gasoline, solvents or other flamma-
running, except when this is specifically required. Do not ble fluids to clean parts. Use proprietary certified non-
wear loose clothing, jewellery or such near moving parts. flammable, non-toxic solvents only.
When service or maintenance require access to areas that When using compressed air to clean parts, wear safety
cannot be reached from the ground, use a ladder or step glasses with side shields. Limit pressure to max 2 bars, in
platform conforming to regulations in force. If such means accordance with local safety regulations in force.
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with the Do not run the engine in closed buildings without proper
greatest care and attention. ventilation capable to remove lethal fumes.
Shop and/or field service platforms or ladders should be Do not smoke, use open flames or produce sparks nearby
manufactured in accordance with safety regulations in while refuelling the unit or handling highly flammable
force. materials.
Disconnect batteries and label all controls to warn that Do not use any flame as a light source during maintenance
service work is in progress. Block the machine and all work or to look for leaks anywhere on the machine.
attachments to be raised.
Make sure that all tools provided are in good condition at
Do not check or fill fuel tanks, batteries and accumulators, all times. NEVER USE tools with mushroomed or dam-
nor use the starting liquid if you are smoking or near open aged heads. Always wear eye protections.
flames. These fluids are flammable!
Move with extreme care when working under the machine,
BRAKES ARE INOPERATIVE when manually released for its attachments, and even on or near them. Always wear
servicing. Provisions must be made to maintain control of protective safety equipment as required, such as hard hat,
the machine using suitable blocks or other means. goggles, safety shoes, and ear plugs.
SAFETY RULES
In case tests during which the engine should be kept Metal cables get frayed after prolonged use. Always wear
runinng, a qualified operator must sit in the drivers seat appropriate protections (heavy gloves, goggles, etc.)
with the mechanic in sight at all times. Place the transmis- while handling them.
sion in neutral, apply and lock the brakes. KEEP HANDS
Handle all parts carefully. Keep hands and fingers away
OFF MOVING PARTS.
from gaps, gears, and similar. Always use and wear the
In case of field service, move machine to level ground, if appropriate protections.
possible, and block it. If work on an incline cannot be
Water can build up in pneumatic systems from condensate
advised, block the machine and its attachments securely.
moisture due to changes in atmospheric conditions. If
Move damaged to level ground as soon as possible.
necessary, drain such deposits following instructions.
Do not trust worn and/or kinked chains and cables. Never
Before carrying out any maintenance work or service, lock
use them for lifting or pulling. Always wear heavy gloves
the machine articulated frame modules using the appro-
to handle chains or cables.
priate safety device. Remember to remove and store it
Be sure chains and cables are firmly fastened and that properly at the end of work.
anchor points are strong enough to withstand the expected If the machine is equipped with hydraulic brakes, make
load. Nobody should stay near the anchor points, cables sure that the reservoir is always filled up to the correct level.
or chains. DO NOT PULL OR TOW UNLESS THE OPERA-
TORS COMPARTMENTS OF THE MACHINES IN- Always block all wheels, front and rear, before bleeding
VOLVED ARE FITTED WITH THE PROPER GUARDS the braking system or disconnecting control hoses and/or
AGAINST BACKLASH IN CASE OF CABLE OR CHAIN cylinders.
FAILURE OR DETACHMENT.
Keep the area where maintenance is carried out CLEAN
and DRY at all times. Clean immediately all water and oil
spillages. STARTING
Do not pile up oily or greasy rags as they represent a major Do not run the engine in closed buildings without proper
fire hazard. Always store them in closed metal containers. ventilation capable to remove lethal exhaust fumes.
Before starting the machine or its attachment, check, adjust Do not place head, body, limbs, feet, hands or fingers near
and lock the operators seat. Also ensure that nobody is rotating fans or belts.
within the machine operating range. Sound the horn.
Be especially careful near blower fans.
Rust inhibitors are volatile and flammable. Use them only
in well ventilated areas. Keep open flames away - DO NOT REMEMBER THAT THE STARTING FLUID IS HIGHLY
SMOKE - Store containers in a cool well ventilatedplace FLAMMABLE. Follow recommendations provided in this
where they could not be reached by unauthorised people. Manual and printed on the containers. Containers must be
stored in a cool, well ventilated place out of the reach of
Do not carry loose objects in your pockets that might fall unauthorised persons.
unnoticed into open compartments. DO NOT PUNCTURE OR BURN CONTAINERS.
Wear safety glasses with side shields, hard hat, safety
shoes, heavy gloves when metal particles or similar may
be ejected and hit you.
Wear appropriate protective equipment such as dark ENGINE
safety glasses, hard hat, protective clothing, special
Loosen the radiator cap very slowly to relieve system
gloves and footwear while welding. Nearby persons
should also wear dark safety glasses even if they are not pressure before removing it. Always top-up coolant level
with the engine off.
welding. DO NOT LOOK THE WELDING ARC WITHOUT
PROPER EYE PROTECTION. Avoid that flammable materials could touch exhaust parts.
If not possible, provide necessary protections.
Become acquainted with all your jacking equipment and
its capacity. Remember that the jacking point on the Do not refuel with the engine running, especially if hot, as
machine should be appropriate for the load applied. Also, this increases fire hazard.
be sure the support area of the jack at the machine and on
Never attempt to check or adjust fan belt tensions when the
the ground is appropriate and stable.
engine is running.
Any load supported by a jack represents a possible haz-
Do not adjust the fuel pump when the machine is motion.
ard. Always transfer the load onto appropriate support
means according to local or national safety requirements Do not lubricate the machine with the engine running.
before proceeding with service or maintenance work.
Do not run the engine with air intakes, door or guards open.
SAFETY RULES
ELECTRICAL SYSTEM Do not use the machine to transport loose objects, unless
proper devices to this purpose are provided.
Always disconnect the batteries prior to any intervention
on the machine or its electrical system (cleaning, repair, Clutches and brakes of this machine as well as auxiliary
maintenance). devices and attachments (such as drive cylinder or winch
control valves) should always be properly adjusted in
Should booster batteries be used, remember to connect
accordance with the instructions provided by the Manufac-
ends of the booster cables in the proper manner: (+) to (+)
turer. Never perform adjustments with the engine running,
and (-) to (-). Do not short-circuit terminals. Thoroughly
except when this is specifically required by the relevant
follow instructions given in this Manual.
procedures.
Before any intervention, make sure that the battery isolator
switch is off.
BATTERY GAS IS HIGHLY FLAMMABLE. Leave the bat-
tery compartment open during recharging to improve
ventilation. Never check battery charge by placing metal
TYRES AND WHEELS
objects across the posts. Keep sparks or open flames away
from batteries. Do not smoke near the battery to prevent Make sure that the tyre inflation pressure corresponds to
explosion hazard. specifications issued by the Manufacturer. Regularly
check inflation pressure.
Before any intervention, make sure that there are no fuel
or electrolyte leakages. If any, correct prior to proceeding Should pressure be changed, do this while staying on the
with further work. Do not recharge batteries in confined tyre side and at a safe distance.
spaces. Ensure proper ventilation is provided to avoid Pressure checks should always be carried out with the
accidental explosions due to build-up of gas released machine unloaded and cold tyres.
during charging.
Never use reconditioned tyre rims, since possible
weldings, incorrect heat-treatments or repairs can
weaken the wheels and cause damages or failures.
Do not cut, nor weld rims with inflated tyres installed.
The spare tyre should be inflated only enough to keep the
HYDRAULIC SYSTEM
rim components assembled. Remember that when not
Pressure fluid escaping from a very small hole can be installed on the disc, a tyre inflated to maximum pressure
almost invisible and still have sufficient force to penetrate can explode.
the skin. Always check any suspected pressure leaks Therefore, maximum care must be taken when handling a
using a piece of cardboard or wood. DO NOT USE HANDS. fully inflated tyre.
If injured by escaping fluid, obtain medical attention imme-
diately or serious infection or reaction may develop. Before servicing tyres, block all wheels, front and rear. After
jacking up the machine, block it in the raised position using
Stop the engine and relieve all system pressure before suitable stands conforming to current safety regulations.
removing panels, housings, caps, plugs or covers.
Deflate the tyre before removing objects from the tyre tread.
Always use gauges of adequate capacity (end-of-scale
reading) and follow recommended procedures. Never inflate tyres with flammable gas: explosions and
severe bodily injuries may result.
When starting your work shift, check for loose wheel or rim
bolts and brackets and retighten to correct torque as
necessary.
TOOLS
Always keep head, body, limbs, feet, or hands away from
bucket, blade, or ripper when in the raised position. Prior
to any intervention, install all safety devices according to
current regulations. In case the attachment is to be oper-
ated through the machine hydraulic system for mainte-
nance purposes, remember to do so only while sitting in the
driver's seat. Make sure that nobody is within the machine
operating range. Before operating the attachment, alert
people by sounding the horn and by voice. Raise the
attachment slowly.
SAFETY RULES
DECOMMISSIONING THE MACHINE
For the decommissioning of the machine, the availability WARNING
of particular tooling (hoists, hydraulic presses. contain- The decommissioning of the machine must be
ers for liquids etc.) is required as well as specific tools performed exclusively by personnel trained,
listed in the Repair Manuals, available from FIAT qualified and authorised to perform such op-
KOBELCO Dealers. eration.
This has the purpose of avoiding that during disassem-
bly operations, dangerous situations may arise both for Start the disassembly of hydraulic components
the personnel involved and the environment. only after the same, the hydraulic oil and lubri-
cants have fully cooled-off and after all residual
In the machine are present: pressures have been released, as described by
Fluids under pressure (hydraulic system, cooling the Repair Instruction Manual.
system etc.)
Gases (air conditioning system and accumulator, if Prior to proceeding with disassembly opera-
installed) tions, comply with the GENERAL SAFETY
Mechanical devices mounted under pressure (track RULES and drain each components of the ma-
tensioner etc.) chine filled with fluids, both in the reservoirs
Heavy machine components (frames, blades, buck- and the relevant systems.
ets etc.)
WARNING
Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing
machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators,
loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, me-
chanically, or cable controlled attachment to gain access to certain items, make sure the attachment is
adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or
mechanical devices used for controlling it.
SPECIFICATIONS
ENGINE - EMISSION
Model F4GE0484E
Fuel #2 Diesel (#1 & 2 Mixture Permitted For Cold

Temperature)
Number of Cylinders 4
Bore and Stroke 4.29" (104 mm) x 5.20" (132 mm)
Displacement 275 cu. in. (4.5 Liters)
Electrical System 24 Volts
Batteries (2) 12 Volts
Alternator 70 Amp
Compression Ratio 17.5 to 1
Fuel Pump
Air Cleaner Dry Type Elements With Warning Restriction Indicator
Oil Filter Full Flow Replaceable Cartridge
Lubrication Positive Pressure
Cooling System Mid-mount Air/Water
Power
- Gross (per SAE J1995) 119 hp (89 kW) Maximum
- Net (per SAE J1349) 110 hp (82 kW) Maximum
Torque, Max.
- Gross (per SAE J1195) 355 lb-ft (481 Nm) @ 1400 RPM
- Net (per SAE J1349) 336 lb-ft (455 Nm) @ 1400 RPM
Valve clearance (Engine cold)

- Intake valves 0.267 mm (0.011 inch)
- Exhaust valves 0.572 mm (0.023 inch)
Governor
Complies with 1996 US EPA and CARB Heavy Duty Non-Road Emissions for 100-750 hp (75-560 kW) engines.
POWER TRAIN
TRANSMISSION
Make ZF
Model 4WG130
Radio 1st 2nd 3rd 4th
Forward 4.012 2.024 1.088 0.619

Reverse 3.804 1.919 1.031 -
TORQUE CONVERTER
Make ZF
Model 06.004.08
Stall Ratio 2.549:1
SPEEDS: mph (km/h)

1st 2nd 3rd 4th
(15.5 x 25 L2/L3 Tires)
- Forward 4.1 (6.5) 7.9 (12.7) 13.9 (22.4) 22.4 (36.1)
- Reverse 4.3 (6.9) 8.3 (13.4) 14.6 (23.4)
(17.5 x 25 L2/L3 Tires)

- Forward 4.3 (6.9) 8.3 (13.3) 14.5 (23.4) 23.4 (37.6)
- Reverse 4.5 (7.2) 8.7 (14.0) 15.2 (24.5)
AXLES Front Rear

- Differential Ratio 2.917 2.917
- Planetary Ratio 6.400 6.400
- Final Axle Ratio 18.67 18.67
Make ZF
Model Front MTL3065
Rear MTL3065
0 - 10 GENERALITIES W110/W110TC
BRAKES
Hydraulic, wet four-wheel disc. One brake pedal, pedal applies brakes and electrically neutralilzes power flow to
wheels with transmission disconnect switch activated. The brake pedal applies brakes only when transmission
disconnect switch is not activated. Hydraulic brake valve for front and rear split system. Spring applied/hydraulic
released disc parking brake on transmission output shaft neutralizes power flow to wheels when it is engaged.
Brake Area of Service Brakes 184 in2 (0.119 m2)/Hub
Brake Area of Parking Brake 9.0 in2 (58 cm2)
Brake Pressure Front: 899 psi (6200 kPa)

(@ 30 sec. Setting method)
Rear : 856 psi (5900 kPa)
ACCUMULATOR DATA
Cut In 2275 psi (15686 kPa)
Cut Out 2800 psi (19305 kPa)
Low Pressure Warning 1500 psi (10342 kPa)
Transmission Declutch 350 psi (2413 kPa)
Charge Pressure (N2) 800 psi (5516 kPa)

Rear : 856 psi (5900 kPa)
TIRES
17.5 R 25 XTLA TL 50 psi Front 40 psi Rear
(345 kPa) (275 kPa)
17.5 R 25 XHA TL 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)
17.5 R 25 GP-2B 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)
W110/W110TC GENERALITIES 0 - 11
HYDRAULICS AND STEERING
Reservoir: Filtered vent with relief on hydraulic reservoir main-

tains 3-5 psi (20-34 kPa) on reservoir. Full time 10
micron return filters furnish only clean oil to all com-
ponents of the system.
Valves: Closed-center, load sensing circuit, positive low pres-

sure regeneration for bucket dump. Remote control
hydraulic power assit with electromagnet detents.
Inlet section gives steering priority with maximum pres-

sure of 3500 psi (24132 kPa). Bucket section gives
bucket priority. Relief valve provides maximum loader
pressure of 3625 psi (25,000 kPa).
Loader control valve section contains float circuitry.
Senses steering demand to control oil flow to loader

valve or steering valve as required by steering de-
mand.
System: A variable displacement piston pump is used to sup-

ply oil to the integrated loader and steering hydraulic
system.
Pump displacement 4.33 in3/rev (71 cc/rev).

35.4 GPM @ 2000 RPM @ 2750 psi
(134 l/min @ 2000 RPM @ 18961 kPa)
Pump uses full displacement at pressures up to 1800

psi. At pressures above 1800 psi the pump destrokes
(reduces its displacement) to prevent increasing the
hydraulic torque load. This allows more power for the
drivetrain in critical or severe applications without
sacrificing hydraulic force.
Steering Section
Center pivot articulated steering - front and rear wheels
always track. Two hydraulic cylinders controlled by a
hydrostatic steering gear and a priority valve.
The steering Orbitrol provider 3.9 turns lock-to-lock.

Lock-to-lock time at high idle is 1.75 sec.
Hydraulic Cylinder:
Dump:
(Z-Bar, XR) 4.50 dia x 20.84 stroke x 2.50 rod
(114.3 mm dia x 529.2 mm stroke x 63.5 mm rod)
(TC) 3.75 dia x 36.32 stroke x 2.25 rod

Lift: 4.00 dia x 30.82 stroke x 2.25 rod

Steer: 2.50 dia x 18.21 stroke x 1.375 rod

(63.5 mm dia x 462.5 mm stroke x 35 mm rod)
Diameter of Hydraulic Inlet and Outlet Ports:
One Inlet 2.0" Split Flange (50.8 mm)
One Outlet 1.0" Split Flange (25.4 mm)
Maximum Oil Velocity at Hydraulic Pump @ 2000 RPM:
Outlets 14.4 ft/sec (4.40 m/sec)
CAPACITIES
Cooling System:
5.8 US/gal (22 liters) to fill system
Gallons Ethylene Glycol (Prestone) required:

2.1 US/gal (7.8 liters) for 0 F
2.5 US/gal (9.5 liters) for -20 F
3.1 US/gal (11.7 liters) for -40 F
Fuel Tank:
50.0 US/gal (189 liters) Usable Fuel
Engine:
Crankcase Only 12 quarts (11.4 liters)
Crankcase and Filter 13 quarts (12.3 liters)
Transmission: 6.78 US/gal (26 liters) initial capacity
5.0 US/gal (18.9 liters) service (w/filter)
Axles: Front/Rear
Total/Axle 23.2 quarts (22 liters)
Hydraulic Reservoir:
Reservoir, oil only 15.0 US/gal (56.8 liters)

Reservoir, oil plus air 23.8 US/gal (90.1 liters)
Total System 30.0 US/gal (113.6 liters)
SOUND LEVEL DATA
Emission Engine Sound Level (Arithmetic Average) dBA
Cab Closed Cab Open Canopy
Exterior Sound Level @ 15 meters

per SAE J88 SEP80
Stationary - Rated Speed - - -

Stationary - High Idle - - -
Moving - - -
IMI - - -
Component Cycling - - -
Operator's Station Sound Level

per SAE J919 JUN86

Moving - - -
IMI - - -
Time Weighted Average Sound Level (Leq) dBA
Operator's Station Work Cycle - - -

per SAE J1166 MAR85
(no blowers)
Emission Engine Sound Level (Arithmetic Average) dBA
Exterior Sound Level @ 15 meters

per SAE J88 SEP80

Moving - - -
IMI - - -
Operator's Station Sound Level

per SAE J919 JUN86

Moving - - -
IMI - - -
Time Weighted Average Sound Level (Leq) dBA
Operator's Station Work Cycle - - -

per SAE J1166 MAR85
(no blowers)
Sound levels per (in dBA)

2000/14/EC
98/37/EC (ISO 6395, 6396, 3744)
Interior LpA Exterior LwA
Combined Dynamic (Test Average) 70.7 103.8

Decal Value 71 105
Note Rated speed of engine is 2000 rpm and High - Idle is 2160 2220 rpm.
The option w Enhanced Sound Package will be developed at the begin of March.
The standard machine will be w/o Enhanced Sound Package.
COMPONENT SPECIFICATIONS
ITEM MODEL SIZE
Injector Pump VE6/12F1000
Primary Fuel Filter 43.061.000.53
Engine oil filter LF16015 JD
Air filter assembly G100376 10 in. Diameter
Starter EV 24 volt 4 kw
Alternator NCB1 24 v, 70 amp
Hydraulic Pump A10V085 5.19 cu. In./rev

(85 cc/rev)
Hydraulic Oil Filter HM K013582,
Assembly HM K0531170 w/ride
control
Head Assy. P178778
Element P165823
Hyd. control P/N C0640-10014

2 Lever
Hyd. control 4TH6F

Joystick P/N 08-350-759
Hyd. control C0640-10013
3 Lever
Hyd. control 4TH6F+2TH6

Joystick + 1 Lever P/N 08-350-759 +
P/N 08-350-766
Loader Control Valve - M6-1044-00/2M6-15

2 Spool ZB

2 Spool TC

3 Spool ZB

3 Spool TC
ITEM MODEL SIZE

4 Spool ZB
Loader Control Valve - M6-1049-00/M6-15

4 Spool TC
Cab Heater/def/AC 441407913 12kW heater

Blower Motor (006-B39/I 22-24 V) 8 kW evaporator
Core (combination) air flow 850 m3/h @
40 mm H2O
441407913
Cab heater defroster (006-B39/I 22-24 V)

blowe motor
Core
Condenser 383912A1 4R/9F 19.84"x11"
Compressor 4611-6000
Front Wiper 441411772 24 V

(150.208) 35 min-1/55 min-1
60 Sweep
Rear Wiper 441412334 24 V

45 min-1
175 sweep
Cab Filter 441407125 Front

Recirculation surface: 90 x 470 mm
Flow 1500 l dm-2
Cab Filter 241405799 Front

External air surface: 445 x 114 mm
Flow 830 l s-1 m-2
Steering valve and 236-4008-002

orbital pump
Cooling Fan 832059 28.0" (711 mm)

Diameter
Standard M080425 Horizontal round

Muffler
Battery 548.450.1ES Cap. 100 Ah

12 V
450 Amp
ITEM MODEL SIZE
Trasmission 8605271
WG 160
Hyd. oil cooler 7A8025901C Air-to-Oilm 9 fins/in
Beacon 35.205.000.14 Halogen 24 V

Rotary Lamp
Front axle MT3075
Rear axle MT3065
Service Brakes Pump WQ09A1
Accumulators
19184-OPA3
Brake Modulation Valve
Secondary steering - 02433A00

electric pump and motor
Engine drive shaft 04085418
Front drive shaft 04085422
Center drive shaft 04085423
Rear drive shaft 04085424
Bucket teeth 87408033
Information Center 11000-MM3600
DIMENSIONS AND WEIGHT
*
40
*
45
*
*
3430
49
1002
377
322 95 970
2750 1860 1850
2339
*
FIG05
Dimensions in mm (in)
Operating weight: 10.530 kg (23215 lbs)
Note Machine equipped with tyres 17.5R25XTLA, fluids and operator.
* Please refer to the table
Type of bucket
With teeth and segment With suppl. cutting edge
Bucket capacity cu m 1.8 2.0 1.8 2.0

Bucket weight kg (lbs) 826 (1821) 797 (1758) 817 (1800) 788 (1737)
Bucket width mm (in) 2482 (97.7) 2482 (97.7) 2440 (96.1) 2440 (96.1)
Dumping height at 45 mm (in) 2604 (102.5) 2558 (100.7) 2634 (103.7) 2588 (101.9)
Dumping reach at 45 mm (in) 1110 (43.7) 1494 (58.8) 1072 (42.2) 1476 (58.1)
Max. length
(w/ bucket on ground) mm (in) 6765 (266.3) 6835 (269.1) 6715 (264.4) 6785 (267.1)
Max. height
(w/ bucket raised) mm (in) 4684 (184.4) 4746 (186.8) 4684 (184.4) 4746 (186.8)
Turning dia.
(in transportation position) m (ft) 10.9 (35.8) 10.9 (36.2) 10.9 (35.8) 10.9 (36.2)
TABLE OF FLUID CAPACITIES 0 - 20
ITEM QUANTITY FLUIDS OR LUBRICANT CLASSIFICATION VISCOSITY OUT DOOR TEMPERAT.

LITRES (USG) SPECIFICATIONS (SAE) OF REFERENCE (C)
API CF-4/SG
10 to 50 C (14 to 122 F)
ENGINE + OIL FILTER 12.5 Super Gold MIL-L-2104E 15W-40
30 to 20 C (-22 to 68 F)
ACEA E2
API CH-4
Mastergold HSP* 15W-40 10 to 50 C (14 to 122 F)
ACEA E3
RADIATOR 22 Agriflu ASTM D-5345 35 to 50 C (-31 to 122 F)
API CF-4/SG
TRANSMISSION + FILTER 18.5 Super Gold MIL-L-2104E 10W-30 30 to 20 C (-22 to 68 F)
ACEA E2
ISO VG 46, DIN 51524

HYDRAULIC SYSTEM 63 (114 TOT.) HITECH 46 Item 1 and 2, QFH583/HD 20 to 50 C (-4 to 122 F)
GENERALITIES
front 22
AXLES rear 22 TRX API GL4 SAE 80W-140 20 to 50 C (-4 to 122 F)
FUEL TANK 18.3 Diesel fuel ASTM no. 2D
Grade 251H-EP
GREASE FITTINGS MG-2 Spec. B-27 40 to 50 C (-40 to 122 F)
AIR CONDITIONER
COMPRESSOR 0.2 (0.05) L BAR 134
WINDSHIELD WASHER
FLUID 4.7 SC 35
Oil quantities indicated are those required for periodical changes following the draining and filling procedures indicated in detail for each group.
* In the event engine oil with "CH4" classification is used, the change interval can be prolonged to 500 hours providing that the outer temperature of operation
does not exceed 38 C (100 F) and that the percentage of sulphur in the fuel does not exceed 0.5 %.
In the event of really heavy duty conditions, reduce the greasing intervals.
W110/W110TC
UNITS OF MEASURE
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile
Mass: kilogram 2.204 622 pound
Mass/Area: kilogram/hectare 0.000 466 ton/acre
Mass/Energy: g/kW/hr. 0.001 644 lbs/hp/hr.
Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.
Power: kilowatt 1.341 02 horsepower
Pressure: kilopascal 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch
Temperature: degree C 1.8 x C +32 degree F
Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.
Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: sq. foot 0.092 903 square meter

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

foot 0.304 8 * meter
mile 1.609 344 * kilometer
Mass: pound 0.453 592 kilogram

ounce 28.35 gram
Mass/Area: ton/acre 2241 702 kilogram/hectare
Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr
Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter
Power: horsepower 0.745 700 kilowatt
Pressure: lbs/sq. in. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm
Temperature: degree F 1.8 F - 32 degree C
Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.
Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact
STANDARD TORQUE SPECIFICATION

TORQUE SPECIFICATIONS - DECIMAL HARDWARE
Grade 8 Bolts, Nuts, and Studs
Use the torques in this chart when special torques
are not given. These torques apply to fasteners with
both UNC and UNF threads as received from suppli-
ers dry, or when lubricated with engine oil. Not appli-
Pound- Newton
cable if special graphitiesm Molydisulfide greases, or Size
Inches metres
other extreme pressure lubricants are used.
1/4 inch 144 to 180 16 to 20
5/16 288 to 348 33 to 39
Grade 5 Bolts, Nuts, and Studs 3/8 inch 540 to 648 61 to 73
Pound- Newton
Pound- Newton Size
Size Feet metres
Inches metres
7/16 inch 70 to 84 73 to 87
1/4 inch 108 to 132 12 to 15
1/2 inch 110 to 132 149 to 179
5/16 204 to 252 23 to 28
9/16 inch 160 to 192 217 to 260
3/8 inch 420 to 504 48 to 57
5/8 inch 220 to 264 298 to 358
3/4 inch 380 to 456 515 to 618
Pound- Newton
Size 7/8 inch 600 to 720 814 to 976
Feet metres
7/16 inch 54 to 64 73 to 87 1.0 inch 900 to 1080 1220 to 1465
1/2 inch 80 to 96 109 to 130 1-1/8 inch 1280 to 1440 1736 to 1953
7/8 inch 400 to 480 542 to 651 Note Use thick nuts with Grade 8 bolts.
1.0 inch 580 to 696 787 to 944

1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983
TORQUE SPECIFICATIONS - METRIC HARDWARE

Grade 10.9 Bolts, Nuts, and Studs
Use the following torques when specifications are not
given. 10.9
These values apply to fasteners with coarse threads

Pound- Newton
as received from supplier, plated or unplated, or when Size
Inches metres
lubricated with engine oil. These values do not apply
if graphite or Molydisulfide grease or oil is used. M4 36 to 48 4 to 5
M5 84 to 96 9 to 11
Grade 8.8 Bolts, Nuts, and Studs
M6 132 to 156 15 to 18
8.8 M8 324 to 384 37 to 43
Pound- Newton
Size Pound- Newton
Inches metres Size
Feet metres
M4 24 to 36 3 to 4
M10 54 to 64 73 to 87
M5 60 to 72 7 to 8
M12 93 to 112 125 to 150
M6 96 to 108 11 to 12
M14 149 to 179 200 to 245
M8 228 to 276 26 to 31
M16 230 to 280 310 to 380
M10 456 to 540 52 to 61
M20 450 to 540 610 to 730
M24 780 to 940 1050 to 1275
Pound- Newton
Size M30 1470 to 1770 2000 to 2400
Feet metres
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172

M16 160 to 200 217 to 271 Grade 12.9 Bolts, Nuts, and Studs
M20 320 to 380 434 to 515 12.9
M24 500 to 600 675 to 815

Usually the torque values specified for grade 10.9
M30 920 to 1100 1250 to 1500 fasten can be used satisfactorily on grade 12.9 fas-
teners.
M36 1600 to 1950 2175 to 2600
TORQUE SPECIFICATIONS - STEEL HYDRAULIC

Tube OD Thread Pound- Newton
FITTINGS
Hose ID Size Inches metres
Tube OD Thread Pound- Newton Straight Threads with O-ring
Hose ID Size Inches metres
1/4 inch 7/16-20 144 to 228 16 to 26
37 Degree Flare Fitting 6.4 mm
1/4 inch 7/16-20 72 to 144 8 to 16 5/16 inch 1/2-20 192 to 300 22 to 34
6.4 mm 7.9 mm
7.9 mm 9.5 mm
9.5 mm 12.7 mm
1/2 inch 3/4-16 180 to 504 20 to 57
12.7 mm
Tube OD Thread Pound- Newton
5/8 inch 7/8-14 300 to 696 34 to 79 Hose ID Size Inches metres
15.9 mm
5/8 inch 7/8-14 58 to 92 79 to 124
15.9 mm
Tube OD Thread Pound- Newton 3/4 inch 1-1/16-12 80 to 128 108 to 174
Hose ID Size Inches metres 19.0 mm
3/4 inch 1-1/16-12 40 to 80 54 to 108 7/8 inch 1-3/16-12 100 to 160 136 to 216
19.0 mm 22.2 mm
7/8 inch 1-3/16-12 60 to 100 81 to 135 1.0 inch 1-5/16-12 117 to 187 159 to 253
22.2 mm 25.4 mm
1.0 inch 1-5/16-12 75 to 117 102 to 158 1-1/4 inch 1-5/8-12 165 to 264 224 to 357
25.4 mm 31.8 mm
1-1/4 inch 1-5/8-12 125 to 165 169 to 223 1-1/2 inch 1-7/8-12 250 to 400 339 to 542
31.8 mm 38.1 mm
1-1/2 inch 1-7/8-12 210 to 250 285 to 338
38.1 mm
Split Flange Mounting Bolts

Pound- Newton
Size
Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Pound- Newton
Size
Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Nom
SAE Thread Pound- Newton Thread Pound- Newton
Tube OD
Dash Size Inches metres Size Inches metres
Size
O-ring Boss End
O-ring Face Seal End
Fitting or Lock Nut
-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
6.4 mm
-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
9.5 mm
-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
12.7 mm
Thread Pound- Newton

Size Inches metres
-10 5/8 inch 1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
15.9 mm
Nom 1-1/16/12 85 to 90 115 to 122

SAE Thread Pound- Newton
Tube OD
Dash Size Inches metres 1-3/16-12 95 to 100 129 to 136
Size
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/18-12 150 to 160 203 to 217
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254
38.1 mm
Working
Similar Gap Strength Fixture/Full Cure
Product Color Temperature Primer Description
Products (In Inches) (Steel/Steel) (Steel/Steel) Time
Range-Farenheit
Form a Gasket (works with oil,
#3 Dark Brown 24 hr N/A
W110/W110TC
fuel or grease) Pliable

80 Yellow Fast N/A Weatherstrip Adhesive
123 Clear N/A N/A Parts Cleaner Fluid
220 Blue 290 0.003 57/143 in lbs -65 to +250 6 min/24 hrs 747 Wicking Threadlocker
221 Purple 222 0.005 75/44 in lbs -65 to +300 2 min/24 hrs 747 Low Strength Threadlocker
Low Strength Threadlocker
222 Purple 0.005 53/30 in lbs -65 to +300 20 min/24 hrs 764
(Small Screws)
225 Brown 222 0.010 45/25 in lbs -65 to +300 7 min/24 hrs 747 Low Strength Threadlocker
242 Blue 0.005 80/50 in lbs -65 to +300 10 min/24 hrs 764 Medium Strength Threadlocker
262 Red 271 0.005 160/190 in lbs -65 to +300 5 min/24 hrs 747 High Strength Threadlocker
270 Green 271 0.007 160/320 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
271 Red 262 0.007 160/320 in lbs -65 to +300 10 min/24 hrs 764 High Strength Threadlocker
272 Red 620 0.007 180/220 in lbs -65 to +450 30 min/24 hrs 764 High Temperature, High Strength
275 Green 277 0.010 210/300 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
277 Red 0.010 225/300 in lbs -65 to +300 60 min/24 hrs 764 High Strength Threadlocker
290 Green 0.003 85/350 in lbs -65 to +300 6 min/24 hrs 764 Wicking Threadlocker
*404 Clear 495 0.006 3200 psi -65 to +180 30 sec/24 hrs NA Instant Adhesive
*406 Clear 0.004 3200 psi -65 to +180 15 sec/24 hrs N/A Surface Insensitive Adhesive
*409 Clear 454 0.008 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Instant Adhesive
GENERALITIES
*414 Clear 0.006 2500 psi -65 to +180 30 sec/24 hrs N/A Instant Adhesive
*415 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Metals)
*416 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Plastics)
LOCTITE PRODUCT CHART
*420 Clear 0.002 2500 psi -65 to +180 15 sec/24 hrs N/A Wicking Instant Adhesive
*422 Clear 454 0.020 2800 psi -65 to +180 60 sec/24 hrs N/A Gap Filling Instant Adhesive
*430 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
*445 White/Black 0.250 2000 psi -65 to +180 5 min/24 hrs N/A Fast Setting 2 Part Epoxy
Surface Insensitive Gen
*454 Clear 0.010 3200 psi -65 to +180 15 sec/24 hrs N/A
Instant Adhesive
*495 Clear 0.004 2500 psi -65 to +180 20 sec/24 hrs N/A General Purpose Instant Adhesive
*496 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
504 Brt Orange 515 0.030 750 psi -65 to +300 90 min/24 hrs None Rigid Gasket Eliminator
509 Light Blue 0.020 750 psi -65 to +320 6 hr/72 hrs 764 Flange Sealant
510 Red 0.020 1000 psi -65 to +400 30 min/24 hrs 764 High Temperature, Gasket Eliminator
515 Purple 0.010 750 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 515
* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity
0 - 27
0 - 28
Working
Similar Gap Strength Fixture/Full Cure
Product Color Temperature Primer Description
Products (In Inches) (Steel/Steel) (Steel/Steel) Time
Range-Farenheit
518 Red 515 0.030 500 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 518 for Aluminum
542 Brown 569 N/A 132/92 in lbs -65 to +300 2 hrs/24 hrs 747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic
545 Purple N/A 25/20 in lbs -65 to +300 4 hrs/24 hrs 747
Sealant
549 Orange 504 0.020 2500 psi -65 to +300 2 hrs/24 hrs 747 Instant Seal Plastic Gasket
554 Red 277 0.015 240/240 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Refrigerant Sealant
567 White 592 N/A 500 psi -65 to +400 4 hrs/24 hrs 764 Pipe Sealant for Stainless Steel
568 Orange 277 0.015 2500 psi -65 to +300 12 hrs/24 hrs 764 Plastic Gasket
569 Brown 545 0.010 40/25 in lbs -65 to +300 1 hr/24 hrs 764 Hydraulic Sealant
570 Brown 592 N/A 25/40 in lbs -65 to +300 6 hrs/72 hrs 764 Steam Sealant
571 Brown 592 0.015 40/20 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Pipe Sealant
572 White 578.575 N/A 80/27 in lbs -65 to +300 24 hrs/72 hrs None Gasketing
592 White 0.020 500 psi -65 to +400 4 hrs/72 hrs 736 Pipe Sealant with Teflon
593 Black 0.250 400 psi -95 to +400 30 min/24 hrs N/A RTV Silicone
601 Green 609 0.005 3000 psi -65 to +300 10 min/24 hrs 764 Current PIN #609
609 Green 0.005 3000 psi -65 to +300 10 min/24 hrs 764 General Purpose Retaining Compound
High Temperature Retaining
620 Green 640 0.015 3000 psi -65 to +450 30 min/24 hrs 747
Compound
GENERALITIES
635 Green 680 0.010 4000 psi -65 to +300 1 hr/24 hrs 747 High Strength Retaining Compound
638 Green 680 0.015 4100 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
640 Green 620 0.007 3000 psi -65 to +400 1 hr/24 hrs 747 High Temperature Retaining Compound
660 Silver 0.020 3000 psi -65 to +300 20 min/24 hrs 764 Quick Metal
675 Green 609 0.005 3000 psi -65 to +300 20 min/24 hrs 747 General Purpose Retaining Compound
680 Green 635 0.015 4000 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
706 Clear 755 N/A N/A N/A N/A N/A Cleaning Solvent
707 Amber N/A N/A N/A N/A N/A Activator for Structural Adhesives
736 Amber N/A N/A N/A N/A N/A Primer NF
738 Amber N/A N/A N/A N/A N/A Depend Activator
747 Yellow N/A N/A N/A N/A N/A N/A Primer T
751 Clear N/A N/A N/A N/A N/A Activator for Structural Adhesives
755 Clear N/A N/A N/A N/A N/A Cleaning Solvent
764 Green N/A N/A N/A N/A N/A Primer N
767 Silver N/A N/A -65 to +1600 N/A N/A Anti-Seize Lubricant
W110/W110TC
SECTION 1
ENGINE
INDEX
PARAGRAPH SUBJECT PAGE
1.1 GENERAL FEATURES ......................................................................................... 1-1
1.2 DESCRIPTION OF MAIN GROUPS ..................................................................... 1-3

Cylinder head .................................................................................................... 1-8
Valves and valve seats ..................................................................................... 1-9
Valve guides ..................................................................................................... 1-10
Engine flywheel ................................................................................................ 1-11
1.3 LUBRICATION ...................................................................................................... 1-13
1.4 OPERATION DESCRIPTION FUEL SYSTEM ...................................................... 1-15
1.5 TROUBLESHOOTING GUIDE .............................................................................. 1-25
1.6 ENGINE OVERHAUL ON BENCH ......................................................................... 1-39

Disassembly of engine ..................................................................................... 1-39
Removal of injection pump................................................................................ 1-42
Removal of rocker arm group ............................................................................ 1-44
Repair interventions on cylinder group .............................................................. 1-47
Timing .............................................................................................................. 1-49
Bushes ............................................................................................................. 1-50
Tappets ............................................................................................................. 1-51
Crankshaft ........................................................................................................ 1-52
Conrods ............................................................................................................ 1-60
Setting the timing ............................................................................................. 1-65
Engine flywheel ................................................................................................ 1-67
Replacing the injectors ..................................................................................... 1-81
Adjusting the valve clearance ........................................................................... 1-82
1.7 TOOLING .............................................................................................................. 1-85

W110/W110TC ENGINE 1-1
1.1 GENERAL FEATURES
Type F4GE0484E
Cycle Diesel 4-stroke

Intake Turbocharged w/aftercooler
Injection Direct
Number of cylinders 4 in-line
Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cu cm 3900
Compression ratio 17 : 1
Maximum power kW 89
(HP) 119
@ rpm 2000
Maximum torque (kgm) Nm 481

@ rpm 1400
Engine low idle @ rpm 1020 to 1080
Engine high idle @ rpm 2050 to 2180
Maximum speed
@ rpm 2000 to 2140
hydraulic stall
Maximum speed
@ rpm 1900 to 2060
transmission stall
Maximum speed
@ rpm 1530 to 1840
total stall (hydr. + transmission)
1-2 ENGINE W110/W110TC
Type F4GE0484E
TURBOCHARGING w/ AFTERCOOLER
CHARGING PRESSURE 1.15 0.1 bar
Turbocharger type: HOLSET HX27W
LUBRICATION Forced by gear pump,
pressure relief valve,
Oil pressure oil filter
bar
with hot engine:
at low idle bar 1.2
at high idle bar 3.8
COOLING Liquid
Water pump drive: Belt
Thermostat starts opening at: C (F) 81 2 (178 3.6)
OIL CAPACITY oil sump + filter
AMBRA SUPER GOLD 1 (USG) 12.5 (3 1/4)
AMBRA MASTERGOLD Hsp l
INJECTION
VE4/ 12F 1100
type Bosch
Injector nozzles type DSLA 145 P603
Firing order 1-3-4-2
bar
Injection pressure bar 245
1.2 DESCRIPTION OF MAIN GROUPS
Upper view
D E F G
C B A
W110R0096
Upper view
A. Alternator - B. Injectors - C. Turbocharger - D. Blow-by - E. Injection pump - F. Intake manifold - G. Fuel filter.
WARNING
Due to application requirements, some auxiliary groups can be located in different positions with respect
to what illustrated in this section of the manual.
Front view
B
H
W110R0097
Front view
A. Blow-by - B. Fuel filter - C. Fuel pump - D. Idle pulley - E. Oil filter - F. Poly-V belt - G. Water pump - H. Alternator -
I. Thermostat.
Right side view
C
L
H
F
W110R0098
Right side view
A. Blow-by - B. Turbocharger - C. Thermostat - D. Alternator - E. Water pump - F. Poly-V belt - G. Oil filter connection -
H. Starter motor - I. Oil discharge pipe from turbocharger - L. Exhaust manifold.
Left side view
L A
B
I
H
C
F G
E D
W110R0099
Left side view
A. Blow-by - B. Injector fuel piping - C. Injection pump - D. Oil filter - E. Fuel pump - F. Fuel filter - G. Fuel heater -
H. Poly-V belt - I. Air heater (optional) - L. Intake manifold.
Rear view
O A B C D
M E
L I
W110R0100
Rear view
A. Blow-by - B. Injector fuel piping - C. WASTGATE valve - D. Turbocharger - E. Oil discharge pipe from turbocharger -
F. Alternator - G. Exhaust manifold - H. Starter motor - I. Engine flywheel - L. Oil filter - M. Injection pump - N. Air heater
(Optional) - O. Intake manifold.
Cylinder head Also on the heads are fitted

On the cast iron made cylinder head, the seats of the single block exhaust manifold 1;
following components are made:
intake valve 2 with seat for cold starting air heater
added valve seats 4; 3.
injector 6;
thermostat 5.
3
6 (OPTIONAL)
W110R0101
Detail of cylinder heads with added valve seats
Valves and valve seats
S 1
W110R0102
A. Intake side - S. Exhaust side - 1. Intake valve - 2. Exhaust valve.
The valve seats added on the cylinder heads have an Exhaust valves 2 differ from the intake valves for
angle of: the presence of a single groove at the tip of the
stem.
- 45 for exhaust valves
- 60 for intake valves
W110R0103
The figure indicates the oil seals installed on the valve stems.
1 - 10 ENGINE W110/W110TC
Valve guides
The valve guides are not machined.
8.019 mm
8.039 mm
INTAKE EXHAUST
W110R0104
W110/W110TC ENGINE 1 - 11
Engine flywheel The same mounting distance of securing holes 2 al-

lows a random installation.
Flywheel 1 does not require a set mounting on the
crankshaft, since it has no etching, mark or reference
holes for sensors or timing.
W110R0105
NOTES:
1.3 LUBRICATION
The forced circulation lubrication is provided by the oil pressure relief valve incorporated in the oil filter
following components: connection;
rotor oil pump, located in the lower side of the cyl- by-pass valve cutting off a clogged filter, incorpo-
inder block, driven by a straight teeth gear mounted rated with the oil filter connection;
on the nose of the crankshaft;
cartridge oil filter.
water/oil heat exchanger located on the cylinder
block, with connection for oil filter;
Oil natural return ducts

Oil pressure ducts
Oil filling
W110R0106
NOTES:
1.4 OPERATION DESCRIPTION FUEL SYSTEM
Supply phase Delivery phase
1 1
2
2
3
6
4
9
7
8 5 5 3 4
W110R0107 W110R0108
1. Fuel inlet duct - 2. Solenoid valve - 3. Axial groove - 1. Fuel inlet duct - 2. Compression chamber - 3. Distribu-
4. Compression chamber - 5. Duct between pumping ele- tion piston inner duct - 4. Fuel duct between pumping
ment and injectors - 6. Distribution piston - 7. Delivery cut- element and injectors - 5. Distribution piston - 6. Injector.
off hole - 8. Sliding element - 9. Injector.
Distribution piston (6) is at B.D.C. and sliding element

(8) closes delivery cut-off hole (7).
The fuel is forwarded to compression chamber (4)
through supply duct (1) kept open by solenoid valve
(2).
Distributor piston (5) under the defect of the rotation

of the cam disc, moves toward the T.D.C. and at the
same time, rotates on its own axis. The combination
of the two movements determines the shutting-off of
fuel inlet duct (q) and at the same time, the compres-
sion oof fuel in chamber (2). Inner duct (5) of the dis-
tributor piston is connected to duct (4) providing the
delivery to injectors (6).
End of delivery phase
6 5 4 3 W110R0109
1. Fuel inlet duct - 2. Compression chamber - 3. Delivery

duct - 4. End of delivery phase - 5. Sliding element - 6.
Distributor piston.
Distributor piston (6) when moving toward the T.D.C.

connects the high pressure inner chamber through duct
(1) providing a pressure equilibrium between the inner
chamber of the distributor piston, the delivery piping
to the injectors and the inside of the pump body.
Since this pressure is lower the value activating the
injector, the delivery ends.
Engine cut-off L.D.A. device (delivery adjustment as a function of

the load)
4
3
1
2
2 3
4
5
5
6
7
8
W110R0110 W110R0111
1. Fuel inlet duct - 2. Mobile plug - 3. Spring - 4. Solenoid Operation of the L.D.A. device
valve - 5. Compression chamber.
The L.D.A. device has the purpose of changing the

The engine cut-off is provided by the cutting-off of the fuel delivery as a ratio of the air pressure monitored in
starter contact. The electric power actuating solenoid the intake manifold.
valve (4) is cut-off. The solenoid valve, under the ef- This air pressure actuates membrane (1) fitted on gov-
fect of spring (3) pushes mobile plug (2) to stroke end ernor pin (4). In the lower side of governor pin (4) a
determining the closing of fuel inlet duct (1). taper seat (5) is made on which sensor pin (6) slides.
The axial movement of governor pin (4) moves sen-
sor pin (6) that in turn actuates cut-off lever (7). The
cut-off lever turns on its axis (8) and actuates the
control plates so that the fuel deliveries are adjusted
to the quantity of air introduced into the cylinders.
Starting Starting device disengaged
6
5 3
6
5
2
1 4
7
1
7 2
4
W110R0112 W110R0113
1. Starting lever - 2. Leaf spring - 4. Sliding element - 5. 1. Starter lever -2. Leaf spring - 3. Tension lever - 4. Sliding
Governor sleeve - 6. Solenoid valve - 7. Compression element - 5. Governor sleeve - 6. Solenoid valve -
chamber. 7. Masses.
After energising solenoid valve (6) fuel enters com- Once the engine is started, governor sleeve (5) under
pression chamber (7). Under these conditions, gover- the effect of the centrifugal force caused by the ex-
nor sleeve (5) has the masses closed, thus leaf spring pansion of masses (7) starts moving axially, pushing
(2) moves lever (1) and sliding element (4) into sup- starter lever (1) against tension lever (3) thus presses
plement position. leaf spring (2).
Thus the entire stroke of the pumping element is used Under these conditions, sliding element (6) moves
as delivery for the injection. determining minimum delivery.
Beginning of delivery depending upon the load

(L.F.B.)
1 2
7 8 5
W110R0114
Structure of the governor group with correction

of the beginning of delivery depending upon the
load
1. Governor spring - 2. Governor sleeve - 3. Tension lever

- 4. Starter lever - 5. Sliding element - 6. Distributor piston
- 7. Regulator shaft - 8. Centrifugal masses.
Description
The correction of the beginning of the delivery as a
function of the load (LFB) provides a "smoother" (less
noisy) operation of the engine.
The arrangement of the LFB device is obtained modi-
fying:
The governor sleeve has a hole supplementary to
the "anti lunging" hole.
The governor support shaft with one longitudinal
hole and two cross-way holes.
The body pump with one hole, closed from the out-
side by a ball communicating with the supply cham-
ber.
Position of the governor sleeve in the LFB
1 2 3 4
5 6 7
W110R0115
a. Sleeve in rest condition - b. Moving sleeve - c. Sleeve

under correction condition, drop of internal pressure - 1.
Longitudinal hole in the governor support shaft - 2. Gov-
ernor shaft - 3. Governor sleeve cross-way hole - 4. Gov-
ernor sleeve - 5. Governor shaft cross-way hole - 6. Edge
of governor shaft - 7. Governor shaft cross-way hole.
Operation
Notwithstanding the position of the outer throttle le-
ver, when, under the increase of the rpm the governor
masses due to the centrifugal force, move governor
sleeve (4) a reduction in the delivery of fuel is deter-
mined. To provide a smoother operation of the engine
diminishing delivery a reduction of the advance must
correspond. Since in a rotary pump the advance de-
vice is hydraulically controlled, to reduce it a transfer
pressure decrement is required: this is provided by
the LFB device.
When governor sleeve (4) sliding on governor support
shaft (2) connects hole (3) with groove (6) and hole
(7) a portion of the fuel under pressure is discharged
through duct (1 and 5) in the supply chamber, causing
a drop of the transfer pressure inside the pump, thus
decreasing the advance.
Cold injection automatic advance device (KKSB)
1 W110R0116
1. KKSB bulb.
The KKSB device has the function of setting an appropriate injection advance on a cold engine.
8
Advance degrees
Starting with KKSB

6
4
SB
KK
ut
tho
2
wi
ing
art
St
0
0 500 1000 1500
RPM
Timing The timing is provided by coinciding marks () etched

on them.
The timing drive is provided by a straight teeth gear
mounted on the rear tip of the crankshaft driving the
gear mounted on the camshaft.
W110R0117
Timing of the injection pump

To set the timing of the crankshaft with the camshaft,
move the first piston to T.D.C. This condition is ob-
tained by turning the crankshaft until the pin on the
gear housing near the injection pump enters the rel-
evant seat of the camshaft gear.
When a spare injection pump is supplied as spare

part, it is already pre-set, thus it is sufficient to install
it on the timing gear, mount it on the gear housing and
remove appropriately the seal ensuring the pre-set-
ting of the pump by locking its shaft.
To check the correct timing, place a dial gauge

380000228 (2) and adapter 99395100 (1) on the pump,
as indicated in the figure.
W110R0118
Turn appropriately the crankshaft to eliminate the gear

backlash and return the engine under the conditions
of first piston at T.D.C.
The dial gauge reads the desired pre-load value (see
Repair Manual). If the prescribed value is not obtained,
loosen the screws securing the pump to the gear hous-
ing and slide the pump body on the slots until the
correct pre-load value is obtained.
When the injection pump is overhauled. it is not pre-

set, thus it is necessary to install it when the first
piston is at T.D.C. and proceed with the setting of the
pre-load value, installing the dial gauge and adapter
sliding it on the slots and secure it to the gear hous-
ing. Proceed with the check as described here above.
Electrical components Pre-post heater controller

Pre-post heater kit Controller 1 establishes the time of intervention of the
heater (pre-post heating) as a function of the signal
KKSB water temperature sensor on injection pump
received from engine coolant temperature sensor 2.
Oil pressure sensors piloting the oil pressure indi-
cator light on instrument dashboard
Thermal bulb for KKSB on injection pump
(*) Controller, engine coolant temperature sensor,

heater.
Principle diagram
W110R0119
1. Pre-post heating controller - 2. Coolant temperature sensor - 3. Heater solenoid switch - 4. Heater - 5. Preheating
dashboard indicator light.
TROUBLES POSSIBLE CAUSES REMEDIES
The engine fails to start 1. Partially discharged batteries. Check, recharge the batteries and replace them if
W110/W110TC
required.
2. Connections to the battery terminals corroded Clean, inspect, tighten fixtures and replace exces-
or loosen. sively corroded terminals and nuts, if required.
3. Wrong timing of injection pump on engine. Have a correct timing of the injection pump on the
engine.
4. Accumulation of sediments and water in the fuel Disconnect pipes, injection pump and clean them
pipes. accurately and if required, clean and dry the fuel
tank.
5. Tank out of fuel. Refill.
6. No supply to injection pump. Check fuel pump and replace it, if required.
ENGINE
7. Presence of air in the fuel system. Check pipes, connections, fuel pump, filters and
injection pump to make sure they are free from air
then bleed the system.
8. Starter motor damaged. Repair or replace the starter motor.

1.5 TROUBLESHOOTING GUIDE
9. Cold starting device inefficient. Check or replace cold starter.
1 - 25
1 - 26
The engine dies 1. Low idle too low. Adjust low idle.
2. Irregular deliveries of injection pump. Re-calibrate on bench.
3. Accumulation of sediments and water in fuel Disconnect pipes, injection pump and clean them
pipes. accurately and if required, clean and dry the fuel
tank.
4. Fuel filters clogged. Replace the filter cartridges.
5. Abnormal valve clearance. Adjust valve clearance.
6. Valves burnt or cracked. Replace valves.
7. Presence of air in the fuel system. Check pipes, connections, fuel pump, filters and
injection pump to make sure they are free from air
ENGINE
8. Injection pump controls damaged. Replace damaged parts.
W110/W110TC
The engine overheats 1. Cooling centrifugal pump inefficient. Overhaul the injection pump and replace it, if re-
W110/W110TC
quired.
2. Thermostat inefficient. Replace the thermostat.
3. Radiator partially inefficient. Eliminate any scaling by flushing. Check and re-
pair any leakage from the tubes.
4. Scaling in the coolant ducts in cylinder head and Flush accurately.

cylinder block.
5. Insufficient tension of centrifugal pump drive and Check and adjust the belt.
fan belt.
6. Coolant insufficient (quantity). Top-up level in the expansion tank using prescribed
liquid.
ENGINE
7. Wrong timing. Check and re-set timing.
8. Injection pump out of calibration both in excess Calibrate injection pump on bench complying with
and defect. the calibration tables.
9. Air cleaner clogged. Clean the group and, if required, replace filtering
the element.
1 - 27
1 - 28
The engine is under powered and 1. Wrong timing of injection pump on engine. Have the injection pump correctly timed on the en-
operates irregularly gine.
2. Advance automatic variator on injection pump Overhaul the injection pump and calibrate it on test
damaged. bench complying with the relevant calibration table.
3. Distributor pumping element worn. Overhaul the injection pump and calibrate it on test
bench complying with the relevant calibration table.
4. Injection pump deliveries irregular. Overhaul the injection pump and calibrate it on test
5. Governor damaged at all speeds. Overhaul the injection pump and calibrate it on test
6. Injectors partially clogged or damaged. Clean, overhaul and calibrate correctly the injectors.
7. Accumulation of sediments or water in fuel Check pipes, connections, fuel pump, filters and in-
ENGINE
pipes. jection pump to make sure they are free from air
8. Fuel pump damaged. Replace fuel pump.
9. Valve clearance abnormal. Adjust valve clearance.
10. Compression in cylinders insufficient. Check compression and overhaul the engine, if re-
quired.
11. Air cleaner clogged. Clean the group and replace filtering element, if
rquired.
12. Length of linkage between throttle and injec- Adjust the length of the linkage.
tion pump to be adjusted.
13. Injection pump with high idle screw out of ad- Adjust high idle screw.
justment.
W110/W110TC
The engine has abnormal knockings 1. Injectors partially clogged or damaged. Clean, overhaul and correctly calibrate the injec-
W110/W110TC
tors.
2. Accumulation of sediments in fuel pipes. Clean the pipes and replace those with consider-
able dents. Clean injection pump, if required.
3. Wrong timing of injection pump on engine. Have the injection pump on the engine correctly
timed.
4. Engine crankshaft knocking due to excessive Regrind the crankshaft journals, install oversized
play of one or more crankshaft or conrod jour- bearings and thrust bearings.
nal bearings or thrust bearings.
5. Crankshaft out of balance. Check the alignment and balance of the crankshaft
and replace it, if required.
6. Flywheel securing screws loosen. Replace loosen screws and tighten all of them to
ENGINE
the prescribed torque + angle.
7. Conrod axes out of line. Straighten the con-rods, check the parallelism of
the centre lines and replace them, if required.
8. Pistons knocking due to abnormal wear. Regrind the cylinder sleeves and install oversized
pistons.
9. Piston pins noisy due to excessive play be- Replace the piston pin with an oversized one, re-
tween piston seat and conrod bushing. Bush- bore the seats on the piston and the conrod bushes.
ing floating in conrod seat. Replace the bushes with new ones.
10. Rattling due to noisy timing. Check that there are no broken springs, there is no
excessive play between stems and guides, tap-
pets and seats. Adjust valve clearance.
1 - 29
1 - 30
The engine smokes abnormally: 1. Maximum delivery of injection pump excessive. Calibrate the injection pump on bench complying
black or dark grey smoke with the calibration table.
2. The injection pump is excessively delayed or Have the injection pump correctly timed on the
the automatic advance variator is damaged. engine and check the automatic advance variator.
3. The injection pump is excessively advanced. Have the injection pump correctly timed on the
engine.
4. Injectors partially and7or fully clogged or out of Clean, overhaul and correctly calibrate the injec-
calibration. tors. replace them, if required.
5. Air cleaner clogged. Clean the group and replace the filtering element, if
required.
6. Loss of compression on engine due to: Replace damaged parts and overhaul the engine,
- Sticky piston rings; if required.
ENGINE
- Worn cylinder sleeves;

- Valves deteriorated or out of adjustment.
7. Injection pumps damaged. Check the conditions of the pipes.
W110/W110TC
Blue, grey-blue or grey tending to white 1. The injection pump is excessively delayed or Have the injection pump correctly timed on the
W110/W110TC
smoke the automatic advance variator is damaged. engine and check the automatic advance variator.
2. Injectors seized or defective. Clean, overhaul and correctly calibrate the injec-
tors. replace them, if required.
3. Passage of oil through piston rings caused by Replace damaged parts and overhaul the engine,
sticky rings or wear of cylinder sleeves. if required.
4. Passage of oil through the intake valve guides Overhaul cylinder head.
due to wear of guides or valve stems.
5. The engine does not reach operation tempera- Replace the thermostat.
ture (thermostat damaged)
Engine does not cut-off 1. Cut-off solenoid valve damaged. Replace the solenoid valve.
ENGINE
2. Governor at all speeds damaged. Overhaul injection pump and calibrate it on test
bench complying with the relevant calibration ta-
ble.
1 - 31
NOTES:
DATA - MOUNTING PLAYS
Type F4GE0484E
CYLINDERS AND CRANKING COMPONENTS GROUP mm

1
Cylinder sleeves 1 102.01 to 102.03
Pistons: supplied as spares

1
parts type
X Position of measurement X 61
Outer diameter 1 101.777 to 101.795
2
Pin seat 2 40.006 to 40.012
Piston - cylinder sleeve 0.215 to 0.253
Diameter of pistons 1 0.5
Position of pistons in cylinder block X 0.28 to 0.52
3 Piston pin 3 39.9968 to 40.0032
Piston pin - pin seat 0.0028 to 0.0152
Type of piston
X1 X1* 2.69
X2 Piston rings seat X2* 2.425 to 2.445
X3 X3* 4.04 to 4.06
* measured on the 99 mm diameter
S1* 2.560 to 2.605

S1 Piston rings S2* 2.310 to 2.340
S2
S3 S3* 3.075 to 4.000
* measured on the 99 mm diameter
Type F4GE0484E
1 0.245 to 0.265
Piston rings - seats 2 0.085 to 0.135
3 0.040 to 0.985
Piston rings 0.5
Gap and end of piston rings in the

X1
X2 cylinder sleeves:
X3 X1 0.40 to 0.70
X2 0.25 to 0.55
X3 0.25 to 0.55
1
Conrod small end bush seat 1 42.987 to 43.013
Conrod large end bearing seat 2 77.075 to 78.25

2
3
Diameter of conrod small end bush
Outer 4 43.279 to 43.553
Inner 3 40.019 to 40.033
S
Conrod half bearings 1.955 to 1.968
Conrod small end bush - seat 0.266 to 0.566
Piston pin - bush 0.0158 to 0.0362
Type F4GE0484E
Position of measurement X -
Maximum error on parallelism

of conrod axes = -
1 2
Main journals 1 82.99 to 83.01
Conrod journals 2 68.987 to 69.013
Main journal half bearings S1* 2.456 to 2.464
S1 S2
Conrod half bearings S2* 1.955 to 1.968
* supplied as spare part
Main journal no.:

3 no. 1 - 5 3 87.982 to 88.008
no. 2-3-4 3 87.977 to 88.013
Half bearings - main journals:

no. 1-5 0.041 to 0.119
no. 2-3-4 0.041 to 0.103
Half bearings - conrod journals 0.033 to 0.041
Main journal half bearings

+ 0.250; + 0.500
Conrod journals bearings
Thrust main journal X1 34.475 to 37.545

X1
Main journal for thrust bearing X2 25.98 to 26.48
X2
X3
Thrust half rings X3 37.28 to 37.38
Crankshaft thrust 0.068 to 0.41
Type F4GE0484E
CYLINDER HEAD - TIMING mm

1
Valve guide seat on cylinder head 1 8.019 to 8.039
4 Valves:
4 7.96 to 7.98
60
4 7.96 to 7.98
45
Valve stem and relevant guide 0.052 to 0.092
Seat on cylinder head

for valve seat:
1 46.987 to 47.013
1 1 43.637 to 43.663
2
Valve seat outer diameter; angle of
valve seats on cylinder head: 2 47.063 to 47.089
60

2 43.713 to 43.739
45
Recess X 0.356 to 1.102

X X 0.104 to 0.84
Between valve seat 0.050 to 0.102

and head 0.050 to 0.102
Valve seats - -
Type F4GE0484E
Height of valve spring:
free length H 63.5
H under a load of:

H1
H2 329 H1 49.02
641 H2 38.2
Protrusion of injectors X not adjustable

X
Camshaft bushes
-
no. 1-5
Camshaft seats
1 2 3 4 5 -
no. 2-3-4
Camshaft support
journals:
1 3 15 53.995 to 54.045
Camshaft bushes outer diameter -
Bushes inner diameter -
Bushes and seats in cylinder block -
Bushes and journal 0.038 to 0.162
H Cam lifting:
-
-
Type F4GE0484E
Seat of tappet plate

in cylinder block 1 -
Outer diameter tappet plate:

2 15.929 to 15.959
3 15.965 to 15.930
Between tappets and seats 0.025 to 0.070
Tappets -
Rocker arm shaft 1 18.963 to 18.975
Rocker arms 2 19.000 to 19.026

2
Between rocker arm and shaft 0.025 to 0.063
1.6 ENGINE OVERHAUL ON BENCH
Disassembly of engine 3 2 1
4
13
5
12
11
6
10
7
1
9
8
W110R0122
W110R0120
- remove engine oil fume recovery pipe from blow-

Drain the engine oil by removing the sump plug and by (1);
the engine oil filler neck from the cylinder head cover. - remove rocker arm cover (4);
Remove the fan group from the fan pulley. - remove electric harness (8);
In order to install the stand mounting bracket 75301886 - remove fuel filter (9);
to the engine cylinder block, it is necessary to oper- - remove intake manifold (3);
ate on the left side of the engine as follows: - remove heater (5);
- remove electric harness (1). - remove LDA system (13);
- remove quick release coupling pipes (7), (10), (11)
and (13);
- remove fuel filter support (6).
7
1
A B
6
2 1
3 5
4
W110R0121
To install bracket 75301886 on the right side, remove:

W110R0123
- starter motor (3);
- securing bracket (2) of oil return pipe (1);
- the oil return piping (1) relative to the turbine; Move fork (1) as indicated in the figure (item A) and
- remove oil pipes (4) and (5) from heater exchanger remove the connection. To prevent deformations when
(6). the connection is removed, return fork (1) into the lock-
ing position (item B).
Install the engine on rotary stand 75296375.
- disconnect turbine lube oil delivery (7);
1 2 3 9
6 1
2
4
3 7
5 6
4 W110R0124 W110R0127
- Disconnect supply pipes (5) of injectors (5) from - Remove belt tensioner (4).
injection pump (6). Remove pipe groups securing - Remove auxiliary organs belt (6) moving bracket
brackets on the cylinder head (1) (2) and (3). (1) securing the alternator.
- Remove fuel pump (4). - Remove alternator (2) water pump (5) fan pulley (8)
and guide pulleys (7).
- Remove pulley support (9).
- Remove engine cooling system connection (3) from
the cylinder block.
1
2
4
W110R0125
- Remove injector supply pump group (1) from the

1
injectors.
- Remove fuel return pipe (2) from the injectors re- W110R0128
moving screws (4) and gasket (3).
Install tool (1) 380000144 on the flywheel housing to
block the flywheel.
1
2
3
W110R0126
- Remove screws (3) and remove turbine (2).

- Remove exhaust manifold (2).
2 1
2
W110R0129 W110R0131
Remove securing screws (1) from pulley (2). Install the appropriate puller (3) of tool 380000669 to
outer seal (2) as described in the figure and pull it out
from front cover (1) using lever (4).
Remove the front cover.
Replacing the seal
3 1
4
5 W110R0130
W110R0132
Install tool (4) 380000665 on nose (2) of the crank-
shaft. Remove oil gear pump (1).
Drill inner seal ring (1) with a drill (3.5 mm diam.)
through the holes of tool 380000665 (4) for a depth of Important Oil pump (1) cannot be overhauled.
5 mm.
Install tool 380000665 (4) on ring (1) tightening the 6
screws (5) provided.
Pullout ring (1) tightening screw (3).
Removal of injection pump A B

2
4
1
2
W110R0135
W110R0133 - Remove cover (1) from gear housing (2).

- Lock the engine flywheel.
Prior to removing the injection pump and the flywheel - Remove nut (3) securing the injection pump drive
locking tool. gear (4).
Turn the crankshaft until the 1st cylinder is at T.D.C.
The condition of cylinder no. 1 in T.D.C. is obtained
when pushing pin (1) indicated by the arrow enters its
seat located on camshaft drive gear (2).
2
1
3
5
W110R0136
1 2 Remove the three nuts (2) (4) (5) securing injection

pump (1) to flywheel housing (3) and pull-it out from
W110R0134 its seat using tool 75295944.
To pre-set correctly the injection pump, loosen screw

(2) and remove (1) "L" spacer.
Retighten screw (2) to contact.
Important Keep the "L" spacer appropriately with

the pump body.
1
3 2
3
2
4
W110R0137 W110R0139
Install tool 380000144 (2) to loosen screws (3). Install tool 380000663 (3) on rear nose (5) of the crank-
Remove tool 380000144 (2). shaft.
Remove screws (3) securing engine flywheel (4) to Drill inner seal ring (1) with a drill (3.5 mm diam.)
the crankshaft. through the holes of tool 380000663 (4) for a depth of
5 mm.
Install tool 380000663 (3) on ring (1) tightening the 6
screws (4) provided.
Pullout ring (1) tightening screw (2).
1
2 1
2
3 3
W110R0138
Install two pins (2) of appropriate length into the holes 4

of crankshaft (3).
Extract engine flywheel (1) so that it is possible to W110R0140
sling it with a hoist and place it in an appropriate con-
tainer. Install the appropriate puller (3) of tool 380000669 to
outer seal (2) as described in the figure and pull it out
from front cover (1) using lever (4).
1
1
2
2
3
W110R0141 W110R0145
Remove screws (2) and remove rear cover (1). Remove screws (1) and gear (3) from camshaft (2).
Important Record the mounting position of screws

(2) since the are dimensionally different.
Removal of rocker arm group
1
1
2 2
3
4
W110R0146
W110R0142
For each cylinder, remove rocker arm group (1) loos-
Turn the engine upside down, remove screws (2) plate ening setting nuts (3), loosen adjusters (2) and re-
(3) and remove oil sump (1). move screws (4).
1 5
3
W110R0143
Remove screws (1) and (4) and remove oil suction

strainer (5).
Remove screws (2) and stiffening plate (3).
1
2
2
W110R0147 W110R0150
Pullout injectors (2) using tool (1) 3800001099. Remove screws (2) and remove timing gears cover
(1).
Important Record the mounting position of secur-

ing screws (2) since they have different dimensions.
1
W110R0148
Remove screws (1) securing the cylinder head to the 2

cylinder block.
W110R0151
Remove screws (1) securing conrod (2) caps and re-

move the caps.
2 Pullout the pistons complete with conrods from the
1 top of the cylinder block.
Important Keep the half bearings in the relevant

seats, since, in case of their re-use, they must be
reinstalled in the position found at the disassembly.
W110R0149
Hook the cables to brackets (1) and (2) and lift to

separate the cylinder head from the cylinder block.
1 1 2
3
W110R0152 W110R0155
Remove screws (1) and remove main journal caps Remove main journal half bearings (1).
(2). Remove screws (2) and remove oil nozzles (3).
2
2 1
W110R0153 W110R0156
The last but one main journal (1) and relevant support Remove screws (1) and plate (2) securing camshaft
have a half bearing (2) equipped with thrust washer (3).
Important Record the installation position of the Important Record the installation position of plate
lower and upper half bearings, since in case of their (2).
reinstallation, they must be located in the same posi-
tion found at the disassembly.
3
1
W110R0157
W110R0154 Extract carefully the camshaft from the cylinder block.
Use tool 75301429 (1) to lift crankshaft (2) from the

cylinder block.
W110R0158 W110R0160
Extract (1) from the cylinder block. The measurements must be done on each single cyl-
inder, at three different heights of the sleeve and on
two planes perpendicular between them: one parallel
to the longitudinal axis of the engine (A) the other one
perpendicular (B). The maximum wear is normally
Repair interventions on cylinder group
found on the latter plane and in correspondence with
Inspections and measurements the first measurement
Once the disassembly of the engine is over, clean In the event an out-of round, tapering or any wear is
accurately the cylinder-cylinder block group. found, re-bore and re-grind the cylinder sleeves. The
To handle the cylinder group use appropriate eyes. reboring of the cylinder sleeves must be done in rela-
Check accurately that the cylinder block is free from tion with the diameter of spare pistons oversized
cracks. 0.5 mm with respect to the nominal size and the pre-
Check the conditions of the machining plugs. Should scribed installation clearance.
they be found rusty or their sealing is in doubts, re-
place them.
Inspect the surface of the cylinder sleeves. They must
be free from signs of seizing, scratches, out-of-round,
tapering or excessive wear.
1
2
1
2
W110R0159
The measurement of the inner diameter of the cylin-

der sleeves, the amount of any out-of-round, tapering
or wear is done with bore gauge 99395687 (1) equipped
with a dial gauge previously zeroed on caliper ring (2)
with the correct diameter of the cylinder sleeve.
Note Should the ring caliper be unavailable, use a

micrometer to zero the dial gauge.
Checking the mating face of the cylinder head

on the cylinder block
1.25 0.25 mm
Rz 12.0 ISO CUT OFF 2.5
3
1
W110R0162
Check that the mating face of the cylinder head on

the cylinder group does not show any deformation.
This check can be done, after removing dowels (4)
using a calibrated ruler (2) and feeler gauge (3).
After identifying any zone of deformation, grind the
mating face using an appropriate grinding machine.
The planarity discrepancy must not exceed 0.075 mm.
Note the grinding of the cylinder block can be done

only when it is ascertained that, once the work is done,
the protrusion of the piston from the cylinder sleeve
W110R0161
does not exceed the prescribed value.
Important In case of re-boring, all the cylinder Check the conditions of machining plugs (1) of the
sleeves must have the same oversizing (0.5 mm). cylinder group. Should they be found rusty or their
sealing is in doubts, replace them.
Check the seats of the main journal bearings, pro- Once the grinding is over, remake the bevel of the
ceeding as follows: cylinder sleeves.
- install the main journal caps without bearings;
- tighten the securing screws to the prescribed
torque;
- using an appropriate bore gauge, check that the
diameter of the seats has the prescribed value.
Should a higher value be measured, replace the cyl-

inder block.
Timing
Camshaft
53.995 mm
54.045 mm
W110R0163
Camshaft main data
The data provided refer to the normal diameter of the journals.
The surfaces of the camshaft journals must be ex-

tremely smooth. Should they show any trace of sei- 1
zure or scratches, it is advantageous to replace the
camshaft and relevant bushes. 2
Checking the cam lifting and journals alignment
Place the camshaft on centres and using a centesimal
dial gauge located on the central journal, check that
the alignment error does not exceed 0.04 mm, other-
wise, replace the camshaft. Also, check the cam lift-
ing. It must result 7.239 mm for the exhaust cams W110R0164
and 6.045 mm for the intake ones. Should different
values be measured, replace the camshaft. Check the diameter of camshaft journals (2) using
micrometer (1) on two axes perpendicular between
them.
Bushes
Camshaft bushes (2) must be tight mounted into their
seats.
The inner surfaces must be free from traces of sei-
zure or wear.
Measure the diameter of the camshaft front and rear
bushes (2) and intermediate seats (1) using bore gauge 1 3
(3).
The measurements must be taken on two axes per-
2
pendicular between them.
W110R0165
Sect. A-A
54.089 mm
54.139 mm
59.222 mm
59.248 mm
54.083 mm
54.147 mm
W110R0166
Main data of bushes for camshaft and relevant seats
* Dimension to be obtained after press fitting the bushes.
Replacing the bushes Installing the tappets -Camshaft
1
3
2
W110R0167 W110R0168
Use punch 75301885 (2) and handle 380000668 (3) to Lubricate tappets (1) and install them into the relevant
remove and install front and rear bushes (1). seats on the cylinder block.
Important - When installing bushes (1), place the so

that the lubrication holes coincide with the holes on
the cylinder block seats.
Tappets
16.000 mm
16.030 mm
15.929 mm
15.959 mm
W110R0170
15.965 mm
15.980 mm Lubricate the camshaft journals and install the cam-
shaft, paying attention that, during this operation, the
15.929 mm
15.959 mm bushes and the journals are not damaged.
W110R0169
Main data of tappets and relevant seats on the cyl-

inder block
Crankshaft
Measuring main and conrod journals
1
1
2
2
W110R0171
Place plate (1) securing camshaft (3) with the slot

directed toward the upper side of the cylinder block W110R0174
and the stamping toward the operator, tighten screws
(2) to the prescribed torque. Should excessive traces of seizing, scratches or out
of round be found, it is necessary to re-grind the jour-
nals. Prior to grinding journals (2) measure the crank-
shaft journals with micrometer (1) and define to what
diameter the journals must be undersized.
Note It is recommended to record the values meas-

ured on a table.
W110R0172
Check the axial play of camshaft (1).
2
W110R0173
Install nozzles (2) and tighten securing screws (1) to

the prescribed torque.
The undersizing classes are 0.250; 0.500 mm. For undersized conrod journals by letter M.
For undersized main journals by letter B.
Important The main and conrod journals must al- For undersized main and conrod journals by letters
ways be reground to the same undersize class. MB.
The undersizing performed on the main and conrod
journals, must be identified by an appropriate stamp-
ing on the side of crank no. 1.
82.99 mm
83.01 mm
68.99 mm
69.01 mm
W110R0175
Data on which to record the values relative to the measurement of crankshaft main and conrod journals
* Nominal value.
W110R0176
Main crankshaft tolerances

Tolerances Features of the subject of tolerance Symbol
Roundness O
Shape
Cilindricity /O/
Parallelism //
Direction Perpendicularity
Straightness
Position Concentricity or radial run-out
Circular oscillation
Oscillation Total oscillation
Tapering
Class of importance given to the feature of the product Symbol

Critical
Important
Secondary c

Journal Intermediate First journal

timing side journals upper side
W110R0177
Replacing the oil pump drive gears Measuring the main journal mounting clearance
3
1
1
2
3
W110R0178 W110R0180
Check that the teeth of gear (1) installed on crank- Install crankshaft (1) on which gears (2) and (3) are
shaft (2) are undamaged and free from wear; other- mounted.
wise pull them using puller (3).
When installing a new gear, it is necessary to warm it
up for 10 minutes in an oven at a temperature of
180 C (355 F) and install it on the crankshaft, mount-
ing the key as well.
2
Installing the main journal bearings
3
4
1
W110R0181
Check the clearance between main journal of the

crankshaft and the relevant bearings, operating as
follows:
- clean accurately the components and eliminate all
races of oil;
W110R0179
- place a piece of calibrated rod (3) on crankshaft
main journals (4) parallel to the longitudinal axis;
Important When it is found that the main journal
- install caps (1), complete with half bearings (2) on
bearings must not be replaced, they are reinstalled in
the relevant supports.
the same sequence and position they were before the
disassembly.
Main journal bearings (1) are supplied as spare parts

undersized 0.250 to 0.500 mm on the inner diameter.
Important Do not attempt adapting the bearings.
Clean accurately main journal half bearings (1) hav-

ing the lube hole and install them in the relevant seats.
The last but one main half-bearing (1) is equipped with
thrust half rings.
1
2
W110R0182 W110R0184
Tighten screws (1) pre-lubricated and tighten them in - remove the caps from the supports.
three subsequent phases.
- 1st phase with torque wrench to 50 6 Nm. The play between main journal bearings and the rel-
- 2nd phase with torque wrench to 80 6 Nm. evant journals is measured by comparing the width
taken by calibrated wire (2) in the point of maximum
squeezing, with the scale provided on wrapping (1)
containing the wire.
The numbers listed by the scale indicate the clear-
ance in mm of the match.
1
Should a clearance different from the prescribed value
be measured, replace the half bearings and repeat
the measurement. Once the prescribed clearance is
achieved, lubricate the main journal bearings and in-
stall definitely the supports, tightening the securing
2 screws, as previously described.
W110R0183 Checking the crankshaft thrust clearance

- 3rd phase with tool 75301460 (1) installed as indi-
cated in the figure and tighten screws (2) further to
an angle of 60 5.
1
2
3
W110R0185
The measurement of the thrust clearance is made by

placing a dial gauge (2) with a magnetic base on crank-
shaft (3) as indicated in the figure. Normal mounting
clearance is 0.068 to 0.410 mm.
Should a higher clearance be measured, replace the
half bearings on the rear last but one main journal (1)
equipped with thrust washer and repeat the check of
the clearance between crankshaft journals and half
bearings.
Conrod - Piston assembly
3 4
7
5
8
1
6
W110R0186
Parts making up the conrod piston assembly
1. Circlips - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws - 6. Half bearings - 7. Conrod - 8. Bush.
Note 0.5 mm oversized pistons are supplied as spare parts.
2 1
3
2
3
W110R0187 W110R0188
Disassembly of piston rings (1) from piston (2) using The disassembly of piston pin (1) circlips (2) is done
pliers 380000221. using scriber (3).
2.425 mm 4.040 mm
2.69 mm
2.560 mm 2.445 mm 4.060 mm
2.605 mm
2.310 mm
2.340 mm
3.075 mm
40.0060 mm 39.9968 mm
4.000 mm
40.012 mm 40.0032 mm
W110R0189
Piston main data
Pistons
Measuring the piston diameter
W110R0190 W110R0191
Measurement of the diameter of piston (1) using mi- The clearance between piston and cylinder sleeve can
crometer (2) to determine the mounting clearance. be measured also using feeler gauge (1) as indicated
in the figure.
Note The diameter must be measured at 61 mm
from the skirt of the piston.
Piston pins
1
2 2
1 3
1
W110R0195
W110R0192 Check the clearance between piston ring (3) of the

3rd groove and the relevant seat on piston (2) with
Measuring the diameter of piston pin (1) using mi- feeler gauge (1).
crometer (2).
Conditions for a correct pin-piston matching 1
1
3
2
W110R0196
Diagram for the measurement of clearance X -

W110R0193
Trapezoidal rings
Lubricate pin (1) and the relative seats on the piston
bosses with engine oil. The pin must slide in under a Due to the particular shape of the first trapezoidal
light finger pressure and must not come-out under its piston ring, the clearance between seat and the ring
own weight. itself is measured in the following manner: have pis-
ton (1) protruding from the cylinder block so that ring
(2) involved protrudes about half from cylinder sleeve
(3).
Piston rings Under these condition, use a feeler gauge to measure
clearance (X) between ring and seat. Such clearance
must be of the prescribed value.
W110R0194
Check the thickness of piston rings (2) using microm-

eter (1).

3
W110R0197 CONROD BODY
CONROD
Measuring the clearance between the tips of piston WEIGHT
No.
rings (2) installed into cylinder sleeve (3) using feeler
gauge (1).
Conrods
42.987 mm
43.013 mm
CONROD CAP
CONROD No. YEAR DAY

43.279 mm 40.019 mm 39.9968 mm
43.553 mm 40.033 mm 40.0032 mm
W110R0199
Important Each conrod is marked:

On the body and cap, by a number indicating their
matching and the cylinder in which it is installed.
Thus, in case of replacement, it is necessary to pro-
ceed with the numbering of the new conrod with the
same number of the one replaced.
1.955 mm On the conrod body, a letter indicates the weight class
77.075 mm 1.968 mm
78.250 mm
of the conrod installed in production:
W110R0198 - V, 1820 to 1860 (identified by a yellow mark);
- W, 1861 to 1900 (identified by green mark),
Main data for conrod, piston pin bush and half - X, 1901 to 1940 (identified by blue mark).
bearings Spare conrods are supplied under class W and marked
green*.
* Dimension of inner diameter to be obtained after Non removal of material is allowed.
press fitting into the bush conrod big end and re-bor-
ing.
** Dimension not measurable under free state.
Important The conrod-conrod cap matching surfaces

are knurled to improve the fitting.
Consequently, it is recommended not to remove the
knurling.
Bushes Check of torsion

Check that bush in the big end of the conrod is not
free and that is free from scratches or seizing. Other-
wise, replace it. 1
The disassembly and reassembly are done using an 2
appropriate punch. B
A
During the press fitting make sure scrupulously that
3
the oil passage holes on the bush and the conrod big
5
end coincide. Use a boring machine to re-bore the 4
bush, so that the prescribed diameter is obtained.
Checking the conrod

W110R0201
Check the torsion of conrod (5) comparing two points

(A and B) of pin (3) on the horizontal plane of the
conrod axis.
Place support (1) of dial gauge (2) so that the latter is
1 pre-loaded ~ 0.5 mm on pin (3) in point (A) and zero
dial gauge (2).
2 Move mandrel (4) with conrod (5) and compare on the
5
3 opposite side (B) of pin (3) for any discrepancy: the
4 difference between (A and B) must not exceed 0.08
mm.
W110R0200
1
Check the parallelism of the conrod (1) axes using 2
device 75301461 (5) operating as follows:
C D
- install conrod (1) on the mandrel of tool 75301461
(5) and secure it with screw (4);
- place mandrel (3) on V blocks resting conrod (1)
5
on stopping bar (2). 3
4
W110R0202
Checking the flexion

Check the flexion of conrod (5) comparing two points
(C and D) of pin (3) on the vertical plane of the conrod
axis. Place vertical support (1) of dial gauge (2) so
that the latter rests on pin (3) point (C). Oscillate the
conrod for and back searching for the highest posi-
tion of the pin and under this condition, zero the dial
gauge (2). Move the mandrel with conrod (5) and re-
peat on the opposite side (D) of pin (3) the check of
the highest point. The difference between point (C)
and point (D) must not exceed 0.08 mm.
Installing the conrod-piston assembly Installing the piston rings

Conrods-bearing matching
1
1
2
2
FRONT 3 W110R0206
W110R0203
To install piston rings (1) on piston (2) use pliers
The following references are etched on the ceiling of 380000221.
the piston:
1. Spare part number and number of the engineering The rings must be installed with the wording TOP
modification; upward. Also arrange the ring gaps so that they offset
2. Date of manufacture 1200 among them.
3. Wording indicating the mounting sign of the piston
into the cylinder sleeve. It must be directed toward Important Piston rings are supplied as spare parts
the front side of the cylinder block. in the following dimensions:
- standard, identified by yellow paint;
- oversized 0.5 mm marked by yellow/green paint.
1
FRONT
2
4 1
5
W110R0204
1
Connect piston (2) to conrod (4) with pin (3) so that
reference marking (1) for the installation of piston (2)
into the cylinder sleeve and digits (5) stamped on W110R0207
conrod (4) are seen as indicated in the figure.

Install half bearings (1) both on the conrod and the
cap.
Important In the event the conrod bearing do not

need replacement, they must be reinstalled in the
1 identical order and sequence found at the disassem-
bly.
2 Do not attempt any adjusting operation.
W110R0205
Insert circlips (2) securing pin (1).
Installation of conrod/piston assemblies into the Measuring the mounting clearance of the conrod
cylinder sleeves journals
1 2
2 4
W110R0208 W110R0210
Lubricate well the pistons, including the piston rings To measure the clearance, operate as follows:
and inside the cylinder sleeves. - clean accurately the parts and eliminate all traces
Using band 380000220 (2) install conrod-piston as- of oil;
semblies (1) into the cylinder sleeves, checking that: - place a piece of calibrated wire (2) on conrod jour-
- the number of each conrod corresponds to the nals (1);
matching number on the cap; - install conrod caps (3) with relevant half bearings
(4).
FRONT 2
W110R0209
W110R0211
Mounting diagram of conrod-piston assembly in

the tunnel - tighten screws (1) previously lubricated with engine
oil using torque wrench (2) to the prescribed torque.
- the gaps of the piston rings are offset 120 among
them;
- the conrod-piston assemblies are all of the same
weight;
- the wording stamped on the top of the pistons is
directed toward the front side of the cylinder block
or the indent on the skirt of the piston corresponds
to the position of the oil nozzles. 1
W110R0212
- install tool 75301460 (1) on the socket wrench and

tighten screws (2) to the angle.
Checking the piston protrusion

2
1 3
2
1
W110R0213
W110R0215
- remove the cap and determine the clearance by
comparing the width of calibrated wire (1) with the
Once the installation of the conrod-piston assemblies
values of the scale provided on wrapping (2) con-
is completed, check the protrusion of pistons (3) at
taining the wire.
T.D.C. with respect to the upper face of the cylinder
block, using dial gauge 380000228 (1) equipped with
base 380000364 (2).
It must be 0.28 to 0.52 mm.
Timing
Timing gear housing
1
W110R0214
If the clearance is not as prescribed, replace the half

bearings and repeat the check.
Once the prescribed clearance is obtained, lubricate W110R0216
the conrod half bearings and install them permanently

tightening the screws securing the conrod caps, as Diagram for the application of sealant Loctite 5999
prescribed.
Clean accurately timing gear housing (1) and the en-
Important Prior to the final installation of the conrod gine cylinder block.
securing screws, check that their diameter measured The cleaning of the surface to be sealed is required
the centre of the threaded length is not smaller than and indispensable to provide an effective sealing.
0.1 mm of the diameter measured about 10 mm from Apply sealant Loctite 5999 on the housing so as to
the tip of the screws. form a bead a few mm diameter. It must result uni-
form (no lumps) free from air bubbles, thin zones or
Check manually that conrod (1) slide axially on the discontinuities.
crankshaft and that the axial play measured with feeler Any imperfection must be corrected as soon as pos-
gauge (2) is 0.10 to 0.33 mm. sible.
Avoid using material in excess to seal the joint.
Excessive sealant could escape on both sides of the
joint and clog lube passages.
After completing the application of the sealant, the
joints require an immediate installation (10 to 20 min-
utes).
3
1
4
2
W110R0217 W110R0219
Tightening diagram for rear gear housing secur- Direct crankshaft (4) and camshaft (2) so that when
ing screws installing on the latter driven gear (1) the marks
stamped on gears (1 and 3) coincide.
Reinstall the housing on the engine cylinder block.
Tighten the securing screws in the position found at
the disassembly to the prescribed tightening torque.
Setting the timing
1
1
W110R0218 W110R0220
Use a felt pen to mark the tooth of drive gear (1) in- Install screws (1) securing gear (2) on camshaft (3)
stalled on crankshaft (2) on the side face of which and tighten them to the prescribed torque.
timing mark () is stamped.
Injection pump Phase I
2
1
2
W110R0223
W110R0221
Install gear (1) driving the pump and manually tighten
nut (2).
Bring the first cylinder to T.D.C. The condition occurs
when pin (1) indicated by the arrow enters the seat on
camshaft drive gear (2).
Flywheel housing
1
1
2
W110R0224
W110R0222
Diagram for the application of sealang Loctite 5999
Install injection pump body (1) in gear housing (2) seat
and secure it with screws (3). Clean accurately flywheel housing (1) and the timing
gear housing.
The cleaning of the surface to be sealed is required
and indispensable to provide an effective sealing.
Apply sealant Loctite 5999 on the housing so as to
form a bead a few mm diameter. It must result uni-
form (no lumps) free from air bubbles, thin zones or
discontinuities.
Any imperfection must be corrected as soon as pos-
sible.
Avoid using material in excess to seal the joint.
Excessive sealant could escape on both sides of the
joint and clog lube passages.
After completing the application of the sealant, the
joints require an immediate installation (10 to 20 min-
utes).
Engine flywheel
1
2
1
W110R0225
W110R0227
Tightening diagram for flywheel housing secur-
ing screws
Check that the clutch disc contact face is free from
Reinstall housing (1) on the cylinder block, tightening scratches, otherwise it is necessary to re-machine it.
the securing screws in the position found at the dis-
assembly to the prescribed torque. Note The nominal thickness of the engine flywheel
is 51 mm.
Screws:
- M12 x 1.75 x 100 80 10 Nm Replacing the engine flywheel ring gear
- M16 x 1.50 x 80 200 20 Nm Check the conditions of the teeth of ring gear (2).
- M16 x 1.50 x 100 200 20 Nm Should breakages or excessive wear of the teeth be
- M12 x 1.75 x 78 80 10Nm found, remove it from flywheel (1) using a punch and
install a new one, previously warmed-up to 150 C
(300 F) for 15 to 20 min. The bevel on the inner diam-
eter of the ring gear must be directed toward the en-
7 gine flywheel.
1
3
4
1
6
5 3
W110R0226
Install part (5) of tool 380000666 on rear nose (6) of

the crankshaft and install on it a new seal (3).
2
Position item (1) on item (5) tightening nut (2) until
W110R0228
seal (3) is fully installed into flywheel housing (7).
Install two pins (2) of appropriate length into the holes

of crankshaft (3) and use an appropriate sling and
hoist to lift flywheel (1).
Injection pump Phase II

4 Installation of injection pump Phase II
1
3
2 1
W110R0229
2
Install tool 380000144 (2) on flywheel housing (1) to
prevent the rotation of flywheel (4). W110R0231
Install screws (3) securing engine flywheel (4) on the

crankshaft. Torque tighten nut (1) with torque wrench (2).
A 1 B 2
1
2
W110R0232
W110R0230
Spread sealant (1) as indicated in the figure and in-

Tighten screws (1) securing engine flywheel (2) in two
stall cover (2) tightening the screws to torque.
phases:
- 1 st phase, tightening with torque wrench to
30 5 Nm;
- 2nd phase, angle tightening to 60 5.
Important The angle tightening is done with tool

75301460.
2
1
W110R0233
Remove pin (1) from the timing gear seat.

Remove pre-setting screw (2) and insert L spacer
(1). Retighten the screw until contacts. Perform the
check of the correct timing as indicated at page 1-23.
Installation of oil and water pump
2
1
2
W110R0237
W110R0234
Remove gasket (2) from front cover (1). Clean accu-
rately the matching face and apply sealant Loctite
Install oil pump (1). 5999 on it.
Install securing screws (2) and tighten them to the
prescribed torque.
1
1
W110R0238
W110R0235
Clean accurately the face of the cylinder block where
front cover (2) is installed and install it.
Install a new gasket (2) on water pump (1). Install screws (1) and tighten them to the prescribed
torque.
1 2
3
2 4 6
W110R0236
5
W110R0239
Install water pump (1).
Install screws (2) and tighten them to the prescribed Install item (5) of tool 380000666 on front nose (6) of
torque. the crankshaft. Secure it with screws (4) and install it
on new seal (3). Place item (1) on item (5) tightening
(2) until seal (3) is fully installed into front cover (7).
1
1 5
2
4
3 3
W110R0240 W110R0243
Install plate (3) strainer (5) and install securing screws Install oil sump (1) and install on it plate (3).
(2, 4 and 1) and tighten them to the prescribed torque. Install screws (2) and tighten them to the prescribed
torque.
Screws:
- M10 x 1.50 x 70 70 5 Nm
- M10 x 1.50 x 45 50 5 Nm
- M10 x 1.50 x 100 70 5 Nm
- M10 x 1.50 x 90 70 5 Nm
1 3
W110R0242
3
Install seal (1) on oil sump (2). 4
2
Important When the seal does not show abnormal 4
signs it can be reinstalled.
W110R0244
Install pulley (1) equipped with spacer (2) on the crank-

shaft and tighten the screws to torque and angle us-
ing tool 75301460.
.
Secure guide pulleys (4) to the front cover using
screws (3) and tighten them to torque.
Installation of water/oil heat exchanger

2
1 1
2
3
W110R0248
W110R0245
Reinstall alternator (1) on alternator support (3).
Install screws (2) without torque tightening them.
Install a new gasket (1) heat exchanger (2) a new
gasket (3) and oil filter support (4) on the cylinder
block.
Install screws (5) and tighten them to the prescribed
torque. Cylinder head
Removal of the valves
4
2
1 1 3
3
2
W110R0246
5
W110R0249
Lubricate seal (1) with engine oil and place it on oil
pipes connection (2).
Install oil tubes connection (2) on support (4). The removal of the valves is done using tool 380000302
Place a new seal (3) in the seat of the cylinder block. (1) pressing plate (3) so that when pressing springs
(4) it is possible to remove half-cones (2). Then re-
move plate (3) and springs (4).
Repeat the operation for all the valves.
2 3
4
W110R0247
Arrange alternator support (1) so that pins (3 and 4)

be against the cylinder block.
Install screws (2) and tighten them to the prescribed
torque.
1 3
1
2
W110R0250 W110R0252
Extract oil seals (1) installed on the valve stems. Remove thermostat group (2) and brackets (1) and
To remove the valves, turn the cylinder head upside (3).
down as required.
Important Identify the exhaust and intake valves

prior to disassembling them.
Inspection of the cylinder head matching face
1
3 1 W110R0253
INTAKE EXHAUST
W110R0251 The inspection of matching face (1) of the cylinder
head to the cylinder block is done using a ruler (2)
Besides the dimensions of the mushroom head ex- and feeler gauge (3).
haust valves differ from the intake valves for the pres- The deformation measured on the entire length of the
ence of supplementary groove (1) on the intake valve cylinder head must not exceed 0.20 mm.
stem. With higher values, regrind the cylinder head in ac-
cordance with the values and notices of the figure to
follow.
Check of hydraulic tightness of cylinder head Valves

Check the tightness of the cylinder head with appro-
EXHAUST VALVE INTAKE VALVE
priate tooling. 7.96 mm 7.96 mm
Pump warm water at 90 C (195 F) at a pressure of 7.98 mm 7.98 mm
2 to 3 bar.
Should leakages occur from the machining plugs, re-
place them using an appropriate punch to remove and
install them.
Important Prior to the installation of plugs, apply

hydro reactive sealing on their sealing faces. 41.87 mm 44.87 mm
42.13 mm 45.13 mm
In case of leakage from the cylinder head, replace it. W110R0255
Main data for intake and exhaust valves
Cleaning inspection and grinding of valves
W110R0254
The nominal thickness (A) of the cylinder head is

95 0.25 mm. The maximum metal grinding depth
W110R0256
allowed must not exceed thickness (B) of 0.13 mm.
Remove carbon deposits from the valves using an
Important After the grinding, check the recess of
appropriate metal brush.
the valves and regrind the valve seats, if required, to
Check that the valves do not show signs of seizing,
the prescribed value.
cracking or burning.
When required, regrind the valve seats using grinder
75301453 removing the least amount of material as
possible.
Valve guides
8,019 mm
1 8,039 mm
W110R0257
INTAKE EXHAUST W110R0259

Use micrometer (2) to measure valve stem (1). It must
be 7.96 to 7.98 mm.
Use a bore gauge to measure the inner diameter of
the valve guides. They must be in accordance with
the value indicated in the figure.
Check the clearance between valve stem and valve

guide and any out-of-round of the valves
Valve seats
Regrinding replacement of valve seats
1
W110R0258 2
The inspections are made using a dial gauge (1) with

a magnetic base arranged as illustrated. The mount-
W110R0260
ing clearance is 0.039 to 0.079 mm.
Rotate valve (2) to check that the out-of-round does
not exceed 0.03 mm. Check valve seats (2). Should slight scratches or burnt
be found, regrind with tool 75301453 (1) in accord-
ance with the angle values indicated in the figure to
follow.
INTAKE EXHAUST
3.40 to 3.66 mm 3.20 to 3.46 mm
W110R0261
Dimensions of valve seats
1.58 mm 1.55 mm
1.98 mm 1.81 mm
EXHAUST INTAKE
49.5 mm 38.52 mm
50.5 mm 38.92 mm
43.637 mm 46.987 mm
43.663 mm 47.013 mm
47 mm 50 mm
W110R0262
Dimensions of seats for valve seats
In the event the valve seats cannot be reconditioned Warm-up the cylinder head to 80 to 100 C (175 to
by just regrinding them, it is possible to replace them 212 F) and using an appropriate punch, install new
with spare ones. Using the same tool 75301453 pay- valve seats previously cooled.
ing attention to prevent denting the cylinder head, re- Then, using tool 75301453, regrind the valve seats,
move as much material as possible from the valve in accordance with the values indicated in the figures.
seats, until it is possible to extract them from the
cylinder head, using a punch.
Reassembly of cylinder head

1
W110R0263
W110R0265
Once the regrinding operations are over, use base
380000364 (2) and dial gauge 380000228 (1) check-
ing that valve recess (3) is according to the prescribed Lubricate the valve stems and install them into the
value. relevant valve guides, in accordance with the loca-
tion as recorded during the disassembly.
Install seals (1) on the valve guides.
Valve springs
2
1
3
5
W110R0264
W110R0266
Main data for the inspection of intake and exhaust

Install on the cylinder head spring (4) upper plate (3).
valve springs
Using tool 380000302 (1) pressing spring (4) and se-
cure the parts to the valve using half-cones (2).
Prior to installing them, check the elasticity of the
valve springs using tool 75301723. Compare the load-
ing and elastic deformation data with the ones of new
springs listed in the table here below.
Height Under a load of

mm N
H (free) 63.50 No load
H1 49.02 P1 329
H2 38.20 P2 641
Reinstallation of the cylinder head
W110R0269
W110R0267
Prior to inserting the tappet rods, check their condi-
tions. The contact ball shaped seats with the rocker
Make sure that the matching face of the cylinder head arm adjusting screw and with the tappet (arrows) must
and the cylinder block are clean. be free from any sign of seizing or wear, otherwise,
Do not foul the cylinder head gasket. replace them. The tappet rods for intake and exhaust
valves are identical, thus they are interchangeable.
Important Prior to using the screws securing the
cylinder head, check that they do not show any sign Rocker arm group
of deterioration or deformation, otherwise replace
them.
4
1
W110R0270
Items composing the rocker arm group

1
1. Support - 2. Rocker arm - 3. Shaft - 4. Screws.
W110R0268
19,000 mm
Install the cylinder head on the cylinder block, tight- 19,026 mm
ening screws (1) without torque tightening them.
18,963 mm
18,975 mm
W110R0271
Main data shaft-rocker arm
Check that the matching surfaces shaft/rocker arm

are free from excessive wear or damages.
2 1
2 3
W110R0272 W110R0275
Check that the rocker arm adjusters are loosen to Adjust the clearance between rocker arms and valves
prevent forcing during the installation of rocker arm using Allen wrench (2) poly wrench (3) and feeler gauge
groups (1). (1).
Then, install the rocker arm group made of rocker arm
support and shafts and secure them without torque The valve clearance is:
tightening screws (2) and (3). - intake valve 0.25 0.05 mm
- exhaust valve 0.50 0.05 mm
1
Installation of injectors
W110R0273
2
Secure the cylinder head screws in accordance with
the prescriptions of Figure.
3
W110R0276
Install a new seal (2) lubricated with vaseline on in-

jector (1) and a new sealing washer (3).
Install the injectors into the seats on the cylinder head
and tighten them with a torque wrench.
W110R0274
Diagram of the tightening sequence for the cylinder

head securing screws:
- 1st phase pre-securing with torque wrench
screw M12 x 1.75 x 70 [ ] 50 Nm 5 Nm;
screw m12 x 1.75 x 140 [ ] 40 Nm 5 Nm;
screw M12 x 1.75 x 180 [ ] 70 Nm 5Nm;
- 2nd phase angle tightening: 90 ;
- 3rd phase, angle tightening for screws 140 and 180
mm long only: 90 .
1 3
2
4 1
13
5 12
6 11
10
3 7 9
2
8
4
W110R0277 W110R0279
Install injector supply pipes group (1). Install injector - Install rocker arm covers (4).
fuel discharge pipes (2), using seals (3) and tighten- - Install heater (2).
ing screws (4). - Install intake manifold elbow (3).
- Install heater controller (5).
- Install fuel filter support (6).
- Install fuel filter (9).
- Connect quick release joint pipes (7) (10) (11 and
1 2
12).
6 - Install electric harness (8).
- Install LDA (13) system pipe.
3 - Connect the engine oil fumes recovery pipe to blow-
by (1).
5 A B
W110R0278
1
Install injector supply pipes (5) of injection pump (6).
Install the brackets on the cylinder head securing tube
groups (1), (2) and (3).
Install fuel pump (4).
1
W110R0280
Press stop (1) in the direction of the arrow (item B)

and connect the piping. Return the stop into the initial
locking position (item A).
1
2
5 3
4
6 1
2
3
W110R0281 W110R0283
The intake manifold group is composed of manifold - Install exhaust manifold (3).
(6) on the cylinder head, cover (5) gaskets (2) and (4) - Install turbine (1) using screws (2).
cold starting heater (3) and elbow (1).
Apply sealant Loctite 5999 between cover (5) and
manifold (6) and tighten the screws to the prescribed
torque.
7
1
6
2
3
5
4
1 W110R0284
- Install starter motor (3).

- Install turbine lubrication oil return (1) pipe with se-
W110R0282 curing bracket (2).
- Install turbine lubrication oil delivery (7) and engine
- Install electric harness (1). oil pipes (4) and (5) to water/oil heat exchanger (6).
Replacing the injectors

1
5 Removal
2
4
3
W110R0285
- Install thermostat group (1) on cylinder head (3)

tightening screws (2) to the prescribed torque. W110R0288
- Install coolant temperature sensor (5) tightening it
with a torque wrench. Have the vehicle set in safe conditions.
- Install pulley fan support (6) on cylinder head (3) Lift the engine compartment hood, disconnect the bat-
using screws (4) tightened to torque. tery cables and operate as follows:
- disconnect engine oil fumes recovery pipe (2) from
the blow-by;
- remove rocker arm cover (1);
- disconnect the fuel manifold pipes (3) from the in-
jectors.
W110R0286
Install fan pulley (2) on support (1) using screws (3)

tightened to torque.
W110R0289
Remove injectors (2) using tool 380001099 (1) and

extract them from the cylinder head.
W110R0287
Install Ply-V belt (5) on pulley (7) on the crankshaft

pulley and guide pulleys (6) water pump (4) and alter-
nator (2). Tension the belt using automatic belt
tensioner (3).
Reinstallation Adjusting the valve clearance
1 3
1
2 2
3
W110R0290 W110R0292
Install a new seal (2) lubricated with vaseline and a Adjust the valve clearance using Allen wrench (1) poly
new sealing washer (3) on injector (1). wrench (2) and feeler gauge (3).
Install the injectors in the seats on the cylinder head The operating clearance is:
tightening them with a torque wrench. - 0.05 mm
- intake valves 0.30 0.05 mm
- exhaust valves 0.55 0.05 mm.
2
1 Removing/installing the rocker arms
Removal
3
W110R0291
4
Install new gaskets (1) on fuel manifolds (2).
Connect the manifolds to the injectors tightening the
securing nuts to a torque of 50 Nm. W110R0293
Reinstall the rocker arm cover.

Reconnect the engine oil fumes recovery pipe to the Loosen nuts (3) securing the tapped adjusters and
blow-by. loosen adjusters (2).
Remove screws (4) and remove rocker arm group (1)
composed of rocker arm supports and shafts and re-
move the valves.
Reinstallation
Check that the rocker arm adjusters are loosen to
prevent forcing during the installation of rocker arm
groups (1).
Then, install the rocker arm groups made of rocker
arm support and shafts and secure them tightening
the securing screws to a torque of 36 Nm.
Adjust the valve clearance as explained here above.
Diagram for the adjustemnt of the valve clearance

on engine NEF 4-cylinder
In order to make quickly the valve clearance adjust-
ment proceed as follows:
Turn the crankshaft and have the valve of cylinder no.
1 balance, then adjust the valves indicated by aster-
isk in the table:
cylinder no. 1 2 3 4
intake - * * *
exhaust - - - *
Turn the crankshaft and have the valve of cylinder no.

4 balance, then adjust the valves indicated by aster-
isk in the table:
cylinder no. 1 2 3 4
intake * - - -
exhaust * * * -
Setting the timing

The timing drive is provided by a straight teeth gear
mounted on the rear nose of the crankshaft driving
the gear on the camshaft.
The time setting is provided by having marks ()
stamped on them coincide.
W110R0294
1.7 TOOLING
TOOL NO. DESIGNATION
380000975 Kit with complete set of valve seat reamers
380000976 Spring load check device
380000301 Group overhaul rotary stand

(capacity 1000 daN, torque 120 daN/m)
380000322 Puller for gear connecting the injection pump to the

engine
380000665 Puller for the removal of the crankshaft front seal
380000663 Puller for the removal of the crankshaft rear seal
380000671 Injector puller
380000980 Double stroke bridge
220 mm
380000981 Set of brackets

120 mm
99341015 Restriction
380000666 Tool for the installation of the crankshaft front seal
380000664 Tool for the installation of the crankshaft rear seal
380000670 Tool for the removal of cartridge filters
380000221 Pliers for the removal and installation of piston rings

(65 to 110 mm)
380000302 Tool for the removal and reinstallation of engine

valves
380000667 Punch for the removal and installation of camshaft

bushes (to be used with 380000668)
380000362 Crankshaft lifting tool
380000216 Bridge type tool for engine removal and installation
380000220 Band for the introduction of pistons into the cylin-

der sleeves (60 to 125 mm)
380000661 Brackets for the installation of the engine on rotary

stand 380000301
380000669 Tool for the extraction of seals
380000668 Handle for interchangeable punches to be used with

380000667
380000364 Base for dial gauge
99395100 Tool holding the dial gauge for timing of rotary in-
jection pump (to be used with 380000228)
380000304 Set of two measuring tools for the angle tightening

with and square drive
380001003 Square assembly for the check of square of conrods
380000228 Dial gauge (0 to 5 mm)
380000144 Engine flywheel retaining tool
3800001099 Injector puller
NOTES:
SECTION 2
TRANSMISSION
INDEX
2.1 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS .................. 2-1

2.1.1 SPECIAL TORQUES ............................................................................................ 2-1
2.1.2 TRANSMISSION .................................................................................................. 2-2
Removal ........................................................................................................... 2-2
Transmission Mounting ..................................................................................... 2-9
Installation ........................................................................................................ 2-10
2.1.3 FRONT AXLE ....................................................................................................... 2-17
Removal ........................................................................................................... 2-17
Front Axle Mounting .......................................................................................... 2-19
Installation ........................................................................................................ 2-20
2.1.4 REAR AXLE ......................................................................................................... 2-22
Removal ........................................................................................................... 2-22
Rear Axle Mounting .......................................................................................... 2-24
Installation ........................................................................................................ 2-25
2.2 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, ..............................

AND TROUBLESHOOTING .................................................................................. 2-27
2.2.1 SPECIAL TOOLS ................................................................................................. 2-27
2.2.2 SPECIFICATIONS ................................................................................................ 2-27
2.2.3 TRANSMISSION OPERATION ............................................................................. 2-33
General ............................................................................................................. 2-33
Transmission ECM............................................................................................ 2-33
Transmission Clutch Calibration ........................................................................ 2-34
Gear Selections ................................................................................................ 2-34
Automatic/Manual Modes ................................................................................. 2-34
Downshift Button .............................................................................................. 2-35
Brake Pedal Transmission Declutch .................................................................. 2-36
2.2.4 TRANSMISSION PRESSURE TEST POINTS DIAGRAM .................................... 2-38
2.2.5 CHART FOR RECORDING PRESSURE READINGS ........................................... 2-40
2.2.6 PRESSURE TEST RESULTS ............................................................................... 2-41
All or Most Pressures Low and/or Flow Test Low .............................................. 2-41
Some Pressures Low ........................................................................................ 2-41
Not Enough Power ............................................................................................ 2-41
Machine Stops or Hesitates While Shifting - Intermittent................................... 2-41
2.2.7 CONVERTER OUT PRESSURE CHECK ............................................................. 2-42
Test Equipment Required .................................................................................. 2-42
Test Procedure ................................................................................................. 2-42
2.2.8 LUBRICATION PRESSURE CHECK ..................................................................... 2-42
Test Procedure ................................................................................................. 2-42
2.2.9 FLOWMETER TEST ............................................................................................. 2-42
Flowmeter Test Procedure ................................................................................. 2-42
2.2.10 CONSUMPTION TEST PROCEDURE .................................................................. 2-42

2.2.11 TRANSMISSION OVERHEATING ........................................................................ 2-43
2.2.12 TROUBLESHOOTING GUIDE .............................................................................. 2-44
2.2.13 TRANSMISSION SHIFTER LOGIC INFORMATION ............................................. 2-63
2.2.14 RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES AND CLUTCHES ..... 2-63
2.3 TRANSMISSION .................................................................................................. 2-64

2.3.1 SPECIAL TOOLS ................................................................................................. 2-64
2.3.2 SPECIAL TORQUES ............................................................................................ 2-65
2.3.3 SPECIFICATIONS ................................................................................................ 2-65
2.3.4 DISASSEMBLY .................................................................................................... 2-66
2.3.5 ASSEMBLY .......................................................................................................... 2-77
2.4 FRONT AND REAR AXLE .................................................................................... 2-100

2.4.1 SPECIFICATIONS ................................................................................................ 2-100
2.4.2 SPECIAL TORQUES ............................................................................................ 2-100
2.4.3 SPECIAL TOOLS ................................................................................................. 2-100
2.4.4 GEAR TOOTH CONTACT PATTERNS ................................................................... 2-101
Ideal Tooth Contact Pattern ............................................................................... 2-101
Pinion Distance Must Be Increased .................................................................. 2-101
Pinion Distance Must Be Decreased ................................................................. 2-102
2.4.5 LUBRICATION ...................................................................................................... 2-103
2.4.6 WEAR MEASUREMENT ON MULTI-DISC BRAKE .............................................. 2-103
2.4.7 WHEEL END AND BRAKE ................................................................................... 2-104
Disassembly ..................................................................................................... 2-104
Cleaning and Inspection .................................................................................... 2-110
Assembly ......................................................................................................... 2-110
Sun Gear Shaft End Play Adjustment ............................................................... 2-117
2.4.8 BRAKE HYDRAULICS LEAKAGE TEST .............................................................. 2-120
High Pressure Test ............................................................................................ 2-120
Low Pressure Test ............................................................................................ 2-120
2.4.9 DIFFERENTIAL CARRIER DISASSEMBLY .......................................................... 2-121
2.4.10 DIFFERENTIAL DISASSEMBLY .......................................................................... 2-124
2.4.11 DRIVE PINION DISASSEMBLY ........................................................................... 2-125
2.4.12 REAR AXLE PIVOT PIN BUSHINGS ................................................................... 2-126
2.4.13 BRAKE TUBES REMOVAL .................................................................................. 2-127
2.4.14 BRAKE TUBES INSTALLATION ........................................................................... 2-128
2.4.15 DIFFERENTIAL CARRIER ASSEMBLY ............................................................... 2-130
Determine Shim Thickness for Correct Tooth Contact Pattern ........................... 2-130
Drive Pinion Bearing Rolling Torque Adjustment ................................................ 2-132
2.4.16 DIFFERENTIAL ASSEMBLY ................................................................................ 2-134
Open Differential Assembly .............................................................................. 2-134
Limited Slip Differential Assembly .................................................................... 2-135
Adjust Backlash and Bearing Preload ............................................................... 2-138
2.5 DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS ...................... 2-140
2.5.1 SPECIAL TORQUES ............................................................................................ 2-140
2.5.2 FRONT DRIVE SHAFT ......................................................................................... 2-140
Removal ........................................................................................................... 2-140
2.5.3 FRONT DRIVE SHAFT ......................................................................................... 2-141
Installation ........................................................................................................ 2-141
2.5.4 CENTER BEARING .............................................................................................. 2-142
Removal ........................................................................................................... 2-142
2.5.5 CENTER BEARING .............................................................................................. 2-143

Installation ........................................................................................................ 2-143
2.5.6 CENTER DRIVE SHAFT ...................................................................................... 2-144
Removal ........................................................................................................... 2-144
Installation ........................................................................................................ 2-144
2.5.7 REAR DRIVE SHAFT ........................................................................................... 2-145
Removal ........................................................................................................... 2-145
Installation ........................................................................................................ 2-145
2.5.8 ENGINE DRIVE SHAFT ....................................................................................... 2-146
Removal ........................................................................................................... 2-146
2.5.9 ENGINE DRIVE SHAFT ....................................................................................... 2-148
Installation ........................................................................................................ 2-148
2.5.10 UNIVERSAL JOINTS ........................................................................................... 2-150
Removal ........................................................................................................... 2-150
Installation ........................................................................................................ 2-150
2.6 WHEELS AND TIRES ........................................................................................... 2-152

2.6.1 WHEELS AND NUTS ........................................................................................... 2-152
General Information .......................................................................................... 2-152
Torque Specification ......................................................................................... 2-152
2.6.2 TIRE PRESSURE ................................................................................................ 2-152
2.6.3 CHANGING TIRES ............................................................................................... 2-153
2.6.4 INSTALLING A WHEEL ........................................................................................ 2-153
2.7 TRANSMISSION CONTROL VALVE ..................................................................... 2-154

2.7.1 SPECIAL TOOLS ................................................................................................. 2-154
2.7.2 SPECIAL TORQUES ............................................................................................ 2-154
2.7.3 DISASSEMBLY .................................................................................................... 2-155
2.7.4 INSPECTION ....................................................................................................... 2-159
2.7.5 ASSEMBLY .......................................................................................................... 2-161
W110/W110TC TRANSMISSION 2-1
2.1 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS
2.1.1 SPECIAL TORQUES

RH and LH Mounting Brackets to Transmission Mounting Bolts ....................... 481 to 590 Nm (355 to 435 lb-ft)
Top Mounting Bracket to Transmission Mounting Bolts .................................... 251 to 319 Nm (185 to 235 lb-ft)
Transmission Mounting Brackets to Chassis Mounting Bolts ......................... 890 to 1000 Nm (655 to 735 lb-ft)
Engine Drive Shaft to Transmission Mounting Bolts ................................................. 34 to 41 Nm (25 to 30 lb-ft)
Fuel Supply Hose Clamp ..................................................................................................... 3.4 Nm (30 lb-inch)
Fuel Return Hose Clamp ..................................................................................................... 3.4 Nm (30 lb-inch)
Transmission Fill Tube Mounting Bolts ..................................................................... 17 to 33 Nm (12 to 24 lb-ft)
Rear Drive Shaft to Transmission Mounting Bolts .................................................... 61 to 81 Nm (45 to 60 lb-ft)
Center Drive Shaft to Transmission Mounting Bolts ................................................. 61 to 81 Nm (45 to 60 lb-ft)
Front Axle Mounting Bolts ................................................................................ 845 to 950 Nm (625 to 700 lb-ft)
Wheel Bolts
Preliminary Torque ............................................................................................................. 298 Nm (220 lb-ft)
Final Torque ................................................................................................. 640 to 720 Nm (475 to 530 lb-ft)
Center Bearing Mounting Bolts .............................................................................. 99 to 128 Nm (73 to 94 lb-ft)
Front Drive Shaft Mounting Bolts ............................................................................. 61 to 81 Nm (45 to 60 lb-ft)
Pivot Pin Caps Mounting Bolts ......................................................................... 251 to 280 Nm (185 to 205 lb-ft)
Rear Drive Shaft to Rear Axle Mounting Bolts ......................................................... 61 to 81 Nm (45 to 60 lb-ft)
2-2 TRANSMISSION W110/W110TC
2.1.2 TRANSMISSION STEP 4

Removal
STEP 1
8 9
Note amount of fuel in fuel tank and remove ROPS 6
cab or ROPS canopy.
STEP 2
5
BD01D304
Loosen clamp (8). Disconnect suction hose (5) from

1 hydraulic reservoir and remove with tube assembly
(4) attached from machine. Disconnect case drain
hose (6) from fitting (9); remove hose (6). Remove
and discard O-ring face seal from fitting. Plug hoses
and cap fittings to prevent entry of foreign matter into
BD01D321 hydraulic system.
Put a 37.8 liter (10 gallon) container under transmis-
STEP 5
sion drain plug (1). Remove drain plug and drain trans-
mission oil. Install drain plug after oil has drained.
11
13
STEP 3
14
4 10
5 2
12
7
BD01D308
3 2 3 Identify, tag, and disconnect pump load sensing hose
6
(10). Remove and discard O-ring face seal from fit-
BD01D303 ting (11). Remove four bolts (12) and washers. Re-
move two split flanges (13). Disconnect pump pres-
Remove four bolts (2) and washers. Remove two split
sure hose (14) from hydraulic pump. Remove and
flanges (3). Disconnect tube assembly (4) with suc-
discard O-ring face seal from flange head of hose
tion hose (5) attached from hydraulic pump. Remove
(14). Plug hoses and pump port and cap fitting.
and discard O-ring face seal from flange head of tube
assembly. Tag and disconnect case drain hose (6)
from fitting (7). Remove and discard O-ring face seal
from fitting. Plug hose, tube assembly, and pump port
and cap fitting to prevent intrusion of foreign matter
into hydraulic system.
STEP 6 STEP 9
17 15
22
18
23
16
BD01D306 BD01D310
Identify, tag, and disconnect brake pump pressure Remove two socket head bolts securing transmis-
hose (15) and brake to hydraulic reservoir hose (16). sion wiring harness clamps (22 and 23).
Position hoses away from transmission. Remove and
discard O-ring face seals from fittings (17 and 18). STEP 10
STEP 7
24
25
19 26
20
BD01D312
Identify, tag, and disconnect transmission wiring har-

BD01D315
ness connectors from engine speed sensor (24), in-
Disconnect transmission wiring harness connector termediate speed sensor (25), and turbine speed
(19) from control valve connector. Remove socket sensor (26). Move transmission wiring harness away
head bolt securing wiring harness clamp (20). Move from transmission.
wiring harness away from transmission.
STEP 11
STEP 8
21 27
BD01D316
BD01D317
Remove socket head bolt securing wiring harness
Just above where clamp (20) was installed, tag and clamp (27). Move wiring harness away from trans-
disconnect transmission wiring harness connector mission.
(21) from torque converter output sender. Move wir-
ing harness away from transmission.
STEP 12 STEP 15
34
28
37
35
36
29
38
BD01D314 BD01D296
Identify, tag, and disconnect transmission wiring har- At front of transmission, identify, tag, and disconnect
ness connectors from filter maintenance switch (28) parking brake hose (34) from parking brake (35). Move
and output speed sensor (29). Move transmission hose away from transmission. Remove four bolts (36)
wiring harness away from transmission. and two straps (37) securing center drive shaft (38)
to transmission output flange. Disconnect center drive
STEP 13 shaft from transmission.
STEP 16
30
39
32
41
31
40
BD01D333
Connect lifting equipment to hydraulic pump (30); take

BD01D323
care not to damage pump tube assembly (31). Take
up all slack in lifting equipment. Remove two bolts Remove four bolts (39) and two straps (40) securing
(32) and washers securing pump to transmission. rear drive shaft (41) to transmission output flange.
Disconnect rear drive shaft from transmission.
STEP 14
STEP 17
43
33 42
44
BD01D335
BD01D324
Pull hydraulic pump from transmission and remove
from loader. Remove and discard O-ring (33). Remove two bolts (42) securing hose bracket (43) to
transmission. Remove bracket from transmission and
lay on rear axle brake hose (44).
STEP 18 STEP 21
46
45 50
BD01D322 BD01D339
Remove two bolts (45). Remove fill tube (46), with Remove fitting (50). Remove and discard O-ring from
cap and oil gauge assembled, two seals, and metal fitting.
strainer. Discard seals.
STEP 22
STEP 19
51
52
47
48 BD01D340
BD01D329
Repeat Steps 20 and 21 to remove cooler hose (51)
Remove two bolts (47) and washers securing hose and fitting (52).
retainer (48) to front of rear chassis. Move hose re-
tainer towards front of machine.
STEP 20
50
49
BD01D318
Identify, tag, and disconnect cooler hose (49) from

fitting (50) installed in LH side of transmission. Re-
move and discard O-ring face seal from fitting (50).
STEP 23 STEP 25
56 57
63
62
64
53
53
W110R0344 BD01D326
At bottom center of fuel tank, loosen clamp (62). Dis-

connect fuel supply hose (63) and remove clamp. Plug
fuel supply hose and cap fuel tank fitting (64).
STEP 26
65
54 66
W110R0345
Remove four bolts (53) and washers securing mount- 67

ing brackets (54), parking brake accumulator (56), and
brake accumulators (57) to rear chassis. Move as-
sembled parts away from transmission as shown.
BD01D328
STEP 24
Remove lock nut (65), washers, and bolt. Remove
vent cover (66) and breather valve installed in vent
hose (67). Route vent hose with breather valve down
to fuel tank.
59
STEP 27
60
61 58
BD01D325
Place a container large enough to hold fuel in fuel

tank under drain valve (58). Open drain valve (58)
and drain fuel tank. Close drain valve after fuel has 68
drained. Loosen clamp (59) and disconnect fuel re-
turn hose (60). Remove clamp. Plug fuel return hose BD01D330
and cap fuel tank fitting (61).
Identify, tag, and disconnect wiring harness wires from
fuel level sender (68).
STEP 28 STEP 30
72
74
70 75
75
A
76
BD01D332 BD01D342
69 In area between rear of transmission and front of

69 engine, remove four bolts (72) and two straps (73).
Discard bolts (72) and straps (73). Use pry bar to
disconnect engine drive shaft (74) from transmission.
Using 3/4 inch drive socket, extensions, and impact
wrench, remove four bolts (75) and washers secur-
69 69 ing transmission to top mounting bracket (76).
69
69 STEP 31
BD01D327
Position a hydraulic jack (A) under fuel tank plate (70)

to support fuel tank and plate. Jack must be at center 79
of plate and as far rearward as possible. Loosen and
80
remove six bolts (69) and washers. With an assist- 77
ant, slowly lower hydraulic jack and carefully move
fuel tank and plate from under machine. 78
STEP 29
BD01D337
Loosen two bolts (77) securing RH and LH mounting

brackets (78) to transmission. Remove bolts (79) and
washers (80) securing RH and LH mounting brack-
71 ets (78) to rear chassis.
71
BD01D343
Connect lifting equipment to transmission lifting eyes

(71). Take up all slack in lifting equipment.
STEP 32 STEP 34
82 81
78
76
77
BD01D344 BD01D361
Raise transmission just enough to enable removal of If top mounting bracket (76) requires removal, remove
RH and LH mounting brackets (78). Remove two bolts bolt (81) and washer (82) then remove bracket.
(77) and washers securing RH and LH mounting
brackets (78) to transmission. Remove RH and LH
mounting brackets.
STEP 33
BD01D345
Slowly and carefully raise transmission from loader

while checking that all hoses, electrical connectors,
and wires have been disconnected and nothing in-
terferes with transmission. Remove transmission from
loader.
Transmission Mounting
79,81 79
80,82
C
B
80
83 83
ISOLATOR 77
INSTALLATION
81
77
82
78
83
79
76
75 80
75 77
83
77
78
BS01E012
A. Rear chassis trunnion - B. Bracket (76 or 78) - C. Smaller piece on top - 75. Bolt - 76. Top mounting bracket - 77. Bolt -
78. Mounting bracket - 79. Bolt - 80. Washer - 81. Bolt - 82. Washer - 83. Isolator.
2 - 10 TRANSMISSION W110/W110TC
Installation STEP 38
STEP 35
Check isolators (83) for deterioration, tears, deforma-
tion, or other damage. Replace as necessary.
STEP 36
78
82 81
77
BD01D344
Install RH and LH mounting brackets (78) on trans-

mission using two washers and bolts (77). Do not
76 tighten bolts.
STEP 39
BD01D361
If top mounting bracket (76) was removed, position

bracket on rear chassis trunnion and secure using
washer (82) and bolt (81). Do not tighten bolt.
STEP 37 79
80
77
78
BD01D337
Loosely install washers (80) and bolts (79) to secure

RH and LH mounting brackets (78) to rear chassis.
Tighten bolts (77) securing RH and LH mounting
brackets to transmission to a torque of 481 to 590
Nm (355 to 435 lb-ft).
BD01D345
Move transmission into position above loader. Slowly

lower transmission into loader.
W110/W110TC TRANSMISSION 2 - 11
STEP 40 STEP 42
Note In this step, new straps (73) and bolts (72)
must be installed whenever these parts are removed.
Bolts have a nylon patch to maintain torque which
requires new bolts.
72 71
73 71
74 81
75
BD01D343
Disconnect lifting equipment from transmission lift-

75 76 ing eyes (71).
BD01D342 STEP 43
Using 3/4 inch drive socket, extensions, and impact
wrench, install four washers and bolts (75) to secure
top mounting bracket (76) to transmission. Then
tighten bolts (75) to a torque of 251 to 319 Nm
(185 to 235 lb-ft). If bracket (76) had been removed,
tighten bolt (81) to a torque of 890 to 1000 Nm (655
to 735 lb-ft). Connect engine drive shaft (74) to trans- 70
mission. Install two new straps (73) and four new bolts
(72). Tighten bolts (72) to a torque of 34 to 41 Nm A
(25 to 30 lb-ft).
STEP 41 BD01D332
69
69
79
69 69 69
69
BD01D337 BD01D327
Tighten bolts (79) securing RH and LH mounting Put fuel tank and plate (70) on hydraulic jack (A) and,
brackets to a torque of 890 to 1000 Nm (655 to with an assistant, move into position beneath loader.
735 lb-ft). Make sure vent hose (67, Step 45) with breather in-
stalled is routed up into engine compartment when
fuel tank is raised. Raise fuel tank and plate, align
mounting holes, and secure using six washers and
bolts (69). Lower and remove hydraulic jack (A) from
under fuel tank plate.
STEP 44 STEP 47
59
60
61 58
68
BD01D330 BD01D325
Connect wiring harness wires to fuel level sender (68) Remove plug from fuel return hose (60) and cap from
following tags installed during removal. Remove and fitting (61). Put clamp (59) on fuel return hose. Con-
discard tags. nect hose to fitting (61) and tighten clamp to a torque
of 3.4 Nm (30 lb-inch). Check that drain valve (58) is
STEP 45 closed.
65 STEP 48
66
67
54
BD01D328
Route vent hose (67) with breather valve up towards

W110R0345
RH side of fan shroud. Put breather valve in vent cover
(66). Install washer and bolt, then washer and nut 56 57
(65) to secure vent cover and breather valve.
STEP 46
63
62
53
53
64 W110R0344
Move mounting brackets (54), parking brake accu-

mulator (56), and brake accumulators (57) into posi-
tion. Secure to rear chassis using four spacers (55),
BD01D326 washers, and bolts (53).
Remove plug from fuel supply hose (63) and cap from
fuel tank fitting (64). Put clamp (62) on hose (63).
Connect fuel supply hose and tighten clamp to a
torque of 3.4 Nm (30 lb-inch).
STEP 49 STEP 52
51
46
52
45
BD01D340 BD01D322
Install new O-ring on fitting (52) and install fitting in Position fill tube (46), two new seals, and metal
transmission. Install new O-ring face seal in fitting then strainer on transmission; metal strainer is installed
connect cooler hose (51) to fitting following tag in- between seals. Secure using two bolts (45). Tighten
stalled during removal. Remove and discard tag. bolts to a torque of 17 to 33 Nm (12 to 24 lb-ft).
STEP 50 STEP 53
50
43
49
44 42
BD01D318 BD01D324
Install new O-ring on fitting (50) and install fitting in Position hose bracket (43) with rear axle brake hose
transmission. Install new O-ring face seal in fitting then (44) on transmission. Install two bolts (42) to secure
connect cooler hose (49) to fitting following tag in- hose bracket to transmission.
stalled during removal. Remove and discard tag.
STEP 54
STEP 51
39
41
40
48 47
BD01D323
BD01D329
Connect rear drive shaft (41) to transmission then
Position hose retainer (48) on front of rear chassis install two straps (40) and four bolts (39). Tighten bolts
and secure using two washers and bolts (47). to a torque of 61 to 81 Nm (45 to 60 lb-ft).
STEP 55 STEP 58
34
28
37
35
36
29
38
BD01D296 BD01D314
Connect center drive shaft (38) to transmission and Connect transmission wiring harness connectors to
install two straps (37) and four bolts (36). Tighten bolts output speed sensor (29) and filter maintenance
to a torque of 61 to 81 Nm (45 to 60 lb-ft). Connect switch (28) following tags installed during removal.
parking brake hose (34) to parking brake (35) follow- Remove and discard tags.
ing tag installed during removal. Remove and discard
tag. STEP 59
STEP 56
27
31
30 33
BD01D316
Install socket head bolt to secure wiring harness

BD01D335
clamp (27).
Install new O-ring (33) on hydraulic pump (30). Move
pump into position taking care not to damage pump STEP 60
tube assembly (31) and install pump in transmission.
STEP 57
24
25
26
BD01D312
32
Connect transmission wiring harness connectors to
turbine speed sensor (26), intermediate speed sen-
BD01D333
sor (25), and engine speed sensor (24) following tags
Install two washers and bolts (32) to secure pump to installed during removal. Remove and discard tags.
transmission. Disconnect lifting equipment from pump.
STEP 61 STEP 64
17 15
22
18
23
16
BD01D310 BD01D306
Install two socket head bolts to secure transmission At brake valve, install new O-ring face seals in fittings
wiring harness clamps (23 and 22). (18 and 17). Connect brake to hydraulic reservoir hose
(16) and brake pump pressure hose (15) following
STEP 62 tags installed during removal. Remove and discard
tags.
STEP 65
21
11
13
14
10
BD01D317
12
Connect transmission wiring harness connector (21)
to torque converter output sender following tag in-
BD01D308
stalled during removal. Remove and discard tag.
At hydraulic pump, remove cap from fitting (11) and
STEP 63 plugs from hoses (14 and 10) and pump port. Install
new O-ring face seal in flange head of hose (14).
Position pump pressure hose (14) on pump port and
secure using two split flanges (13) and four washers
and bolts (12). Install new O-ring face seal in fitting
(11). Connect pump load sensing hose (10) to fitting
following tag installed during removal. Remove and
discard tag.
19
20
BD01D315
Install socket head bolt to secure wiring harness

clamp (20). Connect transmission wiring harness
connector (19) to control valve connector.
STEP 66 STEP 68
8 9
6
BD01D304 BD01D321
Remove plugs from hoses and caps from fittings. In- Check that transmission drain plug (1) is tight.
stall new O-ring face seal in fitting (9). Connect hy-
draulic pump case drain hose (6) to fitting (9). Posi- STEP 69
tion suction hose (5) between reservoir port and hy-
draulic pump inlet port. Connect suction hose (5) to
hydraulic reservoir. Tighten clamp (8).
STEP 67
5 2
7 BS00M474A
Fill transmission with MS-1209 Hy-Tran Ultra oil until

3 2 3 oil level is up to the arrow. Fill fuel tank with fuel drained
6 in Step 24.
BD01D303
STEP 70
At hydraulic pump, remove plug from hoses (6 and 4)
Refer to Section 8 and install ROPS cab or ROPS
and pump port and cap from fitting (7). Install new
canopy.
O-ring face seal in fitting (7). Connect pump case drain
hose (6) to fitting (7) following tag installed during
STEP 71
removal. Install new O-ring face seal in flange head
of tube assembly (4). Position tube assembly (4) with Start and run engine at idle speed with transmission
hose (5) on hydraulic pump port. Install two split in neutral. If transmission oil level is at or below bot-
flanges (3) and secure using four washers and bolts tom of crosshatch region, put articulation lock in
(2). LOCKED position and add MS-1209 Hy-Tran Ultra
oil until oil level is up to crosshatch region. Shut down
engine and put articulation lock in OPERATING posi-
tion.
2.1.3 FRONT AXLE STEP 75

Removal 2
STEP 72
1 3
1 2 1
BD01D370
Remove four bolts (1) and two straps (2) securing

front drive shaft (3) to front axle.
BD00M030
Park machine on level surface. Have assistant put STEP 76

articulation lock in LOCKED position. 4
STEP 73 8
5
3
7
9
5 6
BD01D368
Remove clamp securing lubrication hose (4) to ma-

chine and nut securing opposite end of hose (4).
BD00M048
Remove four bolts (5) and two straps (6) securing
Raise bucket and have assistant install safety link. center drive shaft (7) to front drive shaft (3). Use a
Lower loader arms slowly until safety link is support- pry bar to separate drive shafts. While supporting
ing loader arms. center bearing (9) and front drive shaft (3), remove
four nuts and bolts (8) and eight washers. Lower
STEP 74 center bearing and front drive shaft from mounting
plate and remove from machine.
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from hy-
draulic circuit. Put key switch in OFF position.
STEP 77 STEP 80
11
10
BD01D371 BD01D412
Disconnect brake hose (10) from fitting (11). Remove Use an acceptable jack to hold front axle.
and discard O-ring face seal from fitting.
STEP 81
STEP 78
12
13
BD01D391
BD01D393
Remove 10 bolts (12) and washers from front wheels
(13). Remove both wheels from front axle.
STEP 82
14
BD01D392
Using an acceptable hydraulic jack, raise one tire from

ground and install an acceptable jack stand under
machine. BD01D394
STEP 79 Remove eight nuts and bolts (14) and 16 washers

securing front axle to machine.
Repeat Step 78 to raise other front axle tire from
ground. STEP 83
Carefully lower front axle and remove from under
machine.
Front Axle Mounting
14
14
15
15
18
16
16
17
17 BS01E054
14. Bolt - 15. Washer - 16. Washer - 17. Nut - 18. Front axle.
STEP 84
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 85
14
BD01D412
Remove jack from front axle.
STEP 88
BD01D394
Install eight washers (15), bolts (14), washers (16),

and nuts (17) to secure front axle to machine. For
machines P.I.N. JEE0135500 and below, tighten bolts
to a torque of 845 to 950 Nm (625 to 700 lb-ft); for
machines P.I.N. JEE0135501 and above, tighten bolts
to a torque of 955 to 1075 Nm (705 to 790 lb-ft).
STEP 86
12 BD01D393
13
BD01D391
BD01D392
1
10 8 Using an acceptable hydraulic jack, raise axle and
remove jack stand from under machine.
3 6
STEP 89
5 4 Repeat Step 88 to remove other jack stand from un-
der machine.
7 9
2 BS00J104
Install both wheels (13) on front axle and secure us-

ing 10 washers and bolts (12). Tighten bolts to a pre-
liminary torque of 298 Nm (220 lb-ft) in sequence in-
dicated; then tighten to a torque of 640 to 720 Nm
(475 to 530 lb-ft) in same sequence.
STEP 90 STEP 92
2
11
1
3
10 1 1
2
BD01D371 BD01D370
Install a new O-ring face seal in fitting (11). Connect Secure drive shaft (3) to front axle using two straps
brake hose (10) to fitting. (2) and four bolts (1). Tighten bolts (1) to a torque of
61 to 81 Nm (45 to 60 lb-ft).
STEP 91
STEP 93
4
8 If necessary, fill axle with gear lubricant specified in
Section 0.
5
3 STEP 94
7 Refer to Section 3 and bleed brakes.
9 STEP 95
5 6
BD01D368
Position and support center bearing (9) and front drive

shaft (3) and install eight washers and four bolts (8)
and nuts. Tighten bolts (8) to a torque of 99 to 128
Nm (73 to 94 lb-ft). Install two straps (6) and four bolts
(5). Tighten bolts (5) to a torque of 61 to 81 Nm (45 to
60 lb-ft). Secure lubrication hose (4) to machine us-
ing clamp; secure opposite end of hose using nut.
BD00M048
Start engine and raise bucket. Have assistant remove

safety link. Lower bucket to ground and stop engine.
STEP 96
Put articulation lock in OPERATING position.
2.1.4 REAR AXLE STEP 102

Removal
STEP 97
Park machine on a level surface; be sure to allow ad- 5
equate space at side of machine for removal of rear
axle. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from 4
hydraulic circuit. Note amount of fuel in fuel tank then
put key switch in OFF position.
BD01D369
STEP 98 Disconnect brake hose (4) from fitting (5). Remove

and discard O-ring face seal from fitting.
STEP 103
BD00M030
Put articulation lock in LOCKED position.
STEP 99 BD01D410
Remove fuel tank (Steps 24 through 28). Using an acceptable hydraulic jack, raise one tire from
ground and install an acceptable jack stand under
STEP 100 machine. Repeat this step for other tire.
Install wood blocks between rear axle and chassis to STEP 104
prevent rear axle from pivoting.
STEP 101
1 2
3
BD01D414
1 2 Use an acceptable jack to hold rear axle.

BD01D362
Remove four bolts (1) and two straps (2). Use a pry
bar to disconnect rear drive shaft (3) from rear axle.
STEP 105 STEP 106

6
8
10
A
A
10 9
12
BD01D391 BD01D363
Remove 10 bolts (6) and washers (7) from rear wheels At front of trunnion (9), remove two Allen head bolts
(8). Remove both wheels from rear axle. (10) and washers (11). Remove front cap (12): if nec-
essary use two M12 by 32 mm (1.25 inches) bolts in
puller holes (A); tighten bolts evenly to pull cap from
axle and trunnion. Remove and discard O-ring (15)
from cap. Repeat this step at rear of trunnion except
remove and retain shim(s) (14) after removal of rear
cap (13). Remove pivot shaft (16) using acceptable
sleeve or rod if necessary.
STEP 107
Carefully lower rear axle and remove through side of
machine.
STEP 108
Remove and discard two seals (17) from rear axle
pivot point.
Rear Axle Mounting
10
9
11
12
17
10
15
11
7
14
16
11 15 18
10 17
6
13
11
10
BS01E055
6. Bolt - 7. Washer - 9. Trunnion - 10. Bolt - 11. Washer - 12. Front cap - 13. Rear cap - 14. Shim(s) - 15. O-ring - 16. Pivot
pin - 17. Seal - 18. Rear axle.

Note If shim(s) (14) have been lost or pivot pin (16)
A
has been replaced, do Step 109 to determine required
shim(s) otherwise go to Step 110.
STEP 109
10 10
9 9
13 16 12
BD01D482A
A B
BS01E091A
Install pivot pin (16) and caps (12 and 13) in trunnion
(9) without rear axle or shim(s). Install washers (11)
and bolts (10). Tighten bolts securely. Push assem-
bled pivot pin and caps to rear of machine as far as
possible. Measure and record gap (A) between rear
cap (13) and trunnion. Select shims from the follow-
BD01D499
ing:
Clean front (A) and rear (B) pivot area of rear axle
Note Shims are available in following sizes: where seals (17) will be installed.
0.50 mm (0.020 inch), 1.0 mm (0.039 inch), and
1.50 mm (0.059 inch). STEP 111
MEASURED GAP SHIM(S) REQUIRED A

(mm) (mm)
0.07 to 0.55 None 17
0.56 to 1.09 0.50 12
13
1.10 to 1.59 1.0
1.60 to 2.09 1.50
2.10 to 2.59 0.50 plus 1.50 15 BS01E092
2.60 to 3.02 1.0 plus 1.50

Lubricate two new seals (17) and new O-rings (15)
using MG-2 Grease. Install seals, smooth side out,
into front and rear of axle housing (A) until flush with
housing or recessed 2.0 mm (0.079 inch). Install an
O-ring in each cap (12 and 13).
STEP 112
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in trun-
nion with pivot holes in axle.
STEP 113 STEP 115

Remove hydraulic jack supporting rear axle and jack
14 A 12 10 stands supporting loading.
10 13
STEP 116
9 16 9
BS01E091
Lubricate pivot pin (16) using MG-2 Grease. At rear of 4

trunnion (9), install pivot pin into trunnion and axle
(A). Install shim pack (14), rear cap (13) with O-ring
installed, and two washers and bolts (10). At front of BD01D369
trunnion install front cap (12) with O-ring installed, and
Install a new O-ring face seal in fittings (5). Connect
two washers and bolts (10). Tighten bolts (10) to a
brake hose (4) to fitting.
torque of 251 to 280 Nm (185 to 205 lb-ft).
STEP 117
STEP 114
6
1
8 2
3
1 2
BD01D362
BD01D391
Connect rear drive shaft (3) to rear axle. Install two
straps (2) and four bolts (1). Tighten bolts to a torque
1 of 61 to 81 Nm (45 to 60 lb-ft).
10 8
STEP 118
3 6 Install fuel tank (Steps 43 through 47). Fill fuel tank
with fuel drained in Step 24.
5 4 STEP 119
If necessary, fill axle with gear lubricant specified in
7 9 Section 0.
2 BS00J104
STEP 120
Install both wheels (8) on front axle and secure using
10 washers and bolts (6). Tighten bolts to a prelimi- Refer to Section 3 and bleed brakes.
nary torque of 298 Nm (220 lb-ft) in sequence indi-
cated; then tighten to a torque of 640 to 720 Nm (475 STEP 121
to 530 lb-ft) in same sequence. Put articulation lock in OPERATING position.
2.2 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING
2.2.1 SPECIAL TOOLS

380001743 Transmission supplemental fitting kit.
Includes: 380000509 special 90 degree adapter and 380001749 plug and cap set.
380001739 Master pressure test kit
380001740 Flowmeter kit
380001750 Flowmeter adapter
380001745 Flow test kit
2.2.2 SPECIFICATIONS
Main pressure and clutch pressure ........................................................................ 16 to 18 bar (232 to 261 psi)
Converter in pressure .............................................................................................. 8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ............................................................................... 7 to 9 bar (102 to 131 psi)
Converter out pressure ............................................................................................... 2.5 bar (36 psi) minimum
Lubrication pressure .................................................................................................. 0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .............................................................................. 52 L/min (14 U.S. gpm)
Transmission oil operating temperature ................................................................... 80 to 120 C (176 to 248 F)
Clutch KV ............................................................................................................... 16 to 18 bar (232 to 261 psi)
Clutch KR ............................................................................................................... 16 to 18 bar (232 to 261 psi)
Clutch K1 ................................................................................................................ 16 to 18 bar (232 to 261 psi)
1
4
3 2
12
5
9
6
11
14
13
7
10
BS01A190
Component locations systems
1. Transmission electronic control module - 2. Downshift button - 3. Declutch rocker switch - 4. Manual/automatic rocker
switch - 5. Shifter - 6. Supply system connections B+ and return - 7. Transmission - 8. Inductive transmitter - Intermediate
speed sensor - 9. Inductive transmitter - Turbine speed sensor - 10. Inductive transmitter - Engine speed sensor - 11. Hall
sensor - Output speed sensor - 12. Transmission control valve cable - 13. Declutch limit switch - 14. Plug.
12
1
11
10 3
10
9
15
5
14
6
13
BS01B049
Component locations transmission layout
1. Clutch shaft KR - 2. Power take OFF - 3. Clutch shaft KV - 4. Clutch shaft K2 - 5. Clutch shaft K3 - 6. Output flange rear
- 7. Output flange converter side - 8. Output shaft - 9. Transmission pump - 10. Drive shaft - 11. Converter - 12. Inductive
transmitter for engine speed - 13. Clutch shaft K4 - 14. Converter relief valve - 15. Clutch shaft K1.
2 2
2 2
1
3
4
BS01A191
Component locations front view
1. Attachment for oil filler pipe with oil dipstick - 2. Transmission suspension bores - 3. Output flange converter side - 4. Oil
drain plug.
1
2
3
10
BS01A192
Component locations side view
1. Converter bell housing - 2. Breather - 3. Transmission case cover - 4. Filter head - 5. Filter - 6. Output flange rear - 7. Oil drain
plug - 8. Output flange converter side - 9. Transmission case - 10. Parking brake.
2
1 1
3
7
4 4
BS01B048
Component locations rear view
1. Lifting lugs - 2. Power take off - 3. Transmission control valve - 4. Transmission suspension bores - 5. Output flange rear -
6. Filter - 7. Filter head.
2.2.3 TRANSMISSION OPERATION A. Determines which clutches to engage in the trans-

mission.
General
B. Protects the engine and transmission turbine from
The transmissions for the D series equipment is
overspeed conditions during downloading.
equipped with a Transmission ECM (Electronic Con-
trol Module). This module controls modulation and C. Receives speed information from the engine
shifting that were normally associated with hydrauli- speed sensor, the turbine speed sensor, the in-
cally modulated transmissions, providing smoother termediate clutch speed sensor and the trans-
shifts and enhanced clutch life. mission output speed sensor. These speed sen-
sors are checked to determine if normal sensor
The Transmission ECM relies on signals from sev-
operation is present. The data is also used to
eral solenoids that are incorporated into the design.
control modulation during shifting and to deter-
These solenoids measure the speed of several com-
mine the appropriate shift patterns.
ponents, as well as other sensors that measure tem-
perature. These solenoids and sensors are further D. Detects system failures and determines the ap-
defined in the following paragraphs. propriate alternative actions.
In addition, the transmission incorporates a two-piece E. Provides various diagnostic messages to the In-
transmission case for ease of transmission mainte- formation Center.
nance, helical cut gears that help reduce noise, and
all external hoses have been eliminated (all oil pas- F. Provides other information to the information
sages are internal). center, which in turn displays engine speed, wheel
speed, gear shift selection, and actual gear se-
Transmission ECM lection.
Modulation and shifting are controlled by the Trans- G. Provides a method to calibrate the transmission
mission Electronic Control Module (Transmission clutch control.
ECM). This module replaces the oil and springs that
H. Establishes clutch modulation pressure during
are found in hydraulically modulated transmissions.
transmission shifts.
The Transmission ECM controls the clutch engage-
ment, providing smoother shifts and enhanced clutch Transmission Sensor Data Collection
life, whether the transmission is set to the automatic The Transmission ECM collects and uses informa-
or manual shift mode. tion from four sensors to accurately shift the trans-
The Transmission ECM also informs the Information mission and determine if any clutches are slipping.
Center, by the use of diagnostic codes, of any trans- These sensors are:
mission error and the hours of operation that the er- Engine (Speed) Sensor - monitors engine speed to
ror occurred. determine the load on the engine for shift points and
sends the engine rpm to the Transmission ECM, which
Electrical Shift Solenoids sends the information to the tachometer in the Infor-
Electrical Shift Solenoids control the modulation of mation Center.
the clutches, eliminating the need for a modulation
Turbine (Speed) Sensor - assists the engine speed
valve, and providing a smooth shift while maintaining
sensor in determining the load going into the trans-
constant control over clutch engagement as follows:
mission and helps determine shift points.
A. A temperature sensor relays the oil temperature
Intermediate (Shaft Speed) Sensor - determines dif-
to the Transmission ECM.
ferential gear speed in the transmission to check for
B. The Transmission ECM times the rate the sole- clutch slippage.
noid energizes and de-energizes.
Output (Speed) Sensor - monitors transmission out-
C. As the transmission changes gears, there is re- put shaft speed to help determine the load on the
duced hesitation from one gear to the next. transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM which
Transmission ECM Tasks sends the information to the speedometer in the In-
formation Center.
The Transmission ECM performs a variety of tasks in
the overall system. The Transmission ECM:
The transmission ECM also reviews voltage informa- If the Transmission ECM generates a code, the
tion from the shifter and transmission solenoids to wrench over the service manual icon will be displayed
determine if there are any short circuits or open cir- on the Information Center.
cuits in the system.
Transmission Clutch Calibration
Automatic Problem Modes
The Transmission ECM has the capability to find the
If the Transmission ECM detects an error condition in optimal adjustment of the clutch filling parameters for
the transmission system, it will generate a service each individual transmission, providing the ability to
code in the Information Center and will enter one of individually adjust the optimum fill time for the indi-
three modes: vidual transmission in the machine. Clutch Filling
Parameter Calibration is performed on each machine
A. Clutch Modulation Substitute Mode at the plant and should be repeated at the first 250
B. Limp-Home Mode hours of use and every 1000 hours thereafter.
C. Transmission/Transmission ECM Shutdown Mode
Gear Selections
Clutch Modulation Substitute Mode
The transmission in all D Series models provides 4
In this mode, the transmission clutch modulation is forward and 3 reverse gear selections. The transmis-
time dependant rather than load dependant. The sion ratios were designed to give optimized speed
transmission will go into the Clutch Modulation Sub- and torque for each gear selection. The torque con-
stitute Mode if any of the four speed sensors fail. verter is a single stage torque converter (one locking
If the output speed sensor is working and the trans- unit in the torque converter).
mission is in gear, the shift points in Automatic mode
will be speed dependant but the modulation will be a Automatic/Manual Modes
predetermined amount of time. The automatic/manual switch is located on the right
If the output speed sensor is not working and the control panel. The transmission is in automatic mode
transmission is in gear, the shift points will be load when the top of the automatic/manual switch is de-
dependant but the modulation will still be a predeter- pressed. The Transmission Display Center indicates
mined amount of time. when the machine is in the automatic mode.
If the transmission is shifted from neutral into a direc-

tion in the Clutch Modulation Substitute Mode in au-
tomatic, the transmission will shift into 4th gear and
shift down until it gets the correct output speed from
the turbine.
Limp-Home Mode
In this mode, the transmission will go into second gear,
forward or reverse, no matter what gear is selected.
If second gear is not obtainable, the Transmission
ECM selects a series of prioritized gears until an op- W110R0332
erable gear is found. The transmission will go into the

Auto/Manual transmission switch
Limp Home Mode if there is a fault on one clutch, a
fault on one clutch valve, or a fault on more than one
Upshifting in Automatic Mode
speed sensor.
Upshifting is determined by machine speed and the
Transmission/Transmission ECM Shutdown Mode torque on the transmission.
In this mode, the Transmission ECM has detected a The transmission will shift from first or second gear
severe failure that disables control of the transmis- up to the highest gear selected as the accelerator is
sion. The transmission will go into Shutdown Mode if depressed, machine speed increases, and required
there is a fault on more than one clutch, a fault on the torque is reduced.
solenoid power supply, or invalid voltage. In this mode,
the Transmission ECM will shut off all solenoid valves
and the power supply and the transmission shifts into
and stays in neutral.
If the machine speed is increasing, but the operator

is not depressing the accelerator (such as when go-
ing down a hill), the transmission will not upshift.
As the operator depresses the accelerator and the
torque on the transmission is lowered, the transmis-
sion will upshift.
Downshifting in Automatic Mode

Downshifting is determined directly by machine speed
and transmission torque. The transmission will
downshift to first or second gear as machine speed W110R0334
decreases and transmission torque increases. For 1. Downshift button.

example, if the unit begins to climb a hill in forth gear
and the machine speed decreases, as the torque re- Automatic Mode
quirement increases, the transmission will downshift
into third, then second, and down to first gear, if nec- In the Automatic Mode, the downshift button only shifts
essary. down. The downshift button allows the operator to
downshift through the entire range of gears. This is
Upshifting in Manual Mode useful in long haul applications or roading.
In the manual mode, the transmission starts out in Each time the button is pushed the transmission will
the selected gear and stays in that gear until the op- instantly downshift one gear from 4th to 3rd, then from
erator selects another gear or direction. The trans- 3rd to 2nd, and then from 2nd to 1st.
mission can be upshifted without reducing engine
The transmission will automatically downshift and then
speed or machine speed.
upshift, as needed, to the last gear that was selected
If the gear selected is two or more gears higher than with the downshift button.
the present gear, the transmission will shift up through
the gears at 2.5 second intervals until the selected Example If the downshift button was used to shift
gear has been reached. from 4th to 3rd gear, the transmission will automati-
cally shift from 3rd down and then back up to 3rd
Downshifting in Manual Mode again. It will not shift into 4th until the transmission
has been returned to the full range automatic mode.
The transmission can be downshifted in the manual
mode without reducing engine speed or machine
speed.
If 1st gear is selected from 3rd or 4th gear, the trans-
mission will downshift into 2nd gear for 1.2 seconds
and then will shift into 1st gear.
Downshift Button
The downshift button is located on front of the joy-
stick control lever in machines with a single lever con-
figuration, and on top of the control tower in machines
with a two lever configuration.
With the number of different ways the downshift but-
ton functions, the operator can tailor the use of the
machine to the application at hand.
The transmission will return to the full range auto- Brake Pedal Transmission Declutch
matic mode when:
A transmission declutch feature concentrates more
A. Another gear is selected. engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and starts.
B. The shifter is moved into neutral and then into Total disconnection of the transmission from the en-
forward or reverse. gine is prevented. This feature will function in 1st, 2nd,
C. The autoshift switch is recycled. or 3rd gear only. It will not function in 4th gear.
Manual Mode
In the manual mode, the downshift button toggles
between 1st and 2nd gear. The manual mode is use-
ful in short haul operations. In this mode, the downshift
button functions in two ways in 1st and 2nd gear.
When the operator is in 2nd gear and pushes the
downshift button, the transmission instantly shifts into
1st gear. When the operator pushes the downshift
button again, the transmission upshifts into 2nd gear.
If the machine is in 2nd gear and the downshift but-
ton is pushed, the transmission instantly shifts into
1st gear. When the operator shuttles the shifter, the
transmission upshifts back into 2nd gear. W110R0039
Cold Start Protection System Transmission declutch switch

The transmission has a cold start protection system.
When the transmission sump temperature is minus When the transmission declutch switch is in the on
10 C (14 F), the Transmission ECM will keep the position and the brake pedal is pushed, the Trans-
transmission in neutral. mission ECM reduces the pressure to the transmis-
sion forward or reverse clutch.
When the transmission sump temperature warms up
to minus 10 C (14 F) (within approximately one The Transmission ECM will not completely discon-
minute), the machine will operate in all gears. nect the clutch from the engine, but gradually reduces
the forward or reverse clutch pressure down to a lower
level.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse clutch
back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch will
be filled and maintain a low pressure until the brake
pedal is released. Then the selected forward or re-
verse clutch pressure will gradually increase up to
system clutch pressure.
NOTES:
2.2.4 TRANSMISSION PRESSURE TEST POINTS DIAGRAM
No. IDENTIFICATION/LOCATION CONNECTION DESIGNATION ON

VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter - Opening Pressure 8 bar (116 psi) M10x1 H
52 Behind the Converter - Opening Pressure 2.5 bar (36 psi) M14x1.5
53 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 B
55 Clutch Reverse 16+2 bar (232 + 29 psi) KR M10x1 E
56 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
57 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A
58 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C
60 Clutch 16+2 bar (232 + 29 psi) K4 M10x1 F
63 Behind the Converter Temperature 100 C, Short Time 120 C M14x1/5
65 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16 - 12 UNF-2B
16 Connection from the Heat Exchanger 1 5/16 - 12 UNF-2B
Inductive Transmitter and Speed Sensor
21 Inductive Transmitter n Turbine M18x1.5
34 Speed Sensor n Output and Speedometer
47 Inductive Transmitter n Central Gear Train M18x1.5
48 Inductive Transmitter n Engine M18x1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 System Pressure M16x1.5 G
69 Pilot Pressure M16x1.5 J
Note See figure for Measuring Point, Transmitter, Sensor and Connection locations.
65 51 68
69 49
57 60
53 55
VIEW X
VIEW X
58 56
48 47 21
16
16 15
15
VIEW Y
52
52
63
63
VIEW Y
34
PRESSURE REGULATOR UNDER VOLTAGE

FORWARD REVERSE NEUTRAL
CLUTCH PRESSURE REGULATOR 1 2 3 4 1 2 3
KV Y5
KR Y2
K1 Y3
K2 Y6
K3 Y4
K4 Y1
BC01B047
Measuring points and connections
2.2.5 CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number: Date:

TEST POINTS
Shift P V R 1 2 3 4 5 6 LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
LP. Lube pressure - P. Main pressure - R. Reverse clutch - V. Forward clutch - 1. First gear clutch - 2. Second gear clutch -
3. Third gear clutch - 4. Fourth gear clutch - 5. Converter in - 6. Converter out.
2.2.6 PRESSURE TEST RESULTS Not Enough Power

All or Most Pressures Low and/or Flow Test Possible causes include:
Low 1. Check Electrical Troubleshooting in this Section to
Possible causes include: verify actual gear selected.
1. Oil level not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 1 for specifications.)
2. Oil type and grade not correct.
A. Check engine and fuel system for problem.
3. Oil operating temperature high.
B. Check that torque converter installation is cor-
4. Screen for suction tube plugged.
rect.
5. Suction tube or gaskets leak.
3. Engine RPM above Stall Test specified RPM.
6. Main pressure valve, springs, or valve bore. (Refer to Section 1 for specifications.)
7. Reduction valve, springs, or valve bore. A. Check converter pressures and flow.
8. Charge pump seals or gaskets leak. B. Check that torque converter installation is cor-
rect.
9. Charge pump worn.
10. Oil supply flange not sealing correctly. Machine Stops or Hesitates While Shifting -
Intermittent
Some Pressures Low
Possible causes include:
Possible causes include:
1. Check orifice and O-ring.
1. Circuit isolation does not correct low pressure.
2. Check for foreign material plugging orifices or stick-
A. Control valve or gasket. ing valves.
B. Channel plate or gasket. 3. Check for reduced pressure at test pressure points.
2. Circuit isolation corrects low pressure. 4. See Electrical Troubleshooting in this Section for
electrical system problem.
A. Clutch shaft or seals.
B. Clutch drum or piston.
2.2.7 CONVERTER OUT PRESSURE 2.2.9 FLOWMETER TEST

CHECK Test Equipment Required
Test Equipment Required 380001740 Flowmeter Kit; 380001750 Flowmeter
0 to 28 bar (400 psi) gauge with hose long enough to Adapter.
take readings in the cab and 380000509 Special
Adapter. Flowmeter Test Procedure
1. Block the machine tires.
Test Procedure
2. Apply the parking brakes.
3. Heat the oil to an operating temperature of 80 to
2. Apply the parking brakes. 100 C (176 to 212 F).
3. Install the pressure gauge. 4. Remove the filter and install the 380001750 adapter.
4. Heat the oil to an operating temperature of 80 to 5. Install the flowmeter between the adapter and the
100 C (176 to 212 F). filter.
5. While in the cab, put the transmission in NEUTRAL. 6. While in the cab, run the engine at full throttle. Put
Run the engine at full throttle. Pressure must be a the transmission in NEUTRAL and record the flow
minimum of 2.5 bar (36 psi). measurement. The correct flow for machines is 52
L/min (14 U.S. gpm) at 2000 rpm.
2.2.8 LUBRICATION PRESSURE CHECK

2.2.10 CONSUMPTION TEST PROCEDURE
Test Equipment Required
0 to 7 bar (100 psi) gauge.
2. Apply the parking brakes.
Test Procedure 3. Heat the oil to an operating temperature of 80 to
1. Block the machine tires. 100 C (176 to 212 F).
2. Apply the parking brakes. 4. Install the flowmeter to converter outlet line (line to
cooler) in series.
3. Install the pressure gauge in the cooler return line
at the transmission. 5. While in the cab, run the engine at full throttle. Put
the transmission in NEUTRAL and record the flow
4. Heat the oil to an operating temperature of 80 to
measurement. The flow must be 9.1 L/min (2 U.S.
100 C (176 to 212 F).
gpm).
5. While in the cab, run the engine at full throttle. Put
6. Repeat the procedure with the transmission in
the transmission in each gear. Pressure must be
FORWARD in third gear. The flow must be
0.2 to 1.2 bar (3 to 18 psi).
9.1 L/min (2 U.S. gpm).
7. Repeat the procedure with the transmission in RE-
VERSE in third gear. The flow must be 9.1 L/min
(2 U.S. gpm).
2.2.11 TRANSMISSION OVERHEATING

1. Operate machine in normal operating conditions and
observe:
A. Verify actual oil temperature at test point. Nor-
mal operating temperature can be 56C (100F)
above the ambient temperatures.
B. Use a stop watch to establish the exact length
of time required to reach the overheating condi-
tion.
C. Observe engine temperature, does the engine
overheat? Which overheats first - engine or
transmission?
2. When the transmission reaches overheated con-
dition, shift to Neutral and maintain engine RPM at
a fast idle (1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish
length of time.
1. Check oil level, type and grade is correct.
2. Check operators gear selection is correct
for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall
speeds are correct as specified.
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and
sender or switch.
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the
specifications in this section to determine if any
circuits are not within specifications.
5. Refer to Pressure Test Results to determine pos-
sible cause of any test results not within specifica-
tions.
2.2.12 TROUBLESHOOTING GUIDE

In case of possible errors in the system, a wrench appears on the display, combined with indication of the error
number.
Introduction
Abbreviations
o.c. open circuit
s.c. short circuit
OP-Mode operating mode
TCU transmission control unit
EEC electronic engine controller
PTO power take off
ZF - Display:
If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the
gear selector is on neutral position.
If more than one fault is detected, each fault code is shown for about 1 second.
left right
h f e d character character
S
T
O
P
a b c g
(special symbols a-h)
Display during operation
Symbol meaning remarks

1F, 1R actual gear and direction
2F, 2R left digit shows actual gear
3F, 3R right digit shows actual direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing direction F or R selected while turbine CAUTION gear will engage if turbine speed
speed is too high drops
NN not neutral, waiting for neutral after to engage a gear, first move shift selector to
power up or a severe fault neutral position and again to F or R position
** oil temperature too low, no gear warm up engine / transmission
available
*N oil temperature low, only one gear warm up engine / transmission
available

st
1 bar (special symbol) manual mode 1 gear
2 bars manual mode 2nd gear
3 bars manual mode 3rd gear
4 bars manual mode 4th gear and also 5th
and 6th gear in 6WG
4 bars and 2 arrows automatic mode
Bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed above a
4 WG: Downshift mode activ certain limit and lockup clutch not activated
Spanner at least one fault activ select neutral to get fault code displayed
Fault code see faultcode list
WS warning sump temperature changes between actual gear/direction
while driving, in neutral only displayed if no
fault is detected (spanner)
WR warning retarder temperature changes between actual gear/direction
WT warning torque converter temperature changes between actual gear/direction
WE warning high engine speed changes between actual gear/direction
PN direction F or R selected while transmission in neutral until parking brake
parking brake engaged is releasedCAUTION: vehicle starts to move
after release of parking brake
EE flashing no communication with display checked wiring from TCU to display
Display during AEB-Mode

PL AEB - Starter is plugged at the
diagnostic plug
ST AEB-Starter-button is pressed
K1..K4,KV,KR calibrating clutch K1..K4, KV or KR
resp.
_ and Kx wait for start, initialization of clutch
Kx, x: 1, 2, 3, 4, V, R
and Kx fast fill time determination of clutch Kx
= and Kx compensating pressure determination
of clutch Kx
OK calibration for all clutches finished Transmissions stays in neutral, you have
to restart the TCU (ignition off/on) after
removing AEB-Starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have
to restart the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmissions stays in neutral, you have
calibrated to restart the TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmissions stays in neutral, you have
finished to restart the TCU (ignition off/on)
E engine speed too low,
raise engine speed
E engine speed too high,
lower engine speed
T transmission oil temperature too low,
heat up transmission
T transmission oil temperature too high
cool down transmission
FT transmission temperature not in Transmissions stays in neutral, you have
defined range during calibration to restart the TCU (ignition off/on)
FB operating mode not NORMAL or Transmissions stays in neutral, you have
transmission temperature sensor to restart the TCU (ignition off/on)
defective or storing of Calibrated
values to EEPROM-has failed.
FO Outputspeed_not_zero Transmissions stays in neutral, you have
FN Shift lever not in Neutral position Transmissions stays in neutral, you have
FP Parkbrake_not_applied Transmissions stays in neutral, you have
STOP AEB - Starter was used incorrect Transmissions stays in neutral, you have
or is defective. Wrong device or to restart the TCU (ignition off/on)
wrong cable used
DEFINITION OF OPERATING MODES

NORMAL:
There's no failure detected in the transmission-system or the failure has no or slight effects on transmission
control. TCU will work without or in special cases with little limitations. (see following table)
SUBSTITUTE CLUTCH CONTROL:

TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the
substitute strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25)
LIMP-HOME:
The detected failure in the system has strong limitations to transmission control. TCU can engage only one
gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift
the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward
or reverse, the TCU will select the limp-home gear .
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and
the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direc-
tion.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to
slow down the vehicle and must shift the gear selector into neutral position.
TRANSMISSION-SHUTDOWN:
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission
shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU-SHUTDOWN:
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will
engage, also all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
TABLE OF FAULT CODES 2 - 48
Fault
MEANING OF THE FAULT CODE
Code SPN FMI reaction of the TCU possible steps to repair remarks
possible reason for fault detection
(hex)
11 5000 12 LOGICAL ERROR AT GEAR RANGE TCU shifts transmission to check the cables from TCU to shift lever failure cannot be
SIGNAL TCU detected a wrong neutral check signal combinations of shift lever detected in systems with
signal combination for the gear range OP-Mode: transmission positions for gear range DW2/DW3 shift lever
cable from shift lever to TCU is broken shutdown
cable is defective and is contacted to fault is taken back if TCU
battery voltage or vehicle ground detects a valid signal for
shift lever is defective the position
12 5010 12 LOGICAL ERROR AT DIRECTION TCU shifts transmission to check the cables from TCU to shift lever fault is taken back if TCU
SELECT SIGNAL neutral check signal combinations of shift lever detects a valid signal for
TCU detected a wrong signal combination OP-Mode: transmission positions F-N-R the direction at the shift
for the direction shutdown lever
cable from shift lever to TCU is broken
cable is defective and is contacted to
battery voltage or vehicle ground
shift lever is defective
13 5020 12 LOGICAL ERROR AT ENGINE after selecting neutral, TCU check engine derating device This fault is reset after
DERATING DEVICE changes to OP-Mode limp power up of TCU
TCU detected no reaction of engine home
while derating device activ
TRANSMISSION
15 5040 12 LOGICAL ERROR AT DIRECTION TCU shifts transmission to check the cables from TCU to shift fault is taken back if TCU
SELECT SIGNAL 2. SHIFT LEVER neutral if selector activ lever 2 detects a valid neutral
TCU detected a wrong signal combination OP-Mode: transmission check signal combinations of shift lever signal for the direction
for the direction shutdown if selector activ positions F-N-R at the shift lever
cable from shift lever 2 to TCU is broken
battery voltage or vehicle ground
shift lever is defective
16 5050 12 LOGICAL ERROR AT AXLE OP-Mode: normal check the cables from TCU to
CONNECTION feedback axle connection feedback axle connection switch
measured by TCU and output signal axle check signals of the feedback axle
connection don't fit connection switch
axle can't be connected or
disconnected due to mechanical
problem
one of the cables from feedback
axle connection -switch to TCU is
W110/W110TC
broken
Fault
(hex)
17 5060 4 S.C. TO GROUND AT SPEED SIGNAL customer specific check the cable from TCU to speed
7 KM/HTCU detected a wrong voltage at signal 7km/h device
W110/W110TC
the output pin, that looks like a s.c. check the connectors from speed
to vehicle ground: signal 7km/h to TCU
cable is defective and is contacted to check the resistance of speed signal
vehicle ground 7 km/h device
speed signal 7 km/h device has an
internal defect
connector pin is contacted to vehicle
ground
18 5060 3 S.C. TO BATTERY VOLTAGE AT SPEED customer specific check the cable from TCU to speed
SIGNAL 7 KM/H signal 7 km/h device
TCU detected a wrong voltage at the check the connectors from speed signal
output pin, that looks like a s.c. to 7 k m/h to TCU
battery voltage: check the resistance of speed signal
cable is defective and is contacted to 7 km/h device
battery voltage
speed signal 7 km/h device has
an internal defect
connector pin is contacted to battery
voltage
TRANSMISSION
19 5060 5 O.C. AT SPEED SIGNAL 7KM/HTCU customer specific check the cable from TCU to speed
detected a wrong voltage at the output signal 7 km/h device
pin, that looks like a o.c. for this output pin: check the connectors from speed signal
cable is defective and has no 7 km/h device to TCU
connection to TCU check the resistance of speed signal
speed signal 7 km/h device has an 7 km/h device
internal defect
connector has no connection to TCU
25 5110 3 S.C. TO BATTERY VOLTAGE OR O.C. no reaction, check the cable from TCU to the sensor
AT TRANSMISSION SUMP TCU uses default check the connectors
TEMPERATURE SENSOR INPUT temperature check the temperature sensor
the measured voltage is too high: OP-Mode: normal
cable is defective and is contacted
to battery voltage
cable has no connection to TCU
temperature sensor has an internal
defect
2 - 49
voltage or is broken
Fault
2 - 50
(hex)
26 5110 4 S.C. TO GROUND AT TRANSMISSION no reaction, check the cable from TCU to the sensor
SUMP TEMPERATURE SENSOR INPUT TCU uses default check the connectors
the measured voltage is too low: temperature check the temperature sensor
cable is defective and is contacted to OP-Mode: normal
vehicle ground
temperature sensor has an internal
defect
ground
29 5130 3 S.C. TO BATTERY VOLTAGE OR O.C. TCU uses default value check the cable from TCU to the sensor
AT PARKING BRAKE SENSOR INPUT OP-Mode: normal check the connectors
the measured voltage is too high: check the parking brake sensor
battery voltage
sensor has an internal defect
voltage or is broken
2A 5130 4 S.C. TO GROUND PARKING BRAKE TCU uses default value check the cable from TCU to the sensor
SENSOR INPUT the measured voltage OP-Mode: normal check the connectors
is too low: check the parking brake sensor
TRANSMISSION
vehicle ground
sensor has an internal defect
ground
2B 5313 12 INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU check the cable from TCU to the sensor
the measured voltage from CCO and shifts to neutral check the cable from TCU to the sensor
CCO2 signal don't match: While not inching: check the connectors
cable is defective no change check sensor
sensor has an internal defect OP-Mode: normal
31 5140 3 S.C. TO BATTERY VOLTAGE OR O.C. OP-Mode: substitute clutch check the cable from TCU to the sensor
AT ENGINE SPEED INPUT control check the connectors
TCU measures a voltage higher than check the speed sensor
7.00 V at speed input pin
battery voltage
speed sensor has an internal defect
W110/W110TC
voltage or has no contact

Fault
(hex)
32 5140 4 S.C. TO GROUND AT ENGINE SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor
INPUT control check the connectors
W110/W110TC
TCU measures a voltage less than 0.45V check the speed sensor
at speed input pin
cable / connector is defective and is
contacted to vehicle ground
33 5140 12 LOGICAL ERROR AT ENGINE SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor This fault is reset after
INPUT control check the connectors power up of TCU
TCU measures a engine speed over check the speed sensor
a threshold and the next moment the check the sensor gap
measured speed is zero
cable / connector is defective and has
bad contact
sensor gap has the wrong size
AT TURBINE SPEED INPUT control check the connectors
TCU measures a voltage higher than if a failure is existing at check the connectors
7.00 V at speed input pin output speed,TCU shifts to check the speed sensor
cable is defective and is contacted to neutral
TRANSMISSION
battery voltage OP-Mode: limp home

35 5150 4 S.C. TO GROUND AT TURBINE SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor
INPUT control check the connectors
TCU measures a voltage less than 0.45V if a failure is existing at check the speed sensor
at speed input pin output speed,
cable / connector is defective and is TCU shifts to neutral
contacted to vehicle ground OP-Mode: limp home
36 5150 12 LOGICAL ERROR AT TURBINE SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor This fault is reset after
INPUT control check the connectors power up of TCU
TCU measures a turbine speed over a if a failure is existing at check the speed sensor
threshold and at the next moment the output speed, check the sensor gap
measured speed is zero TCU shifts to neutral
cable / connector is defective and has OP-Mode: limp home
2 - 51
bad contact
Fault
2 - 52
(hex)
AT INTERNAL SPEED INPUT control check the connectors
TCU measures a voltage higher than check the speed sensor
7.00 V at speed input pin
battery voltage
38 5160 4 S.C. TO GROUND AT INTERNAL OP-Mode: substitute clutch check the cable from TCU to the sensor
SPEED INPUT control check the connectors
TCU measures a voltage less than 0.45V check the speed sensor
at speed input pin
cable / connector is defective and is
39 5160 12 LOGICAL ERROR AT INTERNAL OP-Mode: substitute clutch check the cable from TCU to the sensor This fault is reset after
TRANSMISSION
SPEED INPUT control check the connectors power up of TCU

TCU measures a internal speed over check the speed sensor
a threshold and at the next moment the check the sensor gap
measured speed is zero
cable / connector is defective and has
bad contact
3A 5170 3 S.C. TO BATTERY VOLTAGE OR O.C. special mode for gear check the cable from TCU to the sensor
AT OUTPUT SPEED INPUT selection check the connectors
TCU measures a voltage higher than OP-Mode: substitute clutch check the speed sensor
12.5 V at speed input pin control
cable is defective and is contacted to if a failure is existing at
battery voltage turbine speed,
cable has no connection to TCU TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
W110/W110TC
Fault
(hex)
3B 5170 4 S.C. TO GROUND AT OUTPUT SPEED special mode for gear check the cable from TCU to the sensor
INPUT selection check the connectors
W110/W110TC
TCU measures a voltage less than 1.00V OP-Mode: substitute clutch check the speed sensor
at speed input pin control
cable / connector is defective and is if a failure is existing at
contacted to vehicle ground turbine speed,
speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
3C 5170 12 LOGICAL ERROR AT OUTPUT SPEED special mode for gear check the cable from TCU to the sensor This fault is reset after
INPUT selection check the connectors power up of TCU
TCU measures a output speed over OP-Mode: substitute clutch check the speed sensor
a threshold and at the next moment the control check the sensor gap
measured speed is zero if a failure is existing at
cable / connector is defective and has turbine speed,
bad contact TCU shifts to neutral
3E 5180 2 OUTPUT SPEED ZERO DOESN'T FIT special mode for gear check the sensor signal of output This fault is reset after
TO OTHER SPEED SIGNALS selection speed sensor power up of TCU
if transmission is not neutral and the OP-Mode: substitute clutch check the sensor gap of output speed
shifting has finished, control sensor
TRANSMISSION
TCU measures outputspeed zero and if a failure is existing at check the cable from TCU to the sensor
turbine speed or internal speed not turbine speed,
equal to zero. TCU shifts to neutral
54 5260 9 DCT1 TIMEOUT OP-Mode: normal check display computer
Timeout of CAN-message DCT1 from check wire of CAN-Bus
display computer check cable to display computer
interference on CAN-Bus
CAN wire/connector is broken
CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
71 5480 3 S.C. TO BATTERY VOLTAGE AT TCU shifts to neutral check the cable from TCU to the
CLUTCH K1 OP-Mode: limp home gearbox
the measured resistance value of the if failure at another clutch check the connectors from TCU to the
valve is out of limit, the voltage at K1 is pending gearbox
valve is too high. TCU shifts to neutral check the regulator resistance
2 - 53
Fault
2 - 54
(hex)
cable / connector is defective and has OP-Mode: TCU shutdown check internal wire harness of the
contact to battery voltage gearbox
regulator has an internal defect
72 5480 4 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral check the cable from TCU to the
the measured resistance value of the OP-Mode: limp home gearbox
valve is out of limit, the voltage at K1 if failure at another clutch check the connectors from gearbox
valve is too low. is pendingTCU shifts to to TCU
cable / connector is defective and has neutral check the regulator resistance
contact to vehicle ground OP-Mode: TCU shutdown check internal wire harness of the
cable / connector is defective and has gearbox
contact to another regulator output
of the TCU
73 5480 5 O.C. AT CLUTCH K1 TCU shifts to neutral check the cable from TCU to the
valve is out of limit. if failure at another clutch check the connectors from gearbox
cable / connector is defective and has is pending to TCU
no contact to TCU TCU shifts to neutral check the regulator resistance
regulator has an internal defect OP-Mode: TCU shutdown check internal wire harness of the
gearbox
TRANSMISSION
the measured resistance value of the if failure at another clutch check the connectors from gearbox
valve is out of limit, the voltage at K2 is pending to TCU
valve is too low. is pending to TCU
cable / connector is defective and has TCU shifts to neutral check the regulator resistance
contact to another regulator output of
the TCU
W110/W110TC
Fault
(hex)
W110/W110TC
gearbox
valve is out of limit, the voltage at K3 is pendingTCU shifts to to TCU
valve is too high. neutral check the regulator resistance
TRANSMISSION

contact to another regulator output
of the TCU
no contact to TCU is pending check the regulator resistance
regulator has an internal defect TCU shifts to neutral check internal wire harness of the
OP-Mode: TCU shutdown gearbox
valve is out of limit, the voltage at K4 is pending to TCU
2 - 55

Fault
2 - 56
(hex)
the TCU
the measured resistance value OP-Mode: limp home gearbox
of the valve is out of limit. if failure at another clutch check the connectors from gearbox
gearbox
CLUTCH KV OP-Mode: limp home gearbox
valve is out of limit, the voltage at KV is pending to TCU
TRANSMISSION
85 5520 4 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral check the cable from TCU to the
valve is out of limit, the voltage at KV if failure at another clutch check the connectors from gearbox
the TCU
86 5520 5 O.C. AT CLUTCH KV TCU shifts to neutral check the cable from TCU to the
W110/W110TC

Fault
(hex)
gearbox
W110/W110TC
CLUTCH KR OP-Mode: limp home gearbox
valve is out of limit, the voltage at KR is pending to TCU
88 5530 4 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral check the cable from TCU to the
valve is out of limit, the voltage at KR if failure at another clutch check the connectors from gearbox
the TCU
TRANSMISSION
89 5530 5 O.C. AT CLUTCH KR TCU shifts to neutral check the cable from TCU to the
gearbox
91 5560 4 S.C. TO GROUND AT RELAY REVERSE backup alarm will be on check the cable from TCU to the
WARNING ALARM until TCU power down backup alarm device
TCU detected a wrong voltage at the even if fault vanishes check the connectors from backup
output pin, that looks like a s.c. to vehicle (loose connection) alarm device to TCU
ground OP-Mode: normal check the resistance of backup
cable is defective and is contacted alarm device
to vehicle ground
backup alarm device has an internal
defect
ground
2 - 57
Fault
2 - 58
(hex)
92 5560 3 S.C. TO BATTERY VOLTAGE AT RELAY no reaction check the cable from TCU to the
REVERSE WARNING ALARM OP-Mode: normal backup alarm device
TCU detected a wrong voltage at the check the connectors from backup
output pin, that looks like a s.c. to battery alarm device to TCU
voltage check the resistance of backup
cable is defective and is contacted to alarm device
battery voltage
defect
voltage
93 5560 5 O.C. AT RELAY REVERSE WARNING no reaction check the cable from TCU to the
ALARM TCU detected a wrong voltage OP-Mode: normal backup alarm device
at the output pin, that looks like a o.c. for check the connectors from backup
this output pin alarm device to TCU
cable is defective and has no check the resistance of backup
connection to TCU alarm device
defect
connector has no connection to TCU
B1 5660 2 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral check pressure at clutch K1
TCU calculates a differential speed at OP-Mode: limp home check main pressure in the system
TRANSMISSION
closed clutch K1. If this calculated value if failure at another clutch check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch. TCU shifts to neutral check sensor gap at output speed
low pressure at clutch K1 OP-Mode: TCU shutdown sensor
low main pressure check signal at internal speed sensor
wrong signal at internal speed sensor check signal at output speed sensor
wrong signal at output speed sensor replace clutch
wrong size of the sensor gap
clutch is defective
W110/W110TC
clutch is defective
Fault
(hex)
W110/W110TC
clutch is defective
TCU calculated a difference speed at OP-Mode: limp home check main pressure in the system
TCU calculates a differential speed if failure at another clutch check sensor gap at internal speed
at closed clutch K4. If this calculated is pending sensor
value is out of range, TCU interprets this TCU shifts to neutral check sensor gap at turbine speed
as slipping clutch. OP-Mode: TCU shutdown sensor
low pressure at clutch K4 check signal at internal speed sensor
low main pressure check signal at turbine speed sensor
wrong signal at internal speed sensor replace clutch
wrong signal at turbine speed sensor
TRANSMISSION

clutch is defective
B5 5680 2 SLIPPAGE AT CLUTCH KV TCU shifts to neutral check pressure at clutch KV
closed clutch KV. If this calculated value if failure at another clutch check sensor gap at internal speed
slipping clutch. TCU shifts to neutral check sensor gap at turbine speed
low pressure at clutch KV OP-Mode: TCU shutdown sensor
wrong signal at internal speed sensor check signal at turbine speed sensor
wrong signal at turbine speed sensor replace clutch
clutch is defective
B6 5685 2 SLIPPAGE AT CLUTCH KR TCU shifts to neutral check pressure at clutch KR
closed clutch KR. If this calculated value if failure at another clutch check sensor gap at internal speed
slipping clutch. TCU shifts to neutral check sensor gap at turbine speed
2 - 59
low pressure at clutch KR OP-Mode: TCU shutdown sensor

Fault
2 - 60
(hex)
wrong signal at internal speed sensor check signal at turbine speed sensor
wrong signal at turbine speed sensor replace clutch
clutch is defective
B7 5700 0 OVERTEMP SUMP no reaction cool down machine
TCU measured a temperature in the oil OP-Mode: normal check oil level
sump that is over the allowed threshold. check temperature sensor
BA 5730 0 DIFFERENTIAL PRESSURE OIL FILTER no reaction check oil filter
TCU measured a voltage at differential OP-Mode: normal check wiring from TCU to differential
pressure switch out of the allowed range pressure switch
oil filter is polluted check differential pressure switch
cable/connector is broken or cable/ (measure resitance)
connector is contacted to battery
voltage or vehicle ground
differential pressure switch is defective
C3 5760 0 OVERTEMP CONVERTER OUTPUT no reaction cool down machine
TCU measured a oil temperature at the OP-Mode: normal check oil level
converter ouput that is over the allowed check temperature sensor
TRANSMISSION
threshold.
D1 5810 3 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C check cables and connectors to fault codes no. 21 to no. 2C
SUPPLY FOR SENSORS sensors, which are supplied from AU1 may be a reaction of this
TCU measures more than 6V at the pin check the power supply at the pin AU1 fault
AU1 (5V sensor supply) (should be appx. 5V)
D2 5810 4 S.C. TO GROUND AT POWER SUPPLY see fault codes no. 21 to 2C check cables and connectors to fault codes no. 21 to no. 2C
FOR SENSORS sensors, which are supplied from AU1 may be a reaction of this
TCU measures less than 4V at the pin check the power supply at the pin AU1 fault
AU1 (5V sensor supply) (should be appx. 5V)
D3 5820 4 LOW VOLTAGE AT BATTERY shift to neutral check power supply battery
measured voltage at power supply is OP-Mode: TCU shutdown check cables from batteries to TCU
lower than 10 V (12V device) check connectors from batteries to TCU
lower than 18 V (24V device)
D4 5820 3 HIGH VOLTAGE AT BATTERY shift to neutral check power supply battery
measured voltage at power supply is OP-Mode: TCU shutdown check cables from batteries to TCU
higher than 18 V (12V device) check connectors from batteries to TCU
W110/W110TC
higher than 32.5 V (24V device)

Fault
(hex)
D5 5830 2 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral check fuse
W110/W110TC
TCU switched on VPS1 and measured OP-Mode: TCU shutdown check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 check connectors from gearbox to TCU
and measured VPS1 is still on replace TCU
cable or connectors are defect and are
contacted to battery voltage
permanent power supply KL30 missing
TCU has an internal defect
D6 5840 2 ERROR VALVE POWER SUPPLY VPS2 shift to neutral check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shutdown check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 check connectors from gearbox to TCU
and measured VPS2 is still on replace TCU
contacted to battery voltage
permanent power supply KL30 missing
TRANSMISSION
TCU has an internal defect

E3 5860 3 S.C. TO BATTERY VOLTAGE AT no reaction check the cable from TCU to the display
DISPLAY OUTPUT OP-Mode: normal check the connectors at the display
TCU sends data to the display and change display
measures allways a high voltage level
on the connector
cable or connectors are defective and
are contacted to battery voltage
display has an internal defect
E4 5860 4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction check the cable from TCU to the display
TCU sends data to the display and OP-Mode: normal check the connectors at the display
measures allways a high voltage level change display
on the connector
cable or connectors are defective and
are contacted to vehicle ground
display has an internal defect
2 - 61
Fault
2 - 62
(hex)
E5 5270 9 DISPID1_TIMEOUT TCU select parameter set check display controller
Timeout of CAN-message DISPID1 from with ID0 check wire of CAN-Bus
display controller OP-Mode: Limp Home check cable to display controller
interference on CAN-Bus
CAN wire/connector is broken
CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
E6 5880 2 ILLEGAL ID REQUEST VIA CAN transmission stay neutral
OP-Mode: TCU shutdown
F1 5890 2 GENERAL EEPROM FAULT no reaction replace TCU often shown together
TCU can't read non volantile memoy OP-Mode: normal with fault code F2
TCU is defective
F2 5900 13 CONFIGURATION LOST transmission stay neutral Reprogramm the correct configuration
TCU has lost the correct configuration OP-Mode: TCU shutdown for the vehicle (e.g. with cluster
and can't control the transmission. controller,...)
interference during saving data on
non volatile memory
TCU is brand new or from another
TRANSMISSION
vehicle
F3 5910 13 APPLICATION ERROR transmission stay neutral replace TCU !! This fault occurs only if
something of this application is wrong OP-Mode: TCU shutdown an test engineer did
something wrong in the
application of the vehicle
F5 5930 7 CLUTCH FAILURE transmission stay neutral check clutch TCU shows also the
AEB was not able to adjust clutch filling OP-Mode: TCU shutdown affected clutch on the
parameters Display
One of the AEB-Values is out of limit
F6 5930 13 CLUTCH ADJUSTMENT DATA LOST default values = 0 for AEB execute AEB
OR INCHPEDAL CALIBRATION DATA offsets used
LOST OP-Mode: normal
TCU was not able to read correct clutch no Inchmode available
adjustment parameters
interference during saving data on non
volatile memory
TCU is brand new
W110/W110TC
2.2.13 TRANSMISSION SHIFTER LOGIC INFORMATION
Function Shifter Shifter Shifter Shifter Harness Harness Trans.

Wire Tower Shroud Wire # ped/cab # ECM #
Color Connector Connector
power B+ red/black A A 19A 43 45
forward V yellow - B 25F 44 43
reverse R pink - C 25R 45 64
neutral N gray - D 25T 46 67
gear2(3-4) B2 green B - 25W 48 65
gear1(1-2) B1 blue C - 25Z 49 63
downshift DS purple D - 25Y 50 22
Note Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low
and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is
engaged.
2.2.14 RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES
Transmission Transmission Transmission Clutch # Transmission Wire # Trans/Cab

ECM ECM Valve Valve
Function Pin # Pin # Pin #
A1P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 all Y all K 7 25S 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12
2.3 TRANSMISSION
2.3.1 SPECIAL TOOLS
380001559 380001560 380001577 380001568 Transmission

Transmission torque Transmission Transmission valve output shaft seal installation
converter seal input/output shaft seal adjustment tool
installation tool installation tool tool set
W110R0350
380001554 380001556 Clutch pack 380001558 Alignment

Nesting plate holder and spring dowel set
compressor tools
380001555 Gear puller 380001557 Clutch 380001567 Clutch

collet set assembly holding knob spring compressor
set
W110R0351

Oil pipes
Studs ................................................................................................................................. 9 Nm (80 lb-inch)
Socket head screw ........................................................................................................ 23 Nm (204 lb-inch)
Screw plug ............................................................................................................................ 51 Nm (38 lb-ft)
Clutch K1, K2, K3, K4 Stud ................................................................................................ 17 Nm (150 lb-inch)
Plugs .................................................................................................................................. 25 Nm (221 lb-inch)
Output shaft
Output shaft screws (apply Loctite 243 to threads) ........................................................ 23 Nm (204 lb-inch)
Housing cover screws (apply Loctite 574 to threads) ..................................................... 46 Nm (407 lb-inch)
Output flange screws ..................................................................................................... 34 Nm (301 lb-inch)
Oil feed housing and transmission pump
Transmission pump screws ............................................................................................ 46 Nm (407 lb-inch)
Oil feed housing screws ................................................................................................. 25 Nm (221 lb-inch)
Engine connection and converter
Input shaft screws .............................................................................................................. 115 Nm (85 lb-ft)
Converter housing screws .................................................................................................... 68 Nm (50 lb-ft)
Cover .............................................................................................................................. 23 Nm (204 lb-inch)
Converter cover ............................................................................................................. 46 Nm (407 lb-inch)
Input flange ..................................................................................................................... 34 Nm (301 lb-inch)
Duct plate
Screws .......................................................................................................................... 25 Nm (221 lb-inch)
Screw plug ..................................................................................................................... 30 Nm (265 lb-inch)
Hydraulic control unit .......................................................................................................... 9.5 Nm (84 lb-inch)
Filter
Filter head screws ......................................................................................................... 25 Nm (221 lb-inch)
Oil distribution cover screws .......................................................................................... 25 Nm (221 lb-inch)
Speed sensor and inductive transmitter
Speed sensor screw ...................................................................................................... 23 Nm (204 lb-inch)
Inductive transmitter ...................................................................................................... 30 Nm (265 lb-inch)
Cover plate .................................................................................................................... 23 Nm (204 lb-inch)
Screw plug ........................................................................................................................ 140 Nm (103 lb-ft)
Clutch KV and KR plate clearance ............................................................. 2.5 to 2.7 mm (0.098 to 0.106 inch)
Clutch K1, K2,K3 plate clearance .............................................................. 2.1 to 2.3 mm (0.083 to 0.090 inch)
Clutch K4 Plate Clearance ......................................................................... 1.2 to 1.4 mm (0.047 to 0.055 inch)
Note The manufactured reserves the right to make improvements in design or changes in specifications at any
time without incurring any obligation to install them on units previously sold.
2.3.4 DISASSEMBLY STEP 4

STEP 1
GD98M837
GD98M833 Remove two socket head screws and install

380001577 transmission valve adjustment tool set.
Fasten transmission on an assembly stand using
Remove remaining 21 socket head screws securing
transmission mounting brackets.
control valve. Loosen and remove hex rods (part of
380001577) from studs then remove control valve.
STEP 2
STEP 5
GD98M835
Remove and discard oil filter. GD98M838
Remove both gaskets and the intermediate plate.

STEP 3
STEP 6
GD98M836
Remove hex head screws securing filter head. Re- GD98M839
move filter head from transmission.

Remove socket head screws and hex nuts. Remove
duct plate. Remove flat gasket.
STEP 7 STEP 10
GD98M844 GD98M847
Bend lock plate away from hex head screws. Remove Using proper size rod, press input shaft and converter
two hex head screws, lock plate, and washer. Re- from cover.
move input flange from shaft.
STEP 11
STEP 8
GD98M848
GD98M845
Remove retaining ring then remove bearing.
Put alignment marks on converter cover and hous-
ing to aid in assembly. Remove 12 nuts and hex head STEP 12
screws.
STEP 9
GD98M849
Remove four hex head screws and remove diaphragm

and input shaft.
GD98M846
Connect suitable lifting equipment to shaft. Remove

cover, shaft, and converter from transmission and
place in hydraulic press.
STEP 13 STEP 16
GD98M850 GD98M853
Put input shaft and diaphragm in vise as shown. Re- Remove the socket head screws for removal of the
move 12 hex head screws to separate diaphragm and transmission pump.
input shaft.
STEP 17
STEP 14
GD98M854
GD98M851
Apply a bearing separator on the splines shoulder of
Remove the inductive transmitter. the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
STEP 15
Note If traces of wear should be encountered in
the pump housing or the cam disk, the complete pump
has to be replaced.
STEP 18
GD98M852
Remove the hex head screws and remove the con-

verter housing.
GD98M855
Separate the transmission pump from stator. Sepa-

rate the cam plate from pump.
STEP 19 STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
GD98M856
Remove the hex head screws and remove the oil feed
housing. Remove the flat gasket.
STEP 20 GD98M862
Remove the speed sensor and both inductive trans-

mitters.
STEP 25
GD98M860
Remove the hex head screws, cover, and flat gasket.
STEP 21
GD98M863
Remove the hex nuts and the two covers.
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
GD98M864
STEP 22
Pry the shaft seal out of the housing bore. Install 380001558 alignment dowel set.
Note The following steps describe the common re-

moval of all clutches.
STEP 27 STEP 30
Remove 380001557 clutch assembly holding knob set
and lift cover free.
STEP 31
BK00D029
Install 380001557 clutch assembly holding knob set.

With knobs installed on all clutches in housing cover,
install lifting eyebolt set and lifting device to trans-
mission cover. GD98M867
Remove the socket head screws and remove the

STEP 28
output shaft and both oil baffle plates.
STEP 32
BK00D028
Separate the cover along with clutches from the trans-

mission housing, using lifting device. GD98M872
Remove clutch K2.

STEP 29
STEP 33
BK00D026
Place clutch disc carriers onto 380001554 nesting GD98M873

plate.
Remove clutch K1 while lifting clutch K4.
STEP 34 STEP 37
GD98M874 GD98M877
Remove clutch K3. Remove the bearing outer race and pull output shaft
out of the housing bore.
STEP 35
STEP 38
GD98M875
GD98M878
Remove clutch K4 while lifting input shaft slightly.
Remove the rectangular ring and separate ball bear-
STEP 36 ing from the shaft.
Note The following steps are for the disassembly of

the clutch KV. The disassembly of the clutch KR is
similar.
STEP 39
GD98M876
Remove clutches KV and KR together with input shaft.
GD98M879
Remove the sealing ring. Pull the tapered roller bear-

ing from the shaft. Remove the opposite tapered roller
bearing.
STEP 40 STEP 43
GD98M881 BK00D020
Separate the clutch disc carrier from the shaft. Remove snap ring.
STEP 41 STEP 44
GD98M882 BK00D019
Remove the snap ring and remove the clutch disc Remove the compression spring.
pack.
STEP 45
STEP 42
GD98M885
BK00D018
Preload compression spring using 380001556 clutch Remove piston from clutch pack holder. Remove and
pack holder and spring compressor tool. discard the O-rings from piston.
STEP 46 STEP 48
GD98M886 GD98M889
Remove the snap ring. Remove the snap ring and remove the ball bearing.
STEP 47 Note The following steps are for disassembly of

clutch K3. Disassembly of clutches K1 and K2 is simi-
lar.
STEP 49
GD98M887
GD98M890
Remove the rectangular ring. Pull the tapered roller

bearing from the shaft.
STEP 50
GD98M888
Press the idler gear from the shaft using a bearing

separator. Remove released needle bearing.
GD98M892
Remove the thrust washer, thrust bearing, and thrust

washer.
STEP 51 STEP 54
GD98M893 BK00D018
Remove the idler gear. Preload compression spring using 380001556 clutch
pack holder and spring compressor tool.
STEP 52
STEP 55
GD98M894
BKOOD020
Remove the needle bearings and thrust bearing.
Remove the snap ring.
STEP 53
STEP 56
GD98M895
BK00D019
Remove the snap ring and remove the clutch disc
pack. Remove the compression spring.
STEP 57 STEP 59
BS00G001 GD98M800
Remove the sealing ring. Remove bearing using bear- Remove and discard two sealing rings. Pull two bear-
ing puller. Tap assembly until piston drops out of the ings from shaft using bearing puller. Remove the snap
clutch pack carrier. Then, remove and discard O-rings ring and separate the clutch disc carrier from the shaft.
from piston.
STEP 60
STEP 58
GD98M801
BK00D022
Remove the snap ring and remove the clutch disc
Remove the clutch disc carrier from the shaft. pack.
Note The following steps are for the disassembly of STEP 61

the clutch K4.
BK00D018
Preload compression spring using 380001556 clutch

pack holder and spring compressor tool.
STEP 62 Note The following two steps are for disassembly

of the input shaft.
Note A snap ring is used to lock turbine shaft in

input shaft. Snap ring will be destroyed when turbine
shaft is pressed from input shaft.
STEP 64
BK00D020
STEP 63
GD98M803
If turbine shaft is to be removed from input shaft, use

proper size diameter sleeve or rod and press turbine
shaft out of input shaft.
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
Remove the compression spring.
2.3.5 ASSEMBLY STEP 69

Note The following Steps are for the reassembly of
the oil pipes.
STEP 66
2
GD98M607
Install a new O-ring on plug. Tighten the plug to a

3 torque of 51 Nm (38 lb-ft).
STEP 70
GD98M603
Install suction tube (1), pressure pipes (2), and lubri-

cation pressure pipe (3) in housing.
STEP 67
Secure suction tube (1) and pressure pipes (2) with GD98M608
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 lb-in) Install all bearing outer races in housing bores.
STEP 68 STEP 71
GD98M609
GD98M605
Tilt the cover 180 degrees. Install the suction tubes Install both oil pipes into the housing cover. Tilt the
and pressure pipes into the housing bores using a cover 180 degrees and install pipes into the housing
rolling tool. bores using a rolling tool.
Note Pipe end of the pressure pipes must be slightly Note The pipe end must be slightly below the hous-
below the housing plane face. ing plane face.
STEP 72 STEP 75
GD98M610 BK00D019
Install the studs. Tighten the studs to a torque of 9

Nm (80 lb-in).
Note The following Steps are for the assembly of

clutches KV and KR, starting with assembly of the
clutch disc carrier.
STEP 73
BK00D018
Install compression spring and two spring cups in

clutch disc carrier. Preload compression spring using
380001556 clutch pack holder and spring compres-
sor tool.
STEP 76
GD98M612
Check that drain hole is clear and free of foreign mat-

ter. Install both O-rings in recesses of the piston and
apply oil.
STEP 74
BK00D020
Install the snap ring.
Note The following Steps are for the KV and KR

clutch disc packs. The disc stacking of clutches KV
and KR is identical.
GD98M613
Install piston in clutch disc carrier.
STEP 77 STEP 79
A
4
3 3
2 6
7
GD98M617
Install end shim and snap ring.

4 BS02C134
STEP 80
A. Running clearance 2.5 to 2.7 mm (0.098 to 0.106 in) -
1. Plate carrier - 2. Piston - 3. Outer plate - One-sided
coated - 4. Inner plates - 5. Outer plates - Coated on both
sides - 6. Snap ring - 7. End shim.
Install clutch disc plates in KV and KR clutch disc

carriers in position and sequence shown above. In-
stall outer plates (3) with steel faced side facing pis-
ton and end shim (7). Install two inner plates (4) on
the end shim side.
Note Snap rings of different thickness are available

for adjustment of the running clearance. To ensure cor- GD98M618
rect adjustment, do not apply oil to clutch discs until
after adjustment is completed. Adjust running clearance to 2.5 to 2.7 mm (0.098 to
0.106 in). Press down on the end shim with approxi-
STEP 78 mately 10 kg (20 lb). Measure and record dimension
(A) from carrier face to end shim using depth gauge
as shown.
Example
Dimension A ................................ 7,25 mm (0.29 in)
GD98M616
Install the clutch disc pack.
STEP 81 STEP 84
GD98M619 GD98M621
Use tools to lift the end shim against snap ring (up- Apply Loctite 243 to stud. Tighten stud to a torque of
ward) until contact is obtained. Measure and record 17 Nm (150 lb-in).
dimension (B) from carrier face to end shim using
depth gauge as shown. Subtract this measurement STEP 85
from the measurement of Step 80. The difference is
the running clearance.
Example
Dimension A ................................ 7.25 mm (0.29 in)
Dimension B ................................ 4.75 mm (0.19 in)
Difference = Running ................... 2.50 mm (0.10 in)
Clearance
Required running clearance is 2.5 to 2.7 mm (0.098 to

0.106 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance. GD98M622
Install ball bearing until contact is obtained. Secure

STEP 82 using snap ring.
Remove clutch disc pack, apply oil to discs, and in-
stall clutch disc pack, end shim, and snap ring as STEP 86
determined in Step 81.
STEP 83
GD98M623
Install needle bearing.
GD98M620
Install idler gear to align and engage all inner discs,

then remove idler gear.
STEP 87 STEP 90
GD98M624 BP00G020
Support the idler gear on the bearing inner race. Press Install gear and shaft into heated bore.
the idler gear against the shoulder.
STEP 91
STEP 88
BK00D024
GD98M625
Heat bearing.
Secure idler gear using snap ring.
STEP 92
STEP 89
WARNING
Always wear heat protective gloves to prevent
burning your hand when handling heated parts.
BK00D023
Use heat gun to heat assembled clutch disc carrier

inner bore.
BK00D025
Install heated bearing on shaft against shaft shoul-

der.
STEP 93 STEP 96
Check operation of the clutch using compressed air.
Note The following steps are for assembly of clutch

K1, K2, and K3.
STEP 94
GD98M632

ter. Install both O-rings in recesses of piston and ap-
ply oil.
STEP 97
GD98M630
Press bearing against shoulder of shaft. Apply Loctite

243 to the stud and install the stud. Tighten the stud
to a torque of 17 Nm (150 lb-in).
STEP 95
GD98M633
Install piston in clutch disc carrier.
STEP 98
GD98M631
Install the clutch disc carrier until contact is obtained.
GD98M634
Install the compression spring and spring cup.
STEP 99 STEP 101
A
3 5
2
6
7
1
BK00D019
4 BS02C130A

1. Plate carrier - 2. Piston - 3. Outer plate - one-sided
coated - 4. Inner plates - 5. Outer plates - coated on both
Install clutch disc plates in K1, K2, and K3 clutch

disc carriers in position and sequence shown above.
Install outer plate (3) with steel faced side facing pis-
ton. Install two outer and inner plates each on the end
BK00D018 shim side.
Install compression spring and two spring cups in Note Snap rings of different thickness are available
clutch disc carrier. Preload compression spring using for adjustment of the running clearance. To ensure
380001556 clutch pack holder and spring compres- correct adjustment, do not apply oil to clutch discs
sor tool. until after adjustment is completed.
STEP 100 STEP 102
BK00D020
GD98M636
Install the snap ring. Install the clutch disc pack.

Note The following Steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3
is identical.
STEP 103 STEP 105
GD98M637 GD98M639
Install the end shim and snap ring. Use tools to lift the end shim against snap ring (up-
ward) until contact is obtained. Measure and record
STEP 104 dimension (B) from carrier face to end shim using
depth gauge as shown. Subtract this measurement
Example
Dimension A .................................. 8.2 mm (0.32 in)
Dimension B .................................. 6.1 mm (0.24 in)
Difference = Running ..................... 2.1 mm (0.08 in)
Clearance

GD98M638 0.090 in). Use snap ring(s) of different thickness as
Adjust running clearance for K1, K2, and K3 to 2.1 to necessary to obtain correct running clearance.
2.3 mm (0.083 to 0.090 in). Press down on the end
shim with approximately 10 kg (20 lb). Measure and STEP 106
record dimension (A) from carrier face to end shim Remove clutch disc pack, apply oil to discs, and in-
using depth gauge as shown. stall clutch disc pack, end shim, and snap ring as
Example
Dimension A .................................. 8.2 mm (0.32 in) STEP 107
GD98M640
Install the thrust washer (1), thrust bearing (2), and

thrust washer (3).
Note Install the thrust washer (1) with the chamfer

facing the thrust bearing.
STEP 108 STEP 111
GD98M641 BK00D024
Install both needle bearings. Heat bearing.
STEP 109 STEP 112
WARNING
GD98M642
Install idler gear until all inner discs are engaged.
STEP 110
BK00D025
1
Place heated bearing on the shaft.
2
3 STEP 113
GD98M643
Install the thrust washer (3), thrust bearing (2), and

thrust washer (1). Install the thrust washer (1) with the
chamfer facing the thrust bearing.
Note Ensure the thrust washer (1) is overlapping

with the chaff collar to accommodate all the inner
discs.
Note The following steps are for assembly of clutch STEP 116
K4.
STEP 114
WARNING
GD98M649
Apply Loctite 243 to the stud and install the stud.

Tighten the stud to a torque of 17 Nm (150 lb-in).
STEP 117
GD98M647
Heat the gear to about 120 C (248 F) and install

until seated in position.
STEP 115
GD98M650

ter. Install both O-rings in recesses of the piston and
apply oil.
STEP 118
GD98M648
Install retaining ring to secure gear.
GD98M651
Install piston in clutch disc carrier. Be sure piston

bottoms out.
STEP 119 STEP 121
A 5
6
3
2
7
BK00D019
4
BS02C131

1. Plate carrier - 2. Piston - 3. Outer plate - one-sided
coated 4. Inner plates - 5. Outer plates - coated on both
Install clutch disc plates in K4 clutch disc carrier in

position and sequence shown above. Install outer plate
(3) with steel faced side facing piston.
Note Snap rings of different thickness are available

BK00D018 for adjustment of the running clearance. To ensure cor-
Install compression spring and two spring cups in rect adjustment, do not apply oil to clutch discs until
clutch disc carrier. Preload compression spring using after adjustment is completed.
380001556 clutch pack holder and spring compres-
sor tool. STEP 122
STEP 120
GD98M653
Install clutch disc pack.

BK00D020
Install snap ring.
Note The following Steps are for installing the clutch

disc pack in clutch K4.
STEP 123 STEP 125
GD98M654 GD98M656
Install end shim and snap ring. Use tools to lift the end shim against snap ring (up-
ward) until contact is obtained. Measure and record
STEP 124 dimension (B) from carrier face to end shim using
depth gauge as shown. Subtract this measurement
Example
Dimension A .................................. 7.2 mm (0.28 in)
Dimension B .................................. 6.0 mm (0.24 in)
Difference = Running ..................... 1.2 mm (0.04 in)
Clearance

GD98M655 0.055 in). Use snap ring(s) of different thickness as
Adjust running clearance to 1.2 to 1.4 mm (0.047 to necessary to obtain correct running clearance.
0.055 in). Press down on the end shim with approxi-
mately 10 kg (20 lb). Measure and record dimension STEP 126
(A) from carrier face to end shim using depth gauge Remove clutch disc pack, apply oil to discs, and in-
as shown. stall clutch disc pack, end shim, and snap ring as
Example
Dimension A .................................. 7.2 mm (0.28 in) STEP 127
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.
STEP 128 STEP 131

1
2
3
GD98M658 GD98M661
Assemble two thrust washers and thrust bearing. Assemble thrust washer (3), thrust bearing (2), and
thrust washer (1). Install the thrust washer (1) with the
Note Upper and lower thrust washers are the same chamfer facing the thrust bearing.
thickness.
STEP 132
STEP 129
GD98M662
GD98M659
Install the assembled clutch disc carrier until all the
Install both needle bearings. inner discs are engaged.
STEP 130 STEP 133
GD98M660 GD98M663
Install the idler gear. Install snap ring to secure clutch disc carrier.
STEP 134 STEP 138
WARNING
BK00D024
Heat bearing.
STEP 135
GD98M666
WARNING
Heat gear to about 120 C (248 F) and install on input
Always wear heat protective gloves to prevent shaft until contact is obtained.
STEP 139
BK00D025
GD98M667
Install heated bearing on the shaft shoulder.
Secure gear with snap ring.
STEP 136
STEP 140
Repeat Steps 134 and 135 to install bearing on oppo-
site end of shaft.
STEP 137
Note The following steps are for the reassembly of

the input shaft.
GD98M668
Install snap ring into recess of turbine shaft.
STEP 141 STEP 144
GD98M669 GD98M672
Install the turbine shaft until the snap ring snaps into Install output shaft into housing bore until contact is
the recess of the input shaft. made.
STEP 142 Note The following Steps are for the installation of
the output shaft and clutches. All clutches have a
common installation.
WARNING
Always wear heat protective gloves to prevent STEP 145
KR
K1 K4
AN
AB
K3 K2
KV
GD98M673
BK00D024
Install bearing outer races into housing cover until
Heat bearings and install on turbine shaft until bear- contact is obtained.
ings are against shoulder.
STEP 146
STEP 143
BK00F003
GD98M671
Install the clutches onto 380001554 nesting plate.
Install bearing then install rectangular ring.
STEP 147 STEP 150
BK00D029 GD98M681
Using lifting eye bolt set and acceptable lifting equip- Install the sealing rings and insert rings in their re-
ment, install housing cover onto clutches. Install spective grooves. Apply grease to the sealing rings
380001557 clutch assembly holding knob set to se- and align the rings centrally.
cure clutch shafts to cover.
STEP 151
STEP 148
KR
KV
K4
K2
K1 K3
GD98M692
GD98M679
Install both the O-rings into the annular groove of the
The above photo shows the position of the single oil pipes and apply grease.
clutches in the housing cover.
STEP 152
STEP 149
Tilt the housing cover 180 degrees.
KV AN KR
K4
K2
K1
K3
AB
GD98M866
The above shows the position of the single clutches

and the input and output clutches.
STEP 153 STEP 156
BK00D028 GD98M686
Install output gear and shaft in transmission housing. Install screen sheet on output shaft. Press front and
Install alignment screws. Carefully lower the cover and rear bearings on output shaft until contact with shoul-
clutches into the gear box housing. der of output shaft is made.
STEP 154 STEP 157

Remove 380001557 clutch assembly holding knob set.
STEP 155
GD98M688
Install the screening plate.
GD98M685 STEP 158

Separate the housing cover from the gearbox, using
a lifting device.
Note The following steps are for the reassembly of

the output shaft.
GD98M689
Install the output shaft.
STEP 159 STEP 162
GD98M690 GD98M697
Apply Loctite 243 to the socket head screws and in- Heat the output flange to about 90 C (194 F). Apply
stall the screws. Tighten the screws to a torque of 23 Loctite 574 to the contact area and assemble the flange
Nm (204 lb-in). with the washers and hex head screws. Tighten the
screws to a torque of 34 Nm (301 lb-in). Bend corner
STEP 160 of lock plate over hex head screws.
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
Note The following steps are for the assembly of

the oil feed housing and transmission pump.
STEP 164
GD98M691
Install rectangular rings in grooves of clutch shafts.

Apply grease to rings and align rings.
STEP 161
GD98M702
Install two alignment studs and install the gasket.
GD98M696
Position shaft seal with sealing lip facing oil chamber.

Apply grease to sealing lip. Use 380001560 transmis-
sion output shaft seal installation tool to install seal.
STEP 165 STEP 168
GD98M703 GD98M706
Install the oil feed housing with washers and hex head Install transmission pump.
screws. Screw the hex head screws in only until con-
tact is obtained, do not tighten. STEP 169
STEP 166
GD98M707
Apply grease to new O-rings. Install the O-rings on

GD98M704
the socket head screws.
Install the two alignment screws and install the stator
shaft. STEP 170
STEP 167
GD98M708
Secure the transmission pump with the socket head

GD98M705
screws. Tighten screws to a torque of 46 Nm
Apply oil and install the O-ring. (407 lb-in).
STEP 171 STEP 173
GD98M709 GD98M712
Install the oil feed housing with the hex head screws Position converter housing. Secure with hex head
and flat washers. Tighten the screws to a torque of screws. Tighten the screws to a torque of 68 Nm
25 Nm (221 lb-in). (50 lb-ft).
STEP 172 STEP 174
GD98M711 GD98M713
Position the gasket and cover. Secure the cover with Put input shaft in a vise as shown. Position diaphragm
the hex head screws. Tighten the screws to a torque on input shaft and secure using 12 hex head screws.
of 23 Nm (204 lb-in). Tighten screws to a torque of 115 Nm (85 lb-ft).
Note The following steps are for the assembly of STEP 175
the engine connection and converter.
GD98M714
Position diaphragm and input shaft on converter. Ap-

ply Loctite 262 to threads of hex head screws. Install
screws and tighten to a torque of 115 Nm (85 lb-ft).
STEP 176 STEP 178
GD98M715 GD98M718
Position converter cover on converter housing. Make

sure alignment marks made during removal of cover
are aligned. Install input flange, two hex head screws,
lock plate, and washer. Pull cover against housing by
tightening two hex head bolts evenly.
STEP 179
GD98M716
Position converter. Check and ensure that impulse

disk of converter is centered on the bore for the in-
ductive transmitter.
STEP 177
GD98M719
Secure converter cover using 12 hex head screws

and nuts. Tighten screws to a torque of 46 Nm
(407 lb-in).
GD98M717
Position converter cover as shown. Install bearing

against shoulder in cover. Secure using retaining ring.
STEP 180 Note The following steps are for installation of trans-
mission control valve.
STEP 183
2 3
1
GD98M720
Tighten input flange hex head screws to a torque of

34 Nm (301 lb-in). Lock screws by bending corners of
lock plate over screws.
STEP 181
258
Install 380001577 transmission valve adjustment tool

set. Be sure hex rods (part of tool set) are not in-
stalled on studs. Mount the gasket (1), intermediate
plate (2), and gasket (3).
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 lb-in).
GD98M724
STEP 185
Install new sealing rings and both plugs in duct plate.
STEP 182
GD98M727
Install control valve on duct plate and 380001577

GD98M725 studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
Install the gasket and place the duct plate against screws to a torque of 9.5 Nm (84 lb-in). Remove
shoulder. Install socket head screws and hex nuts. 380001577 transmission valve adjustment tool set.
Tighten to a torque of 25 Nm (221 lb-in). Install remaining two socket head screws. Tighten
screws to a torque of 9.5 Nm (84 lb-in).
Note The following steps are for the installation of

the filter.
STEP 186 STEP 189
GD98M729 GD98M735
Install new O-rings in recesses of oil filter head. Posi- Apply grease to the new O-ring and install the speed
tion filter head on transmission and secure using two sensor with the socket head screw. Tighten the screw
socket head screws. Tighten screws to a torque of 25 to a torque of 23 Nm (204 lb-in).
Nm (221 lb-in).
STEP 190
STEP 187
GD98M736
GD98M730
With new O-rings, install the inductive transmitters.
Install a new transmission filter. Tighten to a torque of 30 Nm (265 lb-in).
STEP 188 STEP 191

Install the breather.
STEP 192
GD98M733
Install new O-rings in oil distribution covers. Install

the two oil distribution covers on the housing with hex
nuts and flat washers. Tighten to a torque of 25 Nm GD98M737
(221 lb-in).
Install the gasket and the cover plate. Tighten to a
torque of 23 Nm (204 lb-in). With a new O-ring, install
the screw plug. Tighten to a torque of 140 Nm
(103 lb-ft).
2.4 FRONT AND REAR AXLE
Lubricant Capacity ................................................................................................ 22.1 Liters (23.5 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ................................. 10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim ................................................................. 4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play ............................................................................. 0.5 to 2.0 mm (0.020 to 0.079 inch)
Drive Pinion Rolling Torque ................................................................................ 1.1 to 4.5 Nm (9.7 to 40 lb-inch)
Differential Carrier Bevel Gear End Play .................................................... Zero to 0.15 mm (zero to 0.006 inch)

Bolts Securing Wheel End to Axle Housing ............................................................................ 390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier ................................................................. 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve Fitting ................................................................................................................... 140 Nm (103 lb-ft)
Vent Valve .................................................................................................................................. 80 Nm (59 lb-ft)
Axle Housing Connector for Brake Tube ................................................................................. 140 Nm (103 lb-ft)
Nut Securing Brake Tube to Connector ................................................................................... 140 Nm (103 lb-ft)
Brake Tube Fitting to Wheel End Fitting ...................................................................................... 80 Nm (60 lb-ft)
Breather Plug ......................................................................................................................... 140 Nm (103 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads) ...................................................... 600 Nm (442 lb-ft)
Bolts Securing Differential Ring Gear
M12 Bolts ............................................................................................................................ 120 Nm (88 lb-ft)
M16 Bolts .......................................................................................................................... 300 Nm (221 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ................................ 185 Nm (136 lb-ft)
Differential Carrier Mounting Bolts (Apply Loctite 262 to Threads) .......................................... 390 Nm (288 lb-ft)
2.4.3 SPECIAL TOOLS

Brake housing seal installer ................... 380001574 Alignment Studs .................................... 380001752
Differential bearing cone puller Step plate set (includes 380001539,
collet set ................................................ 380001569 380001541, and 380001542)
Differential bearing preload wrench ......... 380001565 Step plate .............................................. 380001539
Brake housing inner bearing cup Step plate .............................................. 380001541
installer .................................................. 380001572 Step plate .............................................. 380001542
Brake housing outer bearing cup Socket ................................................... 380001571
installer .................................................. 380001573 Planetary Gear Puller ............................. 380001563
Wear ring installer adapter ...................... 380001755 Brake Housing Puller Bridge .................. 380001564
Pinion depth gauge set ........................... 380001570 Pressure Ring Installer ........................... 380001566
Puller body and screw ............................ 380001575 Holding Bracket .................................... 380001562
Support bracket ..................................... 380001576 Puller ..................................................... 380001563
Slide hammer puller adapter ................... 380001545 Pulling Attachment ................................. 380001581
Slide hammer ......................................... 380001582 Puller Legs ............................................. 380001538
Replacer ................................................ 380001552 Step Plate .............................................. 380001540
Dial indicator with magnetic base ........... 380001543 Holding Wrench ...................................... 380001546
Heat gun ................................................ 380001544 Pinion Inner Bearing Cup Installer .......... 380001549
Engine stand .......................................... 380001580 Pinion Outer Bearing Cup Installer ......... 380001550
Snap ring pliers ...................................... 380001584 Pinion Seal Installer ............................... 380001747
Snap ring pliers ...................................... 380001583 Pinion Seal Installer ............................... 380001748
Snap ring pliers ...................................... 380001585 Pulling Attachment ................................. 380001578
2.4.4 GEAR TOOTH CONTACT PATTERNS Pinion Distance Must Be Increased

Ideal Tooth Contact Pattern
BS01D011
Coast Side (concave)
BS01D009
BS01D012
Drive side (convex)
BS01BD013
Coast Side (concave)
BS01D014
Drive side (convex)
Pinion Distance Must Be Decreased
BS01DR016
Drive side (convex)
BS01D010
BS01D015
Coast side (concave)
2.4.5 LUBRICATION
5
4
2
3
1
2
BS02D084
Rear axle shown
1. Oil drain plug (Axle housing) - 2. Oil drain plug (Outputs) - 3. Oil fill plug - 4. Oil dipstick - 5. Brake bleeder - 6. Bleeder.
Note Refer to section 0 of this service manual for proper lubricant.
2.4.6 WEAR MEASUREMENT ON Note A wear measurement on the multi-disc brake

MULTI-DISC BRAKE must be made at least once a year. Wear measure-
ment should also be made if brake noise is heard, if
braking power is reduced, or anytime it is suspected
that braking function is impaired.
Wear measurement must be made on both wheel end

sides.
Remove plug, actuate brake and determine dimen-
sion (A) using a thickness gauge. If dimension (A) is
less than or equal to 4.0 mm (0.16 inch) the lined
discs on both output sides must be replaced. Replace
O-ring when installing the plug. Tighten plug to a torque
of 70 Nm (52 lb-ft).
BD02D001
BS02D085
2.4.7 WHEEL END AND BRAKE STEP 3

Disassembly
Note The following photographs show the rear axle;
dissassembly/assembly procedures are the same for
either axle. Tools and axle shown in the following pho-
tographs may appear slightly different than the tools
and axle you may have. The use of the tools and dis-
assembly/assembly of axles are the same regardless
of appearance.
STEP 1
BD02D005
Using two pry bars, remove cover from output shaft.

Remove and discard O-ring from cover.
STEP 4
BD02D002
Fasten axle on a stand.
STEP 2
BD02D006
Remove pin from lock nut using 380001582 slide ham-

mer and 380001545 adapter.
STEP 5
BD02D003
BD02D007
Remove lock nut using 380001576 support bracket

and 380001571 socket and nuts.
BD02D004
Remove drain plugs and drain oil from axle housing.
STEP 6 STEP 9
BD02D008 BD02D011
Use acceptable lifting equipment to hold wheel end in Remove the shim(s) from the sun gear shaft.
place. Loosen and remove the bolts and washers.
STEP 10
STEP 7
BD02D012
BD02D009
Pull the sun gear shaft out of the planetary gears and
Carefully pull the wheel end from the axle housing. remove.
Remove and discard O-ring from axle housing wheel
end. STEP 11
STEP 8
BD02D013
BD02D010
Using two pry bars, remove ring gear from brake hous-
ing.
Pull the stub shaft out of the sun gear shaft. Be care-
ful not to lose shim(s) that may be installed in sun
gear shaft.
STEP 12 STEP 15
BD02D014 BD02D017
Remove and discard O-rings from ring gear. Using 380001563 planetary gear puller and step plate
380001539, remove planetary gear and outer bearing
STEP 13 from planetary carrier shaft. Using a suitable puller,
remove the inner bearing from carrier shaft.
STEP 16
Repeat Steps 14 and 15 to remove the remaining two
retaining rings, planetary gears, and four bearings.
STEP 17
BD02D015
Using 380001578 pulling attachment, remove the plan-

etary carrier.
STEP 14
BD02D018
Remove and discard O-ring from brake housing port.
BD02D016
Remove retaining ring.
STEP 18 STEP 21
BD02D019 BD02D022
Remove the brake disc pack from brake housing. WEAR FACE PROTECTION WHEN USING COM-
PRESSED AIR. Apply compressed air to brake hous-
STEP 19 ing port to push brake piston from brake housing.
STEP 22
BD02D020
Using suitable tool, push the three pins down until

BD02D023
pins are even with top surface of shim.
Remove the support shim from the brake piston.
STEP 20
STEP 23
BD02D021
BD00M258
Remove three pins from support shim.
STEP 24 STEP 27
BD00M259 BD02D024
Put support shim in a press and compress Belleville Lift and remove the piston from the brake housing.
washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support STEP 28
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
STEP 25
BD02D025
BD00M260
1
Remove seven Belleville washers from each pin.

2
STEP 26 3
4
5
6
7
BS02D086
BD00M261
Using a press, remove four gripping rings from each 1. Brake housing - 2. Guide ring - 3. Support ring - 4. U-
pin. ring - 5. U-ring - 6. Support ring - 7. Wheel end shaft.
Remove the guide ring (2), support rings (3 and 6),

and U-rings (4 and 5) from the grooves of the brake
housing.
STEP 29 STEP 32
BD02D026 BD02D029
Using the 380001564 brake housing puller bridge and Remove the face seal from the brake housing.
380001542 step plate, pull the brake housing from
the wheel end shaft and remove the inner bearing. STEP 33
Using a puller, remove the outer bearing from the wheel
STEP 30
end shaft.
STEP 34
BD02D027
Use acceptable lifting equipment and lift the brake

housing from the wheel end shaft. BD02D030
Remove and discard the face seal metal ring from the
STEP 31
wheel end shaft.
BD02D028
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.
Cleaning and Inspection Assembly

Important Do not use compressed air to dry bear- STEP 40
ings. Allow bearings to air dry.
STEP 35
Clean all parts except friction plates in brake disc
pack using cleaning solvent. WEAR FACE PROTEC-
TION WHEN USING COMPRESSED AIR. Use com-
pressed air to clear passages in planetary ring gear
and brake housing.
STEP 36
Inspect bearing rollers for pitting, scoring, deforma- BD02D031
tion, or other damage. Check inner face and bearing
cage for deformation, dents, and other damage. Check Apply Loctite 574 to inside diameter of a new face
associated bearing cups for scratches, grooves, or seal metal ring. Install face seal metal ring on wheel
cracks. Check bearings for rough spots or binding by end shaft.
holding bearing and rotating. If bearing binds or action
is not smooth, replace the bearing. STEP 41
STEP 37
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
Note If a bearing or bearing cup requires replace-

ment, the associated part must also be replaced.
STEP 38
Check planetary ring gear, planetary gears, and plan- BD01F107
etary carrier gear teeth for cracks, breaks, chipping,
or other damage. Replace the part if any of these con-
ditions are seen. Check planetary carrier shaft splines
for broken, cracked, or twisted condition. Replace if
necessary.
STEP 39
Check wheel end shaft for cracked, broken, or twisted
splines. Replace if any of these conditions are seen.
BD01F105
Install 380001755 pressure ring installer adapter on

wheel end shaft. Press the face seal metal ring over
the collar of the wheel end shaft using 380001566
pressure ring installer.
STEP 42 STEP 45
WARNING
BD02D034
A A
BD02D032
Heat the wheel end shaft outer bearing to 100 C 1

(212 F) in a bearing oven. Wearing heat resistant A
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the shoulder on 2
the wheel end shaft.
STEP 43
BS00M073
1. Face seal - 2. Brake housing - 3. Fill with grease.
Wet the outer diameter of the face seal with a solu-

tion of 50% water and 50% mineral spirits. Use
380001574 seal installer to install the face seal with
BD02D033 the seal lip positioned as shown. Apply grease to seal
as indicated by (A) above.
Using 380001572 inner bearing cup installer, press
the inner bearing cup into the brake housing until
STEP 46
seated against the shoulder in the brake housing.
STEP 44
Using 380001573 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
against the shoulder in the brake housing.
BD02D027
Use acceptable lifting equipment and install the brake

housing on the wheel end shaft.
STEP 47 STEP 48
WARNING
BD02D025
1
BD02D035
2
Heat the wheel end shaft inner bearing to 100 C
(212 F) in a bearing oven. Wearing heat resistant 3
gloves or mittens, install the bearing on the wheel 4
end shaft until the bearing is against the bearing cup 5
in the brake housing. 6
BS02D086
Guide Ring, SupPort rings and U-rings location
1. Brake housing - 2. Guide ring - 3. Support ring - 4. U-ring

- 5. U-ring - 6. Support ring - 7. Wheel end shaft.
Install the support rings and U-rings in the grooves of

the brake housing.
STEP 49 STEP 51
B
A
BD02D036 BD00M282
Clean the groove of the brake housing with cleaning Press the four gripping rings on the pins. Ends of grip-
solvent. Install the guide ring in the groove. Make sure ping rings must be 180 opposite from each other.
the ends (A) of the guide ring are facing up towards
the top (B) of the brake housing and the guide ring is STEP 52
installed completely in its groove in the brake hous-
ing. Apply Loctite 415 to ID of guide ring to secure
guide ring in its groove.
STEP 50
BD00M283
5 4
BD02D037
Apply oil on the sliding surface of the piston, support

rings, U-rings and guide ring. Carefully install piston 3
in the brake housing.
BS00M274
A. 10.5 to 10.8 mm (0.41 to 0.43 inch) - 1. Pin - 2. Gripping

rings - 3. Belleville springs - 4. Support shim - 5. Retaining
ring.
Install the Belleville springs on the pins. Make sure

dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).
STEP 53 STEP 56
BD00M259 BD02D020
Put the assembled pins into the support shim and

install the snap ring.
STEP 54
1 23 4 5
BS02D087
BD02D038
A. 4.5 to 5.0 mm (0.18 to 0.20 inch) - 1. Brake housing -
Put the assembled support shim in the piston. 2. Snap ring - 3. Pin - 4. Support shim - 5. Piston.
STEP 55 Install the three pins (3) in the support shim (4) to
lock the snap ring (2). Dimension (A) between top of
pins (3) and top of support shim (4) must be 4.5 to 5.0
mm (0.18 to 0.20 inch).
STEP 57
BD02D039
Install the snap ring to secure the support shim.
1
BD02D040
1. Spline.
If removed, drive the stop bolt into the planetary car-

rier until contact. Then coat the spline with Loctite No.
767 antiseize lubricant.
STEP 58 STEP 61
BD02D041 BD02D014
Install the planet carrier into the spline of the wheel Apply grease to new O-rings and install on planetary
end shaft. ring gear.
STEP 59 STEP 62
BD02D042 BD02D044
Apply oil to the clutch discs. Install the outer and in- Install two alignment studs in the brake housing. Po-
ner clutch discs alternately starting with an outer clutch sition the planetary ring gear on the brake housing.
disc. Make sure alignment marks made during disassem-
bly are aligned. Press planetary ring gear into brake
STEP 60 housing.
BD02D043
Install a new O-ring in the brake housing port.
STEP 63 STEP 65
WARNING WARNING
Always wear heat protective gloves to prevent Always wear heat protective gloves to prevent
burning your hand when handling heated parts. burning your hand when handling heated parts.
BD02D045 BD02D047
Heat the planetary gears inner bearings to 100 C Heat the planetary gears outer bearings to 100 C
(212 F) in a bearing oven. Wearing heat resistant (212 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft. until the bearing is against the gear.
STEP 64 STEP 66
BD02D046 BD02D048
Install the planetary gears on the bearings. Install the retaining rings on the planetary gear shafts.
Sun Gear Shaft End Play Adjustment STEP 69

STEP 67
BD02D051
BD02D049 Install the sun gear shaft in the stub shaft. Make sure
the stub shaft is installed all the way into the sun gear
Using two M18 bolts of suitable length, secure plan-
shaft.
etary ring gear to brake housing. Then, determine di-
mension A, from the face of the planetary carrier stop
STEP 70
bolt to the mounting face of the planetary ring gear.
Example
Dimension A ......................... 35.60 mm (1.40 inch)
STEP 68
BD02D052
Determine dimension B from the face of the sun gear

shaft to the mounting face of the axle housing.
Example
BD02D050 Dimension B ......................... 31.40 mm (1.24 inch)
Install the stub shaft in the spline of the axle bevel
STEP 71
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear. Subtract dimension (B) from dimension (A). Then sub-
tract 1 mm (0.04 inch) from the difference. The differ-
ence is the required shim size.
Example
Dimension A + 35.60 mm (1.40 inch)
Dimension B - 31.40 mm (1.24 inch)
Difference 4.20 mm (0.16 inch)
Required end play - 1.00 mm (0.04 inch)
Difference = shim size 3.20 mm (0.12 inch)
STEP 72 STEP 75
BD02D012 BD02D154
Install the sun gear shaft in the planet carrier. Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
STEP 73 390 Nm (288 lb-ft).
STEP 76
BD02D011
Install the shim set (size as determined in Step 71

BD02D155
above) into the sun gear shaft with grease.
Install the lock nut by hand and tighten using
STEP 74 380001576 support bracket and 380001571 locknut
socket and nuts. Tighten the lock nut to a torque of
700 to 1000 Nm (516 to 737 lb-ft).
STEP 77
BD02D009
Apply grease to a new O-ring and install O-ring in brake

port. Use acceptable lifting equipment and install the
assembled wheel end onto the axle housing.
BD02D156
Install a new slotted pin into the wheel end lock nut.
STEP 78 STEP 79
BD02D303 BD02D153
1. O-ring. Install the cover into the wheel end.
Install a new O-ring on the wheel end cover.
2.4.8 BRAKE HYDRAULICS LEAKAGE High Pressure Test

TEST STEP 81
Important DO NOT EXCEED 100 BAR (1450 PSI) Operate the hand pump to increase pressure to 100
PRESSURE IN THE FOLLOWING STEPS. If the bar (1450 psi) maximum. Close connection to hand
maximum pressure of 100 bar (1450 psi) is exceeded, pump using the shutoff valve. During a 5 minute pe-
the piston will move too much changing the gripping riod, pressure shall not drop more than 2 bar (29 psi).
rings adjustment. If the gripping rings adjustment
changes, the wheel end must be removed and disas- Low Pressure Test
sembled and the gripping rings adjusted to the cor-
rect dimension (Step 52). STEP 82
Reduce pressure to 5 bar (72.5 psi) and close the
STEP 80 shutoff valve. During a 5 minute period pressure shall
not drop.
BD02D157
Connect a hand pump with pressure gauge to the brake

port as shown above. Fill the hand pump. Build up
pressure in the axle internal brake lines then bleed air
from the lines. After air is bled, actuate the brakes a
minimum of 10 times by operating the hand pump.
2.4.9 DIFFERENTIAL CARRIER STEP 85

DISASSEMBLY
STEP 83
BD02D008
Use acceptable lifting equipment to hold wheel end in

BD02D002 place. Remove the bolts and washers.
Fasten the axle to a stand. STEP 86

STEP 84
BD02D054
BD02D003 Carefully pull the wheel end from the axle housing.
Remove and discard O-ring from axle housing wheel
end.
BD02D004
Remove drain plugs and drain oil from axle.
STEP 87 STEP 91
BD02D010 BD02D057
Pull the stub shaft out of the sun gear shaft. Be care- Mount differential carrier in 380001580 engine stand
ful not to lose shim(s) that may be installed in sun using one 380001562 holding bracket.
gear shaft.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
BD02D058
Drive out the roll pins from the bearing caps.
STEP 93
BD02D055
Remove 15 bolts securing differential carrier.
STEP 90
BD02F158
Remove both adjusting nuts.
BD02D056
Connect lifting equipment to flange and remove the

differential carrier from axle housing.
STEP 94 STEP 96
BD02D059 BD02D061
Heat the differential carrier using a hot air blower. Remove both bearing cups.
Note Bolts are installed with Loctite. STEP 97
STEP 95
Important Do not use an air ratchet or wrench to
remove bolts.
1
BD02D062
Remove the differential from the differential carrier.
BD02D060
1. Alignment mark.
Make alignment marks on bearing caps and differen-

tial housing to aid in assembly. Remove four bolts
then remove both bearing caps.
2.4.10 DIFFERENTIAL DISASSEMBLY STEP 101

STEP 98
BD01F059 BD02D064
Remove the bearing from the differential housing us- Remove the differential cage half and remove all parts
ing 380001563 puller, 380001581 pulling attachment, from the differential housing.
380001538 puller legs, and 380001540 step plate.
STEP 102
STEP 99
Repeat Step 98 to remove the bearing from the hous-
ing cover.
STEP 100
BD02D065
Press the ring gear from the differential cage.
BD02D063
Place the differential in a press to prevent it from turn-

ing. Remove the bolts.
2.4.11 DRIVE PINION DISASSEMBLY STEP 106

STEP 103
Heat nut securing flange with a hot air blower to loosen
Loctite.
STEP 104
BD02D067
Remove the shaft seal from the differential carrier.
STEP 107
Put the differential carrier in a press. Press the drive
BD01F091 pinion from the differential carrier. Remove the pinion
outer bearing.
Install 380001546 holding wrench on input flange. Hold
flange using holding wrench and remove nut and
STEP 108
washer. Remove holding tool from flange.
Remove the spacer ring and inner bearing from the
STEP 105 drive pinion.
STEP 109
BD02D066
Remove the input flange from the drive pinion.

BD02D068
If necessary drive out both bearing cups from the dif-

ferential carrier.
2.4.12 REAR AXLE PIVOT PIN BUSHINGS STEP 112

STEP 110
1 2
1
BD01D495
BD01D482
A
2 1 2
BD01D499
BD01D499 1. Differential carrier pivot pin bushing - 2. Axle housing

pivot pin bushing - 3. Groove.
A. Thrust surface - 1. Differential carrier pivot pin bushing -
2. Axle housing pivot pin bushing.
WARNING
Inspect pivot pin bushings in differential carrier and
axle housing for cracks, breaks, deformation, or other Always wear insulated gloves or mittens when
damage. Check oil splash grooves for scoring or chip- handling frozen parts.
ping. Check for scoring on thrust surface (A). If bush-
ing (1 or 2) requires replacement, do Steps 111 and Freeze new bushing in dry ice for several hours. In-
112. stall bushing in axle housing or differential carrier with
groove (A) on circumference of bushing facing center
STEP 111 of housing or carrier. Install bushing against shoulder
in housing or carrier.
BD01D491
Put axle housing or differential carrier in hydraulic press.

Make sure housing or carrier is properly supported.
Using a 66.6 mm (2.625 inches) diameter by suitable
length rod, press bushing out of housing or carrier.
2.4.13 BRAKE TUBES REMOVAL STEP 116

STEP 113
BD02D072
BD02D069 Loosen the fitting on the opposite end of the brake

tube then remove the brake tube from the axle hous-
Remove the plug with the breather installed from the
ing.
axle housing.
STEP 117
STEP 114
BD02D073
BD02D070
Remove the vent valve from the fitting.
Remove the nut securing the brake tube to the axle
housing.
STEP 118
STEP 115
BD02D074
BD02D071 Remove the fitting. Remove and discard O-ring and

rectangular ring from fitting.
Loosen and remove the connector from the axle.
Note Do Steps 114 to 118 on other wheel end.
2.4.14 BRAKE TUBES INSTALLATION STEP 121

STEP 119
1 2
3
4
BD02D116
BD00M340 Tighten the vent valve to a torque of 80 Nm (59 lb-ft).

1. Vent Valve - 2. Fitting - 3. O-ring - 4. Rectangular ring.
STEP 122
Install new O-ring and rectangular ring on fitting. In-
stall and tighten vent valve in fitting.
STEP 120
BD02D117
Install a new O-ring on the connector. Install the con-

nector in the axle and tighten to a torque of 140 Nm
(103 lb-ft).
BD02D115
Install the assembled vent valve and fitting in the axle. STEP 123
Tighten the fitting to a torque of 140 Nm (103 lb-ft).
BD00M343
1. O-ring.
Install a new O-ring in the groove of the brake tube

fitting.
STEP 124 STEP 126
2
1
BD02D118 BD02D120
1. Brake tube - 2. Fitting - 3. Connector. Connect fitting on opposite end of brake tube to fitting
installed in wheel end. Tighten brake tube fitting to a
Install the brake tube (1) in the axle housing, insert- torque of 80 Nm (60 lb-ft).
ing the fitting (2) through the connector (3).
Note Do Steps 119 to 126 on other wheel end.
STEP 125
STEP 127
1
2
BD02D119
BD00M347
Install the nut to secure the brake tube fitting. Tighten
the nut to a torque of 140 Nm (103 lb-ft). 1. O-ring - 2. Plug - 3. Breather.
Remove and discard O-ring (1) from plug (2) and in-
stall a new O-ring. Install breather (3) in plug.
STEP 128
BD02D121
Install the plug in axle housing. Tighten plug to a torque

of 140 Nm (103 lb-ft).
2.4.15 DIFFERENTIAL CARRIER STEP 131

ASSEMBLY
Note The ring gear and the drive pinion are a matched
gear set and cannot be serviced separately.
Determine Shim Thickness for Correct Tooth

Contact Pattern
Note Make the following measurements at maxi-
mum accuracy. Inaccurate measurements will result
in a faulty tooth contact pattern causing disassembly
of the drive pinion and differential.
BD02D122
STEP 129
Determine dimension C (bearing width).
Install the 380001570 pinion depth gauge set on the Dimension C (Example) ...... 33.65 mm (1.325 inch)
differential carrier.
STEP 132
STEP 130
1
BD02D123
BD01F076
1. 138.00 mm (+/-0 mm).
Determine dimension B (gap between the measuring
shaft and the measuring pin) using a thickness gauge. Read dimension D (dimension for pinion).
Dimension B (Example) ........ 1.00 mm (0.039 inch) Dimension D (Example) .... 138.00 mm (5.433 inch)
Example A Example B
Dimension A 171.75 mm (6.762 inch) Dimension C 33.65 mm (1.325 inch)
(tool constant) Dimension D + 138.00 mm (5.433 inch)
Dimension B (gap) + 1.00 mm (0.039 inch)
Results in Dimension Y 171.65 mm (6.758 inch)
Results in Dimension X 172.75 mm (6.801 inch)
STEP 133
Subtract dimension Y from dimension X. The differ-
ence is the required shim thickness.
Example C
Dimension X 72.75 mm (6.801 inch)
Dimension Y - 71.65 mm (6.758 inch)
Difference = Shim 1.10 mm (0.043 in)
Install Drive Pinion STEP 136

STEP 134
WARNING
Always wear insulated gloves or mittens when
handling frozen parts.
BD02D124
Install the shim set determined in Step 133 in the

bearing bore on the differential carrier.
BD01F062
STEP 135
Freeze new outer bearing cup in dry ice for several
hours. Install bearing cup in differential carrier using
WARNING 380001550.
Always wear insulated gloves or mittens when
handling frozen parts. STEP 137
BD02D125
BD01F064
Press the inner bearing on drive pinion shaft using
Freeze new inner bearing cup in dry ice for several
suitable size sleeve pressing on inner race of bear-
hours. Install bearing cup in differential carrier using
ing.
380001549.
Drive Pinion Bearing Rolling Torque Adjustment STEP 140

STEP 138
BD02D128
BD02D126 Using 380001575 puller tube, press the dust shield

on the input flange.
Install an 16.90 mm (0.665 inch) thick spacer on the
pinion shaft.
STEP 141
STEP 139
WARNING
BD02D129
Install the input flange on the pinion shaft.
STEP 142
BD02D127
Install the assembled pinion shaft in the differential

carrier. Heat the pinion shaft outer bearing to 100 C
(212 F) in a bearing oven. Wearing heat resistance
gloves or mittens, install the bearing on the pinion
shaft until contact.
BD02D130
Put the washer in place on the pinion shaft.
STEP 143 STEP 146
BD01F091 BD02D132
Install 380001546 holding wrench on input flange. Hold Using the 380001747 and 380001748 pinion seal in-
flange using holding tool and tighten nut to a torque of stallers, install the shaft seal with the seal lip down.
600 Nm (442 lb-ft). Remove 380001546.
Note Just before installation, wet the outer diam-
Note When tightening rotate the pinion shaft in both eter of the shaft seal with a solution of 50% water and
directions several times. 50% mineral spirits. Fill the space between the seal-
ing and dust lip with grease.
STEP 144
STEP 147
BD02D131
BD01F091
Check the rolling torque of the drive pinion bearing.
The rolling torque should be 1.1 to 4.5 Nm (9.7 to 40 Install the input flange. Install 380001546 holding
lb-inch). If rolling torque is too low, install a thinner wrench on input flange. Apply Loctite No. 262, on the
spacer (Step 138); if rolling torque is too high, install a threads of the locknut. Install the washer and locknut
thicker spacer (Step 138). by hand. Hold flange using holding tool and tighten
nut to a torque of 600 Nm (442 lb-ft). Remove
STEP 145 380001546.
Remove the nut and input yoke from the drive pinion
shaft.
2.4.16 DIFFERENTIAL ASSEMBLY STEP 149

STEP 148
BD02D134
BD02D133 Using suitable size sleeve press the ring gear (4) onto
the slotted pins until ring gear is against differential
Install two slotted pins (2 and 3) in each of the four
cage half (1).
blind holes in the differential cage half (1). Install slot-
ted pins so that slots are 180 from center of differen-
tial cage and slots of pins are 180 offset to each
other.
Open Differential Assembly
3
8
2
8 7 7
6 13
11 10
7 14
5
9 1
4
7 8 8
12 BS01D140
1. Differential cage half - 2. Slotted pin - 3. Slotted pin - 4. Ring gear - 5. Thrust washer - 6. Bevel gear - 7. Bevel gear -
8. Thrust washer - 9. Shaft - 10. Bevel gear - 11. Thrust washer - 12. Differential cage half - 13. Bolt - 14. Bolt.
STEP 150 STEP 152

Install thrust washer (5) then bevel gear (6) in differ- Install shaft (9) with bevel gears (7) and thrust wash-
ential cage half (1). ers (8) on differential cage half (1). Check that teeth
of bevel gears (7 and 6) mesh.
STEP 151
STEP 153
Install bevel gears (7) and thrust washers (8) on shaft
(9). Install and mesh bevel gear (10) with gears (7) and
install thrust washer (11) on gear (10). Install differen-
tial cage half (12). Go to Step 163.
Limited Slip Differential Assembly STEP 157

STEP 154 10
7 9
7 11
8 5
6 BD02D137
BD02D135 Install assembled shafts (11) with gears (9) and thrust
washers (10) in differential cage (1) making sure gear
Install the thrust washer (5), coated surface to clutch
teeth mesh. Check that tabs on thrust washers (10)
discs, and outer and inner clutch discs (6 and 7) on
are positioned as shown above.
bevel gears (8) in the sequence shown above.
STEP 158
STEP 155
1
A
BD02D138
BD02D142
Carefully assemble the differential cage halves. Make

Put the bevel gear (8) with installed parts (5 through
sure the manufacturers markings (A) on both halves
7) in the differential cage half (1).
are aligned.
STEP 156
STEP 159
8
1
BD02D136
BD02D139
Put the other bevel gear (8) with installed parts (5
Secure the differential cage halves together using two
through 7) in differential cage half (12).
bolts.
13
2
6
6
10 8 3
10 9
14
9 11
5 8
7 7 1 4
7 11 7
5
9 9
10
6 10
6
12
BS01D141
1. Differential cage half - 2. Slotted pin - 3. Slotted pin - 4. Ring gear - 5. Thrust washer - 6. Separator plate - 7. Friction plate
- 8. Bevel gear - 9. Bevel gear - 10. Thrust washer - 11. Shaft - 12. Differential cage half - 13. Bolt - 14. Bolt.
STEP 160 STEP 161

After obtaining the required end play, disassemble the
differential. Install the adjusted clutch pack that was
12 in the differential cage half (12) in the other differen-
tial cage half (1). Repeat Step 160 to check the end
play. After both clutch packs have been adjusted, go
to Step 162.
STEP 162
BD02D140
Check the end play (zero to 0.15 mm (0.006 inch)) of

the bevel gear (8). Do this by mounting a dial indicator
as shown set to indicate from the top separator plate
through one of the top holes in differential cage half
(12). Zero the dial indicator. Using screwdrivers or other
suitable tools inserted in holes in side of cage half,
move the bevel gear up. Record the dial indicator read-
ing. Dial indicator should indicate zero to 0.15 mm BD02D141
(0.006 inch) (required end play).

After adjustment is completed, separate the cage
If required end play of zero to 0.15 mm (0.006 inch) is
halves, and remove the parts. Keep clutch packs to-
not obtained, install new outer clutch discs of thick-
gether and identify which side they are installed. Ap-
ness necessary to obtain required end play.
ply oil to all parts. Do Steps 154 to 158 to assemble
the differential, then go to Step 163.
STEP 163 STEP 166
BD02D143 BD02D146
Put the differential in a press to prevent it from turn- Install both bearing cups and adjusting nuts.
ing. Apply Loctite 262 to threads of bolts (13 and 14).
Tighten M16 bolts (13), to a torque of 300 Nm (221 lb- STEP 167
ft); tighten M12 bolts (14) to a torque of 120 Nm (88
lb-ft).
STEP 164
BD02D147
Position bearing brackets; make sure threads of bear-

ing brackets and adjusting nuts are not crossed. Put
Loctite 262 on threads of four bolts. Install bolts and
BD02D144
tighten to a torque of 185 Nm (136 lb-ft).
Using proper size sleeve pushing on inner race of
bearing, press bearing on differential housing until STEP 168
bearing is against housing. Repeat to install other
Using a spanner wrench, tighten the two adjusting nuts
bearing.
evenly until there is a light pressure against the bear-
ings on each side of the differential.
STEP 165
BD02D145
Install differential in differential carrier.
Adjust Backlash and Bearing Preload STEP 174

STEP 169
BD02D149
BD02D148 Apply marking ink on several teeth of the ring gear

and rotate it in both directions. Compare the obtained
Place 380001543 dial indicator right-angled at the outer
tooth contact pattern with the examples on pages 4
diameter of the tooth flank (ring gear). Adjust the pin-
and 5.
ion to ring gear backlash to the low side of specifica-
tions (see numbers etched on the outer diameter of
Note If the tooth contact pattern differs, the wrong
the ring gear) by alternately turning each of the ad-
shim size was selected in Step 133. Remove differ-
justing nuts to move the ring gear closer to or further
ential and repeat Steps 129 though 133.
away from the pinion.
STEP 175
STEP 170
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release pres-
sure on the bearing. It should be very noticeable that
pressure is released on the bearing, as the adjusting
nut will turn much easier.
STEP 171
Tighten the bearing adjusting nut slowly until firm con-
tact is made with the bearing.
Note As the adjusting nut makes firm contact with BD02D150
the bearing, the adjusting nut will immediately begin Install pins to secure both adjusting nuts.
to turn with more effort.
STEP 176
STEP 172
Apply sealing compound (Three Bond Type 1215) to
To adjust the differential bearing preload, note the differential mounting surface on axle housing. Install
position of the adjusting nut. Now tighten the nut two two 380001752 alignment studs in axle housing to aid
additional notches. installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
STEP 173 housing then remove alignment studs.
When the bearing preload is adjusted the backlash
may increase slightly. Check pinion backlash to con-
firm that it is within specifications as marked on the
ring gear. If within specifications, install the adjusting
nut locking roll pins. If backlash is outside of speci-
fied range, repeat Step 169 through 173 again.
STEP 177 STEP 180
BD02D151 BD02D054
Using new bolts, secure the differential carrier to the Apply grease to a new O-ring and install O-ring in brake
axle housing. Tighten bolts to a torque of 390 Nm (288 port. Position the wheel end on the axle housing.
lb-ft).
STEP 181
STEP 178
BD02D154
BD02D050
Install the washers and bolts on the wheel end. Tighten
Install the stub shaft into the spline of the differential the bolts to a torque of 390 Nm (288 lb-ft).
bevel gear.
Note Repeat Steps 178 through 181 for the other
STEP 179 wheel end.
Note Refer to Section 0 of this service manual for

proper lubricant.
BD02D011
Install the thrust washer removed at disassembly. Use

grease to keep it in the sun gear.
2.5 DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS

Coupler to Flywheel Bolts ........................................................................................ 53 to 62 Nm (39 to 46 lb-ft)
Engine Drive Shaft to Coupler Bolts......................................................................... 53 to 62 Nm (39 to 46 lb-ft)
Engine Drive Shaft to Transmission Bolts ................................................................ 34 to 41 Nm (25 to 30 lb-ft)
Center, Rear and Front Drive Shaft Bolts ................................................................. 61 to 81 Nm (45 to 60 lb-ft)
Carrier Bearing Bolts ............................................................................................. 99 to 128 Nm (73 to 94 lb-ft)
Lock Nut for Yoke on Front Drive Shaft ............................................................ 339 to 375 Nm (250 to 275 lb-ft)
2.5.2 FRONT DRIVE SHAFT STEP 4

Removal Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 1
STEP 5
Loosen the set screws that secure the center bear-
ing to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD01D368 STEP 7
Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
STEP 2
BD01D370

the front drive shaft to the front axle.
STEP 8
BD01D715
Use a prybar to disengage the front drive shaft from
Remove the lock nut that fastens the yoke to the front the front axle and remove the front drive shaft from
drive shaft. the machine.
STEP 3 Note If necessary, use a brass hammer to drive

Make an alignment mark on the yoke and the end of the front drive shaft out of the center bearing.
the front drive shaft to make sure that the yoke is
installed correctly.
2.5.3 FRONT DRIVE SHAFT STEP 14

Installation
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11 BD01D715
Install the lock nut that fastens the yoke to the front
drive shaft. Tighten the lock nut to a torque of 339 to
375 Nm (250 to 275 lb-ft).
STEP 15
Tighten the set screws, that secures the center bear-
ing to the front drive shaft, alternately until they stop
turning and the hex head socket wrench starts to
spring.
BD01D370 STEP 16
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
61 to 81 Nm (45 to 60 lb-ft).
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are BD01D368
aligned. Install the bolts and straps that fasten the front drive
shaft to the center drive shaft. Tighten the bolts to a
Note If a new front drive shaft has been installed, torque of 61 to 81 Nm (45 to 60 lb-ft).
make sure the yoke being installed is 90 to the yoke
on the other end of the front drive shaft.
2.5.4 CENTER BEARING STEP 20

Removal Make an alignment mark on the yoke and the front
drive shaft to be sure that the yoke is installed cor-
STEP 17 rectly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD01D368
Loosen and remove the bolts and straps that fasten STEP 23
the center drive shaft to the front drive shaft. Loosen the set screws that secure the center bear-
ing to the front drive shaft.
STEP 18
STEP 24
BD01D715
BD01D715
Loosen and remove the lubrication hose from the
center bearing. Loosen and remove the bolts, washers and nuts that
fasten the bearing housing to the front frame.
STEP 19
STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD01D715
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
2.5.5 CENTER BEARING STEP 31

Installation
Note The center bearing and the bearing housing
are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is cracked,
a new center bearing and bearing housing must be
used.
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
BD01D715
STEP 27 Install the washer and lock nut that fasten the yoke to
Install the bearing housing so that the lubrication fit- the front drive shaft. Tighten the lock nut to a torque
ting is at the top. of 339 to 375 Nm (250 to 275 lb-ft).
STEP 28 STEP 32
BD01D715 BD01D368
Install the bolts, washers and nuts that fasten the Install the straps and bolts that fasten the center drive
bearing housing to the front frame. Tighten the bolts shaft to the yoke on the front drive shaft. Tighten the
to a torque of 99 to 128 Nm (73 to 94 lb-ft). bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft).
STEP 29 STEP 33
Apply antiseize compound to the splines on the front Install the lubrication hose into the fitting on the bear-
drive shaft. ing housing.
STEP 30 STEP 34
Install the yoke to the front drive shaft, making sure Lubricate the center bearing with the grease speci-
the alignment marks made during removal are fied in Section 0.
aligned.
2.5.6 CENTER DRIVE SHAFT Installation

Removal STEP 39
STEP 35
BD01D331
BD01D368 Hold the center drive shaft in position and install the
bolts and straps that fasten the center drive shaft to
the transmission. Tighten the bolts to a torque of 61
the center drive shaft to the yoke of the front drive
to 81 Nm (45 to 60 lb-ft).
shaft.
STEP 40
STEP 36
Use a prybar to disengage the center drive shaft from
the yoke of the front drive shaft.
STEP 37
BD01D368
Install the bolts and straps that fasten the center drive
shaft to the yoke of the front drive shaft. Tighten the
bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft).
BD01D331

the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the ma-
chine.
2.5.7 REAR DRIVE SHAFT Installation

Removal STEP 45
STEP 41
BD01D362
BD01D323 Hold the rear drive shaft into position and install the
bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 61 to 81 Nm
the rear drive shaft to the transmission.
(45 to 60 lb-ft).
STEP 42 STEP 46
Use a prybar to disengage the rear drive shaft from
the transmission.
STEP 43
BD01D323
Install the bolts and straps that fasten the rear drive
shaft to the transmission. Tighten the bolts to a torque
of 61 to 81 Nm (45 to 60 lb-ft).
BD01D362

the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the ma-
chine.
2.5.8 ENGINE DRIVE SHAFT STEP 50

Removal
Note It may be necessary to remove the fuel tank
to gain access to the bolts and straps that fasten the
engine drive shaft to the transmission. STEP 47 to
STEP 54 show how to remove the fuel tank.
STEP 47
BD01D330
Tag and disconnect the two wires from the fuel level
2 indicator.
STEP 51
1
BD01D325
Connect a drain hose to the drain valve (1) on the

fuel tank and drain the tank.
STEP 48
Loosen the hose clamp and disconnect the return
hose (2) from the fuel tank. Plug the hose and cap
the fitting. Put an identification tag on the hose for
reference during installation. Refer to the above photo. BD01D328
Loosen and remove the bolt and nut that fasten the
STEP 49 breather to the machine.
STEP 52
BD01D326
Loosen the hose clamp and disconnect the fuel sup-

ply hose from the fuel tank. Plug the hose and cap BD01D332
the fitting. Put an identification tag on the hose for Place a jack under the center of the fuel tank plate.
reference during installation.
STEP 53 STEP 56
BD01D327 BD01D199
Loosen and remove the six bolts that fasten the fuel Loosen and remove the six bolts that fasten the en-
tank guard to the machine. gine drive shaft to the engine.
STEP 54 STEP 57
Lower the fuel tank slowly making sure all hoses and Remove the engine drive shaft from the machine.
wires are free and clear.
STEP 55
BD01D342
Remove and discard the bolts and straps that fasten

the engine drive shaft to the transmission.
Important The bolts and straps that fasten the en-

gine drive shaft to the transmission must be replaced
when removed.
2.5.9 ENGINE DRIVE SHAFT STEP 60

Installation
STEP 58
BD01D332
Place the fuel tank onto a jack and raise into position
making sure all hoses are in place.
BD01D342
Place the engine drive shaft into position on the STEP 61

transmission and install new straps and bolts. Tighten
the bolts to a torque of 34 to 41 Nm (25 to 30 lb-ft).
STEP 59
BD01D327
Install the six bolts that fasten the fuel tank and guard
on the machine.
BD01D199
STEP 62
Install the six bolts that fasten the engine drive shaft
to the engine. Tighten the bolts to a torque of 53 to 62
Nm (39 to 46 lb-ft)
BD01D328
Install the bolt and nut that fastens the breather to

the machine.
STEP 63 STEP 65
BD01D325 BD01D330
Install the return hose on the fitting and tighten the Install the two wires to the fuel level indicator.
hose clamp. Make sure that the drain valve is in the
closed position.
STEP 64
BD01D326
Install the fuel supply hose on the fitting and tighten

the hose clamp.
2.5.10 UNIVERSAL JOINTS Installation

Removal Note The bearing race and journal that make up the
universal joint are not serviced separately. If the bear-
STEP 66 ing race or journal is worn or damaged, a new univer-
Remove the drive shaft. sal joint must be used.
STEP 67 STEP 69
Clean the slots in the yoke of the drive shaft.
STEP 70
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 67.
1 STEP 71
2 Install the drive shaft.
BD01D331
Remove the ring (1) and the bearing (2) from the drive
shaft.
Note The above photo shows the drive shaft on the

machine and is for reference of the ring and bearing
only.
STEP 68
Remove the universal joint from the drive shaft.
NOTES:
2.6 WHEELS AND TIRES
2.6.1 WHEELS AND NUTS

General Information
The wheel nuts must be tightened after every 20 hours of operation until the wheel nuts stay tight:
A. If the machine is new.
B. If a wheel has been removed and installed.
Torque Specification
Tighten the wheel nuts to 298 Nm (220 pound-feet) in the sequence shown in Figure 158. Then a final torque of 640
to 720 Nm (475 to 530 pound-feet) in the same sequence.
2.6.2 TIRE PRESSURE

17.5 x 25 L2 ............................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 L3 ............................................................................ Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 XTLA TL .................................................................. Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 XHA TL .................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
15.5 x R25 XTLA TL .................................................................. Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
15.5 x R25 XHA TL .................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
2.6.3 CHANGING TIRES 2.6.4 INSTALLING A WHEEL

1. Make sure the mounting surfaces of the rim and
WARNING axle flange are clean and free of dirt and grease.
The split rim wheels used on this machine can 2. Install the wheel, hardened washers and wheel
be dangerous. When inflating a tire on the ma- nuts.
chine, use a self-locking nozzle and stand at the
3. Use a hand wrench (not an impact) to tighten the
front or rear of the tire.
wheel nuts to pull the wheel against the planetary
housing. DO NOT use an impact wrench to tighten
When inflating a tire off the machine, put the wheel
the wheel nuts.
in a tire inflation cage. The retaining ring and rim
can come off with enough force to result in death 4. Tighten the wheel nuts to 298 Nm (220 pound-
to a person in front of the rim. feet) in the sequence shown in Figure. Then tighten
the wheel nuts in the same sequence to 640 to
1. Have a qualified tire mechanic service the split rim 720 Nm (475 to 530 pound-feet).
wheels used on this machine.
2. The correct tire equipment, especially a tire infla- 1
tion cage, is required. Using the wrong procedure 10 8
for a split rim wheel can result in death.
3 6
Important When installing a Michelin tire, lubricate
the tire with a tire mounting lubricant and inflate the
tire to 551 kPa, 5.5 bar (80 psi) to make sure that the 5 4
tire is seated on the rim. Then decrease the pressure
to the specified pressure. 7 9
2 BS00J104
Wheel nut torque sequence
2.7 TRANSMISSION CONTROL VALVE
2.7.1 SPECIAL TOOLS
380001559 380001560 380001577 380001568 Transmission

Transmission torque Transmission input/ Transmission valve output shaft seal installation
converter seal output shaft seal adjustment tool
installation tool installation tool tool set
W110R0352

Screws Securing End Housings to Valve Housing ................................................................... 5.5 Nm (48 lb-in)
Screws Securing Pressure Regulator Locating Plates ............................................................. 5.5 Nm (48 lb-in)
Screws Securing Covers to End Housings .............................................................................. 5.5 Nm (48 lb-in)
Valve Housing Plugs ................................................................................................................... 6 Nm (53 lb-in)
Screws Securing Distribution Plate to Valve Housing ............................................................... 9.5 Nm (84 lb-in)
2.7.3 DISASSEMBLY STEP 3

STEP 1 Remove distribution plate (2), housing gasket (3),
valve plate (4), and housing gasket (5). Discard hous-
To aid in assembly, put alignment marks on transmis-
ing gaskets (3 and 5).
sion control valve (7), distribution plate (2), and valve
plate (4).
STEP 4
STEP 2 Remove six filter screens (6) from valve plate (4).
Remove 18 screws (1) securing distribution plate (2)
to transmission control valve (7).
5
4
3
2
6
BS98J157
Transmission control valve plates and gaskets
1. Screw - 2. Distribution plate - 3. Housing gasket - 4. Valve plate - 5. Housing gasket - 6. Filter screen - 7. Transmission
control valve.
STEP 5 STEP 13
To aid in assembly, put alignment marks on covers (3 Remove two screws (13) from opposite corners of end
and 6, figure page 157), end housings (14), and valve housing (14).
housing (27). Put alignment marks on wiring harness
(8) connector and cover (3). STEP 14
STEP 6
Remove clamp (1) securing wiring harness (8) con-
nector to cover (3).
STEP 7
Remove 14 screws (2) securing cover (3) to end hous-
ing (14).
STEP 8
Remove cover (3) and gasket (4). Discard gasket (4). BS02C114
Install 380001577 transmission valve adjustment tool

STEP 9 set in holes where screws (13) were removed. Tighten
Remove 14 screws (5) securing cover (6) to end hous- hex rods of 380001577 down against end housing.
ing (14). Remove remaining 16 screws from end housing (14).
Loosen 380001577 hex rods uniformly to release spring
STEP 10 tension. Remove end housing and gasket (15). Dis-
card gasket. Remove 380001577 studs.
Remove cover (6) and gasket (7). Discard gasket (7).
STEP 15
STEP 11
BS02C115
BS02C113
Remove three pistons (16 and 18), springs (17 and
Disconnect wiring harness (8) connectors from six 19), spring (20), and piston (21) from valve housing
pressure regulators (11). Remove wiring harness from (27).
housings (14 and 27) by carefully routing harness
and connectors through openings in housings. STEP 16
STEP 12 Repeat Steps 12 through 14 for other side of valve
housing (27).
Remove three screws (9) and locating plates (10)
securing three pressure regulators (11) to end hous-
ing (14). Remove pressure regulators (11). Remove
and discard O-ring (12) from pressure regulators.
Note End housings (14) are under spring pressure.

Use 380001577 transmission valve adjustment tool
set to hold springs down.
8
1
4
3
21
20
18
19
9
23
25 22
11,12 26
10
18
19
15
13 14
14
15 9 7
10
16 5
17 27
13 11,12
24
17
16
6
BS01B099
Transmission control valve
1. Clamp - 2. Screw - 3. Cover - 4. Gasket - 5. Screw - 6. Cover - 7. Gasket - 8. Wiring harness - 9. Screw - 10. Locating plate
- 11. Pressure regulator - 12. O-ring - 13. Screw - 14. End housing - 15. Gasket - 16. Piston - 17. Spring - 18. Piston -
19. Spring - 20. Spring - 21. Piston - 22. Piston - 23. Spring - 24. Orifice - 25. Plug - 26. O-ring - 27. Valve housing.
STEP 17 STEP 18
BS02C116 BS02C117
Remove three pistons (16 and 18), springs (17 and Remove six orifices (24) from valve housing (27).
19), piston (22), and spring (23) from valve housing
(27). STEP 19
Remove eight plugs (25). Remove and discard
O-ring (26) from plugs.
2.7.4 INSPECTION and other damage. Replace a housing or cover if any

of the above conditions are seen.
STEP 20
Clean all metal parts in cleaning solvent. STEP 25
Check pressure regulators (11) for cracks, breaks, or
STEP 21
other damage. Check connector contacts for loose-
Immerse end housings (14, figure page 160), valve ness or signs of corrosion. Replace a pressure regu-
housing (27), valve plate (4, Figure page 155), and lator if any of these conditions are seen. Check re-
distribution plate (2) in cleaning solvent and agitate sistance of pressure regulators using a multimeter.
cleaning solvent. WEAR EYE PROTECTION WHEN Replace a pressure regulator if resistance is not 17 to
USING COMPRESSED AIR. Use compressed air to 21 ohms.
remove foreign matter from interior of housings and
plates and to ensure that all bores are clear of foreign STEP 26
matter.
Check wiring harness (8) connectors for signs of
breaks, cracks, or other damage. Check contacts for
STEP 22
foreign matter or corrosion. Check harness wiring for
WEAR EYE PROTECTION WHEN USING COM- signs of broken or cracked insulation and broken or
PRESSED AIR. Use compressed air to ensure that frayed wiring at connection to connectors. Replace
orifices (24, figure page 160) are clear of foreign mat- wiring harness if any of these conditions are seen.
ter.
STEP 27
STEP 23 Check springs (17, 19, 20, and 23, figure page 160)
Check filter screens (6, figure page 155) for block- for cracks, breaks, distortion, or signs of permanent
age, rips, or tears. Replace if any of these conditions set. Replace a spring if any of these conditions are
are seen. seen.
STEP 24 STEP 28
Inspect the plates (2 and 4, figure page 155), housings Inspect pistons (16, 18, 21 and 22, figure page 160)
(14 and 27, figure page 160) and covers (3 and 6) for for cracks, breaks, chipping, grooves, or other dam-
corrosion, cracks, breaks, chipping or other damage. age. Replace if any of these conditions are seen.
Check bores in housings for deep scratches, gouges,
8
1
4
3
21
20
18
19
9
23
25 22
11,12 26
10
18
19
15
13 14
14
15 9 7
10
16 5
17 27
13 11,12
24
17
16
6
BS01B099
Transmission control valve
1. Clamp - 2. Screw - 3. Cover - 4. Gasket - 5. Screw - 6. Cover - 7. Gasket - 8. Wiring harness - 9. Screw - 10. Locating plate
- 11. Pressure regulator - 12. O-ring - 13. Screw - 14. End housing - 15. Gasket - 16. Piston - 17. Spring - 18. Piston -
19. Spring - 20. Spring - 21. Piston - 22. Piston - 23. Spring - 24. Orifice - 25. Plug - 26. O-ring - 27. Valve housing.
2.7.5 ASSEMBLY STEP 31

Note Apply clean engine oil (15W-40) to pistons (16,
18, 21, and 22, figure page 160) and springs (17, 19,
20, and 23), orifices (24), new O-rings (12 and 26), and
filter screens (6, figure page 163) before assembly.
STEP 29
BS02C118
Push down on pistons (16) to compress springs (17)

and use 5.0 mm (0.197 inch) diameter pins to hold
pistons in position. Install pins in locations shown
above.
BS02C117 STEP 32
Install six orifices (24, figure page 160) with concave
side facing up. Install orifices until contact with shoul-
der in valve housing (27) is made.
STEP 30 15
A
BS02C119
BS02C115
Install springs (17 and 19) and piston (21) in valve

housing (27) bores then install pistons (16 and 18)
and spring (20).
BS02C120
Install gasket (15) and end housing (14) on valve hous-

ing (27). Make sure 15 mm (0.6 inch) diameter recess
(A) in end housing is facing spring (20). Install
380001577 transmission valve adjustment tool set to
secure end housing. Remove three pins installed in
Step 31 above. Install 16 screws (13) then remove ad-
justment tool set and install remaining two screws (13).
Tighten screws (13) to a torque of 5.5 Nm (48 lb-in).
STEP 33 STEP 36
BS02C121 BS02C123
Install a new O-ring (12) lubricated with clean en- Do Step 33 to install remaining pressure regulators
gine oil (15W-40) on pressure regulators (11). In- (11) except make sure pressure regulators are posi-
stall pressure regulators and locating plates (10). tioned as shown above.
Make sure pressure regulators are positioned as
shown above. Locating plates (10) are installed with STEP 37
the nose (bump) down. Install screws (9) and tighten
to a torque of 5.5 Nm (48 lb-in).
4
STEP 34
BS02C125
Install wiring harness (8) by routing harness and con-

nectors through openings in housings (14 and 27).
Connect harness connectors to pressure regulators
BS02C116
(11). Install gasket (4). Insert wiring harness multi-
At opposite side of valve housing (27), install springs pin circular connector in its hole in cover (3) making
(17, 19, and 23) and pistons (16, 18, and 22) in valve sure marks made in Step 5 are aligned. Secure con-
housing (27) bores. nector to cover using clamp (1).
STEP 35 STEP 38
Install 14 screws (2) to secure cover (3) to end hous-
ing (14). Tighten screws to a torque of 5.5 Nm
(48 lb-in).
A STEP 39
Install gasket (7) and cover (6).
STEP 40
Install 14 screws (5) to secure cover (6). Tighten
screws to a torque of 5.5 Nm (48 lb-in).
BS02C122
Repeat Steps 31 and 32 except when installing end

housing (14), make sure 19 mm (0.75 inch) diameter
recess (A) faces large piston as shown above.
STEP 41 STEP 42
BS02C127 BS02C128
Install a new O-ring (26) on eight plugs (25). Install Install two studs in transmission control valve (7, Fig-
eight plugs and tighten to a torque of 6 Nm (53 lb-in). ure page 163) then install housing gasket (5).
5
4
3
2
6
BS98J157
Transmission control valve plates and gaskets
1. Screw - 2. Distribution plate - 3. Housing gasket - 4. Valve plate - 5. Housing gasket - 6. Filter screen - 7. Transmission
control valve.
STEP 43 STEP 44
BS02C129 BS02C130
Install six filter screens (6) flush in bores of valve plate Install housing gasket (3) then distribution plate (2).
(4). Screens must be facing upward toward distribu- Make sure marks made in Step 1 are aligned. Install
tion plate (2). Make sure marks made in Step 1 are 18 screws (1) and tighten evenly to a torque of 9.5
aligned. Nm (84 lb-in).
STEP 45
Install transmission control valve.
NOTES:
SECTION 3
BRAKE SYSTEM
INDEX
3.1 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS .............................. 3-1

3.1.1 BRAKE VALVE ..................................................................................................... 3-1
Removal ........................................................................................................... 3-1
Installation ........................................................................................................ 3-1
3.1.2 SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS ............................. 3-2
Removal ........................................................................................................... 3-2
Installation ........................................................................................................ 3-2
3.1.3 BRAKE PUMP ...................................................................................................... 3-4
Removal ........................................................................................................... 3-4
Installation ........................................................................................................ 3-4
3.2 HYDRAULIC BRAKE TROUBLESHOOTING ......................................................... 3-5

3.2.1 SPECIFICATIONS ................................................................................................ 3-5
3.2.2 SPECIAL TOOL .................................................................................................... 3-5
3.2.3 TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM ................................. 3-7
3.2.4 CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR ......................... 3-8
3.2.5 CHARGING THE ACCUMULATOR WITH DRY NITROGEN ................................... 3-8
3.2.6 BLEEDING THE BRAKE SYSTEM ...................................................................... 3-9
3.2.7 BRAKE MODULATION PRESSURE CHECK ........................................................ 3-10
Testing the Brake Modulation Pressure ............................................................. 3-10
Adjusting the Brake Modulation Pressure ......................................................... 3-10
3.2.8 CHECKING THE BRAKE SYSTEM ...................................................................... 3-11
3.2.9 BRAKE PUMP OUTPUT TEST ............................................................................ 3-12
3.3 DISASSEMBLY AND ASSEMBLY OF BRAKE ACCUMULATORS ........................ 3-13

3.3.1 SPECIAL TOOL .................................................................................................... 3-13
3.3.2 DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR ................... 3-13
3.3.3 BRAKE ACCUMULATORS .................................................................................... 3-14
Disassembly ..................................................................................................... 3-14
Inspection ......................................................................................................... 3-14
Assembly ......................................................................................................... 3-14
3.3.4 PARKING BRAKE ACCUMULATOR ...................................................................... 3-16
3.4 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ..................................... 3-17

3.4.1 PARKING BRAKE ................................................................................................ 3-17
Removal and Disassembly ............................................................................... 3-17
Inspection ......................................................................................................... 3-18
Assembly and Installation ................................................................................. 3-18
PARKING BRAKE TEST PROCEDURE ............................................................... 3-21
W110/W110TC BRAKE SYSTEM 3-1
3.1 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS
3.1.1 BRAKE VALVE 10. Connect a vacuum pump to the hydraulic reser-
voir. Start the vacuum pump
Removal
11. Disconnect the lines from the brake valve (1) and
1. Park the machine on a level surface and lower the
put plugs in each line.
loader bucket to the floor. Stop the engine.
12. Stop the vacuum pump and remove.
2. Put blocks on both sides of each tire to prevent
machine movement. 13. Remove the mounting bolts (2), washers (3),
brake valve plate (4) and the brake valve (1).
3. Make sure the brake accumulators are completely
discharged. Push down and release the brake ped-
Installation
als at least 30 times.
1. Install the brake valve (1), brake valve plate (4),
4. Turn the master disconnect switch to the OFF po-
washers (3) and mounting bolts (2). Refer to the
sition.
illustration below.
5. Remove the cab skirts located under the cab or
2. Connect a vacuum pump to the hydraulic reser-
canopy.
voir. Start the vacuum pump.
6. To release the pressure on the parking brake ac-
3. Remove the plugs from the hydraulic lines and con-
cumulator, the line at the accumulator must be
nect the hydraulic lines to the brake valve (1).
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil. 4. Stop the vacuum pump and remove.
7. Connect a drain hose to the quick disconnect cou- 5. Connect all of the electrical connections.
plings in each brake circuit to release any pres- Turn the master disconnect switch to the ON posi-
sure in the brake circuit. tion.
8. Clean the brake accumulator charging valve (1) 6. Bleed the brake system.
and lines, refer to the illustration below. 7. Install the cab skirts.
9. Put identification tags on all electrical and hydrau- 8. Check the hydraulic reservoir oil level and add oil
lic lines that are connected to the brake valve (1). as required.
1
W110R0005
Brake accumulator charging valve illustration
1. Brake accumulator charging valve - 2. Mounting bolts - 3. Washers - 4. Brake valve plate - 5. Brake pedal.
3-2 BRAKE SYSTEM W110/W110TC
3.1.2 SERVICE BRAKE AND PARKING Installation

BRAKE ACCUMULATORS 1. Install the brake accumulators (1) to the brake
Removal accumulator mounting brackets (9-10).
1. Park the machine on a level surface and lower 2. Install the washers (7-8) and bolt (6). Tighten the
the loader bucket to the floor. Stop the engine. bolt (6).
2. Put blocks on both sides of each tire to prevent 3. Install the parking brake accumulator (2) to the
machine movement. bracket (9).
3. Make sure the service brake accumulators (1) 4. Install the washers (4) and nuts (3). Tighten the
and the parking brake accumulator (2) are com- nuts (3).
pletely discharged. Push down and release the 5. Connect a vacuum pump to the hydraulic reser-
brake pedal at least 30 times. voir and start the pump.
4. Remove the left cab skirt located under the cab 6. Connect the lines for both brake accumulators
or canopy. (1) and for the parking brake accumulator (2).
5. Connect a drain hose to the quick disconnect cou- 7. Stop the vacuum pump and remove.
plings in each brake circuit to release any pres-
sure in the brake circuit. 8. Install the left cab skirt.
6. Turn the master disconnect switch to OFF. 9. Turn the master disconnect switch to the ON po-
sition.
7. Clean the brake accumulators (1), parking brake
accumulator (2) and lines. 10. Bleed the brake system.
8. Put identification tags on all lines that are con- 11. Perform the Parking Brake Test Procedure.
nected to the brake accumulators (1) and park- 12. Check the hydraulic reservoir oil level and add oil
ing brake accumulator (2). as required.
10. Disconnect the lines from both brake accumula-
tors (1) and parking brake accumulator (2).
11. Install plugs or caps on each line.
13. Remove the nut (3), and O-ring (4).
14. Remove the parking brake accumulator (2).
15. Remove the bolt (6), washers (7-8) and bracket
(8).
16. Remove the brake accumulators (1).
6 4
7 2 1
10
W110R0006
1. Brake accumulator - 2. Parking brake accumulator - 3. Nut - 4. O-ring - 5. Bolt - 6. Mounting bolt - 7-8. Washer -
9-10. Parking brake accumulator bracket.
3.1.3 BRAKE PUMP Installation

Removal 1. Install the brake pump (1), mounting bolts (2) and
lock washers (3). Refer to the illustration below.
1. Park the machine on a level surface and lower the
loader bucket to the floor. Stop the engine. 2. Tighten the mounting bolts (2).
2. Put blocks on both sides of each tire to prevent 3. Connect a vacuum pump to the hydraulic reser-
machine movement. voir. Start the vacuum pump.
3. Raise the engine hood and turn the master dis- 4. Remove the plugs or caps and connect the lines
connect switch to the OFF position. to the brake pump (1).
4. Clean the brake pump (1) and lines, refer to the 5. Turn the master disconnect switch to the ON posi-
illustration below. tion.
5. Put identification tags on all lines that are connected 6. Bleed the brake system.
to the brake pump (1). 7. Check the hydraulic reservoir oil level and add oil
6. Connect a vacuum pump to the hydraulic reser- as required. See Section 0 for the correct oil.
7. Disconnect the lines from the brake pump (1) and
put plugs or caps on each line.
9. Remove the mounting bolts (2) and lock washers
(3) from the brake pump (1) and remove the brake
pump (1).
7
6
4 3
2
5
9
8
7
BS01C125
Brake pump illustration
1. Brake pump - 2. Mounting bolt - 3. Lock washer - 4. Gear - 5. Spacer - 6. Gasket - 7. O-ring - 8. Elbow - 9. Hose.
3.2 HYDRAULIC BRAKE TROUBLESHOOTING
Brake pump output ........................................................................................................... 30.8 L/min at 172 bar
(8.14 gpm at 2500 psi at 2200 rpm)
Accumulator nitrogen charge pressure .................................................................. 53 to 57 bar (775 to 825 psi)

Accumulator valve cut in pressure ................................................................ 147 to 167 bar (2130 to 2422 psi)
Accumulator valve cut out pressure .............................................................. 190 to 196 bar (2756 to 2843 psi)
Brake warning pressure switch ................................................................................... 117 bar (1697 psi) falling
141 bar (2045 psi) rising
Brake redundant pressure switch ............................................................................................. 62 bar (900 psi)
Brake light pressure switch ........................................................................................................ 4.1 bar (60 psi)
Modulation pressure front brake cylinders ................................................................ 60 + 6 bar (870 to 987 psi)
Modulation pressure rear brake cylinders ................................................................. 57 + 6 bar (825 to 943 psi)
3.2.2 SPECIAL TOOL
94L95
380001737 Nitrogen Charging Kit used to check

and charge the accumulator with nitrogen.
25 20 14
18 15 17
24
6
3
5
21
15
19
14
20
16
10
11
23 13 12
8 7
22
9
BC00N001
Brake illustration
1. Front brakes - 2. Rear brakes - 3. Parking brake - 4. Front axle test port - 5. Rear axle test port - 6. Parking brake sole-
noid - 7. Brake pump - 8. Breather - 9. Reservoir - 10. Oil cooler (optional) - 11. Hydraulic filter - 12. By-pass warning
switch - 13. Filter by-pass - 14. Brake accumulator - 15. Brake accumulator test port - 16. Fan reverser (optional) - 17. Brake
warning pressure switch - 18. Parking brake accumulator diagnostic fitting - 19. Brake light pressure switch - 20. Redundant
brake pressure switch - 21. From coupler locking valve (optional) - 22. Not used with optional fan reverser - 23. Reverse flow
check valve (used with ride control only) - 24. Brake and accumulator charging valve - 25. Parking brake accumulator.
3.2.3 TROUBLESHOOTING THE 5. After the alarms stop, run the machine at high idle
HYDRAULIC BRAKE SYSTEM to finish charging the accumulators. The pressure
must increase on both gauges until 190 to 196 bar
Note The hydraulic brake schematic is included in (2755 to 2842 psi) is reached. This is the accumu-
the hydraulic schematic on page 6-75. lator valve cut-out pressure. It is normal for the pres-
sure to drop slightly once the cut-out pressure is
1. Make sure the oil level in the hydraulic reservoir is reached.
correct. Remove all pressure from the brake sys-
tem by pushing and releasing the brake pedal many 6. With the engine running at high idle, push and re-
times with the engine stopped, until there is no pres- lease the brake pedal rapidly while reading the drop
sure on the pedal. in pressure on the gauges. The pressure drops may
not be equal, but as the lowest pressure reaches
2. Install two 207 bar (3000 psi) pressure gauges to 147 to 167 bar (2130 to 2422 psi), the system pres-
both front and rear hydraulic brake accumulator sure must start to increase. This is the valve cut in
lines.The test ports for the accumulators are lo- pressure.
cated behind the left cab skirt.
Note The brake cut-in and cut-out pressures of the
Note On units P.I.N. JEE0135500 and below, there brake system charge valve are factory preset and
are three accumulators and test ports located behind are not adjustable.
the cab skirt. The accumulator and test port closest
to the outside of the machine is for the parking brake. Note If the pressure on one of the pressure gauges
The accumulator and test port located in the middle is lower than specified, the problem can be a bad
is for the rear brakes. The accumulator and test port accumulator valve.
farthest to the inside is for the front brakes. Refer to
the illustration on page 9. On units P.I.N. JEE0135501 7. Stop the engine. Push and release the brake sev-
and above, there are three accumulators and two test eral times while reading the pressure on the
ports located behind the cab skirt. The accumulator gauges. Each push and release of the pedal will
and test port located to the outside of the loader is for result in a slight drop in pressure, but not neces-
the rear brakes. The accumulator and test port to the sarily equal on the two gauges. As the lowest pres-
inside of the loader is for the front brakes. The small sure reaches 110 to 124 bar (1600 to 1800 psi)
bottle type accumulator is for the parking brake. Re- the brake warning lamp and alarm buzzer must
fer to the illustration on page 10. actuate. If the warning lamp and alarm buzzer fail
to work, test the low brake pressure warning
3. Make sure that the hoses on the pressure gauges switches and electrical circuit. If the warning lamp
are long enough so the gauges can be read while and alarm buzzer actuate at a higher or lower pres-
sitting in the operators seat. sure than specified, test the low brake pressure
warning switches and replace as needed.
Note The gauges can not be connected if hydraulic
pressure remains in the system. 8. Continue to slowly push and release the brake
pedal several times until the gauge pressure sud-
4. Start the engine. Run the engine at low idle while denly drops to zero. The last pressure reading be-
reading the pressure gauges. The alarms (buzzer, fore the drop to zero is the nitrogen charge pres-
master warning light and brake pressure warning sure in the accumulator. Test the pressure in both
light) should shut off when the accumulator with accumulators. If the pressure is below 53 to 59 bar
the lowest pressure reaches 126 to 140 bar (775 to 825 psi), charge or replace the
(1825 to 2025 psi). accumulator(s).
Note Cold temperature can cause a drop in pres-

sure.
3.2.4 CHECKING THE NITROGEN 3.2.5 CHARGING THE ACCUMULATOR

CHARGE IN THE ACCUMULATOR WITH DRY NITROGEN
1. Make sure that the oil side of the accumulator is Note Check the pressure in the accumulator ac-
completely discharged by doing the following: cording to the instructions in Checking the Nitrogen
Charge in the Accumulator. Keep the nitrogen charg-
A. Stop the engine.
ing kit connected to the accumulator.
B. Push down and release the brake pedal many
times to release the pressure. 1. Close (turn counterclockwise) valve A and open
valve B. Close valves C and D.
2. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake 2. Turn the stem out of valve F until the stem stops
circuit. moving. Disconnect valve F from the accumulator
3. Close valves B and C on the nitrogen charging valve stem.
kit, refer to the illustration. 3. Connect the nitrogen charging kit to a dry nitrogen
tank.
4. Turn the stem out of valve F until the stem stops.
5. Remove the cap screws and guard from the ac- 4. Slowly turn valve A clockwise and read gauge E
cumulator. until the pressure is 53 to 57 bar (775 to 825 psi).
Stop turning valve A.
6. Remove the cap from the accumulator valve stem.
5. If the pressure increases above 57 bar (825 psi),
7. Connect valve F to the accumulator valve stem. quickly open and close valve D and read gauge E.
If the pressure is still too high, close valve A (turn
E counterclockwise) a small amount and quickly open
C and close valve D. The pressure shown on gauge
E is the charge pressure.
6. Connect valve F to the accumulator valve stem.
F Turn the stem into valve F until the stem stops
moving and open valve D to charge the accumula-
tor.
7. After the accumulator stops charging, turn the stem
D A out of valve F until the stem stops moving.
B 94L95
8. Close valve B and disconnect the nitrogen charg-
Nitrogen charging kit ing kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem. In-
8. Make sure that valve D is open. stall the guard and cap screws on the accumula-
9. Turn the stem into valve F and read the pressure tor.
gauge E.
10. The pressure must be 53 to 57 bar (775 to
825 psi). If the pressure is too low, charge the
accumulator with dry nitrogen.
3.2.6 BLEEDING THE BRAKE SYSTEM Note The fuel solenoid is located behind the fuel
injection pump near the fuel lines.
1. Check the level of hydraulic fluid in the reservoir.
Add fluid to the reservoir if necessary.
6. Loosen pressure side hose fitting (4, page 11 or
12) on brake pump. Pressure side hose is the
smaller of the two hoses connected to the brake
pump. Refer to illustration on page 11 or 12.
7. Turn the engine over until a few drops of oil leak
past the pressure side fitting.
8. Tighten the hose fitting and connect the fuel sole-
noid connector to the engine harness wire (1) con-
1 nector.
9. Start the engine.
BD00M048 10. Keep the engine speed at low idle until both brake
accumulators are fully charged.
2. Raise loader arms and install the safety link (1) for
safe access to the front axle bleed screws.
Note This will be approximately 30 seconds after
3. Apply the parking brake. the low brake pressure light goes out.
4. Stop the engine.
11. Stop the engine.
1 12. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
13. Remove the plastic and rubber caps from each
wheel end and slowly open all four bleed screws.
Note Attach a hose to the bleed screws to prevent

spilling any fluids.
14. Start the engine and run at low idle.

BD01D216
15. Push the brake pedal all the way down and slowly
release for one cycle.
16. Close all four wheel end bleed screws.
17. Fully depress the brake pedal three times in 5
second cycles.
18. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
19. Open the bleed screw on the right front axle. Re-
BS02J060 peat step 18.
Fuel solenoid wire 20. Open the bleed screw on the left rear axle. Re-
peat step 18.
5. Locate connector at end of engine harness wire (1) 21. Open the bleed screw on the right rear axle. Re-
and disconnect connector from fuel injector pump peat step 18.
fuel solenoid connector.
22. Tighten all bleed screws, caps and plugs.
23. Check the hydraulic fluid and add as necessary.
3 - 10 BRAKE SYSTEM W110/W110TC
3.2.7 BRAKE MODULATION PRESSURE Note These test ports are located behind the left
CHECK cab skirt near the brake valve. The test port closest
to the front of the machine is for the front brakes and
Testing the Brake Modulation Pressure the test port for the rear brakes is towards the rear.
1. Make sure the hydraulic accumulator cut-in and cut-
out pressures are correct. 4. Start the engine.
2. Stop the engine. Pump the brake pedal until there 5. Operate the machine at low idle and watch the
is no pressure in the brake system. pressure gauges on the brake accumulators un-
til the gauges rise above 170 bar (2645 psi).
6. Apply and hold the brakes for 10 to 15 seconds.
1
7. Make a note of the pressure on the gauges for
the front and rear axles.
8. The front axle brake pressure should read 60 to
68 bar (870 to 986 psi). This is the modulation
pressure for the front axle.
9. The rear axle brake pressure should read 57 to
1 65 bar (825 to 943 psi).
W110R0007 10. If the pressures are not within the specified range,
it will be necessary to adjust the modulation pres-
3. Connect two 207 bar (3000 psi) pressure gauges sures.
to the front axle test port (1) and the rear axle test
port (2).
Adjusting the Brake Modulation Pressure
Angle adjustment with pedal

released 40 to 60
3
Min. angle from released position

to start sending pressure oil to
the brakes
Max working angle 16
Pedal angle adjust

screw
Backlash
take-up screw Brake oil delivery
spools
Brake feed ports
Brake pressure adjustment stop

screw = Pf Max. W110R0348
Section view of oil delivery spools to users
W110/W110TC BRAKE SYSTEM 3 - 11
3.2.8 CHECKING THE BRAKE SYSTEM 6. Start the engine and let idle until both the front
and rear accumulators (5 and 6) are fully charged.
1. Check the level of the hydraulic fluid in the reser-
The accumulators are fully charged at 190 to 196
voir, add as needed.
bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal (8) down slowly, allowing
for full piston actuation.
Note Depress the brake pedal at the rate of three

strokes per minute.
9. Continue pressing the brake pedal (8) down. The

1 low brake pressure light should activate when the
pressure reaches 110 to 124 bar (1600 to 1800
BD00M030 psi). After the low brake pressure light activates,
press the brake pedal eight more times.
2. Install the articulation lock (1) before doing this test.
3. Remove the left side cab skirt to gain access to 10. Record the readings on the pressure gauges. The
the brake accumulators (2 and 3). Refer to the il- pressure gauges should read at or above 52 to
lustration below. 58 bar (750 to 850 psi).
4. Pump the brake pedal (4) until there is no hydrau- 11. If the pressures are at or above 52 to 58 bar (750
lic pressure in the brake system (approximately to 850 psi), the test is complete.
20 pumps).
12. If the pressures are not within the required speci-
5. Connect two 207 bar (3000 psi) pressure gauges to fications, then the brake system must be bled.
the test ports (5 and 6).
13. After bleeding the brake system, perform the brake
system check again.
5-6 2
3
7
W110R0008
2. Rear brake accumulator - 3. Front brake accumulator - 4. Brake pedal - 5. Front brake accumulator test port - 6. Rear
brake accumulator test port - 7. Parking brake accumulator - 8. Brake and accumulator charging valve.
3.2.9 BRAKE PUMP OUTPUT TEST 3. Measure the flow at 0 bar (0 psi). Record the flow
reading. Slowly close the load valve on the flowm-
1. Connect the flowmeter to the brake pump as shown
eter and read the flow at 170 bar (2500 psi). Record
below for units P.I.N. JEE0135500 and below or as
the flow reading.
shown on page 12 for units P.I.N. JEE0135501 and
above. 4. Divide the flow reading at 170 bar (2500 psi) by the
reading at 0 bar (0 psi). Multiply the result by 100.
2. Make sure the load control of the flowmeter is open.
This is the percent efficiency of the pump. If the
Start the engine. Run the engine at full throttle.
efficiency of the pump is less than 85%, repair or
Make sure the oil is at operating temperature.
replace the pump.
11
NOTE
8
10
6 7
12
5 4
12
2 1
BS01B007
Brake pump output test

1. From hydraulic reservoir - 2. Elbow - 3. Plug - 4. To accumulator valve - 5. Brake pump - 6. Flowmeter inlet hose - 7.
380001731 flowmeter - 8. Flowmeter outlet hose - 9. Filter inlet manifold - 10. Filter - 11. Filter to reservoir hose - 12. O-ring.
Note If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.
3.3 DISASSEMBLY AND ASSEMBLY OF BRAKE ACCUMULATORS
3.3.1 SPECIAL TOOL Note The parking brake accumulator used on P.I.N.
JEE0135501 and above is not rechargeable nor re-
pairable.
1. Use the 380001737 nitrogen charging kit to dis-

charge the accumulator, refer to illustration above.
The tool must be disconnected from the nitrogen
tank.
2. Close valves B, C and D.
3. Adjust the regulator A to the minimum pressure
setting by turning the knob counterclockwise.
94L95A
4. Turn the T-handle on valve F fully out.
380001737 Nitrogen charging kit
5. Remove the guard (2) and valve assembly cap
(9) from the accumulator, refer to Figure on page
3-15.
3.3.2 DISCHARGING THE NITROGEN
CHARGE ON AN ACCUMULATOR 6. Connect valve F to the valve stem on the accu-
mulator.
7. Turn the T-handle inward on valve F to engage the
C E
pin in the valve stem.
8. Open valve D and check the charge pressure on
F gauge E.
9. To discharge the accumulator, partially open valve
B. The accumulator charge will bleed down through
the regulator.
A 10. Once the accumulator is fully discharged, discon-

D B 94L95A nect valve F from the valve stem.
Nitrogen charging kit 11. The accumulator can now be disassembled.
3.3.3 BRAKE ACCUMULATORS Assembly

Disassembly 1. Fasten the body (1) in a vise. Be careful not to
damage the body (1). Refer to the illustration on
Note See Section for the proper procedure to re-
page 5.
move the accumulator.
2. Install a new wear ring (9), O-ring (11) and backup
ring (10) on the piston (5).
WARNING
3. Lubricate the bore of the body (1) and the piston
DO NOT attempt to disassemble any accumulator (5) with clean oil.
until the nitrogen charge is properly discharged.
4. Start the piston (5) into the body (1), round sur-
1. Fasten the body (1) in a vise. Be careful not to face first. Then push the piston (5) farther into the
damage the body (1), refer to the illustration on page body (1).
5.
Note The piston (5) must be installed squarely and
2. Remove the screws (3) and guard (2) from the body slowly into the body (1). Once the piston (5) is started
(1). straight into the bore of the body (1), use a hammer
3. Remove the pressure valve (4) and the elbow (8) and wood block to gently tap the piston into the pol-
from the body (1). ished area of the bore. Keep force on the piston (5)
while tapping into the bore or damage may occur to
4. Remove and discard the O-ring (7) from the elbow the O-ring.
(8).
5. Loosen and remove the gland (6) from the body 5. Install new seals (12) on the gland (6).
(1). 6. Lubricate the seals (12) with clean oil and start
6. Remove the piston (5) from the body (1). the gland (6) into the body (1).
7. Remove and discard the wear ring (9), O-ring (11) 7. Tighten the gland (6).
and the backup ring (10) from the piston (5). 8. Install a new O-ring (7) on the elboW (8).
8. Remove the seals (12) from the gland (6). 9. Install the elbow (8) on the body (1).
Inspection 10. Install the pressure valve (4) in the elbow (8).
1. Clean body (1), gland (6) and piston (5) in cleaning 11. Install the guard (2), screws (3) in the body (1).
solvent, refer to the illustration on page 5. 12. Charge the accumulator with dry nitrogen.
2. Inspect the piston (5) for cracks, burrs or other dam-
age.
3. Inspect the bore of the body (1) for scratches or
scoring using a light.
Note Minor scratches or scoring in the bore of the

body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (4) and replace as

needed.
12 6 5 9 10 11
4
7 8
1
BS01B223
Brake accumulator
1. Body - 2. Guard - 3. Screw - 4. Pressure valve- 5. Piston - 6. Gland - 7. O-ring - 8. Elbow - 9. Wear ring - 10. Backup ring -
11. O-ring - 12. Seals (2).
3.3.4 PARKING BRAKE ACCUMULATOR

The membrane accumulator is used to store pres-
sure oil to release the parking brake.
Oil from the charge pump is diverted by the ckeck
valve to the accumulator which maintains the pres-
sure at a certain value.
Capacity ........................................... 1.4 l (0.36 gal)

Max working pressure for
accumulator ................................ 210 bar (3045 psi)
Gas to be used ..................................... NITROGEN
3
Gas pre-charge pressure ................. 45 bar (652 psi)
Weight ................................... 5.4 kg abt (11.90 lbs)
W110R0336
Accumulator
1. Gas filling plug - 2. Accumulator body - 3. Oil inlet connection.
3.4 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
3.4.1 PARKING BRAKE STEP 6

Removal and Disassembly
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wheel chocks on each wheel to prevent ma-
chine movement.
STEP 3 BD01D296
Loosen and remove the parking brake hose. Cap and

plug the hose and fitting.
STEP 7
BDOOM030
Install the articulation lock.
STEP 4
BD01D346
Loosen and remove the cover from the parking brake.
STEP 8
W110R0004
Place the master disconnect switch in the OFF posi-

tion.
STEP 5 BD01D347
With the engine in the OFF position, pump the brake Loosen the jam nut that secures the center post.
pedal at least 20 times to discharge the accumula-
tors.
STEP 9 Inspection
STEP 12
Clean and inspect all parts for wear and damage.
Inspect the brake disc for wear and damage.
Replace all parts that are worn or damaged.
Assembly and Installation

STEP 13
BD01D347
Turn the center post counterclockwise until the brake

pads are loose.
STEP 10
BD01D350
Install the two brake pads in the parking brake as-

sembly.
STEP 14
Install the parking brake assembly on the brake disc.
BD01D348
STEP 15
Loosen and remove the two bolts holding the parking
brake to the transmission. Remove the parking brake.
STEP 11
BD01D348
Install the two bolts holding the parking brake to the

transmission. Tighten the two bolts.
BD01D351
Remove the two brake pads from the parking brake

assembly.
STEP 16 STEP 20
BD01D296 BD01D346
Remove the plugs and caps and install the hose onto Remove the cover from the front of the parking brake.
the parking brake.
STEP 21
STEP 17
Park the machine on a clear level surface with wheel
chocks and the articulation lock in place.
Important It will be necessary to have an assistant

help for this procedure. An operator must be present
in the cab at all times to apply the service brakes and
shut down the machine in the event of mechanical
failure. 1
2
STEP 18
BD01D347
Start the machine and run the engine at low idle with
the bucket resting on the ground. 1. Jam nut - 2. Center post.
STEP 19 Loosen the jam nut (1) that secures the center post
(2).
Disengage the parking brake.
STEP 22
Note Hydraulic pressure will not be applied to the
parking brake until the parking brake rocker switch is
turned off, the service brakes applied and the trans-
mission is put into gear.
A. Place the parking brake rocker switch in the OFF

position.
B. Apply the service brake and put the machine into
gear.
C. The parking brake light on the cluster will turn off
at this time.
D. Place the transmission back into neutral before
BD01D347
proceeding.
Turn the center post clockwise until both brake pads
contact the brake disc, then turn the center post
counterclockwise one turn.
STEP 23 STEP 27
BD01D347 BD00M030
Tighten the jam nut to secure the center post. Remove the articulation lock.
STEP 24 STEP 28
BD01D346 W110R0004
Install the cover on the parking brake. Place the master disconnect switch to the ON posi-
tion.
STEP 25
Perform the Parking Brake Test Procedure as described
in this section.
STEP 26
Bleeding the Brake System.
PARKING BRAKE TEST PROCEDURE
STEP 29 STEP 37
While testing, the machine must be on a clear level Shift the gear selector into third gear forward and slowly
surface with the bucket in the travel position. increase the engine speed to wide open throttle.
STEP 30 STEP 38
Start the machine and run the engine at low idle in Verify that the machine does not move.
third gear neutral.
STEP 39
STEP 31
Reduce the engine speed to low idle and return the
Place the Transmission-Auto switch to the manual transmission neutral.
position,
STEP 40
STEP 32
Shift the gear selector to third gear reverse and slowly
Place the Parking Brake switch in the ON position. increase the engine speed to wide open throttle.
STEP 33 STEP 41
Press the Program switch on the instrument cluster. Verify that the machine does not move.
STEP 34 STEP 42
Press the Up Count switch until the display reads 011. Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 35
STEP 43
Return the Program switch to the OFF position.
Press the Reset switch on the instrument cluster to
STEP 36 exit the test mode.
Press the UP Count switch until the display reads 01.
STEP 44
This mode will allow the transmission to engage while
the parking brake is applied. If any machine movement was detected, the parking
brake must be adjusted.
NOTES:
SECTION 4
STEERING SYSTEM
INDEX
4.1 REMOVAL AND INSTALLATION OF STEERING COMPONENTS ........................ 4-1

4.1.1 STEERING CONTROL VALVE ............................................................................. 4-1
Removal ........................................................................................................... 4-1
Installation ........................................................................................................ 4-1
4.1.2 PRIORITY VALVE ................................................................................................ 4-3
Removal ........................................................................................................... 4-3
Installation ........................................................................................................ 4-3
4.1.3 AUXILIARY STEERING PUMP AND MOTOR ....................................................... 4-5
Removal ........................................................................................................... 4-5
Installation ........................................................................................................ 4-5
4.1.4 STEERING CYLINDER ........................................................................................ 4-7
Removal ........................................................................................................... 4-7
Installation ........................................................................................................ 4-7
4.2 STEERING SPECIFICATIONS, PRESSURE CHECKS

AND TROUBLESHOOTING .................................................................................. 4-9
4.2.1 SPECIFICATIONS ................................................................................................ 4-9
4.2.2 SPECIAL TOOLS ................................................................................................. 4-10
4.2.3 TROUBLESHOOTING THE STEERING SYSTEM ................................................ 4-10
4.2.4 AUXILIARY STEERING SYSTEM PUMP TEST ................................................... 4-11
Equipment Required ......................................................................................... 4-11
Test Procedure ................................................................................................. 4-11
4.2.5 AUXILIARY STEERING SYSTEM MOTOR TEST ................................................. 4-12
Test Equipment ................................................................................................. 4-12
Test Procedure ................................................................................................. 4-12
4.2.6 UNDERSTANDING THE RESULTS OF THE TEST ............................................... 4-13
4.2.7 STEERING RELIEF VALVE .................................................................................. 4-14
Pressure Setting Test ........................................................................................ 4-14
Pressure Setting Adjustment ............................................................................ 4-16
4.2.8 STEERING CYLINDER LEAK TEST .................................................................... 4-17
4.3 STEERING CONTROL VALVE ............................................................................. 4-19

4.3.1 SPECIFICATIONS ................................................................................................ 4-19
4.3.2 SPECIAL TOOLS ................................................................................................. 4-19
4.3.3 STEERING CONTROL VALVE ............................................................................. 4-19
Disassembly ..................................................................................................... 4-19
Inspection ......................................................................................................... 4-21
Assembly ......................................................................................................... 4-22
4.4 STEERING PRIORITY VALVE ............................................................................. 4-25

4.4.1 SPECIAL TORQUES ............................................................................................ 4-25
4.4.2 STEERING PRIORITY VALVE ............................................................................. 4-26
Disassembly ..................................................................................................... 4-26
Assembly ......................................................................................................... 4-27
4.5 STEERING CYLINDER ........................................................................................ 4-29

4.5.1 SPECIFICATIONS ................................................................................................ 4-29
4.5.2 STEERING CYLINDER ........................................................................................ 4-29
Disassembly ..................................................................................................... 4-29
Inspection ......................................................................................................... 4-29
Assembly ......................................................................................................... 4-31
4.6 CENTER PIVOT ................................................................................................... 4-33

4.6.1 SPECIFICATIONS ................................................................................................ 4-33
4.6.2 SPECIAL TOOLS ................................................................................................. 4-33
4.6.3 CENTER PIVOT ................................................................................................... 4-34
Disassembly ..................................................................................................... 4-34
Assembly ......................................................................................................... 4-36
4.6.4 CONNECTING THE FRONT FRAME TO THE REAR FRAM ................................. 4-39
4.7 AUXILIARY STEERING MOTOR AND PUMP ....................................................... 4-41

4.7.1 SPECIFICATIONS ................................................................................................ 4-41
4.7.2 AUXILIARY STEERING MOTOR AND PUMP ....................................................... 4-42
Disassembly ..................................................................................................... 4-42
Inspection ......................................................................................................... 4-42
Assembly ......................................................................................................... 4-42
W110/W110TC STEERING SYSTEM 4-1
4.1 REMOVAL AND INSTALLATION OF STEERING COMPONENTS
4.1.1 STEERING CONTROL VALVE Installation

Removal 1. Install the bolts (1) and washers (2) to the steering
control valve (3). Refer to the illustration on page
1. Remove the left, right, and front cab skirts, located
4-2.
under the cab or canopy.
2. Connect the hoses to the fitting in the steering con-
2. Remove all dirt and grease from the steering con-
trol valve (5).
trol valve (3) and the area around the steering con-
trol valve (3), refer to the illustration on page 4-2. 3. Install the fill cap on the hydraulic reservoir.
3. Remove the fill cap for the hydraulic reservoir. 4. Start the engine and turn the machine all the way
to the left and right several times to remove any air
4. Fasten identification tags to the hoses at the steer-
in the circuits.
ing control valve (3).
5. Stop the engine and check for leaks.
5. Disconnect the hoses from the fittings in the steer-
ing control valve (3). 6. Check the fluid level in the hydraulic reservoir. Add
oil as required.
6. Cap or plug the fittings and hoses.
7. Remove the bolts (1), washers (2).
8. Remove the steering control valve (3) from the ma-
chine.
4-2 STEERING SYSTEM W110/W110TC
W110R0002
Steering control valve illustration
1. Bolt - 2. Washer - 3. Steering control valve.
4.1.2 PRIORITY VALVE Installation

Removal 1. Start the vacuum pump.
1. Remove all dirt and grease from the priority valve 2. Install the bolt (8), washer (6), and lock nut (7), to
(3) and the area around the priority valve (3), refer fasten the priority valve (3) to the bracket (4). Refer
to the illustration on page 4-4. to the illustration on page 4-4.
2. Remove the fill cap for the hydraulic reservoir. 3. Connect the hose (1) to the elbow in the side of
the priority valve (3).
voir. 4. Connect the hose (10) to the elbow in the side of
the priority valve (3).
4. Start the vacuum pump.
5. Connect the hose (5) to the top of the priority valve
5. Tag and disconnect the hose (9) from the priority
(3).
valve (3).
6. Connect the hose (2) to the top of the priority valve
6. Plug the hose (9).
(3).
7. Connect the hose (9) to the bottom of the priority
valve (3).
valve (3).
8. Stop the vacuum pump.
9. Disconnect the vacuum pump from the hydraulic
valve (3).
reservoir.
10. Install the fill plug on the hydraulic reservoir.
11. Start the engine and run at low idle for 30 sec-
valve (3).
onds. Stop the engine and check for leaks.
12. Check to make sure the priority valve works cor-
13. Tag and disconnect the hose (1) from the priority rectly.
valve (3).
13. Check the fluid level in the hydraulic reservoir.
14. Plug the hose (1). Add oil as required. See page 0-20 for specifica-
tions.
15. Loosen and remove the locknut (7), washer (6)
and bolt (8) which fasten the priority valve (3) to
the bracket (4).
16. Stop the vacuum pump.
1
10
8 7
6
3 4
9 4
11
13
14
12
17
15 16
18
W110R0003
Priority valve illustration
1. Hose - 2. Hose - 3. Priority valve - 4. Bracket - 5. Hose - 6. Washer - 7. Locknut - 8. Bolt - 9. Hose - 10. Hose - 11. Steering
control valve - 12. Solenoid valve - 13. Auxiliary steering pressure fitting - 14. Hose to loader control valve - 15. Hose to
priority valve - 16. Hose to priority valve - 17. Hose to priority valve - 18. Hose to loader control valve.
4.1.3 AUXILIARY STEERING PUMP Installation

AND MOTOR 1. Install the auxiliary steering pump and motor (2).
Removal Install the nuts (4), bolts (5) and flat washers.
Tighten the bolts. Refer to the illustration on
1. Remove the fill cap for the hydraulic reservoir. page 4-6.
2. Connect a vacuum pump to the hydraulic reser- 2. Start the vacuum pump.
voir.
3. Connect the hose (1) to the fitting (9) on the aux-
3. Start the vacuum pump. iliary steering pump and motor (2).
4. Tag and disconnect the hose (1) from the fitting 4. Connect the hose (3) to the elbow (8) on the aux-
(9) on the auxiliary steering pump and motor (2) iliary steering pump and motor (2).
and install a plug in the hose, refer to the illustra-
tion on page 4-6. 5. Stop the vacuum pump. Install the fill cap in the
hydraulic reservoir.
5. Tag and disconnect the hose (3) from the elbow
(8) on the auxiliary steering pump and motor (2) 6. Connect the ground wire to the rear chassis (7).
and install a plug in the hose (3). 7. Connect the electrical wires to the auxiliary steer-
6. Stop the vacuum pump. ing pump and motor (2).
7. Turn the master disconnect switch to the OFF po- 8. Place the master disconnect switch in the ON
sition. position.
8. Tag and disconnect the electrical wires from the 9. Start and run the engine at low idle, loosen the
auxiliary steering pump and motor (2). hose at the pressure switch to bleed out air in the
line.
9. Tag and disconnect the ground wire from the rear
chassis (7). 10. Stop the engine.
10. Remove the nuts (4), bolts (5) and washers (6) that 11. Disconnect the wire from the fuel shutoff sole-
hold the auxiliary steering pump and motor (2). noid on the fuel injection pump.
11. Remove the auxiliary steering pump and motor (2). 12. Actuate the starter for 3 to 5 seconds to actuate
the auxiliary steering pump and motor.
13. Turn the steering wheel all the way to the left and
to the right to make sure that the auxiliary steer-
ing pump and motor works correctly. Turn the key
switch to OFF.
14. Connect the wire to the fuel shutoff solenoid.
5
6 7
4
5
6
8 3
BS01C106
Auxiliary steering pump and motor illustration
1. Hose - 2. Auxiliary steering pump and motor - 3. Hose - 4. Nut - 5. Bolt - 6. Washer - 7. Rear Chassis - 8. Elbow - 9. Fitting.
4.1.4 STEERING CYLINDER Installation

Removal 1. Put the steering cylinder (1) into position in the
machine. Make sure that the washer (15) is in-
1. Loosen the fill cap for the hydraulic reservoir to
stalled between the steering cylinder (1) and the
release pressure in the reservoir, then tighten the
rear frame. Refer to the illustration on page 4-8.
fill cap.
2. Disconnect the hoses (13, 14, 16 and 17) for the Note Use a washer (15) on top and bottm of the
steering cylinder (1), refer to the illustration on steering cylinder (1) if possible. If only one washer
page 4-8. (15) is used, place the washer (15) on the bottom of
the steering cylinder (1).
3. Install plugs in hoses 16 and 17.
4. Remove the grease hose (11) from the tube end 2. Make sure the washers (6) are in position between
of the steering cylinder (1). the steering cylinder (1) and the front frame of the
machine.
5. Loosen and remove the locknut (4) that holds the
pin (2) to the steering cylinder (1). 3. Install the pivot pin (7) to fasten the rear of the
steering cylinder (1) to the machine frame. Install
6. Remove the bolt (3).
the spacer (10), washer (9) and bolt (8) to fasten
7. Remove the pin (2). the pivot pin (7).
8. Remove the washers (6). 4. Tighten the bolt (8).
9. Remove the bolt (8), washer (9) and spacer (10) 5. Install the pin (2) in the front of the steering cylin-
that hold the pivot pin (7) at the rear of the steer- der (1). Make sure that the washers (6) are in the
ing cylinder (1). correct position.
10. Use an acceptable driver and drive the pivot pin 6. Install the bolt (3) and locknut (4) in the steering
(7) out of the steering cylinder (1). cylinder (1) and pin (2). Tighten the locknut (4).
11. Remove the washer(s) (15) from between the
steering cylinder (1) and the rear frame of the ma- Note The bolt (3) should turn freely in the hole after
chine. tightening.
12. Remove the steering cylinder (1). 7. Connect the hoses (13, 14, 16 and 17) to the hy-
draulic cylinders.
8. Connect the grease hose (11) to the base end of
the steering cylinder (1).
9. Tighten the fill cap for the hydraulic reservoir.
11. Turn the steering wheel all the way to the right
and then to the left several times.
12. Stop the engine. Check the hydraulic oil level. See
page 0-20 for specifications.
8
9
16 10
7
13
15
17
14 2
1
8 15 3
9
10 4
7 12 11 14
12 5
15 13 6
2
4
15
1 6
BS01C108
Steering cylinder illustration
1. Steering cylinder - 2. Pin - 3. Bolt - 4. Locknut - 5. Grease fitting - 6. Washer - 7. Pivot pin - 8. Bolt - 9. Washer - 10. Spacer -
11. Grease hose - 12. Tee fitting - 13. Hose - 14. Hose - 15. Washer - 16. Hose - 17. Hose.
4.2 STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING
Auxiliary steering motor
Maximum amperes ...................................................................................................................... 30 amperes
Minimum armature speed ...................................................................................................... 6950 r/min (rpm)
Auxiliary steering pump
Minimum flow ....................................................................................... 24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
Steering relief valve
Pressure setting .......................................................................................... 239 to 243 bar (3465 to 3523 psi)
Location of steering relief valve .............................................................................. in the loader control valve
4 - 10 STEERING SYSTEM W110/W110TC
4.2.2 SPECIAL TOOLS 4.2.3 TROUBLESHOOTING THE

STEERING SYSTEM
Note The steering hydraulic schematic is included
in the hydraulic schematic. Refer to the rear pocket of
this manual.
1. Make sure the oil level in the hydraulic reservoir is

correct. Visually inspect the steering system for
leakage and damage.
2. Do the steering relief valve pressure test. Refer to
page 4-15. If the pressure is above or below speci-
fications, adjust the steering relief valve in the
loader control valve.
B785789 3. Do the main hydraulic pump test. If the main pump
is bad, repair or replace the main hydraulic pump.
380001731 Flowmeter
4. Test the steering cylinders for leakage, refer to in-
structions on page 4-18. If a steering cylinder is
leaking, repair or replace the steering cylinder.
B797157
380001740 Flowmeter fitting kit
B009638
380001739 Pressure test fitting kit
W110/W110TC STEERING SYSTEM 4 - 11
4.2.4 AUXILIARY STEERING SYSTEM

PUMP TEST
Equipment Required
1. 380001731 Flowmeter
2. 380001740 Flowmeter fitting kit
Test Procedure
BB830300
BD00M030
1. Install articulation lock (1). 10. Start and run the engine.
11. Stop the engine and turn the key back to the On
Note When performing this pressure check, always position.
be sure the articulation lock is in place, especially
12. Turn the steering wheel, this will activate the aux-
when working in the articulation joint areas.
iliary steering pump.
2. Loosen and remove the outlet hose of the Auxiliary 13. Turn the load valve on the flowmeter towards
Steering Pump from the Steering Priority Valve. CLOSED until the pressure is 104 bar (1500 psi).
3. Install a plug into the hose. 14. Read the flowmeter and ammeter gauges and
record the readings.
4. Connect the inlet of the flowmeter to the outlet fit-
ting on the Steering Priority Valve. 15. The flowmeter reading must not be less than 24.6
L/min, (6.5 U.S. gpm). The ammeter reading must
5. Install the outlet hose of the flowmeter in the hy-
be 315 amps.
draulic reservoir and hold in place with wire.
16. Turn the key switch to the OFF position. If the
6. Connect the ammeter clamp (1) to the cable as in
flow was less than the specification, or if the am-
illustration above.
perage was more than 315 amperes, remove the
7. Make sure that the parking brake is applied and auxiliary steering motor and pump. Test the auxil-
the bucket is on the floor. iary steering motor. If the motor is good, make
repairs to the pump.
8. Make sure that the oil is at operating temperature.
9. Make sure that the load valve for the flowmeter is
open (zero pressure).
4.2.5 AUXILIARY STEERING SYSTEM

MOTOR TEST
2
Test Equipment 1
1. A 24 volt battery that is fully charged.
Note A 24 volt battery system (two 12 volt batter-

ies in a series) is used for this test. A 12 volt battery
system will cause damage to the auxiliary steering 4
motor.
2. A remote starter switch. 3

3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging Sys-
tem Tester.
5
Test Procedure
1. Remove the connector that is between the termi- B790852
nals on the magnetic switch and the auxiliary steer-
ing motor.
2. Remove the auxiliary steering motor from the aux-
iliary steering pump.
3. Remove the drive coupling from the auxiliary steer-
ing motor (3).
4. Connect the auxiliary steering motor (3), remote 8
6 7
starter switch (1) and tester (2) to the 24 volt bat-
tery system (5).
5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
6. Turn the load control (8) until the voltmeter (7) indi-
cates 24 volts. Look at the ammeter (6) in the tester.
Make a record of the ammeter indication. B795328
7. Hold the tachometer against the armature shaft.

Look at the tachometer. Make a record of the indi-
cation.
8. Release the button on the remote starter switch (1).
4.2.6 UNDERSTANDING THE RESULTS 4. If the armature did not turn, and the ammeter indi-
OF THE TEST cation was zero amperes, possible causes include
the following:
1. If the ammeter indication in step 6 was 30 amperes
or less and the tachometer indication in step 7 was A. An open field coil.
6950 r/min (rpm) or more, the auxiliary steering B. An open armature coil. After the motor is
motor is good. diassembled, look at the commutator on the
2. If the armature speed was less than 6950 r/min armature. If the commutator is badly burned,
(rpm) and the ammeter indication was higher than the armature coil is probably open.
30 amperes, possible causes include the follow- C. Broken brush springs or worn brush springs.
ing:
5. If the armature speed was less than 6950 r/min
A. Damaged bearings. (rpm) and the ammeter indication was less than 30
B. Loose pole shoes. amperes, possible causes include the following:
C. A short circuit in the armature coil. The arma- A. Bad connections between the brushes and the
ture coil must be checked on an armature tester field coil.
after the motor is disassembled. B. Dirty commutator.
D. A ground connection in the field coil. 6. If the armature speed was 6950 r/min (rpm) or more
3. If the armature did not turn and the ammeter indi- and the ammeter indication was more than 30 am-
cation was higher than 30 amperes, possible peres, there is probably a short circuit in the field
causes include the following: coil. A short circuit in the field coil is difficult to
find. It is recommended that a new field frame as-
A. The motor terminal is in contact with the field sembly be installed.
frame.
B. A damaged bearing that will not let the arma-
ture turn.
4.2.7 STEERING RELIEF VALVE

Note The pump differential pressure must be prop-
erly adjusted before doing this test.
Pressure Setting Test
BD00M048
3. Remove the safety link (1) and lower the loader

arms to the ground.
1
4. Stop the engine.
BD00M048
1. Install the safety link (1) and lower the loader arms
slowly, until the safety link is supporting the loader
arms.
BD00M030
5. Install articulation lock (1).

1
Important When performing the following pressure
check and adjustment, the articulation lock must be
BD00M041
installed. Use caution when working in or near the ar-
2. Remove the cover plate (1) to gain access to the ticulation area.
loader control valve.
6. Make sure that the temperature of the hydraulic

oil is at least 52 C (125 F).
7. To measure the temperature of the oil using the
instrument panel:
A. Press the program switch (left side of the pro-
gram/reset switch).
B. Press the up count switch to function 008.
C. Return the program switch to the OFF (center)
2
position.
8. Apply the parking brake. BD00N018
9. Start and run the engine at full throttle. Note Make sure when you connect the pressure
gauge that you do so in a manner that you can read
10. Hold the bucket control lever in the rollback posi-
the pressure gauge while sitting in the operators seat.
tion.
11. Hold the lift lever in the FLOAT position. 17. Start the engine and operate the machine at full
12. Continue holding until the specified temperature throttle.
of the oil is reached. 18. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
19. Continue holding the steering wheel, and read the
14. Remove the cap on the hydraulic reservoir to re-
pressure gauge.
lease any pressure in the hydraulic system.
15. Remove the dust cap from the test port (2). 20. The pressure gauge must indicate 239 to 243 bar
(3465 to 3523 psi). If the pressure is not correct,
16. Connect a 345 bar (5000 psi) pressure gauge to
adjust the steering relief valve.
the test port (2) on the front of the loader control
valve (1).
Pressure Setting Adjustment
1
BD00M048
BD00M048
3. Remove the safety link (1), and lower the loader
arms to the ground.
1. Install the safety link (1) before adjusting the steer-
ing relief valve. 4. If the pressure gauge is still connected, repeat steps
17 through 20 in the Pressure Setting Test Proce-
dure. If the pressure gauge is not connected, do
the entire Pressure Setting Test Procedure.
5. If necessary, adjust the relief valve again until the
relief valve is within the specified range.
6. Stop the engine before removing the pressure
gauge.
BS01A046
1. Loader control valve - 2. Steering relief valve.
2. Turn the adjusting screw clockwise to increase the

pressure setting. Turn the adjusting screw counter-
clockwise to decrease the pressure setting.
Note 1/4 turn of the adjusting screw will change the

pressure by approximately 35 bar (500 psi).
4.2.8 STEERING CYLINDER LEAK TEST 9. Connect the tube to the rod end of the left-hand
steering cylinder.
Note Make sure all persons are clear of the area of
the center pivot. Make sure the center pivot is free of 10. Turn the machine all the way to the left.
any obstructions. 11. Stop the engine.
1. Park the machine on a level surface. 12. Find the tube that is connected to the rod end of
the right-hand steering cylinder. Disconnect the
2. Turn the machine all the way to the right. tube from the right-hand steering cylinder.
3. Stop the engine and apply the parking brake. 13. Install a plug in the tube.
4. Find the tube that is connected to the rod end of 14. Start and run the engine at full throttle.
the left-hand steering cylinder. Disconnect the tube
from the left-hand cylinder. 15. Turn the steering wheel to the left. Hold the steer-
ing wheel for a full left turn. Have another person
5. Install a plug in the tube. check for leakage at the opening of the rod end of
6. Start and run the engine at full throttle. the right-hand steering cylinder.
7. Turn the steering wheel to the right. Hold the steer- 16. If there is constant leakage from the rod end, the pis-
ing wheel for a full right turn. Have another person ton packing in the right-hand steering cylinder is dam-
check for leakage from the opening of the rod end aged. Repairs must be made. See paragraph 4-5.
of the left-hand steering cylinder. 17. Connect the tube to the rod end of the right-hand
8. If there is constant leakage from the rod end, the piston steering cylinder.
packing in the left-hand steering cylinder is damaged.
Repairs must be made. See paragraph 4-5.
NOTES:
4.3 STEERING CONTROL VALVE
Manufacturer ............................................................................................................................................. Eaton
Special Torques
Cap screws for end cap ...................................................................................... 33.9 NM (300 pound-inches)
4.3.2 SPECIAL TOOLS

Retaining ring pliers ................................................................................................... Eaton part number 600610
Splined shaft end tool, #600604 .................................................................................... Eaton part number 8063
Order Special Tools from:

Eaton Corporation, Hydraulics Division, 15151 Highway 5, Eden Prairie, MN 55344
4.3.3 STEERING CONTROL VALVE 7. Hold the gerotor star and drive shaft (6), with your
hand. Protect both the gerotor star and hand with
Disassembly
a shop towel while turning.
1. Clean the port area of the steering control valve
8. Turn the tool clockwise or counter-clockwise to
housing before disconnecting the hydraulic lines.
compress the centering spring (12).
2. Drain the oil, and plug the ports. Clean the exterior
9. Hold the drive shaft (6) stationary.
of the steering control valve housing. Protect the
machines surfaces during repair. 10. Remove the centering spring (12), spool (9) and
sleeve (8), ball checks (10), pin (11), drive shaft
3. Put the steering control valve in a vise so that the
(6), bearing race (14), retaining ring (18) and nee-
end cap (2) is up.
dle thrust bearing (13). Use retaining ring pliers.
11. Remove the back-up washer (15), seal ring (16),
3 and O-ring (17).
12. Carefully pry the dust seal (19) from the steering
2 control valve housing (7), using a small blade
screwdriver. Do not damage the dust seal (19).
Note If the steering control valve housing (7) has

anti-cavitation valves, find the anti-cavitation valves
in the steering control valve housing (7).
1
GS98K501
13. To disassemble these valves, insert soda straws
(3) in each end of the threaded holes, refer to fig-
Steering control valve-end cap up ure on page 4-21. Remove the steering control
valve housing from the vise and tilt it until the
1. Vise - 2. Anti-cavitation valves - 3. End cap.
port face (4) is upward. Continue turning until the
roll pins (2) and ball checks (1) slide through the
4. Remove the seven cap screws (1), end cap (2), straws (3).
O-ring (3), gerotor (4), O-ring (3), spacer plate (5),
and O-ring (3), refer to on page 4-20.
5. Remove the gerotor star from gerotor (4).
6. Using a splined shaft end no. 8063 tool start the
tool on the splined end of the spool (9).
14 18 13
14
17 7
16
15
19
8 10
11
1
9
2 10
12
3
4
3
21
5
3
20
GS98K502
Steering control valve - exploded view
1. Cap screw - 2. End cap - 3. O-ring - 4. Gerotor - 5. Spacer plate - 6. Drive shaft - 7. Steering control housing - 8. Sleeve -
9. Spool - 10. Ball check - 11. Pin - 12. Centering spring - 13. Needle thrust bearing - 14. Bearing race -
15. Backup washer - 16. Seal ring - 17. O-ring - 18. Retaining ring - 19. Dust seal - 20. Ball check - 21. Roll pin.
3
4
5 2
GS98K530
Anti-cavitation valve - disassembly
1. Ball check - 2. Roll pin - 3. Soda straw - 4. Port face - 5. Anti-cavitation valvese.
Inspection 3. If the spool (9) and sleeve (8) or the bore in the
housing of the steering control valve (7) is dam-
1. Clean all parts in cleaning solvent and air dry on
aged or worn, use a new steering control valve.
paper towels. Do not use cloths to wipe parts dry,
as it may leave lint on the parts. 4. Inspect the cap screws (1), pin (11), ball check
(10), backup washer (15), seal ring (16), O-ring (17),
2. Check all machined surfaces for wear or damage.
needle thrust bearing (13) and bearing race (14).
If there are rough places on the ends of the gerotor
Use new parts as required.
star or gerotor (4), steering control valve housing
(7), end cap (2), or spacer plate (5), use 600 grit 5. If your steering control valve has anti-cavitation
emery cloth to smooth the surfaces, refer to figure valves, inspect the ball checks (20) and roll pins
on page 4-20. Place the emery cloth on a flat sur- (21) for damage or wear. Use new parts as required.
face. If the emery cloth is new, rub a piece of steel
across the emery cloth six times to remove the
sharp pieces of grit. Make sure that the part is held
flat on the emery cloth. Rub each part across the
cloth six times. Check to see if the rough places
are removed. Use this method until all rough places
are removed. Clean the parts in cleaning solvent to
remove any grit.
Assembly 3. Lubricate the spool (3) with clean hydraulic fluid

and slide it into the sleeve (2), along with the ball
Note Use new seals (3), (16), and (19) when reas-
check (5), refer to figure on page 4-23.
sembling the steering control valve.
Lubricate the new seals with a petroleum jelly. Lubri- 4. Install the drive shaft (1) and pin (4).
cate machined surfaces with clean hydraulic fluid.
5. Install the centering spring (6). Position one end of
the centering spring (6) in slotted end of spool (3)
1. Use a soda straw (3) as a guide tool. Drop the straw
and sleeve (2). Compress the centering spring (6)
(3) into the anti-cavitation valve (5) to the bottom
by turning it counter-clockwise to engage the free
of the bore. Drop the ball check (2) through the straw
end of the spring.
(3). Pull the straw (3) out and use the same proce-
dure in the second ball seat. 6. Install the bearing race (8) and retaining ring (7),
onto the spool (3), using retaining ring pliers.
2 7. Lubricate, using petroleum jelly, the ID of the dust

seal (19) that is mounted in the steering control
3 1 valve housing (7), refer to figure on page 4-20.
8. Lubricate, using petroleum jelly, the needle thrust
bearing (13), second bearing race (14), backup
4
washer (15), seal ring (16) and O-ring (17). Position
each part onto the spool (9). The needle thrust bear-
ing (13) goes between the two bearing races (14),
and must be centered around the retaining ring (18).
9. Lubricate, using clean hydraulic fluid, the spool (9)
and sleeve (8) assembly and slide it into the steer-
ing control valve housing (7), as follows:
5
GS98K504 Important Do not damage the dust or shaft seals.
Optional anti-cavitation valves assembly A. Protecting the gerotor star and hand with shop
towels, hold the gerotor star and splined end of
1. Roll pin - 2. Ball check - 3. Soda straw - 4. Port face -
5. Anti-cavitation valves. drive shaft (6) to keep it from turning.
B. Insert the splined shaft end No. 8063, into the
2. Use a small light and check each bore to make steering control valve housing (7), and start it
sure each ball check (2) is in the correct place. onto the splined end of the spool (9). Turn the
Add the roll pin (1) in each. tool clockwise or counter-clockwise to compress
the centering spring (12).
Note If the unit is positioned horizontally, keep the

pin horizontal. If the tension on the pin is released
before the assembly is fully engaged, the pin can drop
and lockup can occur if the pin is not horizontal.
1 5
2
4
5 3
2
1
6 6
2
6 8
1 7
4 3
5
GS98K505
Spool and sleeve assembly
1. Drive shaft - 2. Sleeve - 3. Spool - 4. Pin - 5. Ball check - 6. Centering spring - 7. Retaining ring - 8. Bearing race.
10. Compressing the centering spring (12), carefully 16. Lubricate a new O-ring (3) and install into the
insert the assembled bearing races (14), retain- groove of the spacer plate (5).
ing ring (18), needle thrust bearing (13), backup
17. Install the gerotor (4) and align the screw holes.
washer (15), seal ring (16) and O-ring (17).
18. Lubricate a new O-ring (3) and install into the
11. Release the centering spring (12) tension.
groove in the gerotor ring (4).
12. Remove the gerotor star.
19. Install the end cap (2) and seven cap screws (1).
13. Remove the splined shaft end No. 8063 tool. Pre-tighten the cap screws in a criss-cross pat-
tern to 17 Nm (150 pound-inch), and finally, in a
14. Lubricate new O-rings (3) and install in the groove
criss-cross pattern, tighten cap screws (1) to 33.9
of the steering control valve housing (7).
Nm (300 pound-inch).
15. Install the spacer plate (5), O-ring (3), and align
the holes in the spacer plate (5) with the threaded
holes in the housing (7).
4.4 STEERING PRIORITY VALVE

Spool Orifice Screws ......................................................................................... 7.3 to 9.6 Nm (65 to 85 lb-inch)
Plugs and Relief Valve ........................................................................................ 33.9 to 54.2 Nm (25 to 40 lb-ft)
Adapter .............................................................................................................. 8.1 to 9.5 Nm (72 to 84 lb-inch)
4.4.2 STEERING PRIORITY VALVE STEP 4

Disassembly Remove plug (5). Remove and discard O-ring (6) from
plug.
STEP 1
Put the steering priority valve in a soft jawed vise. STEP 5
Remove spring (7).
STEP 2
Remove adapter (1). Remove and discard O-ring (2) STEP 6
from adapter.
Remove spool (8).
STEP 3 STEP 7
Remove relief valve (3). Remove and discard O-ring
Remove plug (9). Remove and discard O-ring (10) from
(4) from relief valve.
plug.
1 2 3 4 11
10
9
7 8
BS01E129
1. Adapter - 2. O-ring - 3. Relief valve - 4. O-ring - 5. Plug - 6. O-ring - 7. Spring - 8. Spool - 9. Plug - 10. O-ring - 11. Housing.
Cleaning and Inspection Assembly

STEP 8 STEP 12
Clean all parts in cleaning solvent. Immerse housing Install new O-ring (10) on plug (9). Install plug and O-
(11) in cleaning solvent and agitate cleaning solvent. ring. Tighten plug to a torque of 33.9 to 54.2 Nm (25 to
WEAR EYE PROTECTION WHEN USING COM- 40 lb-ft).
PRESSED AIR. Use compressed air to remove for-
eign matter from interior of valve housing and to en- STEP 13
sure that all orifices and bores are clear.
Install spool (8) and spring (7),
STEP 9 STEP 14
Inspect spool (8) and housing bores for deep scratches, Install new O-ring (6) on plug (5). Install plug and O-
gouges, and other damage. Replace steering priority ring. Tighten plug to a torque of 33.9 to 54.2 Nm (25 to
valve if any of these conditions are seen. 40 lb-ft).
STEP 10 STEP 15
Check that orifice screws in each end of spool (8) are Install new O-ring (4) on relief valve (3). Install relief
free and clear of foreign matter. WEAR EYE PRO- valve and O-ring. Tighten relief valve to a torque of
33.9 to 54.2 Nm (25 to 40 lb-ft).
TECTION WHEN USING COMPRESSED AIR. If nec-
essary, remove orifice screws and use compressed STEP 16
air to remove foreign matter from interior of spool (8)
and orifice screws. Install orifice screws in spool (8) Install new O-ring (2) on adapter (1). Install adapter
ends. Tighten screws to a torque of 7.3 to 9.6 Nm and O-ring. Tighten adapter to a torque of 8.1 to 9.5
(65 to 85 lb-inch). Nm (72 to 84 lb-inch).
STEP 11
Check spring (7) for cracks, breaks, or signs of per-
manent set. Replace if any of these conditions are
seen.
3 1 11
1 2
10 9
7 8
BS01E129
1. Adapter - 2. O-ring - 3. Relief valve - 4. O-ring - 5. Plug - 6. O-ring - 7. Spring - 8. Spool - 9. Plug - 10. O-ring - 11. Housing.
NOTES:
4.5 STEERING CYLINDERS
Torque for piston cap screw .....................................................................585 to 720 Nm (431 to 531 pound-feet)
Torque for gland .................................................................................... 339 to 475 Nm (250 to 350 pound-feet))
Weight ................................................................................................................................ 18 kg (39.7 pounds)
4.5.2 STEERING CYLINDER Inspection
Disassembly 1. Discard the O-ring (6), backup ring (7), seal (4),
seal (5), wiper (9), and guide (8) from the gland (3).
1. Fasten the tube (1) in a vise. Be careful not to dam- Refer to the illustration on page 4-29.
age the tube (1). Refer to the illustration on
page 4-29. 2. Discard the seal (12), backup ring (13), and wear
ring (14) that were removed from the piston (11).
2. Loosen and remove the gland (3) from the tube (1).
3. Clean all parts in cleaning solvent.
3. Pull the piston (11) straight out of the tube (1).
4. Check to be sure that the piston rod (10) is straight.
4. Fasten the yoke on the piston rod (10) in the vise If the piston rod (10) is bent, install a new piston
and put a support below the piston rod (10) near rod (10).
the piston (11). Use a shop cloth between the sup-
port and the piston rod (10) to prevent damage to 5. Inspect the inside of the tube (1) for deep grooves
the piston rod (10). and other damage. If there is any damage to the
tube (1), a new tube (1) must be used.
5. Loosen and remove the bolt (15) and hardened
washer (16) that hold the piston (11). 6. Remove small scratches on the piston rod (10) or
inside the tube (1) with emery cloth of medium grit.
6. Remove the piston (11) from the piston rod (10). Use the emery cloth with a rotary motion.
7. Remove the seal (12), backup ring (13), and wear 7. Inspect the bushings (2) and replace as required.
ring (14) from the piston (11).
8. Remove the gland (3) from the piston rod (10).
9. Remove the O-ring (6), backup ring (7), seal (4),
seal (5), wiper (9), and guide (8) from the gland (3).
10
9
4
5
3
7
6
8
14
11
12
13
16
15 1
17
BS01B202
Steering cylinder illustration
1. Tube - 2. Bushing - 3. Gland- 4. Seal - 5. Seal - 6. O-ring - 7. Backup ring - 8. Guide - 9. Wiper - 10. Piston rod - 11. Piston
- 12. Seal - 13. Backup ring - 14. Wear ring - 15. Bolt - 16. Hardened washer - 17. Grease fitting.
Assembly 12. Install a new backup ring (13) on the piston (11).
1. Install the seal (4) in the gland (3). The seal (4) 13. Install a new seal (12) over the backup ring (13).
must be installed so that the lips of the seal (4)
14. Clean the threads on the end of the piston rod
are toward the small end of the gland (3). The seal
(10) and the threads of the bolt (15) using
(4) can be difficult to install. Use tools that will not
LOCTITE cleaning solvent. Allow to dry. Apply
damage the seal (4). Refer to the illustration on
LOCTITE 242 to the piston rod threads 1/4 inch
page 4-29.
from the open end of the piston rod so that there
2. Install the seal (5) in the gland (3). is 1/2 inch of LOCTITE 242 on the piston rod
threads. DO NOT apply LOCTITE to the first 1/4
3. Install the guide (8) in the gland (3).
inch of the piston rod threads.
4. Install the wiper (9) in the gland (3).
15. Install the bolt (15) and hardened washer (16) in
5. Install the O-ring (6) on the gland (3). The O-ring the piston (11).
(6) must be toward the small end of the gland (3).
16. Install the piston (11) on the piston rod (10) and
6. Install the backup ring (7) on the gland (3). The start the bolt (15) into the piston rod (10).
backup ring (7) must be toward the large end of
17. Tighten the bolt (15) according to torque specifi-
the gland (3). If the backup ring (7) is not flat on
cations listed on page 4-28.
both sides, the side that is not flat must be to-
ward the O-ring (6). 18. Fasten the tube (1) in the vise. Be careful not to
damage the tube (1).
7. Fasten the yoke on the piston rod (10) in the vise.
19. Apply petroleum jelly to the O-ring (6) and backup
8. Lubricate the piston rod (10) and the bore in the
ring (7) on the gland (3) and to the sealing surface
gland (3) with clean hydraulic oil.
in the tube (1).
Note If a new gland (3) is being installed, write the 20. Lubricate the piston (11) and the inside of the tube
part number of the cylinder on the gland (3). (1) with clean hydraulic oil.
21. Push the piston (11) straight into the tube (1). Be
9. Push the gland (3) onto the piston rod (10). If nec-
careful not to damage the wear ring (14) and seal
essary, use a soft hammer to drive the gland (3)
(12) on the piston (11).
onto the piston rod (10).
22. When the piston (11) is in the smooth part of the
10. Put the support below and near the end of the
tube (1), start the gland (3) into the tube (1).
piston rod (10). Put a cloth between the support
and the piston rod (10) to prevent damage to the 23. Tighten the gland (3) to 339 to 475 Nm (250 to
piston rod (10). 350 pound-feet).
11. Install a new wear ring (14) on the piston (11).
NOTES:
4.6 CENTER PIVOT
Special Torques
M16 bolt for upper pivot pin .................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for the lower pin plate ................................................................................. 124 Nm (91 pound-feet)
M12 bolts screws for the lower pin plate .............................................. 128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ......................................................... 61 to 81 Nm (45 to 60 pound-feet)
Lubricant
Pivot bearings and seals ........................................................................................................................ MG-2
Steering cylinder rod eyes ...................................................................................................................... MG-2
Fluids
Hydraulic system reservoir ...................................................................................... MS-1209, Hy-Tran Ultra
4.6.2 SPECIAL TOOLS

380001730 ............................................................................................................... Hand pump (hydraulic ram)
380001734 ............................................................................................................................... 10 ton ram (long)
380001735 ................................................................................................... Puller set, includes 24827 leg ends
380001736 ........................................................................ Bearing cup and seal puller, includes 24850 adapter
380001729 ..................................................................................................................... Vacuum pump (12 volt)
380001744 ........................................................................... *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from 380001735)
4.6.3 CENTER PIVOT 19. Disconnect the supply hose.

Disassembly 20. Install a cap on the hose and a plug in the fitting.
1. Remove all dirt and grease from the area of the 21. Stop the vacuum pump.
center pivot. Park the machine on a level surface. 22. Loosen and remove the self-locking nut and bolt
2. Lower the bucket until the bucket is flat on the that hold the pivot pin for the steering cylinder rod
floor. eye.
3. Stop the engine and apply the parking brake. 23. Remove the pivot pin from the rear frame and the
steering cylinder rod eye.
4. Remove the covers from both sides of the ma-
chine. 24. Remove the washer from the rear frame. Move
the steering cylinder out of the way.
5. Disconnect the front wiring harness from the cab
floor. 25. Repeat steps 22, 23 and 24 for the other steering
cylinder.
6. Remove any tie straps that fasten the front wiring
harness to the chassis near the center pivot. 26. Loosen and remove the Ferry head screws and
retainers that fasten the drive shaft to the front
7. Loosen and remove the nut and washer that fas-
yoke. Move the drive shaft out of the way.
ten the chassis ground wire and cab ground wire
to the studs. 27. Place two stands below and in contact with the
front frame.
8. Loosen and remove the bolt, lock washer, and
nut that fasten the clamp on the front wiring har- 28. Install blocks between the rear axle and the rear
ness to the bracket on the rear frame. Move the frame on both sides of the machine to prevent
front wiring harness out of the way. the rear frame from tipping.
9. Loosen and remove the fill plug for the hydraulic 29. Put a jack in contact with both sides of the rear
reservoir. frame near the center pivot area. Use another jack
at the rear of the machine to prevent the rear frame
from tipping.
30. Loosen and remove the bolt (1), washer (2), and
11. Disconnect the brake hose from the backside of
spacer (3) that fasten the upper pivot pin (4) to
front brake line bracket.
the rear chassis (5), refer to figure on page 7-34.
12. Install a plug in the tube and a cap on the fitting.
31. Use a prybar to remove the upper pivot pin (4).
13. Disconnect the hoses for the steering cylinder.
32. Loosen and remove the bolts (1) and hardened
14. Install caps on the fittings and plugs in the hoses. washers (2) that fasten the lower pin plate (15) to
the lower pivot pin (10).
15. Loosen and remove the bolts, lock washers, and
self-locking nuts that fasten the mounting bracket 33. Loosen and remove the cap screws (1) and wash-
for the hoses to the bracket on the front frame. ers (2) that fasten the lower pin plate (15) to the
bottom of the rear chassis (5).
16. Loosen and remove the bolts, flat washers, and
self-locking nuts that fasten the bracket for the 34. Use the ram and hand pump to remove the lower
hoses to the rear frame. pivot pin (10).
17. Disconnect the return hose. 35. Install the puller on the bottom spacer (14), see
Special Tools on page 4-32.
18. Install the cap on the hose and a plug in the fit-
ting.
1
2 3
4
5
1
6 2
7
5 9
10
6
5
5 A
16
11
12
6
8
8
13
6 15 2
2 14 1
2
1 1
BS01B225
Center pivot assembly
1. Bolt - 2. Washer - 3. Spacer - 4. Upper pivot pin - 5. Rear chassis - 6. Seal - 7. Bearing retainer - 8. Shim - 9. Upper pivot
bearing - 10. Lower pivot pin - 11. Lower bearing spacer- 12. Lower pivot bearinge - 13. Bearing retainer - 14. Bottom
spacer - 15. Lower pin plate - 16. Front chassis.
36. Remove the bottom spacer (14). Assembly

37. Release the parking brake. 1. Pack the bearing cones with grease. See Specifi-
cations in this section. Be careful not to mix the
38. Use prybars to turn the left rear wheel backwards
bearing cones.
and the right rear wheel forward to move the front
of the rear frame to the left for access to the bear- 2. Lubricate the bore in the top pivot with grease. See
ings. Install blocks under the wheels to prevent Specifications on page 4-32 for the correct grease.
the rear frame from moving.
3. Install a bearing cup in the top pivot.
39. Apply the parking brake.
4. Install the bearing driver and plate.
40. Hold the bearing retainer (13) in place and loosen
and remove the bolts (1) and washers (2) that fas-
ten the bearing retainer (13) and shims (8) to the NUT
bottom of the rear pivot. WASHER TOP PIVOT
TOP BEARING
41. Remove the bearing retainer (13) and shims (8). DRIVER
42. Remove the lower bearing spacer (11) from the

top of the lower pivot.
43. Loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot. BEARING
CUP PLATE
44. Remove the bearing retainer (7) and shims (8). WASHER
TOP
45. Use the puller to remove the seal (6) from the top PIVOT NUT
SCREW
of the bottom pivot.
B1423A88J
46. Use the puller to remove the seal (6) from the
bottom of the top pivot. 5. Tighten a nut on the screw until the bearing cup is
seated in the bore of the top pivot. Remove the
47. Use an acceptable driver, the hydraulic ram, and
bearing driver and plate from the top pivot.
the hand pump to remove the upper pivot bearing
(9) from the top pivot. See Special Tools on page 6. Install a bearing cone, spacer, the other bearing
4-32. cone, and the remaining bearing cup in the top pivot.
Note The spacers are matched to the bearing sets.
Do not mix the spacers. Do not use the old spacers if 8. Tighten a nut on the screw until the bearing cup is
new bearing sets are being installed. seated against the spacer. Remove the bearing
driver and plate from the top pivot.
48. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the lower pivot bearing SCREW
TOP BEARING
(12) from the bottom pivot. See Special Tools on DRIVER NUT
page 4-32. WASHER
BEARING BEARING
Note The spacers are matched to the bearing sets. CUP CONE
Do not mix the spacers. Do not use the old spacers if
new bearing sets are being installed.
49. Use an acceptable driver to press the seal (6) out

of each bearing retainer (7 and 13).
SPACER
TOP PIVOT BEARING

BEARING CONE
WASHER PLATE
CUP
NUT B1424A88J
9. Put the bearing retainer (7) in place on the upper 19. The bottom of the seal (6) must be even with the
pivot bearing (9), refer to figure on page 4-34. bottom of the top pivot.
10. Install the bearing driver and plate. 20. Apply grease to the upper pivot pin (4).
11. Tighten a nut on the screw until the bearing retain- 21. Install the upper pivot pin (4) in the top pivot.
er (7) is tight against the upper pivot bearing (9).
22. Lubricate the top pivot until grease is forced out
of the seal (6). See Specifications on page 4-32.
BEARING RETAINER 23. Rotate the upper pivot pin (4) to check the bear-
GAP ing assembly. The upper pivot pin (4) must rotate
smoothly, but not easily. Leave the upper pivot
pin (4) in place to keep dirt out of the upper pivot
bearing (9).
24. Lubricate the bore for the bottom pivot with grease.
Install a bearing cup in the bottom pivot.
TOP PIVOT UP
B1425A88J
12. Measure the gap between the bearing retainer (7)

and the top pivot. Make a record of the measure-
ment. Subtract 0.0762 to 0.1016 o 0.004 inch) from
the measurement. Select shims (8) equal to that
value.
13. Remove the bearing driver, plate, and bearing re-
tainer (7) from the top pivot.
14. Install the shims (8) and the bearing retainer (7).
B1430A88J
15. Install the washers (2) and bolts (1). Tighten the
bolts (1) to 124 Nm (92 pound-feet).
SCREW
16. Install the seal (6) in the bearing retainer (7). The
top of the seal (6) must be even with the top of
the bearing retainer (7). NUT
WASHER
UP BEARING CUP PLATE
BOTTOM
BOTTOM WASHER BEARING
B1426A88J PIVOT NUT DRIVER
B1427A88J
17. Fill the other seal (6) for the top pivot with grease.
See Specifications in this section for the correct
grease.
18. Use an acceptable driver to install the seal (6) in
the bottom of the top pivot.
26. Tighten a nut on the screw until the bearing cup is 35. Measure the gap between the bearing retainer (13)
seated in the bore in the bottom pivot. and the bottom pivot. Make a record of the meas-
urement. Subtract 0.0762 to 0.1016 mm (0.003 to
27. Remove the bearing driver and plate from the bot-
0.004 inch) from the measurement. Select shims
tom pivot.
(8) equal to that value.
28. Install a bearing cone, spacer, the other bearing
36. Remove the bearing driver, plate and bearing re-
cone, and the remaining bearing cup in the bot-
tainer (13) from the bottom pivot.
tom pivot.
37. Install the shims (8), the bearing retainer (13),
washers (2) and bolts (1).
SCREW 38. Tighten the bolts (1) to 124 Nm (92 pound-feet).
NUT 39. Fill the seal (6) for the bearing retainer (13) with
WASHER
grease. See Specifications in this section for the
PLATE correct grease.
BEARING BEARING
CUP CONE 40. Install the seal (6) in the bearing retainer (13). The
bottom of the seal (6) must be even with the bot-
tom of the bearing retainer (13). Be careful not to
damage seal (6).
UP
SPACER
BEARING
CUP BEARING
BOTTOM CONE
BOTTOM WASHER BEARING
PIVOT NUT DRIVER B1428A88J
30. Tighten a nut on the screw until the bottom bear-

ing cup is seated against the spacer.
31. Remove the bearing driver and plate from the bot-
tom pivot.
32. Put the bearing retainer (13) in place on the lower B1430A88J
pivot bearing (12).
33. Install the bearing driver and plate. 41. Install the other seal (6) in the bottom pivot. The
top of the seal (6) must be even with the top of
the bottom pivot.
BOTTOM
PIVOT
UP
GAP
BEARING
RETAINER
B1429A88J B1426A88J
34. Tighten a nut on the screw until the bearing retainer 42. Install the lower bearing spacer (11) and the bot-
(13) is tight against the lower pivot bearing (12). tom spacer (14).
43. Apply grease to the lower pivot pin (10). See 15. Start the six outer bolts (1) into the lower pin plate
Specifications on page 4-32. (15) and the bottom pivot.
44. Install the lower pivot pin (10) in the bottom pivot. 16. Install the shims (8).
45. Hold the bottom spacer (14) in place and lubri- 17. Tighten the six outer bolts (1) to 128 to 136 Nm
cate the bottom pivot until grease is forced out of (94 to 100 pound-feet).
the seal (6).
18. Tighten the three inner bolts (1) to 124 Nm (92
46. Rotate the lower pivot pin (10) to check the bear- pound-feet).
ing assembly. The lower pivot pin (10) must rotate
19. Remove the jacks from the rear frame.
smoothly, but not easily.
20. Remove the blocks from the rear axle.
47. Remove the lower pivot pin (10) and the upper
pivot pin (4). 21. Remove the stands from the front frame.
48. Remove the bottom spacer (14). 22. Put the drive shaft in position on the front yoke.
23. Install new Ferry head screws that fasten the drive
shaft to the front yoke.
4.6.4 CONNECTING THE FRONT FRAME
TO THE REAR FRAM 24. Tighten the Ferry head screws to 61 to 81 Nm (45
to 60 pound-feet).
1. Release the parking brake.
25. Put the steering cylinder rod eye in position in the
2. Move the rear frame into alignment with the front frame. Install the washer between the steering
frame. cylinder rod eye and the rear frame.
3. Move the steering cylinders as required to move 26. Align the hole in the pivot pin with the holes in the
the rear frame into alignment with the front frame. steering cylinder rod eye, and install the pivot pin.
4. Apply the parking brake. 27. Install the bolt and self-locking nut that hold the
5. Apply grease to the upper pivot pin (4), refer to pivot pin.
figure on page 4-34. 28. Repeat steps 25, 26 and 27 for the other steering
6. Install the upper pivot pin (4), spacer (3), washer cylinder.
(2) and bolt (1). Be careful not to damage the seal 29. Start the vacuum pump.
(6).
30. Connect the return hose
7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184
pound-feet). 31. Connect the supply hose.
8. Apply grease to the lower pivot pin (10). 32. Put the bracket for the hoses in position on the
rear frame. Install the bolts, flat washers, and self-
9. Install the lower pivot pin (10) in the frames. Be locking nuts that fasten the bracket to the rear
careful not to damage the seal (6). frame.
10. Use the ram and hand pump to install the bottom 33. Put the bracket for the hoses in position on the
spacer (14). front frame.
11. Install the lower pin plate (15), three inner bolts 34. Install the bolts, flat washers, and self-locking nuts
(1), and washers (2) that fasten the lower pin plate that fasten the bracket to the front frame.
(15) to the lower pivot pin (10).
35. Connect the hoses for the steering cylinders.
12. Tighten the bolts (1) to 69 Nm (51 pound-feet).
36. Connect the brake hose for the front brakes at
13. Measure the gap between the lower pin plate (15) the front bracket.
and the bottom pivot. Make a record of the meas-
urement. Subtract 0.0762 to 0.1016 mm (0.003 to 37. Stop the vacuum pump.
0.004 inch) from the measurement. Select shims 38. Connect the front wiring harness to the rear wiring
equal to that value. harness.
14. Loosen the bolts (1) that fasten the lower pin plate
(15) to the lower pivot pin (10).
39. Put the clamp on the wiring harness in position 43. Check the fluid level in the hydraulic reservoir.
on the bracket. Install the bolt, lock washer, and Add oil as required. See Specifications on page
nut that fasten the clamp on the wiring harness to 4-32.
the bracket.
44. Install the fill plug on the hydraulic reservoir.
40. Put the ground wire in position on the stud. Install
45. Bleed air from the front axle bleed screws.
the washer and nut that fasten the ground wire to
the stud. 46. Lubricate the pivot pins for the steering cylinder
rod eyes.
41. Install a tie strap to fasten the wiring harness to
the tube. 47. Install the covers on both sides of the machine.
42. Disconnect the vacuum pump from the hydraulic
reservoir.
4.7 AUXILIARY STEERING MOTOR AND PUMP
Auxiliary steering motor
Maximum amperes ...................................................................................................................... 30 amperes
Minimum armature speed ...................................................................................................... 6950 r/min (rpm)
Motor ................................................................................................................................................. 24 volts
Auxiliary steering pump

Minimum flow ....................................................................................... 24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
4.7.2 AUXILIARY STEERING MOTOR AND Assembly

PUMP 1. Lubricate all parts with clean hydraulic oil before
Disassembly assembly.
Note The pump is the only component that is disas- 2. Lubricate and install a new seal (4) and retaining
sembled. The switch (8) and motor (1) are replaced as ring (3) on the plate (17). Refer to the illustration
units and are not serviced. Refer to the illustration on on page 4-42.
page 4-42. 3. Lubricate and install a new backup ring (5) and a
new seal (6) on the plate (17).
1. Make an alignment mark on the pump assembly
4. Lubricate and install new O-rings (7) on the body
and motor (1).
(18).
2. Loosen and remove the two screws (15) and lock
washers (14) that hold the pump assembly to the 5. Lubricate and install the pins (22), drive gear (20),
motor (1). driven gear (19) and wear plates (23) on the body
(18).
3. Remove and discard the mounting gasket (13),
retaining ring (3) and seal (4) from the pump as- 6. Lubricate and install a new backup ring (5) and a
sembly. new seal (6) on the end plate (21).
4. Loosen and remove the four bolts (2) that hold 7. Align the marks, made during disassembly, on
the pump assembly together. the end plate (21), body (18) and plate (17) and
install the four bolts (2). Tighten the four bolts (2).
5. Remove the end plate (21) from the body (18).
6. Remove and discard the seal (6) and backup ring 8. Install a new gasket (13) on the pump assembly.
(5) from the end plate (21). 9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1).
driven gear (19) from the body (18). 10. Install the lock washer (14) and screw (15). Torque
8. Remove the body (18) from the plate (17). the screw (15) to 35 to 39 Nm (312 to 348 pound-
inches).
9. Remove and discard the O-rings (7) from the body
(18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup ring
(5) from the plate (17).
Note The only serviceable items on the pump as-

sembly are the seals (6), backup rings (5), O-rings
(7), seal (4), retaining ring (3) and gasket (13). If any
of the other items are damaged, replace the pump
assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 4-42.
2. Inspect the drive gear (20) and driven gear (19). If
the shafts are worn or damaged, replace the pump
assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.
8
10 9
11
12 16
1
13
3 17
4 14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
Auxiliary steering pump and motor illustration
1. Motor - 2. Bolt - 3. Retaining ring - 4. Seal - 5. Backup ring - 6. Seal - 7. O-ring - 8. Switch - 9. Cable - 10. Screw - 11. Lock
washer - 12. Washer - 13. Gasket - 14. Lock washer - 15. Screw - 16. Wire - 17. Plate - 18. Body - 19. Driven gear - 20. Driven
gear - 21. End Plate - 22. Pins - 23. Wear Plate.
NOTES:
SECTION 5
BUCKET BOOMS AND FRAME

INDEX
5.1 LOADER .............................................................................................................. 5-1

5.1.1 GENERAL DESCRIPTION ................................................................................... 5-1
5.1.2 SPECIFICATIONS ................................................................................................ 5-2
5.1.3 BUCKET TEETH .................................................................................................. 5-2
Replacement of the Tooth Points ...................................................................... 5-2
Replacement of the Bucket Teeth ..................................................................... 5-2
Replacement of the Bucket Corner Teeth ......................................................... 5-2
5.1.4 RETURN TO DIG ADJUSTMENT (Z-BAR MODELS) .......................................... 5-3
5.1.5 HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
(Z-BAR MODELS AND TC) .................................................................................. 5-4
5.1.6 RETURN TO DIG ADJUSTMENT (TC MODELS) ................................................. 5-6
5.1.7 REMOVING THE LOADER FRAME (Z-BAR MODELS) ........................................ 5-7
5.1.8 INSTALLING THE LOADER FRAME (Z-BAR MODELS) ...................................... 5-9
5.1.9 REMOVING THE LOADER FRAME (TC MODELS) .............................................. 5-12
5.1.10 INSTALLING THE LOADER FRAME (TC MODELS) ............................................ 5-14
5.2 FRAME ................................................................................................................ 5-15

5.2.1 FRAME CENTRAL PIVOT .................................................................................... 5-16
W110/W110TC BUCKET BOOMS AND FRAME 5-1
5.1 LOADER
5.1.1 GENERAL DESCRIPTION The bucket positioner device and the boom kick-out
ensure an optimised efficiency of the equipment.
The load handling system is composed of:
All pivot pins of the handling system have dust seals
- booms
to prevent the entry of debris.
- strut
The three bucket pivot pins and the lower strut hing-
- link
ing pin are equipped with O-rings. All pivot pins are
- bucket
mounted with securing screws.
- bucket cylinder
For the part relative to bucket and boom cylinders,
- boom cylinders
please refer to Section 6 (Hydraulic system).
- pins
3 4
2
6
5
8 9
11
7
7 12
8
12
11
9
10
10
Detail of typical pin Bucket pins
W170-5R001
Booms, strut and bucket
Note Apply grease to the inner surfaces of the bushings and dust seals, prior to inserting the pins. Apply rust
preventing oil to the inner surfaces of the bosses.
1. Bucket - 2. Strut - 3. Boom - 4. Bucket cylinder - 5. Link - 6. Boom cylinder - 7. Locking screw - 8. Dust seal - 9. Bushing -
10. Pin - 11. Grease fitting - 12. O-Ring.
5-2 BUCKET BOOMS AND FRAME W110/W110TC
Special Torques
Bolts for the Bucket Teeth ..................................................................... 515 to 618 Nm (380 to 456 pound-feet)
5.1.3 BUCKET TEETH

Replacement of the Tooth Points
3
1. Use a hammer and punch to drive the retaining pin 4 5
(1) for the tooth point (2) out of the tooth shank (3),
refer to the illustration on this page. 2 1
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank (3).
7
4. Install the retaining pin (1) into the tooth point (2) 6
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use a
hammer to hit the retaining pin (1) until the retain- 8 10
ing pin (1) is even with the outside of the tooth shank 3
(3).
1
Replacement of the Bucket Teeth 2
1. Loosen and remove the nuts (4), hardened wash-

ers (5), and bolts (6) from the bucket teeth. 9
7
Note If wear of the bolt or nut makes removal diffi-
cult, the bolt or nut can be cut off.
B0740A88
2. Remove the tooth.

Bucket teeth illustration
3. Install the new tooth on the bucket cutting edge
(7). 1. Retaining ring - 2. Tooth point - 3. Tooth shank - 4. Nut -
5. Hardened washer - 6. Bolt - 7. Cutting edge - 8. Plow
4. Use new nuts (4), hardened washers (5), and bolts bolt - 9. Nut - 10. Corner tooth.
(6) for the tooth being installed.
5. Tighten the nuts (4) to 515 to 618 Nm (380 to 456
lb ft).
Replacement of the Bucket Corner Teeth

1. Loosen and remove the nuts (9) and bolts (8) from
the bucket corner teeth (10).
Note If wear of the bolt or nut makes removal diffi-

cult, the bolt or nut can be cut off.
2. Remove the corner tooth (10).

3. Install the new corner tooth (10) on the bucket cut-
ting edge (7).
4. Use new nuts (9) and bolts (8) for the corner tooth
being installed.
5. Tighten the nuts (9) to 515 to 618 Nm (380 to 456
lb ft).
5.1.4 RETURN TO DIG ADJUSTMENT (Z-BAR MODELS)
2
6
1
3
4
5 BS01C083
Return to dig adjustment illustration Z-bar models
1. Target mounting bracket - 2. Bucket cylinder - 3. Target bar - 4. Proximity switch mounting bracket - 5. Proximity switch -
6. Proximity switch guard.
Important Before adjusting the return-to-dig, make 7. Loosen the bolts holding the target bar (3) to the
sure that the target bar on the bucket linkage is not target mounting bracket (1). Slide the target bar
damaged. Slowly roll back and dump the bucket and (3) towards the proximity switch (5) until the face
make sure that the target bar stays the same dis- of the proximity switch (5) is completely covered.
tance from the switch. The switch mounting bracket 8. Align the target bar (3) parallel to the tilt cylinder
protects the switch. Make sure the target bar cannot (2) and tighten the bolts.
touch the switch when the bucket is dumped. 9. Turn the ignition switch to the ON position. Do
NOT start the engine.
1. Park the machine on a level surface. Raise the lift
arms until they are approximately horizontal and 10. Place the bucket control lever in the ROLLBACK
dump the bucket. Lower the bucket until the bucket position.
edge is on the ground. 11. Loosen the bolts holding the target bar (3) to the
2. Apply the parking brake and stop the engine. target mounting bracket (1).
12. Slide the target bar (3) slowly away from the prox-
3. Loosen the bolts holding the target mounting
imity switch (5), until the control lever returns to
bracket (1) to the tilt cylinder eye. Align the target
the center position. Tighten the bolts holding the
mounting bracket (1) parallel to the tilt cylinder (2).
target bar (3).
Tighten the bolts, refer to the illustration on this
page. 13. Check to make sure that the 3.5 to 5.0 mm (1/8
to 3/16 inch) gap is still maintained.
4. Loosen the bolts holding the proximity switch
mounting bracket (4) to the tilt cylinder (2). Posi- 14. Start the engine.
tion the proximity switch (5) parallel to the target 15. Place the detent switch in the ON position and
bar (3) and tighten the bolts. place the return to travel/float detent switch to the
5. Adjust the proximity switch (5) out towards the tar- TRAVEL position.
get bar (3), until an air gap of 3.5 to 5.0 mm (1/8 to 16. Raise the lift arms approximately horizontal, and
3/16 inch) is obtained. Torque the jam nut to 6 to put the bucket in the fully dumped position.
7.5 Nm (4.5 to 5.5 pound-feet).
17. Place the loader control lever in the ROLLBACK
Note The proximity switch (5) must not protrude position, and verify that the electromagnet holds
past the proximity switch guard (6). it in that position until the end of the target bar (3)
passes in front of the proximity switch (5).
6. Start the engine, position the bucket to the cor- 18. Lower the lift arms and verify that the bucket is at
rect digging angle and stop the engine. the correct digging angle.
5.1.5 HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT (Z-BAR MODELS AND TC)
5
6
2
1
BS01C081
Height control and return to travel adjustment illustration (Z-bar and TC)
1. Target mounting plate - 2. Height control target - 3. Proximity switch - 4. Lift arm - 5. Return to travel target - 6. Front
chassis (top left hand side).
1. Park the machine on a level surface. 5. Position the return to travel target (5) opposite the
proximity switch (3) and tighten it to the target
2. Start the engine and apply the parking brake.
mounting plate (1).
3. Lower the lift arms and place the bucket flat on the
6. Adjust the proximity switch (3) out towards the re-
ground.
turn to travel target (5) until an air gap of 3.5 to
4. Stop the engine. 5.0 mm (1/8 to 3/16 inch) is obtained.
7. Lock the proximity switch (3) in this position with
Note To avoid damage to the proximity switch (3), it
the jam nut. Torque the jam nut to 6 to 7.5 Nm
must be adjusted back to clear everything on the lift
(4.5 to 5.5 pound-feet).
arm as it passes. Refer to the illustration on this page.
WARNING
Raised equipment on the machine without an
operator can cause injury or death. Before you
leave the operators compartment, always support
or lower the equipment (backhoe, blade, boom,
bucket, etc.) to the ground and stop the engine.
2
A
B
1
BS01C082
Height control and return to travel adjustment illustration Z-bar - TC Models
1. Height control target - 2. Return to travel target - 3. Target mounting plate.
APPROXIMATE
RESULTING APPROXIMATE
RETURN TO RESULTING
MACHINE A TRAVEL HINGE B HEIGHT CONTROL
PIN HEIGHT HINGE PIN HEIGHT
57 mm 358 mm 54 mm 3302 mm
W110 Z-BAR
(2.24 in.) (14.09 in.) (2.12 in.) (130 in.)
47 mm 438 mm 48 mm 3302 mm
W110 TC
(1.85 in.) (17.24 in.) (1.88 in.) (130 in.)
8. Refer to the table and the illustration on this page. 13. Place the detent switch in the ON position, and
Position the height control target (1) on the target set the return to travel/float detent switch to the
mounting plate (3) using the table above. return to travel position.
14. Place the loader control lever in the raise position
Note The higher the height control target (1) is po-
and verify that the electromagnet holds it in that
sitioned in its slot in the target mounting plate (3), the
position until the height control target (2) passes
lower the lift arms will stop as they are raised.
in front of the proximity switch (3). Refer to the
9. Tighten the height control target (1). illustration on page 5-4.
10. Position the return to travel target (2) using the 15. With the lift arms still raised, place the loader con-
table above. trol lever in the lower position and verify that the
electromagnet holds it in that position until the
Note The higher the return to travel target (2) is return to travel target (5) passes in front of the
positioned in its slot in the target mounting plate (3), proximity switch (3). Refer to the illustration on
the lower the lift arms will stop as they are lowered. page 5-4.
16. Repeat steps 8 through 15 until the desired
11. Check to make sure the proximity switch (3) and heights are reached.
all of the mounting bolts are tight. Refer to the
illustration on page 5-4. 17. Lower the bucket to the ground and stop the en-
gine.
5.1.6 RETURN TO DIG ADJUSTMENT (TC MODELS)
2
3
1 5
6 BS01C084
Return to dig adjustment illustration TC models

1. Bucket cylinder (left hand side) - 3. Target mounting bracket - 5. Proximity switch - 2. Proximity switch mounting bracket
- 4. Proximity switch guard - 6. Target bar
IMPORTANT Before adjusting the return-to-dig, 8. Loosen the bolts holding the target bar (6) to the
make sure that the target bar on the bucket linkage is target mounting bracket (3). Slide the target bar
not damaged. Slowly roll back and dump the bucket (6) away from the proximity switch (5) until the
and make sure that the target bar stays the same face of the proximity switch (5) is completely un-
distance from the switch. The switch mounting bracket covered.
protects the switch. Make sure the target bar cannot 9. Align the target bar (6) parallel to the bucket cyl-
touch the switch when the bucket is dumped. inder (1) and tighten the bolts.
1. Park the machine on a level surface. Raise the 10. Turn the ignition switch to the ON position. Do
lift arms until they are approximately horizontal NOT start the engine.
and dump the bucket. Lower the bucket until the 11. Place the bucket control lever in the ROLLBACK
bucket edge is on the ground. position.
2. Apply the parking brake and stop the engine.
12. Loosen the bolts holding the target bar (6) to the
3. Loosen the bolts holding the target mounting target mounting bracket (3).
bracket (3) to the bucket cylinder clevis. Align
the target mounting bracket (3) parallel to the 13. Slide the target bar (6) slowly towards the proxim-
bucket cylinder (1) and tighten the bolts. Refer to ity switch (5), until the bucket control lever re-
the illustration on this page. turns to the center position. Tighten the bolts hold-
ing the targe bar (6).
4. Loosen the bolts holding the target bar (6) to the
target mounting bracket (3). Align the target bar 14. Check to make sure that the 3.2 to 5.0 mm (1/8
(6) parallel to the bucket cylinder (1) and tighten to 3/16 inch) gap is still maintained.
the bolts. 15. Start the engine.
5. Loosen the bolts holding the proximity switch
16. Place the detent switch in the ON position and
mounting bracket (2) to the bucket cylinder (1).
set the return to travel/float detent switch to the
Position the proximity switch (5) face parallel to
return to travel position.
the target bar (6) and tighten the bolts.
17. Raise the lift arms to approximately the horizon-
6. Adjust the proximity switch (5) out towards the
tal position and put the bucket in the fully dumped
target bar (6) until an air gap of 3.2 to 5.0 mm
position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). 18. Place the loader control lever in the ROLLBACK
position and verify that the electromagnet holds it
NOTE The proximity switch (5) must not protrude in that position until the end of the target bar (6)
past the proximity switch guard (4). passes in front of the proximity switch (5).
7. Start the engine, position the bucket to the cor- 19. Lower the lift arms to the ground and verify that
rect digging angle and stop the engine. the bucket is at the correct digging angle.
5.1.7 REMOVING THE LOADER FRAME 12. Use an acceptable driver and drive the pivot pin
(Z-BAR MODELS) (7) out of the piston rod eye of the bucket cylin-
der (8).
1. Park the machine on a level surface and apply
the parking brake. Roll the bucket all the way for- 13. Raise the bucket cylinder (8) and use a chain or
ward and lower the bucket to the floor. Stop the other acceptable holding equipment to hold the
engine. bucket cylinder (8) in place.
2. Loosen the filler plug in the reservoir to release 14. If the machine is equipped with auxiliary hydrau-
the air in the reservoir. lics, disconnect the two hoses from the tubes at
the bracket on the right side of the loader frame
3. Fasten a chain hoist to the crossmember (1) of (2). Install caps on the hoses and plugs in the
the loader frame (2), refer to the illustration on tube fittings.
page 5-8.
15. If the machine is equipped with front lamps, loosen
4. Loosen and remove the bolt (12), flat washer (13), and remove the cap screws and lock washers
and spacer (14) that fasten the pivot pin (3) to the that fasten the lamp brackets to the front frame.
piston rod yoke of the right lift cylinder (4). Put the lamp brackets on the fenders.
5. Use an acceptable driver and drive the pivot pin 16. Connect the chain hoist to the loader frame (2).
(3) out of the piston rod yoke of the right lift cylin-
der (4). Do not remove the driver. 17. Loosen and remove the bolt (19), flat washer (20)
and spacer (21) that fasten the pivot pin (9 or 10)
6. Repeat Steps 4 and 5 for the left lift cylinder (6). to the front frame.
7. Start the engine. Roll the bucket back and lower 18. Raise the loader frame slightly. Use an accept-
the bucket so that the bucket is flat on the floor able driver and drive the pivot pin (9 or 10) out of
and fasten the chain hoist to a lift cylinder (4 or the front frame. Do not lose the washers (18) and
6). wipers (22) between the front frame and the
8. Raise the lift cylinder (4 or 6) slightly and remove loader frame (2).
the driver. 19. Repeat Steps 17 and 18 for the other pivot pin (9
9. Repeat steps 7 and 8 for the other lift cylinder (4 or 10).
or 6). 20. Raise the loader frame (2) out of the front frame.
10. Connect the chain hoist to the bucket cylinder (8). Carefully move the machine out of the loader
frame (2).
11. Loosen and remove the bolt (15), flat washer (16),
and spacer (17) that fasten the pivot pin (7) for
the piston rod eye of the bucket cylinder (8) to
the bellcrank (11).
10
8
18
22 16 15
17
18 7
9
20
19 2
6
11
21 1
5
5
5
4
14
23
12 3
13
BS01C087
Loader frame - Z-bar model illustration
1. Crossmember - 2. Loader frame - 3. Pivot pin - 4. Lift cylinder - 5. Pivot pin - 6. Lift cylinder - 7. Pivot pin - 8. Bucket cylinder
- 9. Pivot pin - 10. Pivot pin - 11. Bellcrank - 12. Bolt - 13. Washer - 14. Spacer - 15. Bolt - 16. Washer - 17. Spacer -
18. Washer - 19. Bolt - 20. Washer - 21. Spacer - 22. Wiper - 23. Dump link.
5.1.8 INSTALLING THE LOADER FRAME 17. Fasten the chain hoist to one of the lift cylinders
(Z-BAR MODELS) (4 or 6).
1. Apply antiseize compound to the inner bores and 18. Raise the piston rod yoke of the lift cylinder (4 or
outer bores for the pivot pins of the front frame, 6) so the piston rod yoke is aligned with the loader
refer to the illustration on page 5-8. frame (2).
2. Move the machine into alignment with the loader 19. Install a driver in the piston rod yoke and the
frame (2). loader frame (2).
3. Lower the loader frame (2) into alignment with 20. Repeat Steps 17, 18, and 19 for the other lift cyl-
the front frame. inder (4 or 6).
4. Apply antiseize compound to the pivot pins (9 and 21. Disconnect the chain hoist from the lift cylinder
10) that fasten the loader frame (2) to the front (4 or 6).
frame. 22. Start the engine. Raise the loader frame and roll
5. Start the pivot pins (9 and 10) into the front frame. the bucket all the way forward. Lower the bucket
Install the washers (18) and new wipers (22) be- to the floor. Stop the engine.
tween the loader frame (2) and the front frame. 23. Fasten the chain hoist to the crossmember (1) of
6. Install the pivot pins (9 and 10) all the way. the loader frame (2).
7. Install the bolt (19), washer (20) and spacer (21) 24. Start the engine and run the engine at low idle.
that fasten the pivot pins (9 and 10). Tighten the 25. Have another person help you at this time. Move
bolt. the lift control lever as required to align the piston
8. Disconnect the chain hoist from the loader frame rod yoke of one of the lift cylinders (4 or 6) with
(2). the loader frame (2).
9. If the machine is equipped with front lamps, hold Important Do not use your fingers to check the
the front lamps in place and install the cap screws alignment of the cylinder rod. Personal injury can be
and lock washers that fasten the front lamps to the result.
the front frame. Tighten the cap screws.
10. If the machine is equipped with auxiliary hydrau- 26. Remove the driver and install the pivot pin (3).
lics, remove the plugs from the tube fittings and 27. Install the bolt (12), washer (13), and spacer(14)
the caps from the hoses. Connect the hoses to that fasten the pivot pin (3). Tighten the bolt.
the tubes.
28. Repeat Steps 25, 26, and 27 for the other lift cyl-
11. Connect the chain hoist to the bucket cylinder (8) inder (4 or 6). Stop the engine.
and lower the bucket cylinder (8).
29. Lubricate the pivot pins with molydisulfide grease.
12. Start the engine and run the engine at low idle.
30. Disconnect the chain hoist from the crossmember
13. Have another person help you at this time. Move (1) of the loader frame (2).
the bucket control lever as required to align the
piston rod eye of the bucket cylinder (8) with the 31. Tighten the filler plug in the reservoir.
bellcrank (11). Stop the engine. 32. If the machine is equipped with auxiliary hydrau-
lics, start the engine and run the engine at low
Important Do not use your fingers to check the idle.
alignment of the cylinder rod. Personal injury can be
the result. 33. Slowly extend and retract the clam cylinders four
times to remove air from the auxiliary circuit.
14. Install the pivot pin (7) in the bellcrank (11) and 34. Stop the engine, check the level of the oil in the
the piston rod eye of the bucket cylinder (8). reservoir, and check for leaks. Add oil to the res-
15. Install the bolt (15), washer (16), and spacer (17) ervoir as required.
that fasten the pivot pin (7). Tighten the bolt.
16. Disconnect the chain hoist from the bucket cylin-
der (8).
5 - 10 BUCKET BOOMS AND FRAME W110/W110TC
BS01C089
Bucket cylinder hydraulic circuit - Z-bar model
1. Bucket cylinder - 2. Control valve.
W110/W110TC BUCKET BOOMS AND FRAME 5 - 11
BS01C088
Lift cylinder hydraulic circuit - Z-bar
1. Left lift cylinder - 2. Right lift cylinder - 3. Control valve.
5.1.9 REMOVING THE LOADER FRAME 13. Disconnect the hoses to the bucket cylinders.
(TC MODELS) Disconnect the hoses from the tubes at the bucket
cylinders.
1. Remove all dirt and grease from the hose and
tube connections for the bucket cylinders and clam 14. Install a cap on each hose and a plug in each
cylinder, if equipped. tube.
2. With the engine running at low idle, roll the bucket 15. If equipped, disconnect the clam hydraulic con-
all the way forward and lower the loader frame nections, the auxiliary hydraulic connections, and
until the bucket is on the floor. the coupler connections as necessary. Plug and
cap lines as needed.
3. Stop the engine and apply the parking brake.
16. Disconnect the wiring harnesses.
4. Loosen the filler plug in the reservoir to release
the air in the reservoir. 17. Connect the chain hoist to the loader frame (3).
5. Loosen and remove the bolt (7), washer (8), and 18. Loosen and remove the bolt (11), washer (12),
spacer (9) that fasten the pivot pin (1) to the pis- and spacer (13) that fasten the loader frame (3),
ton rod yoke of the lift cylinder (2 or 10), refer to pivot pin (4) and anchor link pivot pin (5) to the
the illustration on page 5-13. machine frame.
6. Use an acceptable driver and drive the pivot pin 19. Raise the loader frame (3) slightly. Use an ac-
(1) out of the piston rod yoke of the lift cylinder (2 ceptable driver and drive both the pivot pins (4
or 10). Do not remove the driver. and 5) from the loader frame (3) and anchor link
(6).
7. Repeat Steps 5 and 6 for the other lift cylinder (2
or 10). 20. Do not lose the washers (14) between the front
frame and the loader frame (3).
8. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor. 21. If equipped, remove the proximity switch cover
Fasten the chain hoist to a lift cylinder (2 or 10). and the proximity switch from the left-hand side
of the machine.
9. Raise the lift cylinder (2 or 10) slightly and re-
move the driver. 22. Repeat Steps 18 and 19 on the opposite side of
the machine.
10. Repeat Steps 8 and 9 for the other lift cylinder (2
or 10). 23. Raise the loader frame from the machine. Be sure
all the necessary hydraulic lines, wiring etc. are
11. Stop the engine. properly disconnected.
12. Move the bucket control lever to the ROLLBACK 24. Carefully move the machine out of the loader
position and the lift control lever to the LOWER frame.
position to relieve any pressure in the circuits.
14
15
13 4
12
11
5
3
89
7 1
W110R0353
Loader frame - TC models illustration
1. Pivot pin - 2. Lift cylinder - 3. Loader frame - 4. Pivot pin - 5. Pivot pin - 6. Anchor link - 7. Bolt - 8. Washer - 9. Spacer -
10. Lift cylinder (not shown) - 11. Bolt - 12. Washer - 13. Spacer - 14. Washer - 15. Wiper.
5.1.10 INSTALLING THE LOADER FRAME 15. Repeat Steps 12, 13, and 14 for the other lift cyl-
(TC MODELS) inder (2 or 10).
16. Disconnect the chain hoist from the lift cylinder
1. Apply antiseize compound to the inner bores and (2 or 10).
outer bores of the front frame. 17. Start the engine. Raise the loader frame (3) and
2. Move the machine into alignment with the loader roll the bucket all the way forward. Lower the
frame (3), refer to the illustration on page 12. bucket to the floor. Stop the engine.
3. Lower the loader frame (3) into alignment with the 18. Fasten the chain hoist to the crossmember of the
machine frame. loader frame (3).
4. Apply antiseize compound to the pivot pins (4) 19. Start the engine and run the engine at low idle.
and (5) that fasten the loader frame (3) to the
machine frame.
5. Start the loader frame pivot pin (4), washer (14) IMPORTANT
and wiper (15). Do not use your fingers to check the alignment of
the cylinderrod. Personal injury can be the result.
6. Install the loader frame pivot pin (4) and anchor
link pivot pin (5) on one side of the machine.
7. Repeat Steps 5 and 6 for the opposite side of the 20. Have another person help you at this time. Move
machine. the lift control lever as required to align the piston
rod yoke of one of the lift cylinders (2 or 10) with
8. Install the bolt (11), washer (12) and spacer (13) the loader frame (3).
that secure the pivot pins (4 and 5) to the ma-
chine on each side of the machine. Tighten the 21. Remove the driver and install the pivot pin (1).
bolt. 22. Install the bolt (7), washer (8), and spacer (9) that
9. Disconnect the chain hoist from the loader frame fasten the pivot pin (1). Tighten the cap bolt.
(3). 23. Repeat Steps 20, 21, and 22 for the other lift cyl-
10. If the machine is equipped with auxiliary hydraul inder (2 or 10). Stop the engine.
ics, clam hydraul ics, or coupler hydraulics, re- 24. Lubricate the pivot pins with molydisulfide grease.
move the plugs from the tube fittings and the caps
from the hoses and make the necessary connec- 25. Disconnect the chain hoist from the crossmember
tions. of the loader frame (3).
11. Connect the hoses and tubing to the bucket cyl- 26. Start the engine and run the engine at low idle.
inders. 27. Slowly extend and retract the cylinders four times
12. Fasten the chain hoist to one of the lift cylinders to remove air from the hydraulic circuit.
(2 or 10). 28. If equipped with auxiliary hydraulics, slowly ex-
13. Raise the piston rod yoke of the lift cylinder (2 or tend and retract the clam cylinders four times to
10) so the piston rod yoke is aligned with the loader remove air from the auxiliary circuit.
frame (3). 29. Stop the engine, check the level of the oil in the
14. Install a driver in the piston rod yoke and the loader reservoir, and check for oil leaks. Add oil to the
frame (3). reservoir as required.
5.2 FRAME
The frame is of a type with welded steel plates with

two modules pivoting between them, and the equip- WARNING
ment mounted on the front module and the engine-
Do not attempt any modification on the ROPS (Roll
transmission on the rear one.
over protection structure) if mounted, without the
previous authorisation by the Manufacturer. In the
event the ROPS is damaged or deformed as a con-
sequence of a roll over or a collision, it is recom-
mended that it is replaced with a new one, since a
damaged or deformed ROPS has a low structural
strength.
18
17
16 15
14 32
13
12
25 32
26
27
2 11
33 32
10
32 32
1
8 30
20 9 28
19 29
21 3 31
22 6 5 6
6 23 4 7
24
W110R0093
Frame
1. Bearing - 2. Bearing - 3. Retainer - 4. Spacer - 5. Seal - 6. Washer, lock 12x24x3 - 7. Screw M12x100 - 8. Spacer -
9. Gasket - 10. Pin - 11. Seal - 12. Retainer - 13. Seal 12x1,75x80 - 14. Screw M12x80 - 15. Handled shaft - 16. Spacer -
17. Washer - 18. Screw M16x35 - 19. Shim (0,25) - 20. Shim (0,10) - 21. Shim (0,50) - 22. Plate - 23. Screw M12x30 -
24. Screw M12x70 - 25. Shim (0,10) - 26. Shim (0,50) - 27. Shim (0,25) - 28. Shim (0,50) - 29. Shim (0,25) - 30. Shim (0,10)
- 31. Nipple - 32. Rear main frame - 33. Front main frame.
Ballast for model with Z bar Ballast for model with Z - TC bar
Ballast weight 346 Kg Ballast weight 755 Kg W110R0354
Rear ballast installation
Note - 1 955 - 1075 Nm
5.2.1 FRAME CENTRAL PIVOT
The loader is of an articulated frames type: the front

frame is connected to the rear frame by two hinging
pins around which the loader is pivoting, when steer-
ing.
WARNING
The steering action could crush the body between

the two modules (front and rear) of the frame.
Block the articulation with the safety bar, prior to
transporting the machine or performing repair in- (With loader under repairs)
terventions. On the other hand, relocate the safety
bar in its original position, prior to starting oper-
ating the machine. Safety bar
(Upper hinging)
3 1
1
7
4 2
8
3
(Lower hinging)
13
9
14
3 1
15
16
10
17 4
11 18
12
1 2
W110R0095
Central hinging
Note 1 90 Nm 3 Threaded area: Loctite 262
2 223 Nm 4 Ring outer area: Loctite 262
1. Cover - 2. Dust seal - 3. Bushing - 4. Cover - 5. Shim - 6. Grease fitting - 7. Bearing - 8. Pin - 9. Bushing - 10. Cover -
11. Shim - 12. Washer - 13. Pin - 14. Cover - 15. Shim - 16. Bearing - 17. Dust seal - 18. Bushing
NOTES:
SECTION 6
EQUIPMENT HYDRAULIC SYSTEM

INDEX
6.1 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS ...................... 6-1

6.1.1 REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE ................. 6-1
Removal ........................................................................................................... 6-1
Installation ........................................................................................................ 6-4
6.1.2 REMOVAL AND INSTALLATION OF THE REMOTE CONTROL VALVE ................ 6-7
Removal ........................................................................................................... 6-7
Installation ........................................................................................................ 6-8
6.1.3 REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP ............................. 6-13
Removal ........................................................................................................... 6-13
Installation ........................................................................................................ 6-15
6.1.4 REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS ................................ 6-17
Removal ........................................................................................................... 6-17
Installation ........................................................................................................ 6-18
6.1.5 REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER - Z-BAR LOADER .. 6-20
Removal ........................................................................................................... 6-20
Installation ........................................................................................................ 6-22
6.1.6 REMOVAL AND INSTALLATION OF THE OIL COOLER ....................................... 6-24
Removal ........................................................................................................... 6-24
Installation ........................................................................................................ 6-25
6.1.7 REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATOR ....... 6-27
Removal ........................................................................................................... 6-27
Installation ........................................................................................................ 6-28
6.1.8 REMOVAL AND INSTALLATION OF THE RIDE CONTROL VALVE ...................... 6-29
Removal ........................................................................................................... 6-29
Installation ........................................................................................................ 6-31
6.1.9 REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE .................... 6-33
Removal ........................................................................................................... 6-33
Installation ........................................................................................................ 6-34
6.2 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING

AND PRESSURE CHECKS .................................................................................. 6-35
6.2.1 SPECIFICATIONS ................................................................................................ 6-35
6.2.2 SPECIAL TOOLS ................................................................................................. 6-36
6.2.3 TROUBLESHOOTING PROCEDURE ................................................................... 6-37
Problems in All Circuits .................................................................................... 6-37
Problem in All Loader Circuits ........................................................................... 6-37
Problem in the Braking Circuit .......................................................................... 6-37
Problem in a Single Loader Circuit .................................................................... 6-38
Problem in the Steering Circuit ......................................................................... 6-38
Problem in the Ride Control .............................................................................. 6-38
6.2.4 TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE ............... 6-39
Pressure Check ................................................................................................ 6-39
Adjusting the Main Hydraulic Pump .................................................................. 6-40
6.2.5 TESTING THE HYDRAULIC PUMP PERFORMANCE AND TORQUE LIMITER ... 6-40
6.2.6 TESTING AND ADJUSTING THE MAIN RELIEF VALVE ..................................... 6-42
Pressure Check ................................................................................................ 6-42
Adjustment ....................................................................................................... 6-43
6.2.7 TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES .............................. 6-44
Pressure Check ................................................................................................ 6-44
Adjustment ....................................................................................................... 6-44
Leak Test .......................................................................................................... 6-44
6.2.8 TESTING THE RIDE CONTROL ........................................................................... 6-45
6.2.9 HYDRAULIC COMPONENT LOCATIONS ............................................................. 6-46
6.2.10 HYDRAULIC COMPONENT LOCATIONS ............................................................. 6-47
6.3 CLEANING THE HYDRAULIC SYSTEM ............................................................... 6-49

6.3.1 SPECIAL TOOLS ................................................................................................. 6-49
6.3.2 GENERAL INFORMATION ................................................................................... 6-50
6.3.3 TYPES OF CONTAMINATION .............................................................................. 6-50
6.3.4 CLEANING THE HYDRAULIC SYSTEM ............................................................... 6-51
6.3.5 FLUSHING WATER FROM THE HYDRAULIC SYSTEM ....................................... 6-53
6.4 CYLINDERS ......................................................................................................... 6-55

6.4.1 SPECIFICATIONS ................................................................................................ 6-55
6.4.2 SPECIAL TORQUES ............................................................................................ 6-55
6.4.3 SPECIAL TOOLS ................................................................................................. 6-55
6.4.4 LIFT CYLINDER ................................................................................................... 6-56
Disassembly ..................................................................................................... 6-56
Inspection ......................................................................................................... 6-56
Assembly ......................................................................................................... 6-58
6.4.5 BUCKET CYLINDERS Z-BAR MODELS .............................................................. 6-59
Disassembly ..................................................................................................... 6-59
Inspection ......................................................................................................... 6-59
Assembly ......................................................................................................... 6-61
6.4.6 REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS Z-BAR MODELS AND TC 6-62
Disassembly ..................................................................................................... 6-62
Assembly ......................................................................................................... 6-62
6.4.7 REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS ........ 6-62
Disassembly ..................................................................................................... 6-62
Assembly ......................................................................................................... 6-62
6.5 COUPLER SOLENOID LOCKING VALVE ............................................................. 6-63

6.5.1 DISASSEMBLY AND ASSEMBLY COUPLER SOLENOID LOCKING VALVE ....... 6-63
Disassembly ..................................................................................................... 6-63
Assembly ......................................................................................................... 6-63
6.6 PILOT PRESSURE ACCUMULATOR AN RIDE CONTROL ACCUMULATOR ........ 6-65

6.6.1 SPECIFICATIONS ................................................................................................ 6-65
6.6.2 SPECIAL TORQUES ............................................................................................ 6-65
6.6.3 SPECIAL TOOLS ................................................................................................. 6-65
6.6.4 DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR ................... 6-66
6.6.5 RIDE CONTROL ACCUMULATOR ........................................................................ 6-68
Disassembly ..................................................................................................... 6-68
Inspection ......................................................................................................... 6-68
Assembly ......................................................................................................... 6-68
6.6.6 PILOT PRESSURE ACCUMULATOR ................................................................... 6-70

Disassembly ..................................................................................................... 6-70
Inspection ......................................................................................................... 6-70
Assembly ......................................................................................................... 6-70
6.6.7 CHARGING THE ACCUMULATOR WITH NITROGEN ........................................... 6-72
HYDRAULIC SCHEMATIC ................................................................................... 6-75

W110/W110TC EQUIPMENT HYDRAULIC SYSTEM 6-1
6.1 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS
6.1.1 REMOVAL AND INSTALLATION STEP 5

OF THE LOADER CONTROL VALVE Release the pressure in the ride control accumulator
Removal with the manual bleeder valve at the rear of the front
chassis.
STEP 1
Park the machine on a level surface. STEP 6
Loosen the filler cap on the reservoir to release the air
STEP 2 pressure in the reservoir.
STEP 7
Drain the hydraulic reservoir.
STEP 8
BD00M068
Raise the lift arms and install the safety link on the lift
arm cylinder.
STEP 3
Stop the engine and apply the parking brake. BD00M061
Loosen and remove the bolts and washers that fas-

Important Pump the brake repeatedly to be sure ten the access cover plate for the loader control valve.
the brake accumulators have no hydraulic pressure, Remove the cover plate.
then move the loader control valve back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 4
W110R0004

tion.
6-2 EQUIPMENT HYDRAULIC SYSTEM W110/W110TC
GREEN & WHITE

RED & WHITE
RED & BLACK
GREEN & BLACK
6
REAR OF MACHINE
ORANGE & BLACK

4
YELLOW & BLACK
YELLOW & WHITE
ORANGE & WHITE
BS01D179
4 Spool line removal and installation illustration
1. Loader control valve - 2. Pilot accumulator hose - 3. Pilot pressure hose - 4. Check valve - 5. Pressure switch fitting -
6. Float switch.
STEP 9 STEP 10
Disconnect the hoses from the remote control valve(s) Install a plug in each hose and a cap on each fitting.
at the loader control valve one at a time and fasten an
identification tag to each hose. Refer to the illustra-
tion above.
STEP 11 STEP 12
1
2 2
4
3 1 3
4
6 5
BD01D376 BD01D381
1. Valve return hose - 2. Ride control tank hose - 3. Accu- 1. Rod end tilt tube - 2. Head end tilt tube - 3. Head end lift
mulator drain hose - 4. Pump load sensing hose - 5. Steer- tube - 4. Rod end lift tube.
ing load sensing hose - 6. Steering pressure hose -
7. Pump pressure hose (not shown). A. Tag and disconnect the rod end tilt tube (1) from
the loader control valve and install a plug in the
A. Tag and disconnect the valve return hose (1) at tube and a cap on the fitting.
hose and a cap on the fitting. B. Tag and disconnect the head end tilt tube (2) from
B. Tag and disconnect the pump pressure hose (7) tube and a cap on the fitting.
and install a plug in the hose and a cap on the
fitting. C. Tag and disconnect the head end lift tube (3) from
Note The pump pressure hose (7) will be connected tube and a cap on the fitting.
to a elbow at the bottom of the loader control valve. D. Tag and disconnect the rod end lift tube (6) from
C. Tag and disconnect the ride control tank hose (2) tube and a cap on the fitting.
and install a plug in the hose and a cap on the
fitting. E. Tag and disconnect any auxiliary spool tubes if
equipped.
D. Tag and disconnect the accumulator drain hose
(3) and install a plug in the hose and a cap on the STEP 13
fitting.
E. Tag and disconnect the pump load sensing hose
(4) and install a plug in the hose and a cap on the
fitting.
F. Tag and disconnect the steering load sensing hose
fitting.
G. Tag and disconnect the steering pressure hose
fitting. BS01D190
Loosen and remove the three bolts and washers that

hold the loader control valve to the valve mounting
plate.
STEP 14 STEP 17
Use proper lifting device to lift and remove the loader
control valve.
2
Installation
STEP 15 4
3 1
6 5
BD01D376
1. Valve return hose - 2. Ride control tank hose - 3. Accu-

mulator drain hose - 4. Pump load sensing hose - 5. Steer-
ing load sensing hose - 6. Steering pressure hose -
7. Pump pressure hose (not shown).
BS01D190
A. Connect the steering pressure hose (6) to the
A. Install and align the loader control valve with the loader control valve.
valve mounting plate. B. Connect the steering load sensing hose (5) to the
B. Install the bolts and washers that fasten the loader loader control valve.
control valve to the valve mounting plate. Tighten C. Connect the pump load sensing hose (6) to the
the bolts. loader control valve.
Important Before installing the fittings or connect- D. Connect the accumulator drain hose (3) to the
ing the tubes to the fittings, install new O-rings on the loader control valve.
fittings. E. Connect the ride control tank hose (2) to the loader
control valve.
STEP 16
F. Connect the pump pressure hose (7) to the bot-
1 tom of the loader control valve.
2 G. Connect the valve return hose (1) to the loader

control valve.
3
4
BD01D381
1. Rod end tilt tube - 2. Head end tilt tube - 3. Head end lift
tube - 4. Rod end lift tube.
A. Connect the rod end lift tube (4) to the loader con-
trol valve.
B. Connect the head end lift tube (3) to the loader
control valve.
C. Connect the head end tilt tube (2) to the loader
control valve.
D. Connect the rod end tilt tube (1) to the loader con-
trol valve.
GREEN & WHITE

RED & WHITE 7
RED & BLACK
GREEN & BLACK 6
REAR OF MACHINE
ORANGE & BLACK

YELLOW & BLACK 4
YELLOW & WHITE
ORANGE & WHITE
8
BS01D179
4 Spool line removal and installation illustration
1. Loader control valve - 2. Pilot accumulator hose - 3. Pilot pressure hose - 4. Check valve - 5. Pressure switch fitting -
6. Float switch - 7. Optional - 8. Optional.
STEP 18 STEP 19
Connect the lines from the remote control valve to Fill the hydraulic reservoir with oil. Refer to page 0-20
the loader control valve. Refer to the above illustra- for the correct oil.
tion.
STEP 20 STEP 22
Start the engine and run at half throttle.
STEP 23
Slowly and completely extend and retract all cylin-
ders at least 10 times to remove any air from the
circuits.
STEP 24
Stop the engine and check for leaks.
W110R0004 STEP 25
Place the master disconnect switch in the ON posi- Install the access cover on the front of the machine.
tion.
STEP 26
STEP 21
Check the level of the hydraulic oil and add hydraulic
oil as required.
BD00M068
Raise the loader arms and remove the safety link.

OF THE REMOTE CONTROL VALVE Unlatch and open the window on the right hand side.
Removal
STEP 35
STEP 27
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the park-
ing brake.
Important Pump the brake repeatedly to be sure

the brake accumulators have no hydraulic pressure,
then move the loader control lever back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 28 W110R0333
Open the access panel.
STEP 36
Lock the access panel.
STEP 37
Disconnect the electric cables.
STEP 38
W110R0004
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
Place the master disconnect switch in the OFF posi- plugs in the hoses and caps on the fittings.
tion.
STEP 39
STEP 29
Tag and disconnect the electrical connectors for the
Loosen and remove the bolts and washers that fas- remote control valve.
ten the right skirt panel under the right side of the
ROPS cab or ROPS canopy. Remove the right skirt
panel.
STEP 30
Loosen the filler cap on the reservoir to release any
air in the reservoir.
STEP 31
STEP 32
Unlatch and open the right hand side access door.
STEP 33
Lift the access door up and remove the access door
from the pins.
STEP 40 Installation
STEP 43
Install new O-rings on the adapters for the remote
control valve.
STEP 44
W110R0334
Loosen the three knobs of the valves indicated in the

figure.
1
STEP 41
W110R0335
Install the valves with securing nuts (2) and connect

hydraulic hoses (1).
STEP 45
Connect the electrical connectors for the remote con-
trol valve.
STEP 46
W110R0333
Open the panel located on the right side of the ma-

chine.
STEP 42
Remove hydraulic pipes (1) connected to the valves
loosening securing nuts (2) as indicated in the figure.
W110R0334
2 Install the three valve knobs.
STEP 47
Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
1
fittings according to the identification tags. (Refer to
illustrations on pages 12 through 16 as necessary).
W110R0335
STEP 48
Fill the hydraulic reservoir. See page 0-20 for the cor-
rect hydraulic oil.
STEP 49 STEP 54
W110R0004 W110R0333
Place the master disconnect switch in the ON posi- Unlock the access door.
tion.
STEP 55
STEP 50
Close the right hand window.
Start the engine and run the engine at low idle.
STEP 56
STEP 51
Close the access door.
Check to see that the remote control valve works
correctly. STEP 57
Install the right skirt panel under the ROPS cab or the
STEP 52
ROPS canopy and tighten the bolts.
Check for hydraulic oil leakage at the remote control
valve.
STEP 53
Check the level of hydraulic oil in the reservoir and
add as required.
6 - 10 EQUIPMENT HYDRAULIC SYSTEM W110/W110TC
GREEN & WHITE

ORANGE & WHITE
RED & WHITE
YELLOW & WHITE
GREEN & BLACK
RED & BLACK

2
YELLOW & BLACK

1
ORANGE & BLACK
ORANGE & BLACK RED & BLACK
YELLOW & BLACK GREEN & BLACK
2
1
YELLOW & WHITE RED & WHITE
ORANGE & WHITE GREEN & WHITE
BS01D180
Joystick and 2 lever hose illustration
1. Pilot tank hose - 2. Pilot pressure hose.
W110/W110TC EQUIPMENT HYDRAULIC SYSTEM 6 - 11
RED & WHITE
1 YELLOW GREEN &

& BLACK
WHITE
RED &
BLACK
2 2
ORANGE &
RED & BLACK
YELLOW & BLACK BLACK
GREEN &
ORANGE & BLACK BLACK YELLOW &
BLACK
ORANGE & BLACK GREEN & BLACK

YELLOW & BLACK GREEN & BLACK
RED & BLACK
YELLOW & BLACK 2 1
1 2
YELLOW & BLACK RED & WHITE
W110R0346 BS01D178
3 Lever hose illustration Joystick and 1 lever hose illustration
1. Pilot tank hose - 2. Pilot pressure hose. 1. Pilot tank hose - 2. Pilot pressure hose.
2 GREEN &
BLACK
1 RED &
BLACK
2 1
YELLOW &
YELLOW & BLACK
BLACK
RED & BLACK
GREEN & BLACK ORANGE & BLACK

ORANGE & BLACK

GREEN &
ORANGE & BLACK GREEN &
BLACK YELLOW & BLACK
RED & BLACK
YELLOW & BLACK BLACK
1 2 2 1
W110R0347 BS01D177
2 Lever hose illustration Joystick hose illustration
1. Pilot tank hose - 2. Pilot pressure hose. 1. Pilot tank hose - 2. Pilot pressure hose.

OF THE HYDRAULIC PUMP
Removal
STEP 58
bucket to the floor. Stop the engine and apply the park- 3
1
ing brake.
1
STEP 59
2 4
BD01D303
A. Loosen and remove the four bolts (1) connecting

the suction hose (3) to the hydraulic pump (4).
B. Tag and disconnect the case drain hose (2) from
the top of the hydraulic pump (4).
C. Plug all lines and cap all fittings.
STEP 62
W110R0004

tion.
STEP 60
Drain the hydraulic reservoir then refer to Section 8
and remove the ROPS cab or ROPS canopy.
BD01D329
Loosen and remove the bolts holding the bracket for

the hydraulic hoses. Slide the bracket up to gain enough
clearance for the hydraulic pump to be removed.
STEP 63 STEP 65
2
4
1
3
BD01D308 BD01D307
A. Loosen and remove the four bolts (1) connecting Loosen and remove the two bolts that fasten the hy-
the pressure hose (3) to the hydraulic pump (4). draulic pump to the transmission.
B. Tag and disconnect the load sensing hose (2) from
STEP 66
the hydraulic pump (4).
Remove the hydraulic pump from the machine.
C. Plug all lines and cap all fittings.
STEP 67
STEP 64
BD01D335
BD01D333
Remove and discard the O-ring from the hydraulic

Use proper lifting device to strap and support the hy-
pump.
draulic pump.
STEP 68
BD01D308
BD01D335 A. Install the pressure hose (1) to the hydraulic pump

(2).
Use proper lifting device to lift and support the hy-
draulic pump. Install a new O-ring on the hydraulic B. Install the load sensing hose (3) to the hydraulic
pump. pump (2).
STEP 69 STEP 72
2
3
BD01D336 BD01D303
Install the hydraulic pump on the transmission. A. Install the suction hose (1) to the hydraulic pump
(2).
STEP 70
B. Install the case drain hose (3) to the hydraulic
pump (2).
BD01D307
Install the two bolts that fasten the hydraulic pump to

the transmission. Tighten the two bolts to a torque of
335 to 375 Nm (265 to 275 lb-ft).
STEP 73 STEP 76
BD01D329 W110R0004
Install the bracket holding the hydraulic hoses. Tighten Place the master disconnect switch in the ON posi-
the bolts. tion.
STEP 74 STEP 77
See Section 8 for installing the ROPS cab or ROPS Start the engine and run the engine at low idle for two
canopy. minutes.
STEP 75 Note If any unusual vibration is heard coming from

the pump, stop the machine immediately and check
Fill the hydraulic reservoir with hydraulic oil. See page
for obstructions in the pump suction line.
0-20 for correct oil type.
STEP 78
Stop the engine and check for hydraulic oil leakage at
the hydraulic pump.
STEP 79
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.

OF THE LIFT CYLINDERS
Removal
STEP 80
ing brake.
STEP 81
Pump the brake repeatedly to be sure the brake ac-
cumulators have no hydraulic pressure, then move BD01D709
the loader control lever back and forth several times
to release any hydraulic pressure in the pilot control Loosen and remove the bolt, washer and spacer that
circuit. hold the pivot pin for the yoke.
STEP 82 STEP 86
Relieve the pressure in the ride control accumulator

with the manual bleeder valve located at the rear of
the front chassis.
STEP 83
Loosen the filler cap on the hydraulic reservoir to re-
lease any pressure.
STEP 84
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 87
BD01D708
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.
STEP 91
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 92
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 89
BD01D716
Use a proper lifting device and position the lift cylin-

der on the machine.
STEP 93
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 90
Remove the lift cylinder from the machine. BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.
STEP 94 STEP 97
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 98
STEP 95
BD01D709
BD01D708
Align the pivot pin with the yoke and install the spacer,
Remove the caps and plugs and connect the hoses washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 99
STEP 96
SLOWLY extend and retract the piston rod three times
If the yoke of the lift cylinder is not aligned with the to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 100
SLOWLY move the yoke into alignment with the loader
Lubricate the pivot pins with molydisulfide grease.
frame.
STEP 101
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the hydraulic
reservoir.

OF THE BUCKET CYLINDER -
Z-BAR LOADER
Removal
STEP 102
ing brake.
STEP 103
With the engine stopped, move the bucket control le- BD01D695
ver to release pressure in the bucket circuit.
Loosen and remove the two bolts that fasten the
mounting bracket to the machine. Remove the mount-
STEP 104 ing bracket.
STEP 107
BD01D696
Disconnect the proximity switch connector from the

BD01D697
wiring harness connector.
Loosen and remove the two bolts that fasten the
STEP 105 mounting bracket for the proximity switch to the bucket
cylinder. Remove the mounting bracket and switch.
BD01D696
Loosen and remove the two bolts that fasten the tar-
get bar to the mounting bracket. Remove the target
bar.
STEP 108 STEP 111
BD01D699 BD01D701
Disconnect the hoses from each side of the bucket Remove the pivot pin from the rod end of the bucket
cylinder. Install plugs in the hoses and caps on the cylinder.
fittings.
STEP 112
STEP 109
BD01D706
BD01D700
Remove the pivot pin from the head end of the bucket
Use acceptable equipment to hold the bucket cylin- cylinder.
der.
Note It is not necessary to remove the grease line
STEP 110 from the pivot pin unless the pivot pin is to be re-
placed.
STEP 113
BD01D698
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket cyl-
BD01D706
inder.
Raise the bucket cylinder and remove the cylinder
from the machine.

STEP 114
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 115
BD01D699
Connect the hoses to each side of the bucket cylin-

der.
STEP 119
If the rod end of the bucket cylinder is not aligned
BD01D706 with the bellcrank, have another person start the en-
gine and run the engine at low idle and use the bucket
Use acceptable lifting equipment to lower the bucket
control lever to SLOWLY move the piston rod eye into
cylinder into position.
alignment with the bellcrank.
STEP 116
STEP 120
Install the pivot pin and stop the engine.
STEP 121
BD01D706
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 117
Install the spacer, washer and bolt that fasten the pivot
Install the spacer, washer and bolt that fasten the pivot
pin to the bellcrank. Tighten the bolt.
pin to the front frame. Tighten the bolt.
Note If a new pivot pin is being installed, connect

the grease line to the pivot pin.
STEP 122 STEP 125
BD01D697 BD01D696
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 123 STEP 126

See Section 8 for the adjustment procedure for ad-
justing the proximity switch.
STEP 127
Start and run the engine at low idle.
STEP 128
SLOWLY extend and retract the piston rod three times
to remove any air from the bucket cylinder.
BD01D695 STEP 129

Install the two bolts for the mounting bracket for the Lubricate the pivot pins with molydisulfide grease.
target bar.
STEP 130
STEP 124
and add as required. Tighten the filler cap on the hy-
draulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.

OF THE OIL COOLER
Removal
STEP 131
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 132
BD01D236
Disconnect the top hose and install a plug in the hose

and a cap on the fitting.
STEP 137
W110R0004

tion.
STEP 133
BD01D231
Disconnect the hose from the bottom of the oil cooler.

Install a plug in the hose and a cap on the fitting.
BD01D230
With the hood raised loosen the two bolts holding the
shield in place and remove the shield.
STEP 134
lease the air pressure in the reservoir.
STEP 135

STEP 140
Place the oil cooler in position in the cooling frame.
STEP 141
BD01D236
BD01D231
BD01D231
Loosen and remove the bolts and washers that fas-

ten the oil cooler to the cooling frame.
STEP 139
BD01D236
Remove the oil cooler from the machine.

Install the bolts and washers that fasten the oil cooler
to the cooling frame.
STEP 142
BD01D231
Connect the hose to the bottom of the oil cooler.
STEP 143 STEP 146

Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 147
BD01D236
Connect the hose to the top of the oil cooler.
STEP 144
Fill the hydraulic reservoir with hydraulic oil. See page
BD01D230
0-20 for the correct hydraulic oil.
Install the shield and tighten the two bolts holding the
STEP 145 shield.
STEP 148
and add hydraulic oil as required.
W110R0004
Place the master disconnect switch in the ON posi-

tion.

OF THE RIDE CONTROL
ACCUMULATOR
Removal
STEP 149
ing brake.
STEP 150
With the engine NOT running, pump the brake repeat- BD01D716
edly to be sure the brake accumulators have no hy-
Loosen and remove the nuts and washers from the U-
draulic pressure, the move the loader control lever
bolt. Remove the U-bolt.
back and forth several times to release any hydraulic
pressure in the pilot control circuit.
STEP 155
STEP 151
the front chassis.
STEP 152
lease any air in the reservoir.
STEP 153
BD01D717
Loosen and remove the two bolts that fasten the ac-
cumulator bracket to the front frame.
STEP 156
Remove the ride control accumulator from the ma-
chine.
BD01D717
Disconnect the hose from the elbow at the bottom of

the ride control accumulator. Install a plug in the hose
Note The above photo shows the center drive shaft

removed and was done for photographic reasons only.

STEP 157
Place the ride control accumulator in position on the
front frame.
STEP 158
BD01D717
Remove the caps and plugs and install the hose on

the elbow at the bottom of the ride control accumula-
tor.
STEP 161
BD01D717
Refer on page 6-36 Testing the Ride Control for the

Install the two bolts that fasten the accumulator
proper charging of the accumulator to check for leaks.
bracket to the front frame. Tighten the bolts.
STEP 162
STEP 159
draulic reservoir.
BD01D716
Install the U-bolt, washers and nuts. Tighten the nuts.

OF THE RIDE CONTROL VALVE Loosen the filler cap on the hydraulic reservoir to re-
Removal lease any air in the reservoir.
STEP 163 STEP 169

Park the machine on a level surface and apply the
parking brake.
STEP 164
W110R0004

tion.
BD00M068
STEP 170
Raise the loader arms and install the safety link.
STEP 165
BD01D376
Disconnect the electrical connector on top of the ride

control valve.
BD00M061
Remove the access cover. STEP 171

Tag and disconnect the accumulator bleed hose (4)
STEP 166 from the elbow (5) at the ride control valve (3). Install
With the engine NOT running, pump the brake repeat- a plug in the hose and a cap on the fitting. Refer to the
edly to be sure the brake accumulators have no hy- illustration on page 6-30.
draulic pressure, then move the loader control lever
back and forth several times to release any hydraulic STEP 172
pressure in the pilot control circuit. Tag and disconnect the ride control tank hose (6) from
the adapter (14). Install a plug in the hose and a cap
STEP 167 on the fitting.
the front chassis.
STEP 173 STEP 175

Tag and disconnect the ride control accumulator hose Loosen and remove the four bolts (12) and washers
(10) from the elbow (11). Install a plug in the hose and (13) that fasten the ride control valve (3) to the ride
a cap on the fitting. control bracket (2).
STEP 174 STEP 176

Tag and disconnect the ride control head tube (8) from Remove the ride control valve from the machine.
the fitting (9). Install a plug in the hose and a cap on
the fitting. STEP 177
Remove and discard all O-rings.
4
3
2
5
14
6
13
9
11 12
8
7
10
BS01D191
Rade control valve illustration
1. Front frame (left side) - 2. Ride control bracket - 3. Ride control valve - 4. Accumulator bleed hose - 5. Elbow - 6. Ride
control tank hose - 7. Elbow - 8. Ride control head tube - 9. Fitting - 10. Ride control accumulator hose - 11. Elbow - 12. Bolt
(4) - 13. Washer (4) - 14. Adapter.

STEP 178
Install the ride control valve (3) in position on the front
frame (1). Refer to the illustration on page 6-30.
STEP 179
Install the washers (13) and bolts (12) through the
ride control bracket (2) and into the ride control valve
(3). Tighten the bolts (12).
STEP 180
W110R0004
Lubricate and install new O-rings to all necessary fit-
tings. Place the master disconnect switch in the ON posi-
tion.
STEP 181
STEP 187
Connect the ride control head tube (8) to the fitting (9)
at the ride control valve (3). Start and run the engine at low idle for two minutes.
STEP 182 STEP 188

Connect the ride control accumulator hose (10) to the Stop the engine and check for hydraulic oil leakage at
elbow (11) at the ride control valve (3). the ride control valve.
STEP 183 STEP 189

Connect the ride control tank hose (6) to the adapter
(14) at the ride control valve (3).
STEP 184
Connect the accumulator bleed hose (4) to the elbow
(5) at the ride control valve (3).
STEP 185
BD00M061
Install the access cover.
BD01D376
Connect the electrical connector to the ride control

valve.
STEP 190 STEP 191

draulic reservoir.
STEP 192
Refer on page 6-36 and perform the Ride Control Test
Procedure.
BD00M068
Raise the loader arms and remove the safety link.

OF THE FAN REVERSING VALVE
Removal 5
STEP 193 4

bucket to the ground. Stop the engine and apply the 3
parking brake.
2
STEP 194
1
With the engine NOT running, pump the brake repeat- 5 5
edly to be sure the brake accumulators have no hy- BD01D360
draulic pressure, then move the loader control lever
back and forth several times to release any hydraulic A. Tag and disconnect the fan forward hose (1) from
pressure in the pilot control circuit. the fan reversing valve. Install a plug in the hose
STEP 195 B. Tag and disconnect the fan reverse hose (2) from
Loosen the filler cap on the hydraulic reservoir to re- the fan reversing valve. Install a plug in the hose
lease any air in the reservoir. and a cap on the fitting.
C. Tag and disconnect the fan valve return hose (3)
STEP 196 from the fan reversing valve. Install a plug in the
hose and a cap on the fitting.
D. Tag and disconnect the fan valve supply hose (4)
from the fan reversing valve. Install a plug in the
hose and a cap on the fitting.
E. Loosen and remove the nuts (5), washers (6) and
bolts (7).
STEP 198
Remove the fan reversing valve from the machine.
BD01D359
STEP 199
Disconnect the electrical connector for the fan revers- Remove and discard all O-rings from the fittings.
ing valve.

STEP 200
Place the fan reversing valve into position on the
machine.
STEP 201
Lubricate and install new O-rings in the fittings.
STEP 202
5 BD01D359
4
Connect the electrical connector for the fan reversing
valve.
3
STEP 204
2
Check the level of the hydraulic oil in the reservoir.
1
5 5 STEP 205
BD01D360 Start the engine and run the engine at low idle for two
minutes.
A. Install the bolts (7), washers (6) and nuts (5).
Tighten the nuts (5).
STEP 206
B. Connect the fan valve supply hose (4) to the fit-
Stop the engine and check for hydraulic oil leakage at
ting on the fan reversing valve.
the fan reversing valve.
C. Connect the fan valve return hose (3) to the el-
bow on the fan reversing valve. STEP 207
D. Connect the fan reverse hose (2) to the fitting on Check the level of the hydraulic oil in the reservoir
the fan reversing valve. and add as required. Tighten the filler cap on the res-
E. Connect the fan forward hose (1) to the fitting on ervoir.
the fan reversing valve.
6.2 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING

AND PRESSURE CHECKS
Pump Output ........................................................................................ 135 to 138 L/min at 2000 rpm at 138 bar
(35.5 to 36.5 gpm at 2000 rpm at 2000 psi)
Main relief valve pressure settings
W110 (Z-Bar) .............................................................................................. 248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (Z-Bar) ............................................................................................ 290 bar (4206 psi)
Bucket A and B port (Z-Bar) .............................................................................................. 290 bar (4206 psi)
Steering relief valve pressure setting ........................................................................................... See Section 4
Accumulator pressure .................................................................................................................. See Section 3
6.2.2 SPECIAL TOOLS
B877168V
633L95
380001740 Flowmeter Fitting Kit

380001741 Pressure Fitting Kit
632L95
B877895M
380001726 Hand Pump
B877558M
B785789M
380001731 Flowmeter
6.2.3 TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage

and damaged or missing parts. Repair or
replace any damaged or missing parts.
Check the oil level in the hydraulic reser- Fill the hydraulic reservoir with the hydrau-
No
voir. Is the oil level correct? lic oil specified in page 0-20.
Yes
Heat the oil in the hydraulic system to op-

erating temperature. Operate the machine
to find which circuits have problems.
Problems in All Circuits - See the following pages for other circuits
Replace the return line hydraulic filter.

Do the stall test to see if the engine is
good.
See page 6-40. Do the flowmeter tests of
See page 6-50 and check for contaminated No the hydraulic pump.
oil. Is the oil contaminated?
Yes
See page 6-50 and clean or replace the oil.
Problem in All Loader Circuits
See page 6-41 and check the pressure set-

ting of the main relief valve in the loader No Adjust the main relief valve. See page
6-41.
Problem in the Braking Circuit
See Section 3.2 and check the braking

circuit.
Problem in a Single Loader Circuit
Start and run the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. page 6-55 and repair the loader control
Does the cylinder move in both direc- No
valve.
tions?
Yes
Check the cylinder piston packing. Is the See page 6-55 and repair the cylinder.
No
packing good?
Yes
See page 6-43. Check and adjust the cir-

See page 6-55. Disassemble the loader con-
cuit relief valves. Then check the opera-
No trol valve and check for worn or damaged
tion of the circuit again. Does the circuit
parts.
work correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit
See Section 4-2 and check the steering cir-

No Repair the component as necessary.
cuit. Is the steering circuit good?
Yes
See page 6-40. Do the primary pump out-

put test.
Problem in the Ride Control

Lift arms rapidly and continuously sink to- See the ride control test procedure page
No
wards the ground. 6-44 in this section.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.
6.2.4 TESTING AND ADJUSTING STEP 3

THE PUMP DIFFERENTIAL
PRESSURE
Note The Pump Differential Pressure must be set
before attempting any other tests.
Pressure Check
1
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 52 C to 60 C (125 F to 140 F). The follow-
ing is the procedure for heating the hydraulic oil.
BD00N020
A. Start the engine and run at high idle.
B. Lower the loader bucket to the ground.
C. Hold the lift control lever in the FLOAT position.
D. Roll the bucket back against the stops and hold.
E. View the oil temperature by pressing the program
switch, then press the up count switch to func-
tion 008. Return the program switch to the center
2
(OFF) position.
STEP 2
BD00N017
Connect two 69 bar (1000 psi) test gauges to the test

ports (1) and (2) located on the loader control valve.
STEP 4
Start the engine and run at low idle.
STEP 5
1 Make sure all of the controls are in the neutral posi-

tion and record the readings on the test gauges (1)
BD00M041
and (2).
Remove the cover plate (1) to gain access to the loader STEP 6
control valve.
The pressure on test port (1) should read approxi-
mately 29 bar (420 psi). The pressure on test port (2)
should read approximately 51 bar (740 psi).
Note These readings may vary from one machine

to another. The important value is the difference be-
tween the two readings.
STEP 7 6.2.5 TESTING THE HYDRAULIC PUMP

Subtract the reading of the test port (1) from the read- PERFORMANCE AND TORQUE
ing of the test port (2). LIMITER
STEP 1
STEP 8
Make sure that the temperature of the hydraulic oil is
The difference between the two readings should be at least 52 C to 60 C (125 F to 140 F). The follow-
22 + 1/-0 bar (320 + 15/-0 psi). ing is the procedure for heating the hydraulic oil.
STEP 9 A. Start the engine and run at high idle.
If this reading is more or less than that specified, it B. Lower the loader bucket to the ground.
will be necessary to adjust the pump. C. Hold the lift control lever in the "FLOAT" posi-
tion.
Adjusting the Main Hydraulic Pump
View the oil temperature by pressing the program
STEP 10 switch, then press the up count switch to function
008. Return the program switch to the center (OFF)
position.
STEP 2
Connect the flowmeter (5) by installing a tee fitting (1)
between the pump and the loader control valve (2).
Refer to illustration on page 6-42.
STEP 3
Make sure that the flowmeter valve is in the closed
position. Raise the lift arms to the stops and secure
the lift control lever in the RAISE position.
STEP 4
Operate the engine at 2000 rpm and open the flowm-
BS01B022 eter valve until the pump pressure is 500 psi. The flow
at this point should be 36.5 to 37.5 gpm.
Turn the pump adjusting screw closest to the pump
as illustrated. Turn the screw clockwise to increase STEP 5
the differential pressure. Turning the screw
counterclockwise will decrease the differential pres- Close the flowmeter valve slowly and read the flow at
sure. 2000 psi @ 2000 rpm. The flow should read 35.5 to
36.5 gpm.
Note One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi). STEP 6
Continue slowly closing the flowmeter valve, monitor-
ing the flow with the engine speed at 2000 rpm. At a
point between 2200 and 2400 psi, the flow should no-
ticeably start decreasing. This is the torque limit set-
ting of the pump. Record this pressure.
STEP 7 STEP 8
Continue slowly closing the flowmeter valve until 3300 If any of the pump flow readings are not within speci-
psi is reached. The flow should read between 23.5 fications, the pump may be out of calibration and Tech-
and 26.0 gpm. nical Services Group should be contacted.
7
NOTE
BS01A308
1. Tee - 2. Loader control valve - 3. Flowmeter inlet hose - 4. Loader control valve inlet hose - 5. 380001731 flowmeter -
6. Flowmeter outlet hose - 7. Filter inlet manifold - 8. Filter - 9. Filter to reservoir hose.
Note If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.
6.2.6 TESTING AND ADJUSTING STEP 3

THE MAIN RELIEF VALVE
Note The Pump Differential Pressure must be set
before attempting any other tests. Refer to page 6-40
of this section.
Pressure Check
STEP 1
BD00M041
Remove the cover plate to gain access to the loader

control valve.
STEP 4
1
BD00M030
Install the articulation lock (1).

1
STEP 2
BD00N017
Stop the engine and install a 345 bar (5000 psi) pres-
sure gauge to the test port (2) on the front of the loader
1 control valve (1).
BD00M048
Raise the loader arms and install the safety link (1).
STEP 5 Adjustment
Make sure that the temperature of the hydraulic oil is STEP 10
at least 52 C to 60 C (125 F to 140 F). The follow-
ing is the procedure for heating the hydraulic oil.
A. Start the engine and run at high idle.
B. Lower the loader bucket to the ground.
C. Hold the lift control lever in the FLOAT position.
E. View the oil temperature by pressing the program
switch, then press the up count switch to func-
tion 008. Return the program switch to the center
(OFF) position.
STEP 6
Start the engine and remove the safety link (refer to
step 2) and lower the loader arms to the ground.
STEP 7 2
Operate the machine at full throttle. Tilt the bucket to

a full rollback position and hold while observing the 1
pressure gauge.
BS01A046
STEP 8
1. Loader control valve - 2. Relief valve adjustment.
The pressure should read between 248 and 252 bar
(3596 to 3654 psi). With the engine running and the loader on the ground,
loosen the jam nut and turn the adjustment screw (2)
STEP 9 clockwise for higher pressure or counterclockwise for
lower pressure.
If the pressure is not within the specifications, it will
be necessary to adjust the main relief valve.
Note 1/4 turn of the adjusting screw changes the
pressure setting approximately 35 bar (500 psi).
STEP 11
Repeat the Pressure Check Procedure.
STEP 12
If the pressure is not within the specifications, repeat
steps 10 and 11 until pressure is within the required
range.
STEP 13
Stop the engine before removing the pressure gauge.
6.2.7 TESTING AND ADJUSTING THE STEP3

CIRCUIT RELIEF VALVES Connect the hand pump to the disconnected line that
Pressure Check goes to the loader control valve.
STEP 1 STEP 4
Circuit relief valves are located as shown below. Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21 C (70 F).
6
5 1 1 5 STEP 5
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
4 STEP 6
4
Compare the reading to the specifications on page 6-36.
STEP 7
If the pressure is not correct, adjust the circuit relief
valve.
3
3 Adjustment
1 1
2 STEP 1
Loosen the lock nut. Turn the adjustment screw clock-
BS01A046 wise to increase the pressure or counterclockwise to
decrease the pressure.
1. Circuit relief valve - 2. Main relief valve - 3. Bucket spool
- 4. Lift spool - 5. Auxiliary spool - 6. Loader control valve. STEP 2
Remove the cover at the front of the machine. Check the pressure again. Repeat the adjustment as
necessary.
STEP 2
Lower the bucket to the floor. Shut off the engine. Find Leak Test
an easy place to disconnect the line for the circuit to
be tested. Test for internal leakage by raising the lift arms to the
top and shutting the engine off.
A. Turn the key to the RUN position and disengage
the controller lock-out switch.
B. Wait for the buzzer to stop.
C. Repeatedly put the lift control lever into the
FLOAT position and back to neutral. The system
must allow a minimum of 10 actuations into float
and still cause the lift arms to come down.
D. If 10 full actuations cannot be made, an internal
hydraulic leak exists.
6.2.8. TESTING THE RIDE CONTROL STEP 8

STEP 1 Accelerate the machine to at least 5 km/hr (3 mph).
At 5km/hr (3 mph) the lift arms should raise a visible
Verify that the manual ride control accumulator bleeder
amount, 102mm to 635mm (4 to 12 inches) depend-
valve is closed.
ing on bucket and coupler weight. This is an indica-
tion that the ride control is functioning. As the ma-
Note The bleeder valve is located on the left wall of
chine continues to travel there should be visible cyl-
the front chassis immediately behind the ride control
inder movement in response to the road conditions.
accumulator. If this valve is left open, the lift arms will
rapidly and continuously sink. Ride control will not
Note With an empty bucket, cylinder travel will not
function in this state because the ride control accu-
exceed 25mm (1 inch).
mulator cannot charge.
STEP 9
STEP 2
With the machine traveling over 5 km/hr (3 mph) check
Move the machine to a clear level area with sufficient
the indicator light on the ride control rocker switch, it
space to accelerate the machine to 5 km/hr (3 mph)
should be illuminated.
for 30 seconds and stop.
STEP 10
STEP 3
Slow the machine down and observe the indicator light.
Start the engine.
The indicator light should go out when the machine
slows below 5 km/hr (3 mph).
STEP 4
Activate the ride control. Press down on the symbol STEP 11
side of the switch to activate. The indicator light WILL
Stop the machine.
NOT illuminate at this time.
STEP 12
Note The ride control switch is located in the bank
of rocker switches to the right of the operators seat. De-activate the ride control with the rocker switch.
It is in the center row, second switch from the front. Repeat steps 5, 6 and 7.
STEP 5 STEP 13
Raise the lift arms to near the top of their travel. Accelerate the machine to at least 5 km/hr (3 mph).
This time there should be no visible raising of the
STEP 6 liftarms and the light should remain off. The quality of
the ride should be noticeably worse with the ride con-
Rapidly dump the bucket until it hits the dump stops.
trol de-activated.
This will create a down force on the liftarms and they
should drop visibly. Repeat this process 2 or 3 times
STEP 14
if necessary.
Stop the machine.
Note The oil displaced from the lift cylinders is used
to charge the ride control accumulator.
STEP 7
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the liftarms or the bucket on
their stops.
6.2.9 HYDRAULIC COMPONENT LOCATIONS
15, 20
6
13, 14
2, 3
1
4 10, 11
5
9
12, 16 4
18
19
7 8
17
BC00N140
1. Ride control valve (optional) - 2. Ride control accumulator - 3. Ride control accumulator bleeder valve - 4. Lift cylinders
- 5. Bucket cylinder (tilt cylinder) - 6. Steering control valve - 7. Steering cylinders - 8. Auxiliary steering pump and motor
(option - north american models) - 9. Auxiliary steering priority valve (option - north american models) - 10. Auxiliary
steering pressure switch - 11. Steering pressure diagnostic coupler - 12. Brake accumulators - 13. Brake and accumulator
charging valve - 14. Brake warning pressure switch - 15. Brake light pressure switch - 16. Brake accumulator pressure
diagnostic coupler - 17. Rear brake cylinders - 18. Front brake cylinders - 19. Parking brake cylinder - 20. Front and rear
axle brake pressure diagnostic couplers.
Note The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
6.2.10 HYDRAULIC COMPONENT LOCATIONS
38
30 39
22
40, 41 24 32, 33, 35, 36, 37
34
25
25
29 28
21
31
26
27
23
BC00N140
21. Fan drive motor - 22. Fan reversing valve - 23. Brake hydraulic pump - 24. Coupler locking valve - 25. Coupler locking
cylinders - 26. Implement hydraulic pump - 27. Hydraulic filter - 28. Hydraulic reservoir - 29. Hydraulic reservoir breather -
30. Hydraulic cooler - 31. Pilot pressure accumulator - 32. Pilot pressure diagnostic coupler - 33. Float switch -
34. Controller - 35. Loader control valve - 36. Pump pressure diagnostic coupler - 37. Load sensing diagnostic coupler -
38. Brake pressure switch (2) - 39. Auxiliary steering load sense solenoid valve (optional) - 40. Parking brake accumulator
- 41. Parking brake accumulator diagnostic coupler.
Note The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
NOTES:
6.3 CLEANING THE HYDRAULIC SYSTEM
6.3.1 SPECIAL TOOL
806128
The part number for the Fitting Kit is 380001733.
806127
The part number for the Portable Filter is 380001727.
6.3.2 GENERAL INFORMATION 6.3.3 TYPES OF CONTAMINATION

Contamination in the hydraulic system is a major There are two types of contamination, microscopic
cause of the malfunction of hydraulic components. and visible.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 1. Microscopic contamination occurs when very fine
several ways. particles of foreign material are in suspension in
the hydraulic oil.
1. When you drain the oil or disconnect any line.
2. These particles are too small to see or feel. Micro-
2. When you disassemble a component. scopic contamination can be found by identifica-
tion of the following problems or by testing in a
3. From normal wear of the hydraulic components.
laboratory. Examples of the problems:
4. From damaged or worn seals.
A. Cylinder rod seal leak.
5. From a damaged component in the hydraulic sys-
B. Control valve spools do not return to NEUTRAL.
tem.
C. The hydraulic system has a high operating tem-
All hydraulic systems operate with some contamina- perature.
tion. The design of the components in this hydraulic
3. Visible contamination is foreign material that can
system permits efficient operation with a small amount
be found by sight, touch, or odor. Visible contami-
of contamination. An increase in this amount of con-
nation can cause a sudden failure of components.
tamination can cause problems in the hydraulic sys-
Examples of visible contamination:
tem. The following list includes some of these prob-
lems. A. Particles of metal or dirt in the oil.
B. Air in the oill.
1. Cylinder rod seals leak.
C. The oil is dark and thick.
2. Control valve spools do not return to neutral.
D. The oil has the odor of burned oil.
3. Movement of control valve spools is difficult.
E. Water in the oil. See page 6-54.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rap-
idly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been re-
paired.
8. Cycle times are slow; machine does not have
enough power.
If your machine has any of these problems, check

the hydraulic oil for contamination. See Types of Con-
tamination below. If you find contamination, use the
Portable Filter to clean the hydraulic system.
6.3.4 CLEANING THE HYDRAULIC 8. See the fitting kit shown on page 6-50. Install the
SYSTEM valve in the hole for the drain plug. Make sure
that the valve is closed.
1. Prepare the portable filter on page 6-50 by doing
the following steps: 9. Stop the vacuum pump.
A. Remove all the hydraulic oil from the inlet and 10. Connect the inlet hose for the portable filter to the
outlet hoses for the portable filter. valve that is installed in the hole for the drain plug.
B. Remove the filter element from the portable fil- 11. Disconnect the vacuum pump from the filler cap
ter. opening on the hydraulic reservoir.
C. Remove all hydraulic oil from the portable fil- 12. Install the outlet hose for the portable filter in the
ter. hydraulic reservoir.
D. Clean the inside of the housing for the filter 13. Open the valve that is installed in the hole for the
element. drain plug.
2. You must know whether the contamination is mi- 14. Move the switch for the portable filter to the ON
croscopic or visible. See Types of Contamination position. Start and run the engine at 1500 rpm (r/
on page 6-51. min).
3. If the contamination is microscopic: 15. Run the portable filter for 10 minutes.
A. Check the maintenance schedule for the ma- 16. Continue to run the portable filter. Increase the
chine to learn if the hydraulic oil must be engine speed to full throttle. Heat the oil to oper-
changed. If needed, change the hydraulic oil. ating temperature by doing the following steps:
See page 0-20 for specifications. Change the A. Hold the bucket control lever in the
hydraulic filter. ROLLBACK position for 15 seconds.
B. Do steps 6 through 38. B. Return the bucket control lever to NEUTRAL
4. If the contamination is visible: for 30 seconds.
A. Change the hydraulic oil and hydraulic filter. See C. Repeat steps 17a through 18b until the oil in
page 0-20 for oil specifications. the hydraulic system is at operating tempera-
ture.
B. Do steps 5 through 38.
17. Continue to run the engine at full throttle. Con-
5. Check the amount of contamination in the hydrau- tinue to run the portable filter.
lic system by doing the following steps:
18. Operate each hydraulic circuit to completely ex-
A. Disassemble one cylinder in two different cir- tend and retract the cylinders. Continue to oper-
cuits. Check for damage to seals, scoring of ate each hydraulic circuit two times, one after the
the cylinder wall, etc. Repair the cylinders as other, for 45 minutes.
necessary.
19. Decrease the engine speed to low idle.
B. If, in your judgment, the damage to the cylin-
ders was caused by severe contamination and 20. Continue to run the portable filter for 10 minutes.
is not the result of normal wear, it is necessary 21. Stop the portable filter.
to remove, clean and repair valves, pump, lines,
cylinders, hydraulic reservoir, etc. in the hydrau- 22. Stop the engine.
lic system. 23. Remove the hose from the hydraulic reservoir.
6. Connect a vacuum pump to the hydraulic reservoir
air breather hose. Start the vacuum pump.
7. Loosen and remove the drain plug from the reser-
voir.
24. Close the valve that is installed in the hole for the
drain plug.
25. Disconnect the inlet hose for the portable filter
from the valve.
26. Connect a vacuum pump to the breather hose of
the hydraulic reservoir.
27. Start the vacuum pump.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
30. Stop the vacuum pump. Disconnect the vacuum
pump from the hydraulic reservoir.
31. Remove the hydraulic filter element from the ma-
chine.
32. Install a new hydraulic filter element on the ma-
chine.
33. Check the oil level in the hydraulic reservoir. Add
oil as required. See page 0-20 for specifications.
34. Start the engine. Check for oil leakage around the
new hydraulic filter.
6.3.5 FLUSHING WATER FROM THE 9. Move each control lever in both directions to re-
HYDRAULIC SYSTEM lease pressure in the hydraulic circuits.
1. Start and run the engine at 1500 rpm (r/min). 10. Disconnect the line from the rod end and closed
end of each cylinder.
2. Completely retract the cylinders of all attachments
on the machine. 11. Be sure all control levers are in the NEUTRAL
position.
WARNING 12. Start the engine and run the engine at low idle.
If retracting the cylinder rods causes the attach- Important Check the oil level in the hydraulic reser-
ment to be raised, block the attachment in place voir frequently while doing step 14. Have another per-
before proceeding to the next step! son hold a container under the hydraulic lines while
you do step 14.
Note Any attachment or part of an attachment that
is raised must be supported with acceptable equip- 13. Slowly move each control lever in both directions
ment to prevent the attachment from falling. until oil begins to flow from the open line. Hold the
control lever in place until clean oil flows from the
3. Loosen and remove the filler cap from the reser- open line.
voir.
4. Drain the hydraulic oil from the reservoir.
A. The reservoir holds approximately 15 U.S. gal- Note Any attachment or part of an attachment that
lons (56.8 litres) of hydraulic oil. is raised must be supported with acceptable equip-
ment to prevent the attachment from falling.
B. Have available acceptable equipment to drain
the hydraulic oil. 15. Connect the line to the CLOSED end of each cyl-
C. Remove the drain plug from the bottom of the inder.
reservoir. 16. Start the engine and run the engine at low idle.
5. Remove the hydraulic oil filter from the machine. 17. Slowly and completely extend all cylinders. As
6. Install a new hydraulic oil filter on the machine. the piston rod comes out of the cylinder, oil will
be pushed out of the rod end of the cylinder.
7. Install the drain plug in the bottom of the reservoir.
18. Support the loader frame so that the loader frame
8. Fill the hydraulic reservoir with 14.4 U.S. gallons will stay in the RAISED position.
(54.5 litres) of AMBRA HITECH 46.
20. Connect the lines to the rod end of the cylinders.
21. Check the oil level in the hydraulic reservoir. Add
oil as required. See page 0-20 for specifications.
22. Install the filler cap for the reservoir.
NOTES:
6.4 CYLINDERS
Approximate weight
Lift Cylinder - Z-Bar - TC .................................................................................................... 75.7 kg (167 pounds)
Bucket Cylinder - Z-Bar Models ......................................................................................... 75.6 kg (167 pounds)

Screw in Gland Z-Bar Bucket Cylinder ....................................................... 135 to 542 Nm (100 to 400 pound-ft)
Screw in Gland for Lift Cylinders Z-Bar Models - TC .................................. 135 to 542 Nm (100 to 400 pound-ft)
Piston Bolt for Lift Cylinders Z-Bar Models - TC .................................. 1780 to 2180 Nm (1312 to 1607 pound-ft)
Piston Bolt for Z-Bar Bucket Cylinder .................................................. 3310 to 3850 Nm (2440 to 2838 pound-ft)
Lock Screw for all Cylinders ........................................................................................... 2.3 Nm (20 pound-inch)
6.4.3 SPECIAL TOOLS

Torque Multiplier ................................................................................................................................ 380001732
6.4.4 LIFT CYLINDER

Disassembly Inspection
1. Clean the outside of the cylinder. If the hoses were 1. Discard the parts that were removed from the pis-
removed with the cylinder, remove the hoses from ton and the gland.
the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to figure on page
3. Check to be sure that the piston rod is straight. If
6-57. Do not damage the tube (1).
the piston rod is not straight, replace it with a new
3. Loosen and remove the self-tapping screw (12). piston rod.
4. Use a spanner wrench to loosen and remove the 4. Illuminate the inside of the tube for deep grooves
gland (4) out of the tube (1). and other damage. If there is any damage to the
tube, replace it with a new tube.
5. Pull the piston rod (13) straight out of the tube (1)
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
inside the tube with emery cloth of medium grit. 6.
6. Fasten the piston rod eye or yoke in a vise and
Use the emery cloth with a rotary motion.
put a support under the piston rod (13) near the
piston (15). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or yoke
and the piston rod (13) to prevent damage to the and the tube. Replace as required.
piston rod (13).
7. Inspect the gland for rust. Clean and remove rust
7. Use a torque multiplier, 380001732, to loosen and as necessary.
remove the bolt (14), washer (19) that fastens the
8. Inspect the gland end of the tube for sharp edges
piston (15) to the piston rod (13).
that will cut the gland O-ring and remove as neces-
8. Remove the piston (15) from the piston rod (13). sary.
9. Remove the gland (4) from the piston rod (13). 9. Inspect the piston for damage and wear. If the pis-
ton is damaged or worn, replace it with a new pis-
10. Remove the seal (16), ring (17)and the wear ring
ton.
(18) from the piston (15).
11. Remove the O-ring (10), ring (9), O-ring (11), wiper
(5), seal (6), seal (7), and bushing (8) from the
gland (4).
13
5
6
7
4
8
11
9
10
15
17
16
18
19
14 1
3 2
2
3
BC01A163
Lift cylinder
1. Tube - 2. Bushing - 3. Wiper - 4. Gland - 5. Wiper - 6. Seal - 7. Seal - 8. Bushing - 9. Ring - 10. O-ring - 11. O-ring - 12. Screw
(not shown) - 13. Rod - 14. Bolt - 15. Piston - 16. Seal - 17. Ring - 18. Wear ring - 19. Washer.
Assembly 16. Install the bolt (14) into the piston rod (13). Tighten
the bolt (14) to a torque of 1780 to 2180 Nm (1312
Note If a new gland is being used, put the part
to 1607 pound-feet). A torque multiplier can be
number of the cylinder on the new gland.
used to help torque the bolt (14).
1. Install the bushing (8) in the gland (4), refer to 17. Install a new wear ring (18) in the wide groove on
figure on page 6-57. the outside of the piston (15), refer to figure on
page 6-57.
2. Install the seal (6) in the gland (4). The seal (6) is
to be installed so that the lips of the seal (6) are 18. Install a new ring (17) in the other groove on the
toward the bushing (8). The seal (6) can be diffi- outside of the piston (15).
cult to install.
19. Install a new seal (16) on the top of the ring (17).
3. Install the seal (7) in the gland (4). The side of the
20. Fasten the tube (1) in an acceptable repair stand
seal (7) with the groove must be toward the bush-
or other holding equipment. Be careful to prevent
ing (8).
damage to the tube (1).
4. Install a new wiper (5) in the gland (4). The lips of
21. Lubricate the inside of the tube (1) and the piston
the wiper (5) must be toward the outside end of
(15) with clean oil.
the gland (4).
22. Push the piston (15) straight into the tube (1).
5. Install a new O-ring (11) in the groove on the OD
of the gland (4). 23. When the piston (15) is in the smooth part of the
6. Install a new ring (9) in the groove on the OD of
the gland (4). If both sides of the ring (9) are not 24. Lubricate the O-rings (10 and 11) on the gland (4)
flat, the side that is not flat must be toward the with clean oil.
small end of the gland (4). 25. Turn the gland (4) into the tube (1). Tighten the
7. Install a new O-ring (10) next to the ring (9) in the gland (4) to a torque of 135 to 542 Nm (100 to 400
groove on the outside of the gland (4). The O-ring pound-feet).
(10) must be toward the small end of the gland.
26. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise.
A. Tighten the gland to a torque of 135 to 542 Nm
9. Remove any marks and sharp edges on the cham- (100 to 400 pound-feet).
fer at the end of the piston rod (13). Make sure
B. Install and tighten the lock screw (12) to a torque
that the piston rod (13) is clean.
of 2.3 Nm (20 inch-pounds).
10. Lubricate the bore of the gland (4) and the piston
C. If, after tightening the gland, the lock screw
rod (13) with clean oil.
(12) holes are not aligned, a new hole for the
11. Push the gland (4) onto the piston rod (13). If nec- lock screw (12) must be drilled. See Step 27.
essary, use a soft hammer to drive the gland (4) 27. If a new gland (4) or a new tube (1) are being
onto the piston rod (13). assembled:
12. Put a support below and near the end of the pis-
A. Tighten the gland (4) to 135 to 542 Nm (100 to
ton rod (13). Use a shop cloth between the sup-
400 pound-feet).
port and the piston rod (13) to prevent damage to
the piston rod (13). B. Use a No. 27 drill bit and drill a hole half in the
gland (4) and half in the tube (1). Drill to a
13. Start the piston (15) onto the piston rod (13). depth of 11 mm (7/16 inch). Do not drill within
14. Put the washer (19) on the bolt (14). 13 mm (1/2 inch) of a hole for the gland
wrench.
and the threads of the piston bolt using Loctite C. Install and tighten the lock screw (12) to a
cleaning solvent. Allow to dry. Apply Loctite 242 torque of 2.3 Nm (20 inch-pounds).
to the piston rod threads 1/4 inch from the open 28. If the hoses were removed with the cylinder, in-
end of the piston rod so that there is 1/2 inch of stall new O-rings, if equipped, on the hose fittings.
Loctite 242 on the piston rod threads. DO NOT Lubricate O-rings with clean oil. Install the hoses.
apply Loctite to the first 1/4 inch of the piston rod
threads.
6.4.5 BUCKET CYLINDERS Z-BAR MODELS

Disassembly Inspection
1. Clean the outside of the cylinder. If the hoses were 1. Discard the parts that were removed from the pis-
removed with the cylinder, remove the hoses from ton and the gland.
the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to figure on page
3. Check to be sure that the piston rod is straight. If
6-60. Do not damage the tube (1).
the piston rod is not straight, replace it with a new
3. Loosen and remove the locking screw (12) from piston rod.
the gland (4) and tube (1).
4. Illuminate the inside of the tube for deep grooves
4. Use a spanner wrench to loosen and remove the and other damage. If there is any damage to the
gland (4) out of the tube (1). tube, replace it with a new tube.
5. Pull the piston rod (12) straight out of the tube (1) 5. Remove any small scratches on the piston rod or
to prevent damage to the tube (1). inside the tube with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (12) near the 6. Inspect the bushings in the piston rod eye or yoke
piston (17). Put a shop cloth between the support and the tube. Replace as required.
and the piston rod (12) to prevent damage to the
7. Inspect the gland for rust and clean and remove
piston rod (12).
rust as necessary.
7. Use a torque multiplier, 380001732 to loosen and
8. Inspect the gland end of the tube for sharp edges
remove the bolt (15), washer (14) that fastens the
that will cut the gland O-ring and remove as neces-
piston (17) to the piston rod (12).
sary.
8. Remove the piston (17) from the piston rod (12).
9. Inspect the piston for damage and wear. If the pis-
9. Remove the gland (4) from the piston rod (12). ton is damaged or worn, replace it with a new pis-
ton.
10. Remove the seal (18), backup ring (19) and wear
ring (20) from the piston (17).
11. Remove the O-ring (11), backup ring (10), wiper
(5), seal (6), seal (7) and bushing (8) from the
gland (4).
14
13
13
14
5
12 6
4
8
10
20
11
17
16
19
15
18
2
BS01A174
Bucket cylinder for z-bar models
1. Tube - 2. Bushing - 3. Screw (not shown) - 4. Gland - 5. Wiper - 6. Seal - 7. Seal - 8. Bushing - 9. O-ring - 10. Backup ring -
11. O-ring - 12. Piston rod - 13. Bushing - 14. Wiper- 15. Bolt - 16. Washer - 17. Piston - 18. Seal - 19. Backup ring - 20. Wear
ring.
Assembly 16. Install the bolt (15) into the piston rod (12). Tighten
the bolt (15) to a torque of 3310 to 3850 Nm (2440
Note If a new gland is being used, put the part number
to 2838 pound-feet). A torque multiplier can be
of the cylinder on the new gland.
used to help torque the bolt (15).
1. Install the bushing (8) in the gland (4), refer to 17. Install a new wear ring (20) in the wide groove on
figure on page 6-60. the outside of the piston (17), refer to figure on
page 6-60.
2. Install the seal (6) in the gland (4). The seal (6) is
to be installed so that the lips of the seal (6) are 18. Install a new backup ring (19) in the other groove
toward the bushing (8). The wide seal (6) can be on the outside of the piston (17).
difficult to install.
19. Install a new seal (18) on the top of the backup
3. Install the seal (7) in the gland (4). The side of the ring (19).
seal (7) with the groove must be toward the bush-
20. Fasten the tube (1) in an acceptable repair stand
ing (8).
or other holding equipment. Be careful to prevent
4. Install a new wiper (5) in the gland (4). The lips of damage to the tube (1).
the wiper (5) must be toward the outside end of
21. Lubricate the inside of the tube (1) and the piston
the gland (4).
(17) with clean oil.
5. Install a new O-ring (9) in the groove on the gland (4).
22. Push the piston (17) straight into the tube (1).
6. Install a new backup ring (10) in the groove on the
23. When the piston (17) is in the smooth part of the
OD of the gland (4). If both sides of the backup
ring (10) are not flat, the side that is not flat must
be toward the small end of the gland (4). 24. Lubricate the O-rings (9 and 11) on the gland (4)
with clean oil.
7. Install a new O-ring (11) next to the backup ring
(10) in the groove on the outside of the gland (4). 25. Turn the gland (4) into the tube (1). Tighten the
The O-ring (11) must be toward the small end of gland (4) to a torque of 407 +/- 68 Nm (300 +/- 50
the gland. pound-feet).
8. Fasten the piston rod eye or yoke in the vise. 26. If the original parts are being assembled:
9. Remove any marks and sharp edges on the cham- A. Tighten the gland to a torque of 135 to
fer at the end of the piston rod (12). Make sure 542 Nm (100 to 400 pound-feet).
that the piston rod (12) is clean.
B. Install and tighten the lock screw (3) to a torque
10. Lubricate the bore of the gland (4) and the piston of 2.3 Nm (20 inch-pounds).
rod (12) with clean oil.
C. If, after tightening the gland, the lock screw
11. Push the gland (4) onto the piston rod (12). If nec- (3) holes are not aligned, a new hole for the
essary, use a soft hammer to drive the gland (4) lock screw (3) must be drilled. See Step 27.
onto the piston rod (12). 27. If a new gland (4) or a new tube (1) are being
12. Put a support below and near the end of the pis- assembled:
ton rod (12). Use a shop cloth between the sup-
A. Tighten the gland (4) to a torque of 135 to 542
port and the piston rod (12) to prevent damage to
Nm (100 to 400 pound-feet).
the piston rod (12).
B. Use a No. 27 drill bit and drill a hole half in the
13. Start the piston (17) onto the piston rod (12). gland (4) and half in the tube (1). Drill to a
14. Put the washer (16) on the bolt (15). depth of 11 mm (7/16 inch). Do not drill within
13 mm (1/2 inch) of a hole for the gland
wrench.
and the threads of the piston bolt using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242 C. Install and tighten the lock screw (3) to a torque
to the piston rod threads 1/4 inch from the open of 2.3 Nm (20 inch-pounds).
end of the piston rod so that there is 1/2 inch of 28. If the hoses were removed with the cylinder, in-
Loctite 242 on the piston rod threads. DO NOT stall new O-rings, if equipped, on the hose fittings.
apply Loctite to the first 1/4 inch of the piston rod Lubricate O-rings with clean oil. Install the hoses.
threads.
6.4.6 REPLACING THE BUSHINGS FOR 6.4.7. REPLACING BUSHINGS FOR THE
THE LIFT CYLINDERS BUCKET CYLINDER Z-BAR
Z-BAR MODELS - TC MODELS
Disassembly Disassembly
1. Put the piston tube (4) in a press, refer to figure. 1. Put the piston rod eye (7) in a press, refer to
2. Use an acceptable driver to press the wipers (1) figure.
and bushings (2) out of the piston tube (4). 2. Use an acceptable driver to press the wipers (5)
3. Clean the bore for the bushings (2) in the tube (4). and bushing (6) out of the piston rod eye (7).
3. Put the tube (8) in a press.
Assembly 4. Use an acceptable driver to press the bushings (6)
1. Use an acceptable driver to press a new bushing out of the tube (8).
(2) into the tube (4) until the bushing (2) is centered 5. Clean the bore for the bushings (6) in the piston rod
in the tube (4). eye (7) and the tube (8).
2. Use an acceptable driver to install the wipers (1) in
the tube (4). The lips of the wipers (1) must be to- Assembly
ward the outside of the bore. 1. Use an acceptable driver to press new bushings
(6) into the piston rod eye (7). Refer to figure.
2. Use an acceptable driver to install the wipers (5) in
3 the piston rod eye (7). The lips of the wipers (5)
must be towards the outside of the bore.
3. Use an acceptable driver to press new bushings
(6) into the tube (8).
5
1 6 7
4
6
2 2 5
1
8
BS01C003
6
Bushing and wiper removal and replacement lift
cylinders
1. Wiper - 2. Bushing - 3. Piston rod yoke - 4. Tube.
BS01C004
Bushing and wiper removal and replacement

z-bar bucket cylinder
5. Wiper - 6. Bushing - 7. Piston rod yoke - 8. Tube.
6.5 COUPLER SOLENOID LOCKING VALVE
6.5.1. DISASSEMBLY AND ASSEMBLY Assembly

COUPLER SOLENOID LOCKING STEP 9
VALVE
Install new O-rings (4 and 5) and back-up rings (6) as
Disassembly shown.
STEP 1
STEP 10
Clean exterior of valve.
Lubricate O-rings (4 and 5) using clean oil then install
STEP 2 valve cartridge (3) in valve housing (7).
Remove nut (1) and solenoid (2) from valve cartridge STEP 11
(3).
Install solenoid (2) on valve cartridge (3).
STEP 3
STEP 12
Remove valve cartridge (3) from valve housing (7).
Install nut (1) to secure solenoid (2).
STEP 4
Remove and discard all O-rings (4 and 5) and back- 1
up rings (6).
Cleaning and Inspection

2
STEP 5
Immerse valve cartridge (3) and valve housing (7) in
cleaning solvent and agitale cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter 3
from interior of valve cartridge and housing and to
ensure that all passage ways and bores are clear.
4
STEP 6
6
Check valve cartridge for (3) for cracks, breaks, chip- 5
ping, or other damage. Replace if any of these condi- 6
tions are seen. 6
5
STEP 7 6
6
Check bores in valve housing (7) for deep scartches, 5
gouges, and other damage. Replace valve if any of 6
these conditions are seen. 7
STEP 8
Connect and ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve cartridge
(3) if ohmmeter indicates short or open circuit. GS98J818
1. Nut - 2. Solenoid - 3. Valve cartridge - 4. O-ring -

5. O-ring - 6. Backup ring - 7. Valve housing.
NOTES:
6.6 PILOT PRESSURE ACCUMULATOR AN RIDE CONTROL ACCUMULATOR
Ride Control Accumulator Dry Nitrogen Pressure ....................... 17.2 +/- 1.7 bar (250 +/- 25 psi) at 21 C (70F)
Ride Control Accumulator Fluid Capacity ...................................................................... 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure ....................................................... 207 bar (3000 psi)
Pilot Pressure Accumulator Dry Nitrogen Pressure .................. 13.8 +/- 1.7 bar (200 +/- 25 psi) at 21 C (70 F)
Pilot Pressure Accumulator Fluid Capacity .................................................................. 0.95 liters (59.5 cu. inch)
Pilot Pressure Accumulator Maximum operating Pressure ..................................................... 207 bar (3000 psi)

Accumulator Gas Charging Valve Cap ............................................................................... 13.6 Nm (10 pound-ft)
Gas Charging Valve .......................................................................................... 88 to 102 Nm (65 to 75 pound-ft)
Cap screws for the protection bracket ........................................................ 54 to 61 Nm (480 to 540 pound-inch)
Gland ......................................................................................................... 163 to 176 Nm (120 to 130 pound-ft)
6.6.3 SPECIAL TOOLS
94L95
B786441M
380001737 Nitrogen accumulator charging kit 380001738 Gland Wrench
6.6.4 DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C
E
D B A
94L95
380001737 Nitrogen charging kit
1. Use the 380001737 Nitrogen Charging Kit to dis- 7. Turn the T-handle inward on valve F to engage the
charge the accumulator, refer to the illustration pin in the valve stem.
above. The tool must be disconnected from the ni-
8. Open valve D and check the charge pressure on
trogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open valve
3. Adjust the regulator A to the minimum pressure B. The accumulator charge will bleed down through
setting by turning the knob counterclockwise. the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged, discon-
nect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the accumu-
lator.
NOTES:
6.6.5 RIDE CONTROL ACCUMULATOR Assembly

Note Refer to page 6-1 for the proper procedure for
page 7.
the removal of the ride control accumulator.
WARNING
6-69.
3. Remove the pressure valve (4) from the body (1). and wood block to gently tap the piston into the pol-
ished area of the bore. Keep force on the piston (5)
4. Remove and discard the O-ring (7) from the pres- while tapping into the bore or damage may occur to
sure valve (4). the O-ring.
5. Loosen and remove the cap (12) from the body (1).
5. Install and tighten the cap (12) into the body (1).
6. Loosen and remove the gland (6) from the body
(1). 6. Install new seals (11) on the gland (6).
7. Remove the piston (5) from the body (1). 7. Lubricate the seals (11) with clean oil and start
the gland (6) into the body (1).
8. Remove and discard the wear ring (8), O-ring (10)
and the backup ring (9) from the piston (5). 8. Tighten the gland (6).
9. Remove the seals (11) from the gland (6). 9. Install a new O-ring (7) on the pressure valve (4).
10. Install the pressure valve (4) in the body (1).
Inspection 11. Install the guard (2), screws (3) in the body (1).
1. Clean body (1), gland (6), cap (12) and piston (5) in clean- 12. Charge the accumulator with dry nitrogen accord-
ing solvent, refer to the illustration on page 6-69. ing to instructions on page 6-72.
age.
3. Inspect the bore of the body (1) for scratches or
scoring using a light.


needed.
11 6 5 8 9 10 12 3
7
2
1 3
BS01B224
Ride control accumulator illustration
1. Body - 2. Guard- 3. Screw - 4. Pressure valve - 5. Piston - 6. Gland - 7. O-ring - 8. Wear ring - 9. Backup ring- 10. O-ring -
11. Seals (2) - 12. Cap.
6.6.6 PILOT PRESSURE ACCUMULATOR Assembly

Note See page 6-1 for the proper procedure to re-
page 9.
move the accumulator.
WARNING
6-71.
3. Remove the pressure valve (4) from the body (1). and wood block to gently tap the piston into the pol-
ished area of the bore. Keep force on the piston (5)
4. Remove and discard the O-ring (7) from the pres- while tapping into the bore or damage may occur to
sure valve (4). the O-ring.
5. Loosen and remove the cap (12) from the body (1).
5. Install and tighten the cap (12) into the body (1).
6. Loosen and remove the gland (6) from the body
(1). 6. Install new seals (11) on the gland (6).
7. Remove the piston (5) from the body (1). 7. Lubricate the seals (11) with clean oil and start
the gland (6) into the body (1).
8. Remove and discard the wear ring (8), O-ring (10)
and the backup ring (9) from the piston (5). 8. Tighten the gland (6).
9. Remove the seals (11) from the gland (6). 9. Install a new O-ring (7) on the pressure valve (4).
10. Install the pressure valve (4) in the body (1).
Inspection 11. Install the guard (2), screws (3) in the body (1).
1. Clean body (1), gland (6), cap (12) and piston (5) in clean- 12. Charge the accumulator with dry nitrogen accord-
ing solvent, refer to the illustration on page 6-71. ing to instructions on page 6-72.
age. WARNING
3. Inspect the bore of the body (1) for scratches or Use only nitrogen when charging the accumula-
scoring using a light. tor. DO NOT use air or oxygen that will cause an
explosion.

needed.
11 6 5 8 9 10 12 3
7
2
1 3
BS01B224
Pilot pressure accumulator illustration
1. Body - 2. Guard- 3. Screw - 4. Pressure valve - 5. Piston - 6. Gland - 7. O-ring - 8. Wear ring - 9. Backup ring- 10. O-ring -
11. Seals (2) - 12. Cap.
6.6.7 CHARGING THE ACCUMULATOR WITH NITROGEN
5 4 3 2
GS98N801
Nitrogen charging kit 380001737
1. To nitrogen tank - 2. Valve A - 3. Valve B - 4. Valve D - 5. To accumulator - 6. Valve C.
WARNING WARNING
Use only nitrogen when charging the accumula- Do not expose the accumulator to temperatures
tor. Do not use air or oxygen that will cause an above 49 C (120 F). A charged accumulator con-
explosion. tains nitrogen compressed to 31 bar (450 psi). High
heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will pro-
WARNING pel the accumulator at a dangerous rate of speed.
Do not drop the accumulator. A charged accumu-
lator contains nitrogen compressed to 31 bar Important The four valves must be in the positions
(450 psi). If the charging valve breaks away from noted in the procedure before connecting the Nitro-
the accumulator, the escaping nitrogen will pro- gen Accumulator Charging Kit to the machine or ni-
pel the accumulator at a dangerous rate of speed. trogen, refer to the above illustration.
Important To help prevent equipment damage, the

low pressure gauge valve C MUST BE SHUT OFF
during high pressure (10 bar/150 psi and above) appli-
cations.
1. Close the shutoff valve A by turning it all the way 10. Install the charging hose fitting onto the accumu-
to the left (counterclockwise), refer to the illustra- lator pressure valve (4), refer to the illustrations
tion on page 6-76. on pages 6-69 and 6-71.
2. Open valve B by turning it out all the way to the left 11. Tighten the needle valve by turning it clockwise.
(counterclockwise). Slowly open the gauge valve D and observe the
reading on the gauge. This reading is the nitrogen
3. Close valve C by turning it all the way to the right
pressure level inside the accumulator, refer to il-
(clockwise).
lustration on page 6-72.
4. Close the gauge valve D by turning it all the way to
12. Open the shutoff valve A on the nitrogen supply
the right (clockwise).
tank. While observing the pressure on the gauge,
5. Connect the charging hose to the nitrogen supply slightly open the needle valve on the accumula-
tank. tor charge hose. By regulating the needle valve,
fill the accumulator to 31 bar (450 psi). Close the
6. SLOWLY turn valve A clockwise while watching the
needle valve. Close the shutoff valve A on the
high pressure gauge. Stop turning valve A when
nitrogen supply tank.
the needle on the gauge reaches 31 bar (450 psi).
13. Close valve B by turning to the right (clockwise).
Note If the needle goes over the needed pressure, After a few minutes, check the accumulator for
quickly open and close valve D and check the pres- leakage.
sure setting again.
14. Back off the needle valve on the accumulator end
of the charging hose by turning it counterclockwise
The charging kit is now ready to be installed on the
the maximum amount. This will prevent nitrogen
accumulator.
from escaping from the accumulator as the hose
is removed. Remove the charging hose from the
7. Remove the two cap screws (3) and the protection
accumulator pressure valve (4), refer to the illus-
bracket (2) from the body (1) on the accumulator,
trations on pages 6-69 and 6-71.
refer to the illustrations on pages 6-69 and 6-71.
15. Install the valve cap onto the pressure valve (4)
8. Remove the valve cap from the pressure valve (4)
on the accumulator.
on the accumulator.
16. Install the protection bracket (2) over the pres-
9. Back off the needle valve on the accumulator end
sure valve (4) and secure it with cap screws (3).
of the charging hose by turning it counterclockwise
to the maximum amount. This prevents nitrogen 17. Remove the charging hose from the nitrogen sup-
from escaping from the accumulator when the charg- ply tank, refer to the illustration on page 6-72.
ing hose is attached to the accumulator gas charg-
ing valve, refer to the illustration on page 6-72.
NOTES:
W110/W110TC HYDRAULIC SCHEMATIC 6 - 75

12
HYDRAULIC
43 SYMBOLS
13 44
R R1 R2
P
Pressure
15 6
41
L
45
19
P
39 LS Component
16
T2
17 18 7
R
T
P
M 46
T1 32 Return
20
31 T Pst P
47
42 241 BAR
SX
45 BAR
(653 PSI)
30 BAR
(435 PSI)
(3495 PSI)
Load sense
N
14 35 LS
37
48
38 S
40
11 10
TC MODELS
250 bar
(3626 psi) Pilot pressure
25
49
0.7 L/min
XY
XZ 5
Z-BAR and
b1
NOTE 3 XR MODELS
a1
TC MODELS Crossing lines
50 290 bar
(4206 psi) A1
XY XY
XZ XZ
B1
5
M1 TANK Z-BAR and XR MODELS

NOTE 1
21 193
BAR Line connection
(2800 PSI)
M1 TANK a2
136 34
BAR 136
30 M2 (1975 PSI) BAR
(1975 PSI)
A2
IN 1 6-8 bar
b2 (87-116 psi) B2 4
23 M2
IN
P
22
Check valve
2
T
3
b3 a3
33 290 bar
(4206 psi) A3
B3
290 bar
(4206 psi) Restrictor
4 1
MP SOLENOID
B X
27 26 2 36 VALVE A B
P T
FR1
NOTE 2
1
SEQUENCE 2
VALVE Y
FR2
Filter or screen
LR
9 LS EF CF
X Z1 Y X2
24 PP X1
LOGIC
240 bar
(3481 psi) VALVE
MX
29
MA
RELIEF
3
VALVE
T P
8
S L1 L
A T Oil cooler
M
28
W110R0355
COMPONENTS
P. Brake pedal 1. Ride control valve (option) 2. Ride control accumulator (option) - Precharge: 14.5 bar (250 psi) - Capacity: 3.78 litres (231 cu in.) 3. Ride control accumulator bleeder valve 4. Lift cylinders - Bore: 101.60 mm (4.00 in) - Rod: 57.15 mm (2.25 in) - Stroke:
783.00 mm (30.83 in) 5. Bucket cylinder - Bore: 114.30 mm (4.50 in) - Rod: 63.50 mm (2.50 in) - Stroke: 529.40 mm (20.84 in) 6. Steering control valve - Displacement: 462 cc/rev (28.2 cu in./rev) 7. Steering cylinders (2) - Bore: 63.5 mm (2.50 in) - Rod: 34.93 mm
(1.375 in) - Stroke: 489.20 mm (19.26 in) 8. Auxiliary steering motor and pump (option - north american models) - Displacement: 11 cc/rev (0.671 cu in./rev) 9. Auxiliary steering priority valve (option - north american models) - Relief pressure: 241.3 bar (3500 psi)
10. Auxiliary steering pressure switch 2.4 bar (35 psi) 11. Steering pressure diagnostic coupler 12. Brake accumulators (2) - Precharge: 55 1.7 bar (800 25 psi) - Capacity: 0.95 litres (58 cu in.) 13. Accumulator control pressure switch 14. Parking brake control
solenoid valve 15. Brake pedal valve 16. Flow regulation valve 17. Rear brakes 18. Front brakes 19. Main check valve 20. Front axle brake control spool 21. Fan drive motor - Displacement: 14 cc/rev (0.85 cu in./rev) 22. Fan reversing valve (option) - Relief setting:
170 bar (2466 psi) 23. Fan valve (standard) relief setting: 136 bar (1975 psi) 24. Brake hydraulic pump 25. Spool TC Models 26. Implement hydraulic pump - Displacement: 71 cc/rev (4.33 cu in./rev) - Cutoff: 280 bar (4061 psi) - Delta: 22 bar (319 psi) - Start of torque
limit destroke: 175 bar (2538 psi) 27. Hydraulic filter assembly - Bypass valve: 3.4 bar (50 psi) - Warning switch: 2.7 bar (40 psi) 28. Hydraulic reservoir - Total volumn: 83.3 litres (22 u.s. gallons) - Oil capacity: 56.8 litres (15 u.s. Gallons) 29. Hydraulic reservoir breather
- 20 micron breather 30. Hydraulic cooler (option) 31. Pilot pressure accumulator - Precharge: 13.8 1.7 bar (200 25 psi) - Capacity: 0.95 litre (58 cu in.) 32. Pilot pressure diagnostic coupler 33. Float switch - Closes at 24 bar (350 psi) 34. Controller with two spool
loader valve - Two lever or joystick controller 34. Controller with three spool loader valve - Three lever or joystick with one lever controller 34. Controller with four spool loader valve - Joystick with two lever controller 35. Loader control valve - Two spool (standard) - Three
spool (option) - Four spool (option) 36. Pump pressure diagnostic coupler 37. Load sensing pressure diagnostic coupler 38. Quick release pressure pick-up 39. Auxiliary steering load sense solenoid valve (option - north american models) 40. Parking brake
accumulator 41. Parking brake accumulator - Pressure diagnostic coupler 41-42. Check valves 43-44. Quick release pressure pick-ups 45. Rear brake control spool 46. Transmission cut-off pressure switch 47. Stop light pressure switch 48. Parking brake pressure
switch 49. Parking brake 50. Pilot valve cut-off valve.
SECTION 7
ELECTRICAL SYSTEM
INDEX
SAFETY RULES .................................................................................................. 7-1
7.1 GENERAL LAYOUT OF THE ELECTRICAL SYSTEM ......................................... 7-3
7.2 MAIN CONNECTORS .......................................................................................... 7-5
7.3 MAIN COMPONENT CONNECTIONS (CAB) ...................................................... 7-11

7.3.1 FUSES ................................................................................................................. 7-12
7.3.2 CAB INSTRUMENT PANEL ................................................................................. 7-18
7.3.3 SWITCH PANEL ................................................................................................... 7-21
7.3.4 AUTOMATIC TRANSMISSION ............................................................................. 7-22
7.4 COMPONENTS ON MACHINE ............................................................................ 7-27

7.4.1 RELAY AND FUSE BOX IN ENGINE COMPARTMENT ....................................... 7-27
7.4.2 FRONT FRAME RELAY BOX ............................................................................... 7-28
7.4.3 EMERGENCY STEERING ................................................................................... 7-29
7.4.4 LOAD SENSING SYSTEM (LTS) ......................................................................... 7-30
7.4.5 TRANSMISSION COMPONENTS ....................................................................... 7-31
7.4.6 BRAKE SYSTEM COMPONENTS ....................................................................... 7-33
7.4.7 HYDRAULIC SYSTEM COMPONENTS .............................................................. 7-34
7.4.8 ENGINE COMPONENTS (STANDARD) .............................................................. 7-35
7.5 FUNCTIONS OF DIGITAL DISPLAY

(DISPLAY OF OUTPUT SIGNALS FROM BROWN BOX) .................................... 7-37
7.5.1 DESCRIPTION OF HOME PAGE (DEFAULT PAGE) ............................................ 7-37
7.5.2 PARKING BRAKE EFFICIENCY TEST ................................................................ 7-38
7.5.3 EMERGENCY STEERING SYSTEM EFFICIENCY TEST ................................... 7-41
7.5.4 CALIBRATION OF TRANSMISSION GEARSHIFTS ............................................ 7-44
7.5.5 DISPLAY OF TRANSMISSION FAULT CODES .................................................... 7-47
7.5.6 INITIAL SET-UP OF THE "BROWN BOX" CONTROLLER ................................... 7-49
7.5.7 READING OF THE ENGINE OPERATION PARAMETERS .................................. 7-52
7.5.8 READING OF THE TRANSMISSION OPERATION PARAMETERS .................... 7-53
7.5.9 READING OF THE BRAKE SYSTEM OPERATION PARAMETERS .................... 7-54
7.5.10 READING OF THE ELECTRICAL SYSTEM OPERATION PARAMETERS .......... 7-55
ELECTRICAL SYSTEM FOLDING DIAGRAMS ................................................... 7-57

W110/W110TC ELECTRICAL SYSTEM 7-1
SAFETY RULES
WARNING
When working on the electrical system always
wear protective gloves and remove rings, wrist
watches and any other metallic jewel.
W110R0337
DISCONNECT
WARNING
Prior to proceeding with inspection or repair in- A C
terventions of electrical components DISCON- B
NECT GROUND CABLE "A" from negative termi-
nal "B" of the battery. DISCONNECT THE CABLE
from positive terminal "D".
BATTERY 12 Volt x 2
GROUND W110R0338
WARNING
NEVER REST METALLIC ITEMS on the battery
to prevent the danger of short circuits.
W110R0339
WARNING
BATTERY GASES ARE FLAMMABLE.
Never place open flames or generate sparks near batteries. During the recharging, the emission of
gases is higher.
WARNING
BATTERY GASES ARE DANGEROUS if in contact with the skin or materials.
7-2 ELECTRICAL SYSTEM W110/W110TC
NOTES:
7.1 GENERAL LAYOUT OF THE ELECTRICAL SYSTEM
WARNING
Always disconnect the battery cable prior to cleaning, repairing, connecting or disconnecting any cable of
the electrical system to prevent the possibility of personal injuries.
Always keep all the lights equipping the machine efficient. Replace at once any burnt-out bulb.
A 1
2
Left side
W110R0009
Left side of machine
A. Machine/l.h. cab connector - 1. Cab harness - 2. Transmission harness.
1 B
3 4
Right side
W110R0010
Right side of machine
B. Machine/r. h. cab connections - 1. Cab harness - 3. Rear frame harness - 4. Front frame harness.
NOTES:
7.2 MAIN CONNECTORS
3
1
2
4
5
Left side Right side

W110R0011 W110R0012
Left side of machine Right side of machine

1. X21 connection (Transmission harness) - 2. Plaid cable 3. X20 connection (Front frame harness) - 4. X22 connec-
(cab ground/frame ground). tion (Rear frame harness) - 5. X23 connection (Rear frame
harness) - 6. Cab ground.
DETAIL OF X21 CONNECTION

(TRANSMISSION HARNESS) 23 poles
Left side
W110R0014
W110R0013
X21 CONNECTION
SOCKET ROUTING WIRE NO. WIRE NO.
(Cab side) (Machine side)
A Proportional solenoid Y1 ZF56 430
B Proportional solenoid Y2 ZF10 434
C Proportional solenoid Y3 ZF32 438
D Proportional solenoid Y4 ZF55 442
E Proportional solenoid Y5 ZF9 446
F Proportional solenoid Y6 ZF51 450
G Joint positive proportional solenoids ZF12 454
J Control valve temp. sensor power ZF39 458
K Convert. temp. sensor power ZF49 574
L Contr. valve temp. sensor return signal ZF46 462
M Engine speed sensor signal ZF19 GE2
N Engine speed sensor ground ZF3 BL2
O Turbine speed sensor signal ZF41 GN3
P Turbine speed sensor ground ZF3A SW3
Q Intermediate speed sensor signal ZF42 RT4
R Intermediate speed sensor ground ZF3B BL4
S Speed sensor output ground ZF4 500
T Speed sensor output signal ZF62 504
U Speed sensor output power ZF45_A 508
V Oil filter clogging sensor power ZF17 480
W Oil filter clogging sensor signal return ZF46B 484
X Convert temp. sensor signal return ZF46A 570

(FRONT FRAME HARNESS) 31 poles
Right side
W110R0016
W110R0015
X20 CONNECTION
1 LTS relay power 169_FB 169_D
2 Not connected 553_B 553_D
3 Brake low pressure signal 613_A 613_B
4 Horn pedal signal 116 116_E
5 Horn signal 138 138_E
6 R. h. front turning light power 103 103_E
7 L. h. front turning light power 109 109_E
8 TUV lights power 124 (OPT)
9 TUV lights power 126 (OPT)
10 R. h. head light power 330-FA 330_E
11 L. h. head light power 339_FA 339_E
12 Fused power 835 835_D
13 Fused power 895_M 895_L
14 L. h. low beam light power 231_A 231_E
15 R. h. low beam light power 223_A 223_E
16 L. h. high beam light power 219_A 219_E
17 R. h. high beam light power 221_A 221_E
18 Parking brake solenoid 945_A 945_E
19 Transm. cut-off pressure switch power 975 975_E
20 Transm. cut-off pressure switch signal ZF66 974_E
21 Boom proximity sensor power 995_F 995_G
22 Boom proximity sensor signal 980_C 980_H
23 Bucket proximity sensor power 994_H 994_G
24 Bucket proximity sensor signal 981_E 981_H
25 LTS solenoid power 952_B 952_D
26 Pilot. safety valve solenoid 859_B 859_A
27 LTS switch signal 956_B 956_D
28 LTS switch power ZF5 954_D
29 Boom proximity sensor signal 994_L 994_M
31 Emergency steering pressure switch 844 844_D

(FRONT FRAME HARNESS) 21 poles
Right side
W110R0018
W110R0017
X22 CONNECTION
A Parking brake switch ground N_RCC 978_B
C Parking brake pressure switch ground 996_A 996_B
F R. h. tail light 331_FA 331
H L. h. tail light 332_FA 332_L
J L. h. rear turning light 120 120_E
K R. h. rear turning light 125 125_E
L Starting relay 802_RA 802_T
M Back-up alarm relay (ground) ZF7 556
N Back-up alarm relay (positive) ZF45_FB 558
P Fan reverser solenoid power 876_B 876_C
R From M contact starter switch 895_F 895_E
S From ACC contact starter switch 801_F 801_T
U Engine coolant high temp. signal 552 552-B
W Engine coolant temperature signal 528 528-B
X Engine oil low temperature signal 503 503_B

(REAR FRAME HARNESS 2) 18 poles
Right side
W110R0020
W110R0019
X23 CONNECTION
1 Power B+ from batteries R_B 772_A
2 Engine pre-heating grill signal 965_D 965_B
3 Engine temp. sender signal 827-C 827_T
6 Ground N_RCG N_CHA
7 Ground N_RCH N_CHB
8 Rear work lights power 225_E 225_D
10 Alternator signal 637 637_A
11 W alternator 552_A
12 Air cleaner clogging pressure switch 663 663_B
13 Fuel level sensor signal 557 557_B
15 Engine coolant thermostat signal 824_C 824_A
16 Rear windshield washer power 886_F 886_RR
17 Front windshield washer power 885_F 885_RF
7 - 10 ELECTRICAL SYSTEM W110/W110TC
NOTES:
W110/W110TC ELECTRICAL SYSTEM 7 - 11
7.3 MAIN COMPONENT CONNECTIONS (CAB)
1 2
W110R0021 W110R0022
1. Transmission controller ZF EST37 - 2. Brown Box controller - 3. Diagnostic connection group - 4. Service relay 90 Amp
- 5. Flasher unit - 6. Relay group 7.5 Amp - 7. F fuse group.
Driver compartment rear panel
WARNING
It is essential that during the connecting and disconnecting phases of the ZF controller the electrical
system is disconnected (battery main switch and starter switch in position "OFF") to prevent possible
damages to the unit.
7.3.1 FUSES
WARNING F1 F2
Always disconnect the battery cable prior
to cleaning, repairing, connecting or discon-
necting any cable of the electrical system A B C A B C
to prevent the possibility of personal inju- X1
ries. F3 F4
Always keep all the lights equipping the
machine efficient. Replace at once any burnt-
out bulb.
A B C A B C
Note In the event a fuse is burnt out, it is

necessary to replace it at once. Search for the F5 F6
cause of the failure. If the trouble presists, have X2
the system inspected by competent person-
nel. A B C A B C
F7 F8
A B C A B C
X3 F9 F10
A B C A B C
F11 F12
X4
A B C A B C
X5 ACC +B
W110R0023
Pos. Amp Circuit under protection Connect.

A 7.5 Cab ceiling light X4
F1 B 7.5 Emergency lights X4
C 7.5 Turning light switch/indicators X1
A 7.5 Rotary beacon X1
F2 B 7.5 Not connected X1
C 7.5 Front wiper motor X1
A 15 Climate conditioner X5
F3 B 5 Main light switch X1
C 5 Bucket roll-back detent solenoid/boom and bucket proximity/float solenoid X1
A 5 Flasher unit X1
F4 B 7.5 Voltage converter X1
C 7.5 Seat heater X1
A 15 + ACC relay box in engine compartment X5
F5 B 10 Rear work lights X1
C 10 Front work lights X1
A 7.5 Climate conditioner controls X1
F6 B 5 Rear wiper motor X1
C 5 LTS solenoid valve solenoid X1
A 15 Engine electric cut-off/EF2 fuse + EF5 fuse (fuse box in engine compartm.) X5
L. h. front head light and r. h. tail light/plate light/l.h. side light/dashboard light/cigarette
F7 B 3 X3
lighter light
C 3 R. h. head light and l. h. tail light7r. h side light X3
A 5 Seat regulation air compressor X2
B 5 Parking brake solenoid valve coil X2
F8 Back-up alarm relay / + 24 V transmission output speed sensor /aut-man switches,
C 7.5 transmission cut-off and reverser aux /ZF controller keyed power / outer display X2
power socket / gearshift pilot valve / parking brake relay
A 3 Not connected X2
F9 B 3 Not connected X3
C 7.5 Buzzer / dashboard / digital monitor X2
A 7.5 Cigarette lighter X4
F10 B 7.5 B+ ZF EST 37 transmission controller X4
C 7.5 High beam relay X4
A 7.5 Horn relay X4
F11 B 20 Starter switch X5
C 3 Transmission diagnostic socket X4
A 3 +30 Brown Box X3
F12 B 7.5 B+ main light switch X4
C 10 High beam relay X4
Description of cab relays Connections of ZF EST 37 transmission controller
W110R0024 W110R0026
Components
K1. High beam relay - K2. LTS (Speed = 0 kmph) engage-

ment control relay - K3. Flasher - K4. Low beam relay -
K5. Starter safety relay in neutral - K6. Horn relay (control
by gearshift selector) - K7. Horn relay (control by pedal
switch) - K8. Parking brake relay - SERV. Service relay.
K3
K1 K2 SERV
X C
K 4 K 5 K 6 K 7 K 8 X25A
X33 X34 X25_2 X D

X25_1
B+ Cab X19
W110R0025 W110R0027
Connections
X33. Contacts and relay K1, K2, K4, K5 coils - X34. Con-
tacts and relays K6, K7, K8; Service relay 90 Amp coil;
Flasher K3 contacts - XC. 90 Amp service relay input con-
tact (+ 30) - XD. Diversion from batteries to 90 Amp serv-
ice relay (+ 30) - X25_A. 90 Amp service relay output
contact (G) (to connection ACC cab fuse board) -
X25_1. Power from batteries (from box B+ in engine com-
partment) - X25_2. Diversion from batteries to connection
+B cab fuse board.
X19 CONNECTION
SOCKET CONTROLLER FUNCTION REMARKS
1 Ground
2 Ground
3 Ground, engine rpm, turbine and intermediate sensor
4 Ground, output shaft speed sensor
5 LTS signal
7 Ground, back-up alarm relay coil
9 Proportional solenoid valve Y5 coil Negative signal
10 Proportional solenoid valve Y2 coil Negative signal
12 +24V (common) to proportional solenoids
13 +24V (common) to proportional solenoids
14 Signal for external display connections
15 Signal for diagnostic connection
16 Signal for diagnostic connection
17 Signal, oil filter clogging sensor
19 Signal, engine rpm sensor
20 Signal, forward speed From aux reverser
21 Signal, kick-down
22 Power from batteries
23 Power from batteries Under fuse F10B
25 Can Bus (H)
26 Can Bus (L)
27 Can Bus (L)
29 Signal, AUT/MAN selection switch
30 Signal, aux reverser selection switch
31 Signal, reverse From aux reverser
32 Solenoid valve Y3 proportional solenoid Negative signal
39 Signal, control valve oil temperature sensor
41 Signal, converter turbine rpm sensor
42 Signal, intermediate gear rpm sensor
43 Signal, forward speed From gearshift selector
44 Signal in neutral From aux reverser
45 Power under key (pos ON) Under fuse F8C
46 Return from control valve temperature sensor
49 Signal, converter output oil temp. sensor
62 Signal, output shaft speed sensor
63 Signal, 1st and 4th gear From gearshift
64 Signal, reverse From gearshift
65 Signal, 3rd and 4th gear From gearshift
66 Signal, transmission cut-off From press, switch
67 Signal in neutral From gearshift
68 Power from batteries Under fuse F10B
W110R0028
Brown box controller connections
CN2 CN1
Detail "A"
W110R0029
Resistor 160 ohm
CAN_ SPL
Can_SPL Joint
XA. CAN line from ZF EST

X72 XA 37 - X72. Controller CAN line
Detail "B" from Brown box controller.
W110R0030
BROWN BOX CONNECTION CN1 (INPUT)

SOCKET CONTROLLER FUNCTIONS
2 Can Bus (H) To joint CAN_SPL connection X72 pin B
3 Signal, brake accumulators low pressure pressure switch
4 Can Bus (L) To joint CAN-SPL connection X72 pin A
5 Signal from L alternator
9 Signal, engine coolant temperature switch
11 Signal, air cleaner clogging sensor
14 Ground
15 Direct power from batteries (under fuse F9C)
16 Variable signal, engine coolant temperature sensor
17 Signal, emergency steering low pressure
19 Signal, emergency steering high pressure
21 Signal, engine oil low pressure pressure switch
22 Signal, fuel level sensor
23 Signal, LTS engaged
25 Signal, transmission cut-off engaged
28 Ground
29 Power from starter switch in position ON (under fuse F12A)
42 Ground
BROWN BOX CONNECTION CN2 (OUTPUT)

SOCKET CONTROLLER FUNCTIONS
1 Signal, battery charge indicator light
3 Signal, emergency steering indicator light
5 Signal, general alarm buzzer
9 Signal, air cleaner clogging indicator light
10 Signal, engine oil low pressure indicator light
11 Signal, transmission oil temperature indicator light
12 Signal, transmission oil temperature indicator
13 Signal, fuel indicator light
16 Signal, engine coolant temperature indicator light
17 Signal, service brake oil low pressure indicator light
18 Signal, 1st gear engaged indicator light
19 Signal, 2nd gear engaged indicator light
20 Signal, 3rd gear engaged indicator light
21 Signal, 4th gear engaged indicator light
22 Signal, fuel level indicator light
23 Signal, engine coolant temperature indicator
24 Signal, signal, vehicle speed
26 Emergency steering relay coil negative
27 Digital display
30 Digital display
31 Digital display
32 Digital display
33 Digital display
34 Digital display
35 Serial interface screening (outside connection)
36 Serial interface RX_B (data input) (outer connection)
37 Serial interface RX_V (data input) (outer connection)
38 Serial interface TX_R (data transmission) (outer connection)
39 Serial interface TX_G (data transmission) (outer connection)
40 Interface 12V power (outer connection)
42 Interface ground (outer connection)
7.3.2 CAB INSTRUMENT PANEL The instrument board is composed of instruments in-
cluding the tachometer, control indicator lights signal-
The monitoring system monitors the operating condi-
ling that all systems are operating correctly or not
tions of the loader through sensors and switches in-
(alarm indicators) and signalling indicators.
stalled on the machine and provides information to
the instrument board located in the operator's com-
partment indicating the current operational conditions
of the loader.
6 2 16 4 11
7
12
8
13
9
14
10
15
3 1 3
W110R0356
Dashboard
1. Tachometer - 2. Coolant temperature gauge - 3. Fuel level indicator - 4. Transmission oil temperature gauge - 5.
Hourmeter - 6. Coolant temperature indicator light - 7. Engine oil low pressure indicator light - 8. Alternator indicator light
- 9. Air cleaner clogging indicator light - 10. Fuel reserve indicator light - 11. Transmission oil temperature indicator light -
12. Brake oil low pressure indicator light - 13. Emergency steering indicator light - 14. Parking brake engaged indicator
light - 15. General alarm indicator light (+ buzzer) - 16. Speed engaged indicator lights.
CN2
CN3 CN1
W110R0032
Connection CN1
1. Indicator light, accumulator oil pressure low pressure - 2. Indicator light, engine coolant - 3. Coolant temperature
indicator - 4. Instrument panel light - 5. Left turning light indicator light - 6. Instrument panel light - 7. High beam indicator
light - 8. Instrument panel light - 9. Ground - 10. Fuel level - 11. Indicator light, parking brake - 12. Indicator light, battery
failure - 13. Indicator light, fuel reserve - 14. Not connected - 15. Instrument panel light - 16. Right turning light indicator light
- 17. Tachometer - 18. Buzzer - 19. General signal - 20. Instrument panel lights.
Connection CN2
21. Indicator light, transmission oil temperature - 22. Indicator light, air cleaner clogging - 23. Indicator light, emergency
steering - 24. Batteries - 25. Indicator light, engine oil pressure - 26. Indicator light, transmission high oil temperature.
Connection CN3
27. Hourmeter (ground) - 28. Hourmeter (battery).
On-board instrumentation
2 3 4 5
6 7 8
9 10 11
W110R0033
Digital monitor
1. Multi-function digital display - 2. Button P0 (Set-up) - 3.

Button P1 (Home/Service) - 4. Button P2 (Selection/Entry)
- 5. Button p3 (Menu).
Switch panel
6. Rotary beacon switch (optional) - 7. Rear washer switch

- 8. Rear wiper switch - 9. Rear work lights switch - 10.
Front work lights switch - 11. Main light switch.
7.3.3 SWITCH PANEL
3 4 5 6
2
8
10 9
7
W110R0349
Right side console
1. Starter switch - 2. Cigarette lighter - 3. LTS control switch - 4. Switch, transmission cut-off selection - 5. Switch, transmis-
sion aut/man selection - 6. Switch, boom kick-out engagement - 7. Indicator light, engine pre-post heater - 8. Switch, fan
rotation reverser - 9. Reverser safety auxiliary switch button, optional - 10. Inhibiting valves cut-off switch, optional.
7.3.4 AUTOMATIC TRANSMISSION

Gearshift selector (ZF DW3)
X7
X6
W110R0035
X6 Transmission pilot valve
A. Not connected - B. Signal 3rd and 4th speed -

C. Signal 1st and 4th speed - D. Horn.
X7 Transmission pilot valve
A. Pilot valve power - B. Forward speed signal -

C. Reverse signal - D. Signal in neutral position.
Transmission gearshift pilot valve
BLACK
GREEN
To controller EST 37 Signal 3rd and 4th gear
BLUE
To controller EST 37 Signal 1st and 4th gear
VIOLET
To horn relay (K6)
RED
Power
YELLOW
To controller EST 37 Signal forward gear
PINK
To controller EST 37 Signal reverse
GREY
To controller EST 37 Signal in neutral
W110R0340
Auxiliary reverser controls To select the auxiliary F/R function:

(with joystick version hydraulic pilot valve)
Start the engine.
Hold the transmission pilot valve in neutral posi-
tion.
1 Keep buttons 2 (KD) and 3 (N) pressed simultane-
3 ously.
Under these conditions, activate button 1 toward F
F R or R.
The machine starts moving in the direction selected.
2 To reverse the travel direction, actuate button 1. The
function is neutralised by pressing button 3 (N) or by
actuating again the gearshift pilot valve on the steer-
ing column. To re-select the function, repeat the de-
scription above.
W110R0036
1. Sliding button forward (F) - reverse (R) - 2. Kick-down

button - 3. Return to neutral button.
BROWN
GREY
WHITE
YELLOW
BLUE
GREEN
AUX. REVERSER CONTROL (JOYSTICK) X11 W110R0341
CONNECTION X11
SOCKET ROUTING WIRE NO.
1 Signal, forward ZF20
2 Signal, in neutral position ZF44
3 Signal, reverse ZF31
4 Power (from fuse F8C-key ON) ZF45
5 Signal, kick-down ZF22
6 Signal, monitoring and selection ZF30
Auxiliary reverser controls

(with 2/3 lever hydraulic pilot valve)
3 1
W110R0037
2
1. 3-position switch for auxiliary reverser control - 2. Aux-

iliary reverser function selection button - 3. Kick-down
W110R0038
button.
To select the auxiliary F/R

KICK-DOWN BUTTON function:
Start the engine.
Keep the pilot valve in neutral posi-
KICK-DOWN signal
tion.
Actuate button 2 (auxiliary reverser
Arrangement for
joystick version function selection).
Select the travel direction by actu-
ating control switch 1 (auxiliary re-
verser control).
AUX.REV. CONTROL (MULTI-LEVER)
The machine starts moving in the di-
Reverse signal rection selected. To reverse the travel
direction actuate switch 1. The func-
Signal in neutral position
Signal in forward travel tion is deactivated byJ actuating again
the transmission pilot valve on the
steering column. To re-select the func-
tion repeat the procedure described.
AUX SEL.REV. (Ground bridge with centr. lube switch)
(Ground bridge with centr. lube switch)
(Ground bridge with seat. heat switch)
(Ground bridge with seat. lube switch)
Monitoring and selection control
+24V from fuse F8C

W110R0342
Parking brake controls
ON OFF
W110R0039 W110R0040
CAB GROUND CONN. GND FCAB
FROM FUSE F8B (Key ON)
FROM FUSE F3B (Key ACC)
PARKING
BRAKE
CONTROL Grounding bridge with
SWITCH emergency lights switch
PARKING
REAR FRAME GROUND CONN. GND
BRAKE
SOLENOID
VALVE COIL
W110R0343
NOTES:
7.4 COMPONENTS ON MACHINE
7.4.1 RELAY AND FUSE BOX IN ENGINE COMPARTMENT
4 2 Rear view
13
12
3
10 9 8 7 6 5
Front view
W110R0042
11
3
4
2 1
W110R0041 W110R0043
Relays
1. Starter relay - 2. Relay, conditioner compressor engagement (optional) - 3. Relay, back-up alarm and light - 4. Diode
holder module.
Fuses - Group E
5. Fuse EF1 (5Amp) Stop lights - 6. Fuse EF2 (3Amp) Fuel filters pre-heating (optional) - 7. Fuse EF3 (7.5 Amp) Back-up
alarm relay input contact - 8. Fuse EF4 (3Amp) Not connected (reserve) - 9. Fuse EF5 (3Amp) 15 Alternator - 10. Fuse EF6
(7.5 Amp) Engine cut-off solenoid valve coil.
Other components
11. Fuse link 50 Amp - 12. Block B+ (power to box in battery compartment conn-TB6) - 13. Block B+ (distribution +24V
on cab fuse board and services relay 90 Amp).
7.4.2 FRONT FRAME RELAY BOX
1
2
W110R0046
W110R0044
W110R0045
Relays
1. LTS engagement relay (speed > 7 kmph forward and
> 5 kmph in reverse - 2. Emergency steering pump elec-
tric motor engagement relay
Connections
3. LTSF connection - 4. LTS solenoid valves and steering
system LS line cut-off solenoid valve ground.
7.4.3 EMERGENCY STEERING
W110/W110TC
1 5
CN2 CN1
GROUND AP Signal
RELAY COIL
2
ELECTRICAL SYSTEM
1. Emergency steering pump electric motor - 2. Steering circuit low
pressure pressure switch (diverter pressure: 2.4 bar) - 3. LS steer-
ing line cut-off solenoid valve coil - 4. Emergency steering system
engagement relay - 5. Brown Box controller.
KEY "ON" W110R0047
7 - 29
7.4.4 LOAD SENSING SYSTEM (LTS)
2 1st STEP 2nd STEP
= 0 Km/h
5 3
>7 Km/h
>7 Km/h
Signal LTS ON on
digital monitor
W110R0048
1. 3-position switch LTS engagement control - 2. LTS engagement relay (front frame speed > 7 kmph) - 3. LTS solenoid
valve coil - 4. LTS engagement relay (K2 in cab speed = 0 kmph) - 5. ZF EST37 transmission controller - 6. Brown Box
controller.
7.4.5 TRANSMISSION COMPONENTS
1 2 3
W110R0049
3
2 5
W110R0052
W110R0050
1. Swing motor speed sensor - 2. Intermediate gear speed

sensor - 3. Torque converter turbine speed sensor -
4. Output shaft speed sensor (vehicle speed) - 5. Trans-
mission oil filter clogging signal differential pressure
5 switch.
Note Sensors 1,2,3 are equal and interchangeable.

They are sensors of an inductive type, which output
signal is provided by a variable voltage as a function
of the rotating speed measured. Sensor no. 4 is a Hall
4 effect type, i. e. it provides a constant voltage output
signal, but of a variable frequency.
W110R0051
W110R0053 W110R0055
1. Connection X12 (transmission connecting harness

control valve harness) - 2. Solenoid valves Y1, Y2, Y3, Y4,
Y5, Y6 proportional solenoids - 3. Transmission oil tem-
perature sensor (in the control valve) - 4. Torque con-
verter output oil temperature sensor.
W110R0054
7.4.6 BRAKE SYSTEM COMPONENTS
3
1
W110R0056
1. Accumulator low pressure pressure

switch (Normally closed - open at 115 5
bar) - 2. Transmission cut-off pressure switch
(Normally open - closed at 25 1 bar) -
3. Stop lights pressure switch (Normally
open - closed at 1.8 0.5 bar) - 4. Parking
brake solenoid valve coil (Off = brake en-
gaged /On = brake disengaged) - 5. Park-
ing brake pressure switch (Normally closed
- open at 82 2 bar).
W110R0057
7.4.7 HYDRAULIC SYSTEM COMPONENTS
W110R0058
1. Lowering float engagement pressure

switch (Normally open closed at 19 bar).
It measures the pressure on the boom low-
ering piloting circuit) - 2. Float engage-
ment solenoid valve coil. Powered by pres-
sure switch 1 under closed condition -
3. Fan reverser solenoid valve coil Pow-
ered by button in cab. With solenoid ON
the fan reverses rotation direction.
W110R0059
7.4.8 ENGINE COMPONENTS (STANDARD)
1
5
2
3
4
7 9
8
10
W110R0060
1. Alternator - 2. Connection B+ alternator (battery charge) - 3. Connection ALT alternator - 4. Starter motor - 5. Connection
CSM starter motor (pickup power by starter relay) - 6. Block B+ starter motor (power from batteries) - 7. Coolant
temperature sensor - 8. Engine oil low pressure pressure switch (normally closed - open at 0.7 bar) - 9. Engine cut-off
solenoid valve coil - 10. Air cleaner clogging pressure switch (normally open - closed at 62 bar).
NOTES:
7.5 FUNCTIONS OF DIGITAL DISPLAY

(DISPLAY OF OUTPUT SIGNALS FROM BROWN BOX)
7.5.1 DESCRIPTION OF HOME PAGE

(DEFAULT PAGE)
After the initial check subsequent to the switching-on
of the machine, the digital monitor in the cab shows
the initial default page shown on the right.
1 2
1. Current date
It is set-up by entering the menu SET through
button 10.
2. Current hour
It is set-up by entering the menu SET through 3 6
button 10.
3. LTS indicator engaged
It is shown when the system is activated by the 4 7
operator through the appropriate switch.
4. Transmission cut-off engaged indicator
It shows when the function is selected by the op-
erator through the appropriate switch.
5. Transmission use mode indicator (aut./man.) 5 8
It shows when the automatic mode is selected by
the appropriate switch.
6. Parameter visible on the initial page
In the setting-up at 1 parameter the engine rpm is
always shown. 9
7. Value of the parameter shown
8. Unit of measure of the parameter shown 10 11 12
W110R0061
9. Button P0 (machine configuration)
To be used simultaneously with button 11 to per-
form the initial set-up of the machine.
10. Button P1 entering the SERVICE menu
To be used to perform the efficiency tests on the
parking brake and emergency steering and the
calibration of the clutch packs of the transmis-
sion.
11. Button P2 entering the SET menu
Used individually to enter the setting utilities proper
to the monitor.
12. Button P3 entering the MACHINE menu
It provides the entry to the under menus readings
for the parameters relative to engine, transmis-
sion, brakke systema nd electrical system.
7.5.2 PARKING BRAKE EFFICIENCY TEST 7 - 38
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, 3RD GEAR FORWARD OR REVERSE ENGAGED, TRANSMISSION IN
MANUAL MODE, TRANSMISSION CUT-OFF DISENGAGED.
ELECTRICAL SYSTEM
W110R0062
1. From the initial page enter the 2. The SERVICE PAGE is normally 3. Confirm the selection through but-
SERVICE menu through button set on CLUTCH CALIBRATION ton P3.
P1. (clutch calibration). Select TEST
W110/W110TC
through button P2.

W110/W110TC
ELECTRICAL SYSTEM
W110R0063
4. The display TEST is already set 5. The system asks the operator to 6. The test is started. the system per-
on PARKING BRAKE TEST. if confirm the start of the test. Con- forms automatically an engage-
not, select the option by using the firm through button P3. ment and disengagement manoeu-
central button, then confirm the vre of the parking brake, deacti-
selection through button P3. vating, when the brake is en-
gaged, the transmission cut-off.
during the test, verify that the
machine does not move. Wait for
7 - 39
the complete execution of the test.

7 - 40
ELECTRICAL SYSTEM
W110R0064
7. Once the test is completed, the 8. The display positions itself auto- 9. The monitor is positioned again on
operator is warned by the display matically in the tests selection the home page.
W110/W110TC
indicated in the figure. mode. Press button P1 to exit.

7.5.3 EMERGENCY STEERING SYSTEM EFFICIENCY TEST
Test conditions: ENGINE INOPERATIVE AND STARTER SWITCH IN POSITION ON (2ND STEP)
W110/W110TC
ELECTRICAL SYSTEM
W110R0065
1. From the home page enter the 2. The SERVICE PAGE is normally 3. Confirm the selection through but-
menu SERVICE through button set on CLUTCH CALIBRATION. ton p3.
7 - 41
P1. Select TEST through button P2.

7 - 42
ELECTRICAL SYSTEM
W110R0066
4. The display TEST is set on 5. The system asks the operator to 6. The test is started. the system ac-
PARKING BRAKE TSET. Select confirm the start of the test. Con- tivates automatically for 20 sec.s
option SEC STEERING TEST firm through button P3. the electric motor driving the emer-
through button P2, then confirm the gency steering pump. During this
selection through button P3. interval actuate the steering wheel
in the two directions to check that
the machine is operating the steer-
W110/W110TC
ing with engine inoperative.

W110/W110TC
ELECTRICAL SYSTEM
W110R0067
7. Once the test is completed, the 8. The display is automatically posi- 9. The monitor is positioned again on
operator is informed by the display tioned on test selection. Press the home page.
7 - 43
indicated in the figure. button P1 to exit.

7.5.4 CALIBRATION OF TRANSMISSION GEARSHIFTS 7 - 44
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, GEARSHIFT IN NEUTRAL, TRANSMISSION IN MANUAL MODE,
TRANSMISSION CUT-OFF DISENGAGED, TRANMSISSION OIL TEMPERATURE AT 80 C (176 F), ENGINE SPEED AT LOW IDLE.
ELECTRICAL SYSTEM
W110R0068
1. From the home page enter the 2. The SERVICE PAGE is normally 3. The system ask for the confirma-
menu SERVICE through button set on CLUTCH CALIBRATION. tion to start the calibration. Con-
P1. Confirm the selection through but- firm through button P3.
W110/W110TC
ton P3.
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, GEARSHIFT IN NEUTRAL,

TRANSMISSION IN MANUAL MODE, TRANSMISSION CUT-OFF DISENGAGED, TRANMSISSION OIL
TEMPERATURE AT 80 C (176 F), ENGINE SPEED AT LOW IDLE.
4. At this stage the system, after verifying that the

test conditions of the machine are complied with,
starts automatically the procedure on all the 6
clutch packs of the transmission in the following
sequence.
K1 for the engagement of 1st speed;
K2 for the engagement of 2nd speed;
K3 for the engagement of 3rd speed;
K4 for the engagement of 4th speed;
KV for the engagement of forward direction;
KR for the engagement of reverse direction.
For each engagement the calibration phases are moni-

tored on a horizontal filling bar located in the lower
side of the monitor.
The system moves forward automatically at the sub-
sequent engagement after finding the optimised modu-
lation on the current engagement.
if the system finds a trouble on a determined engage-
ment, the calibration is suspended and the monitor
indicates the clutch on which the procedure has been
interrupted.
On the other hand, if the system is able to calibrate
without any problem all 6 engagements, the message
W110R0069
CALIBRATION COMPLETED is shown. At this stage
it is necessary TO CUT-OFF THE ENGINE for about
10 seconds.
Thus, the procedure is completed.
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, GEARSHIFT IN NEUTRAL,

TRANSMISSION IN MANUAL MODE, TRANSMISSION CUT-OFF DISENGAGED, TRANMSISSION OIL
TEMPERATURE AT 80 C (176 F), ENGINE SPEED AT LOW IDLE.
5. In the event even just one of the test conditions is

not complied with, the procedure does not start and
the system displays the reason for the failed start-
ing. Under these conditions, it is necessary to
exit the program through button P1 and to cut-
off the engine. Then, reinstate the test conditions
and restart the procedure.
In the example in the figure, the system warns the
operator that the oil temperature is too low (< 80 C
176 F).
Other fault messages could appear depending upon
which one of the conditions is not complied with:
Oil temperature too high
(temperature oil too high)
Engine speed too low
(engine speed too low)
Engine speed too high
(engine speed too high)
Output speed is not 0
(the machine is moving)
Parking brake not engaged
(the parking brake is not engaged)
Gearshift lever not in neutral
(the selector is not in neutral)
W110R0070
7.5.5 DISPLAY OF TRANSMISSION FAULT CODES

In the event, during the operation of the machine, the
transmission controller should monitor a malfunction,
the fault messages are transferred through line CAN
Bus from ZF EST37 controller to the Brown Box con-
troller, that transforms them into output digital signals
the monitor, that shows the numerical code corre-
sponding to the ZF coding (See list of fault codes in
the chapter Transmission).
If the machine stops (while the engine is still in opera-
tion) it means that the failure generated is such that
the transmission is set into recovery mode (Op mode:
Limp-Home). Under this condition it is necessary to
move the gearshift selector into neutral, then re-shift
into forward or reverse. The speed gearshifting is in-
hibited and the machine would travel, generally, in 2nd
gear only. Also the direction reversing is inhibited. To
reverse direction it is necessary to stop, then reverse
the travel direction.
In the event the malfunction is not particularly seri-
ous, the machine continues to perform normally (Op
Mode: NORMAL).
A medium level malfunction would result, when work-
ing in automatic mode, abnormal gearshifting, not cor-
responding to the load conditions of the machine (Op
Mode: SUBSTITUTION) although it maintains all the
gears available when working in manual mode.
A malfunction due to the transmission controller sets
W110R0071
the system under the condition where the machine
cannot move unless it is towed (Op Mode: TCU SHUT-
DOWN).
CODE DESCRIPTION OPERATING MODE

11 Logical error at direction range signal t/m shutdown
12 Logical error at direction signal t/m shutdown
15 Logical error at direction signal; auxiliary selector selector active
31 Short circuit or open circuit at engine speed input subs clutch ctrl
32 Short circuit to ground at engine speed input subs clutch ctrl
33 Logical error at engine speed input subs clutch ctrl
34 Short circuit or open circuit at turbine speed input subs clutch ctrl
35 Short circuit to ground at turbine speed input subs clutch ctrl
36 Logical error at turbine speed input subs clutch ctrl
37 Short circuit or open circuit at internal speed input subs clutch ctrl
38 Short circuit to ground at internal speed input subs clutch ctrl
39 Logical error at internal speed input subs clutch ctrl
3A Short circuit or open circuit at output speed input subs clutch ctrl
3B Short circuit to ground at output speed input subs clutch ctrl
3C Logical error at output speed input subs clutch ctrl
3E Logical error between speed input subs clutch ctrl
71 Short circuit to at clutch K1 limp home
72 Short circuit to ground at clutch K1 limp home
73 Open circuit at clutch K1 limp home
84 Short circuit to at clutch KV limp home
85 Short circuit to ground at clutch KV limp home
86 Open circuit at clutch KV limp home
87 Short circuit to at clutch KR limp home
88 Short circuit to ground at clutch KR limp home
89 Open circuit at clutch KR limp home
B1 Slippage at K1 limp home
B5 Slippage at KV limp home
B6 Slippage at KR limp home
D3 Low voltage at battery TCU shutdown
D4 High voltage at battery TCU shutdown
D5 Error at valve power supply VPS1 TCU shutdown
D6 Error at valve power supply VPS2 TCU shutdown
F3 Application error TCU shutdown
F5 Clutch failure TCU shutdown
F6 Execute AEB (Calibration clutch) NORMAL
7.5.6 INITIAL SET-UP OF THE BROWN BOX CONTROLLER
1. Prior to proceeding with the initial setting-up of the con-

troller, disconnect connection XA from the 3-way joint CAN-
SPL (cab rear panel) to cut-off the CAN bus line, then turn
the starter key onto ON (second step).
W110R0072
2. From the initial page, enter the menu SET-UP press- 3. Keep buttons P0 and P2 pressed until the monitor
ing buttons P0 and P2 simultaneously. displays the picture illustrated above (about 3
sec.s).
In the event the Brown Box controller is replaced, it is necessary to perform the setting-up procedure to provide
the controller with the following information:
MODEL ON WHICH THE CONTROLLER IS GOING TO BE INSTALLED
This information is required to choose the set of parameters to be used by the transmission controller (the ZF
controller contains 3 sets of parameters relative to models W110, W130 and W170).
CONFIGURATION OF HYDRAULIC CONTROLS
This information identifies whether the model is equipped with the 2/3 lever optional or the joystick control. This
identification is important, since the function of the hydraulic control type changes the operational logic of the
auxiliary direction control (FNR by a switch instead of the gearshift selector).
7 - 50
W110R0073
ELECTRICAL SYSTEM
4. After a few seconds, selection 5. After the confirmation of the pre- 6. Select the type of hydraulic con-
page Brand is displayed, after ceding step, the model choice trol installed on the machine with
performing the procedure, during page is entered. Select the model button P2, then confirm the selec-
the initial check when the machine with button P2 (pressing n times tion with button P3. Warning: this
is turned ON. Select FK with but- until the desired model is dis- selection is important, since it
ton P2, then confirm with button played) then confirm the selection defines the operation logic of the
W110/W110TC
P3. with button P3. FNR auxiliary control.

STAR
ON T
C
W110/W110TC
AC
OFF
9. Cut-off the starter switch

ELECTRICAL SYSTEM
7. The setting up on the monitor is 8. The monitor returns to home page.

now over. Exit the program by se-
lecting exit set-up with button p2
and confirm the selection with but-
ton P3.
10. Reconnect line CAN rein-sert-
END OF PROCEDURE ing connector XA into joint
CAN_SPL.
7 - 51
W110R0074
7.5.7 READING OF THE ENGINE OPERATION PARAMETERS 7 - 52
W110R0075
ELECTRICAL SYSTEM
1. From the home page, enter menu 2. Select the under menu TRANS- 3. The display shows in sequence:
MACHINE through button P3. MISSION with button P2 to enter
- Oil temperature
the reading of the operation param-
Value in C
eters of the transmission, then
- Trasm, cut-off selection
confirm the selection with button
OFF or ON
P3.
- Automatic mode select.
OFF or ON
- Gear engaged
1, 2, 3 or 4
- Vehicle travel speed
Value in km/h
To return to home page, press button
P1 (HOME). To return to the previous
W110/W110TC
menu, press button P3 (MACHINE).

7.5.8 READING OF THE TRANSMISSION OPERATION PARAMETERS
W110/W110TC
W110R0076
ELECTRICAL SYSTEM
1. From the home page, enter menu 2. Select the under menu TRANS- 3. The display shows in sequence:
MACHINE through button P3. MISSION with button P2 to enter
- Oil temperature
the reading of the operation param-
Value in C
eters of the transmission, then
- Trasm, cut-off selection
confirm the selection with button
OFF or ON
P3.
- Automatic mode select.
OFF or ON
- Gear engaged
1, 2, 3 or 4
- Vehicle travel speed
Value in km/h
7 - 53

7.5.9 READING OF THE BRAKE SYSTEM OPERATION PARAMETERS 7 - 54
W110R0077
ELECTRICAL SYSTEM
1. From the home page, enter menu 2. Select the under menu BRAKES 3. The display shows in sequence:
MACHINE through button P3. with button P2 to enter the read-
- State of parking brake
ing of the operation parameters of
OFF or ON
the transmission, then confirm the
- State of accumul. press.
selection with button P3.
OK or LOW
W110/W110TC
7.5.10 READING OF THE ELECTRICAL SYSTEM OPERATION PARAMETERS
W110/W110TC
W110R0078
ELECTRICAL SYSTEM
1. From the home page, enter menu 2. Select the under menu ELECTRIC 3. The display shows in sequence:
MACHINE through button P3. with button P2 to enter the read-
- Alternator output voltage;
ing of the operation parameters of
- Voltage of batteries prior to start-
the transmission, then confirm the
ing
selection with button P3.
- Charge condition of batteries (OK
or LOW)
7 - 55

NOTES:
ELECTRICAL SYSTEM FOLDING DIAGRAMS
FUSE LINK 50 Amp
BOX B+
Connection XD
Cab
To Mega fuse 150 Amp Starter switch
Connection X23
BOX B+
Engine
To fuse Link 20/30 Amp
compartment
To starter motor
(3 A) Brown Box
(7.5 A) Cab Ceiling Light
(7.5 A) +B Emergency lights
(7.5 A) Horn relay
(7.5 A) +B Main light switch
BATTERIES
(7.5 A) Cigarette lighter
(7.5 A) Transmission ZF EST37 Controller power

BATTERY
MASTER (3 A) +30 Diagnostic connection
SWITCH (3 A) Not connected
(10 A) Low beam relay
(10 A) High beam relay

MASTER Rear Frame
SWITCH
Cab fuse board
GND STUD
W110R0079
POWER SUPPLY FROM STARTER SWITCH (ACC)
Connection X13 Connection S16
From fuse F11B
90 Amp SERVICES RELAY

Connection X34
Starter switch
(10 A) Front work lights

CAB GROUND
BOX B+
Cab
(10 A) Rear work lights
BOTTOM
GND
STUD
(5 A) LTS solenoid valve solenoid
(5 A) Bucket rollback lever detent solenoid

(5 A) Boom and bucket levelling proximity sensors GND
(5 A) Float position lever detent solenoid
(5 A) Flasher unit JUMPER
STUD
(7.5 A) Front wiper motor

To frame ground GND_RC
(7.5 A) Light diverter switch

From connection X23F (Direct power supply from batteries - see Fig. 1)
(7.5 A) Turning light control
(7.5 A) Automatic loading control

(7.5 A) Climate conditioner control
(5 A) Rear wiper motor
(5 A) Dashboard light switch

Connection GND_RCAB
(5 A) Main light switch
(7.5 A) Power partitioner
(5 A) Seat heater
(7.5 A) Rotary beacon
(7.5 A) Not connected
(15 A) +ACC engine compartment relay box
(15 A) Cab climate conditioner

W110R0080
Cab fuse board
POWER SUPPLY FROM STARTER SWITCH (ON)
From fuse F11B (Page 1)
(battery charge and hour meter signal)

To relay services 90 Amp
Starter switch
To Brown Box controller

(5 A) Parking brake solenoid valve solenoid
Connection X22
SOLENOID VALVE FUEL SUPPLY
Not connected
(5 A) Seat adjusting compressed air
(7.5 A) Back-up alarm relay coil positive

(7.5 A) +24 Volt Transmission output speed sensor
(7.5 A) Aut/man, transm. cut-off & FNR switches
(7.5 A) Transmission ZF EST37 controller under key power supply ALT
(7.5 A) Display and transmission diagnostic socket power supply
(7.5 A) Transmission gearshift pilot valve
(7.5 A) Parking brake relay (coil and contact positive)
(5 A) Buzzer
(5 A) On-board instrumentation
(5 A) Digital monitor ALTERNATOR
Connection XD
(7.5 A) Not connected
To batteries through
connection CN2
on block B+
(5 A) Brown box under key power supply starter motor
(3 A) Not connected Stop lights
Fuel pre-heating
relay (opt) DIODES MODULE (BOX IN ENGINE COMPARTMENT)
CAB FUSE BOARD
Back-up alarm
relay cont.
Not connected
BLOCK B+ (BOX IN ENGINE COMPARTMENT)
FUSE BOX E GROUP (BOX IN ENGINE COMPARTMENT)
W110R0081
From batteries (page 1)
STARTING (STANDARD)
Connection XD
Connection X13
Connection S16
To services relay 90 Amp (page 2)
To connectionXF5 cab fuse board (Page 3)

Connection X22
STARTING SAFETY RELAY IN NEUTRAL STARTER RELAY
Cab ground connection

Connection X33 GND_RCAB
DIODES MODULE
PARKING BRAKE RELAY

BOX B + (ENGINE COMPARTMENT)
Machine frame ground

connection GND_F
PARKING BRAKE PRESSURE SWITCH
Connection X34 N.C. - Opening at 82 2 bar
Connection X16
Connection X22
BLACK
GREEN BATTERIES
To transmission controller
BLUE
VIOLET
To horn relay
RED
YELLOW To transmission controller
PINK
GREY
TRANSMISSION GEARSHIFT From battery main switch (Page 1)

PILOT VALVE
From fuse F8C (Page 3)
Power supply with key in ON
Connection X15 W110R0082
COLD STARTING (OPTIONAL)
(Battery charge and hour meter indicator light)

To connectionXF5 cab fuse board (Page 3)
Starter switch
STARTING SAFETY RELAY IN NEUTRAL
To Brown Box controller

To starting relay (Page 4) PRE-POST HEATING INDICATOR LIGHT
(R.h. operator compartment console)
Cab Ground conn. GND_SCF

Connection X33
Connection X12
PRE-POST HEATING CONTROLLER

PRE-POST HEATING INDICATOR
NOT CONNECTED
FEEDBACK GRILL ON
ALTERNATOR SIGNAL
STARTER SIGNAL
SIGNAL GRILL ON
POWER SUPPLY From fuse F7A (Key ON) (Page 3)
GROUND
NOT CONNECTED Cab ground conn. GND_RCAB
TEMPERATURE SENSOR SIGNAL
MEGA fuse 150 Amp
Connection XE Connection X23
ENGINE AIR
COLD STARTING RELAY TEMPERATURE
SENDER
Machine Frame Ground conn. GND_FH
INTAKE MANIFOLD
PRE-HEATING GRILL ALTERNATOR
From batteries (Page 1) 100 A 8% A 22 V
BOX B+ ENGINE
COMPARTMENT
Ground on engine block
W110R0083
FUEL FILTER PRE-HEATING (OPTIONAL)
To starting safety relay in neutral (Page 4) Starter switch
BOX B+ ENGINE COMPARTMENT
FUSE GROUP F (INSIDE CAB)

To batteries (Page 1)
Ground engine air temperature sender (Page 5)

Connection X13
Ground cold starting relay coil (Page 5)

FUSE LINK
FUEL FILTER
NO. 1 HEATER RESISTANCE
500W at 24 Volt
FUEL FILTERS
PRE-HEATING RELAY
FUEL FILTER
NO. 2 HEATER RESISTANCE
500W at 24 Volt (W130 only)
Connection XD
FUEL TEMPERATURE SENDER

Stop lights closed: -3 3 C
open: +5 3 C
Back-up alarm relay cont.
Not connected
Frame ground
Alternator (+15)
Connection GND_FH
Engine cut-off solenoid W110R0084
FUSE GROUP E (BOX IN ENGINE COMPARTMENT)
AUTOMATIC TRANSMISSION (PART ONE)
TRANSMISSION GEARSHIFT PILOT VALVE

X6 - TRANSMISSION PILOT VALVE
BLACK
NOT CONNECTED
GREEN
SIGNAL 3RD AND 4TH GEAR
BLUE
SIGNAL 1ST AND 4TH GEAR VIOLET
HORN To horn relay
RED
X7 - TRANSMISSION PILOT VALVE
YELLOW
PILOT VALVE POWER SUPPLY
PINK
FORWARD SIGNAL
GREY
REVERSE SIGNAL
NEUTRAL POSITION SIGNAL To starting safety relay in neutral (Page 4)
65 SIGNAL 3RD AND 4TH GEAR

63 SIGNAL 1ST AND 4TH GEAR
43 FORWARD SIGNAL
64 REVERSE SIGNAL
TRANSMISSION CONTROL VALVE 67 NEUTRAL SIGNAL
FORWARD REVERSE NEUTRAL
CLUTCHES
X12 - TRANSMISSION CONTROL VALVE
SOLENOID PROPORT. VALVE Y1 56 SOLENOID PROPORT. VALVE Y1
+24 V SOLENOIDS (KEY ON) 12 +24 V SOLENOIDS (KEY ON)
CON. VALVE TEMP. SENSOR SIGN. 13 + 24 V SOLENOIDS (KEY ON)
RETURN CON. VALVE TEMP. SENS. 39 SIGNAL CONTROL VALVE TEMP. SENSOR
46 RETURN CONTROL VALVE TEMPERATURE SENSOR
INDUCTIVE SENSOR
TRANSMISSION CONTROLLER ZF EST37

19 SIGNAL ENGINE SPEED SENSOR
ENGINE REVOLUTION SPEED 03 GROUND INDUCTIVE SPEED SENSORS
41 SIGNAL TURBINE SPEED SENSOR
INDUCTIVE SENSOR
42 SENSOR INTERMEDIATE SPEED SENSOR
REVOLUTION SPEED
TORQUE CONVERTER TURBINE
4 GROUND OUTPUT SPEED SENSOR
62 SIGNAL OUTPUT SPEED SENSOR
INDUCTIVE SENSOR
REVOLUTION SPEED
IDLE GEAR 49 SIGNAL CONVERTER TEMP. SENSOR
SENSOR (HALL EFFECT) 17 SIGNAL FILTER CLOGGING SENSOR

REVOLUTION SPEED
OUTPUT SHAFT
05 L.T.S.
07 GROUND BACK-UP ALARM RELAY COIL GROUND
TEMPERATURE SENSOR 14 DISPLAY CONNECTION
Back-up alarm relay coil positive
See page 7B (Part two)

TORQUE CONVERTER OUTPUT OIL 15 SIGNAL DIAGNOSTIC SOCKET
16 SIGNAL DIAGNOSTIC SOCKET
Aut/Man, Transm. cut-off & FNR switches 20 SIGNAL FORWARD FROM AUX REVERSER
21 SIGNAL FROM PARKING BRAKE
Display and diagnostic supply socket 22 SIGNAL KICK-DOWN
CLOGGING SENSOR 25 CAN BUS (H)
OIL FILTER Parking brake relay 26 CAN BUS (L)
27 CAN BUS (L)
29 SIGNAL AUT/MAN SELECTION
30 SIGNAL AUX REVERSER SELECTION
31 SIGNAL REVERSE FROM AUX REVERSER
FROM STARTER SWITCH - KEY ON 44 SIGNA NEUTRAL FROM AUX REVERSER
66 SIGNAL TRANSMISSION CUT-OFF
68 SUPPLY (FROM BATTERIES)
23 SUPPLY (FROM BATTERIES)
45 POWER SUPPLY (KEY ON)
FROM BATTERIES (DIVERS. B+ INSIDE CAB) 2 GROUND CONTROLLER EST37
1 GROUND CONTROLLER EST37
W110R0085
Cab ground - Connection GND_RCAB
See page 7B (Part two) Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
AUTOMATIC TRANSMISSION (PART TWO)
SIGNAL REVERSE FROM AUX REVERSER (REVERSE)

SIGNAL NEUTRAL FROM AUX REVERSER (NEUTRAL)
TRANSMISSION CONTROLLER
SIGNAL FORW. FROM AUX REVERSER (FORWARD)
SIGNAL KICK-DOWN (KICK-DOWN)
SIGNAL AUT/MAN SELECTION
SIGNAL FROM PARK. BRAKE RELAY
GROUND BACK-UP ALARM RELAY COIL (AUT-MAN SEL)
ZF EST37
SIGNAL TRANSMISSION CUT-OFF
SIGNAL AUX REVERSER SELECTION
KICK-DOWN
L.T.S.
DISPLAY CONNECTION BUTTON
DISPLAY CONNECTION BROWN
SIGNAL DIAGNOSTIC SOCKET
SIGNAL DIAGNOSTIC SOCKET
CAN BUS (H) GREY
CAN BUS (L)
CAN BUS (L)
To connection CAN_SPL
(Triple connection - cab rear)
DIAGNOSTIC CONNECTION
YELLOW
BLUE
From relay LTS (cab ground)
GREEN
KEY ON
Output speed sensor supply AUX. REVER.CONTROL
ZF controller supply (JOYSTICK)
(Bridge to ground with seat heater)

Transm. pilot valve supply AUX. REVER.CONTROL (MULTI LEVER)
Cab ground connect. GND_RCAB

AUX. REVER. SEL. (Bridge to ground with centr. lub. switch)
PARKING BRAKE (Bridge to ground with sed. heat. switch)
PRESSURE SWITCH (Bridge positive with se. heat. switch)
(Bridge positive with centr. lub. switch)
(n.c. open at 82 2 bar)
PARKING BRAKE REALY

(Board inside cab)
From parking brake indicator light (dashboard)
From starter safety in neutral relay coil
(Bridge to ground with cut-off switch)

SIGNAL 3RD AND 4TH GEAR From batteries (diver. B+ engine compartment conn. t3b
SIGNAL 3 RD AND 4TH GEAR To fuse E (engine comp. box)
SIGNAL FORWARD (Bridge positive cut-off switch)
SIGNAL REVERSE
TRANSMISSION CONTROLLER ZF EST37
SIGNAL NEUTRAL
SOLENOID PROPORT. VALVE Y1
Se Page 7A (Part one)

+ 24 V SOLENOIDS (KEY ON)
+ 24 V SOLENOIDS (KEY ON) TRANSM. CUT-OFF (Bridge to ground with fan rev. switch)
SIGNAL CONTR. VALVE TEMP. SENSOR
RETURN CONTR. VALVE TEMP. SENSOR TRANSMISSION CUT-OFF
SIGNAL ENGINE SPEED SENSOR PRESSURE SWITCH (Bridge positive with fan rev. switch)
GROUND INDUCTIVE SPEED SENSORS
(n.a. closed at 25 1 bar) (Cab Ground conn. GND_SCF)
SIGNAL TURBINE SPEED SENSOR
SIGNAL INTERM. SPEED SENSOR
GROUND OUTPUT SPEED SENSOR
SIGNAL OUTPUT SPEED SENSOR
SIGNAL TORQUE CONV. TEMP. SENSOR
SIGNAL FILTER CLOGGING SENSOR
SUPLLY (FROM BATTERIES)
SUPPLY (FROM BATTERIES)
SUPPLY (KEY ON)
GROUND CONTROLLER EST37
GROUND CONTROLLER EST37
To controller Box conn. Cnl pin 25
W110R0086
ON-BOARD INSTRUMENTATION
TO CONNECTION X34F (relay board)

(Connection to ground through parking
brake pressure switch)
Cab ground conn. GND_FCAB
FROM FUSE F9C (KEY ON)
To emergency steering pressure switch through conn. X20 and LTS
To emergency steering pressure switch through conn. X20 and LTS HOURMETER
To connection ALT (L) through conn. X23
BROWN BOX (INPUT) BROWN BOX (OUTPUT)

CONNECTION CN(L) CONNECTION CN(R) BACK LIGHT
DASHBOARD
SIGNAL FROM ALTERNATOR SIGNAL BATTERY CHARGE INDICATOR
EMERG. STEERING
SIGNAL EMERGENCY STEERING INDICATOR
Air cleaner clogging pressure switch SIGNAL EMERG. STEERING LOW PRESSURE
GENERAL ALARM
N.A. Closed at 62 mbar SIGNAL EMERG. STEERING HIGH PRESSURE SIGNAL GENERAL ALARM BUZZER
Ground rear frame conn. GND_E AIR CLEANRER CLOGGING

SIGNAL AIR CLEANER CLOGGING INDICATOR LIGHT
ENGINE OIL PRESS.
SIGNAL ENGINE OIL LOW PRESS. PRESSURE INDICATOR LIGHT TRANSM. OIL PRESS.
SIGNAL AIR CLEANER CLOGGING SENSOR SIGNAL TRANSM. OIL TEMPERATURE INDICATOR LIGHT
FROM FUSE F7C (MAIN LIGHTS SWITCH)

SIGNAL TRANSM. OIL TEMPERATURE INDICATOR
SIGNAL FUEL LEVEL SENSOR
FUEL LEVEL
SIGNAL FUEL LEVEL INDICATOR
Fuel level sensor ENGINE COOLANT TEMP.
SIGNAL ENGINE COOLANT TEMP. INDICATOR LIGHT
BRAKE OIL PRESS.
SIGNAL BRAKE OIL LOW PRESSURE INDICATOR LIGHT PARKING BRAKE
Ground rear frame conn. GND_E
ALTERNATOR
FROM FUSE F9C (KEY ON)

RH TURNING LIGHT
Brake accumulators low pressure pressure switch LH TURNING LIGHT
HIGH BEAM
N.C. Open at 0.7 0.15 bar
Ground rear frame conn. GND_A 1ST GEAR ENGAGED
SIGNAL 1ST GEAR ENGAGED INDICATOR LIGHT 2ND GEAR ENGAGED
SIGNAL BRAKES ACCUMUL. PRESSIRE SWITCH SIGNAL 2ND GEAR ENGAGED INDICATOR LIGHT
3RD GEAR ENGAGED
SIGNAL 3RD GEAR ENGAGED INDICATOR LIGHT 4TH GEAR ENGAGED
SIGNAL 4TH GEAR ENGAGED INDICATOR LIGHT
SIGNAL OIL LEVEL INDICATOR FUEL LEVEL INDIC.
Engine oil low pressure pressure switch SIGNAL ENGINE COOLANT TEMP. INDICATOR COOLANT TEMP. INDIC.
N.C. Open at 0.7 0.15 bar TRANSM. OIL TEMP. INDIC.
Ground rear frame conn. GND_E SIGNAL VEHICLE SPEED SPEEDOMETER
SIGNAL ENGINE OIL LOW PRESS. PPRESSURE SWITCH
NEGATIVE EMERGENCY STEERING RELAY To emergency steering relay (through conn. X20 and LTS) To high beam relay (through conn. X5) SPEEDOMETER
To emergency lights switch
To emergency lights switch
VAREIAB. SIGNAL ENGINE COOLANT TEMP. SENSOR
BUTTONS DISPLAY
CONNECTION CN7
SIGNAL ENGINE COOLANT TEMP. SWITCH BUTTON P1 (SIGNAL)
DIGITAL DISPLAY
BUTTON P1 (GROUND)
(BUTTONS)
BUTTON P0 (SIGNAL)
BUTTON P0 (GROUND)
BUTTON P3 (SIGNAL)
Engine coolant temperature sensor BUTTON 3 (GROUND)
BUTTON P2 (SIGNAL)
BUTTON P2 (GROUND)
DISPLAY SPI Tx (SERIAL INTERFACE DATA TRANSMISSION)

DISPLAY SPI Rx (SERIAL INTERFACE DATA RECEPTION)
CONNECTION CN6
DISPLAY SPI Rx (SERIAL INTERFACE DATA RECEPTION)
DIGITAL DISPLAY
LINE CAN BUS (L)
(INTERFACE)
DISPLAY SPI Rx CHECK (MONITORING DATA RECEPTION)
LINE CAN BUS (H) DISPLAY SPI Rx CHECK (MONITORING DATA RECEPTION)
DISPLAY SPI Tx (DERIAL INTERFACE DATA TRANSMISSION)
SIGNAL LTS ENGAGED POWER SUPPLY +12V (Not used)
SIGNAL TRANSM. CUT-OFF ENGAGED Not used
SERIAL INTERFACE SCREENING Not used
DIRECT POWER SUPPLY FROM BATTERIES SERIAL INTERFACE RX_B (RECEIVING) Not used
SERIAL INTERFACE RX_V (RECEIVING) Not used
POWER SUPPLY FROM KEY POS. ON SERIAL INTERFACE TX_R (TRANSM.) GROUND (not used)
SERIAL INTERFACE TX_G (TRANSM.)
GROUND
POWER SUPPLY INTERFACE 12V
Not used
GROUND GROUND INTERFACE
Not used
GROUND GROUND
GROUND
CONNECTION CN5
(POWER SUPPLY)
DIGITAL DISPLAY
GROUND
To transm. cut-off switch through conn. X32
To transmission controller ZF EST 37
To LTS switch through connect. X12
GROUND
GROUND
GROUND
POWER SUPPLY + 24V
POWER SUPPLY + 24V
POWER SUPPLY + 24V
POWER SUPPLY + 24V
Cab ground connection GND_RCAB Not used
Not used
From fuse F9C (See page 3) Not used
Not used
From fuse F12A (See page 1)
W110R0087
LEVER DETENTS AND FDS REVERSER CONTROL
Bridge to ground with switch S9 (LTS)

Bridge to ground with switch S11 (Cut-off)
Bridge to positive with switch S9 (LTS)
Bridge to positive with switch S11(Cut-off)
From fuse F3C (key ACC)
BOOM KICK-OUT
PROXIMITY SENSOR
BOOM KICK-OUT SELECTION SWITCH (NPN-N.C.)
BUCKET LEVELER
PROXIMITY SENSOR
(PNP-N.A.)
FLOAT ENGAGEMENT
PRESSURE SWITCH
(N.A. Closed at 19 bar)
FAN REVERSER CONTROL SWITCH
FLOAT
ENGAGEMENT SOLENOID
DIODES CONNECTOR (39.7 ohm at 20 C)
Max. boom height
Rear frame ground conn. GND_A
Rear frame ground conn. GND_A
Rear frame ground conn. GND_D

From fuse F3C (ACC)
From fuse F3C (ACC)
Bucket level
Float position
HYDRAULIC LEVERS DETENT SOLENOID

cab Ground
Conn. GND_SCF
A: From ground with seat heater switch

B: Bridge to ground with transmission cut-off switch (Page 7B)
C: Bridge to positive with seat heater switch
DIODES MODULE Rear frame ground conn. GND_G D: Bridge to positive with transmission cut-off switch (Page 7B)
(Box in eng. comp.) FANS REVERSER
CONTROL SOLENOID
W110R0088
LTS, EMERGENCY STEERING AND CUT-OFF
From fuse F3B (Key ACC)

From fuse F6C (Key ACC)
RELAY LTS
(cab relay board)
Cab ground conn. GND RCAB
positive with switch Bomm kick-out

Brown Box conn. Cn1 pin 23
ground with switch Boom kick-out

(Control signal)
positive with switch Aut/Man

ground with switch Aut/Man
Rear frame ground conn. GND_D
Controller ZF EST 37 pin 5
Fuse F6C (Key ACC)
CUT-OFF
SOLENOID VALVE COIL
EMERGENCY STEERING RELAY BOX GROUND (22.7 ohm at 20 C)
to
to
to
to
Bridge
Bridge
Bridge
Bridge
CUT-OFF SOLENOID
VALVE SWITCH
Brown box conn. Cn2 pin 5
EMERG. STEERING
PRESSURE SWITCH
(Diverting pressure: 2.4 bar)
EMERG. STEERING EMERG. STEERING RELAY

SOLENOID
(39.3 ohm at 20C)
Fuse F6C (Key ON)
Rear frame ground conn. GND_SSS LTS SOLENOID
Bridge to positive with switch boom kick-out

Cab ground conn. GND_SCF
Bridge to ground with switch Bomm kick-out

Cab ground conn. GND_SCF
VALVE SWITCH
B+ FROM CONN. Tb7 (Diversion on starter motor)
LTS SOLENOID
Rear frame ground conn. GND_SST
RELAY LTS
VALVE COIL
(22.7 ohm at 20C)
EMERG. STEERING RELAY BOX
W110R0089
EMERG. STEERING
PUMP ELECTRIC MOTOR
WIPER AND WASHER DEVICES

FRONT WIPER & WASHER CONTROL
SIGNAL 53 FRONT TIMER

FRONT
FRONT WIPER HIGH SPEED
WIPER
FRONT WIPER LOW SPEED
MOTOR
SIGNAL J FRONT TIMER
FRONT WIPER POWER SUPPLY
FRONT WASHER TIMER SIGNAL
+ 24 V
PIN 4 AND 6 ARE CONNECTED INTERNALLY
+ 24V IMPULSES
FRONT WIPER TIMER
FRONT TIMER GROUND

TIMER SIGNAL FRONT WIPER FROM FUSE F2C (key ACC page 2)
REAR
WIPER SWITCH SIGNAL J FRONT TIMER
Bridge to ground FROM FUSE F6B (key ACC page 2)
SIGNAL 53 FRONT TIMER
with main lights switch
POWER TO FRONT TIMER
TIMER SIGNAL FRONT WIPER
Frame ground conn. GND_G
FRONT
WASHER
MOTOR
Frame ground conn. GND_G
REAR
WASHER
MOTOR
Bridge to ground
with rotary beacon switch

REAR
WASHER REAR WIPER TIMER
SWITCH
REAR TIMER GROUND
TIMER SIGNAL REAR WIPER
SIGNAL J REAR TIMER
REAR SIGNAL 1ST SPEED REAR WIPER
MOTOR
POWER TO REAR TIMER
SWITCH
TIMER SIGNAL REAR WIPER
W110R0090
PARKING BRAKE AND HORN CONTROLS

PARKING BRAKE CONTROL CIRCUIT
CAB GROUND CONN. GND_FCAB
FROM FUSE F8B (key ON)
FROM FUSE F3B (key ON)
PARKING BRAKE
CONTROL SWITCH
Bridge to ground with
emergency lights switch
PARKING BRAKE
REAR FRAME GROUND CONN. GND_B SOLENOID VALVE COIL
HORN CONTROL CIRCUIT
FROM FUSE F11A (Directly powered from batteries see page 1)

HORN RELAY (1)
HORN
HORN RELAY (2)
FROM HORN BUTTON ON GEARSHIFT

SELECTOR (Through connection X16)
SERVICES RELAY HORN PEDAL

90 Amp (See page 2) CONTROL
REAR FRAME GROUND CONN. GND_B
CAB GROUND CONN. GND_RCAB
CAB RELAY BOARD W110R0091
LIGHTING DEVICES CONTROLS
TO DASHBOARD Fg 8 Bridge to ground with

Connection X1C/Cn1 parking brake switch
339 _ E H 1.0
330 _ E H 1.0
From Fuse F12 C (from batteries page 1)

From Fuse F10 C (from batteries page 1)
From Fuse F1 C (Key "ACC" Page 2)
EMERGENCY LIGHTS SWITCH From Fuse F1 B (From Batteries - Page 1)
From Fuse F4 A (Key "ACC" Page 2)
REAR WORK LIGHTS SWITCH Rear frame ground

connection GND_C
Rear frame ground connection "GND_C"
FRONT LEFT TURNING LIGHT
HEADLIGHTS
HIGH BEAM
HIGH BEAM
LOW BEAM
LOW BEAM
RIGHT FRONT TURNING LIGHT

HEADLIGHTS
Fromm Fuse F5 B (Key ACC - Page 2)
LEFT FRONT TRI-LIGHT RIGHT FRONT TRI-LIGHT

FLASHER HIGH BEAM LOW BEAM
REAR WORK LIGHTS SWITCH UNIT RELAY RELAY
REALY BOARD INSIDE CAB

Back-up alarm
From fuse EF3 (Box engine compartm. Back-up alarm relay closed)
From fuse E1F (Box engine comp. - key "ACC")
HEAD/TAIL LIGHTS ITALIAN HOMOLOGATION

RIGHT STOP LIGHTS RELAY
D.A. CLOSED AT 1.6 0.5 bar
FRONT WORK LIGHTS SWITCH

From fuse FC C (Key ACC Page 2)
Rear wiper (page 11)
166_D B - 1.5 Conn. LCD pin 3 (Page 8)
166_B B - 1.5 LEFT

166_A B - 1.5 166_C B - 1.5 166_FA B - 1.5
331_R H - 1.0
332_L H - 1.0
337 H - 1.0
Climate conditioner panel lighting
MAIN LIGHTS SWITCH RIGHT
339 _ FA B -10
330 _ FA B -10
331 _ FA B -10
331 _ FA B -10
From fuse F1C (Key ACC Page 2) Rear frame ground Rear frame ground
From fuse F12B (Directly powered by batteries)
FRONT WORK LIGHTS
connection GND_G connection GND_F
A Left tail light (Through conn. X22)

B Right clearance light
C Right tail light (Through conn. X20)

From fusible F7C
From fusible F7B
From fusible F7B
From fusible F7C
D Right tail light license plate light (Through conn. X22)

LEFT Work Stop Direction Head lights Back-up Work Stop Direction Head lights Back-up
E Left head light (Through conn. X20)
F Left clearance light
G Dashboard back lighting (Through conn. X15 and X5 Page 4) LEFT REAR LIGHT GROUP LICENCE PLATE LIGHT RIGHT REAR LIGHT GROUP
Cab ground (roof)
H Cigarette lighter back lighting (Through conn. X8) W110R0092
connection X2_GND
CAB FUSE BOARD (fuse group F)
SECTION 8
CAB
INDEX
8.1 GENERAL DESCRIPTION ................................................................................... 8-1
8.2 REPAIR ................................................................................................................ 8-3

8.2.1 CAB ..................................................................................................................... 8-3
Removal ........................................................................................................... 8-3
Reinstallation .................................................................................................... 8-4
8.3 WINDSCREEN WIPERS AND WASHERS ........................................................... 8-5
8.4 HEATER ............................................................................................................... 8-7

8.4.1 GENERALITIES ................................................................................................... 8-7
8.4.2 MAIN COMPONENTS AND SPECIFICATIONS ................................................... 8-7
8.5 CAB GLAZING ..................................................................................................... 8-9

8.5.1 DISASSEMBLY AND ASSEMBLY ........................................................................ 8-10
8.6 AIR CONDITIONING UNIT .................................................................................. 8-13

8.6.1 OPERATING INSTRUCTIONS ............................................................................. 8-13
8.6.2 TECHNICAL DATA ............................................................................................... 8-14
8.6.3 SERVICE PRECAUTIONS ................................................................................... 8-15
8.6.4 TOOL CONNECTIONS ........................................................................................ 8-17
8.6.5 DISCHARGING .................................................................................................... 8-18
8.6.6 REFRIGERANT CHARGING ............................................................................... 8-18
8.6.7 LEAK INSPECTION ............................................................................................. 8-19
8.7 TROUBLESHOOTING ......................................................................................... 8-21

W110/W110TC CAB 8-1
8.1 GENERAL DESCRIPTION
W110R0296
The cab is a tested protection structure against roll-

over hazard (ROPS).
The cab is complete with the drivers seat, steering
column, controls and instruments to drive and oper-
ate the machine.
Other standard features are the heating system, de-
mister, front and rear windscreen washer-wipers, ceil-
ing light, clock/thermometer, loud-speakers, safety
glasses, rear-view mirrors, sun visor, and emergency
exit.
Access inside the cab is through the left-hand door.
The right-hand door is used to gain access to the
heater/air conditioning system compartment. Doors
can be locked wide open and are fitted with a key W110R0297
lock.
The main components such as the hydraulic reser-
voir, hydraulic pump and control valve, steering con-
trol valves and cylinders, and drive shafts can be re- The cab serial number is etched on a plate located on
moved or repaired without disassembling the cab. the inner side of the cab left-hand post.
8-2 CAB W110/W110TC
NOTES:
W110/W110TC CAB 8-3
8.2 REPAIR
8.2.1 CAB Loosen the four safety screws and the four screws
securing the cab to the frame.
Removal
Install an appropriate lifting device over the cab hook-
Park the machine on level ground and block wheels ing the 4 lifting eyes previously tightened (weight of
securely to prevent motion. the cab about 700 kg - 1540 lbs) and set a slight
Disconnect the battery isolator switch. tension on the lifting chain.
WARNING
WARNING
Always disconnect the battery isolator switch
Always use hoists or similar devices of suitable
before cleaning, repairing, overhauling or park-
capacity to lift or move heavy components. En-
ing the machine.
sure that the sling is perfectly made.
Use the lifting eyes.
W110R004
Remove the guards around the bottom of the cab from

both sides.
Disconnect the ground plait and the electric connec-
tions between cab and frame.
W110R0299
Lifting cab
Slightly raise the cab taking care not to tension any

electrical cables or hoses.
Lifting height should be such to allow detachment of
all lines and cables from machine assemblies.
W110R0298
8-4 CAB W110/W110TC
Disconnect the sensor and potentiometer wires from Close the heater feeding valves.
the accelerator pedal. Disconnect the two heater hoses located in the rear
Disconnect, after labelling them, the pipes to orbitrol right side of the cab.
(6). Loosen the screws securing the brake pedal valve Make sure that all connections on the machine are
and remove the pedal assembly without sisconnecting disconnected, then lift the cab, moving it sideways.
the pipes.
Open the panel on the right side of the machine and Reinstallation
label the hoses of equipment control levers (3) and
The installation is the reversal of the removal.
three-way valve (4). Disconnect the pipes of the
Tighten the cab screws to the frame to the specified
windshield washer from the washer liquid tank.
torque.
5
4
3
11
6
1 7 2 11 1
8 1
W110R0300
Note 1 Screw M16 - Tightening torque 23 daNm
1. Safety screw M30 - 2. Safety screw M24 - 3. Equipment control lever pipes - 4. Three-way valve pipes - 5. Throttle ball
joint - 6. Orbitrol valve - 7. Cab and frame front securing nut M16 - 8. Cab and frame rear securing nut m16 - 9. Accelerator
pedal - 10. Steering column - 11. Elastic pads.
W110/W110TC CAB 8-5
8.3 WINDSCREEN WIPERS AND WASHERS
The front windscreen wiper motor (1) is located at the Note 1 Before setting the wiper blades in motion,
front of the steering column. The front windscreen wiper operate the windscreen washer to minimise the risk
has two intermittent working speeds: 35 strokes per of scratching the glass.
min (slow) and 55 strokes per min (fast).
A dog-leg mechanism transforms the motor shaft ro- Note 2 Use the cleaning fluid DP1 diluted with wa-
tary motion into 45 strokes of the wiping arm. ter dependent upon working temperature. A 50% de-
The rear windscreen wiper motor (2) is located un- tergent/water solution does not freeze down to
der the cab trim behind the drivers seat, on the right- -10 C (50 F). Below this temperature, use cleaning
hand side. The rear windscreen motor has but one fluid only.
speed (approx. 54 strokes per min).
Internal gears provide an 80 oscillation of the wiping Pump hoses are connected to the nozzles located at
arm. the sides of the wiping arms.
4 5
W110R0301 W110R0302
The windscreen washer fluid bottle (3) is located in- In case of motor or arm assembly replacement, it will
side the engine compartment, on the left-hand side. be necessary to reassemble the arm assembly to the
The bottle is fitted with two pumps (4) and (5) for the drive part correctly to centre the wiping action over
front and rear windscreens, respectively. the glass width.
To this aim, select the most suitable position for the
Specifications arm on the knurled drive part shown by the arrow in
the figure.
Bottle capacity ............................... 2.5 lt. (0.87 gal)
Rated voltage ................................................... 24V
Absorbed current ............................................. 2A
Max. flow ........................ 3 lt./min (0.6 USG/min)
8-6 CAB W110/W110TC
NOTES:
W110/W110TC CAB 8-7
8.4 HEATER
8.4.1 GENERALITIES
The cab heater is placed in a special compartment,
on the cab right-hand side. 6
The associated switches are located on the control
2
console and are used to: 1
- adjust air temperature; 3

9
- control air flow intensity;
- admit air from the outside or recirculate the air in-
side the cab.
In case of air intake from the outside, air is drawn in

through the filter (A). If air is being recirculated, inter-
nal cab air is driven through the filtering panel (B). 4
Both filter (A) and filtering panel (B) should be re-
placed periodically.
7
A
5
W110R0304
8.4.2 MAIN COMPONENTS

AND SPECIFICATIONS
B The heater main components are:
W110R0303 1. Electrical fan

2. Outside air filter
3. Filtering panel
4. Heat exchanger
5. Shroud
6. Housing
7. Water lines
8. Air ducting
9. Feed valve
Specifications
Heat value .........................................10 000 Kcal/h
Air flow ........................................... 575 10% m3/h
Absorbed power .......................................... 400 W
Working temperature range ....................................
....................................... 15 + 50 C (14 + 122 F)
8-8 CAB W110/W110TC
NOTES:
W110/W110TC CAB 8-9
8.5 CAB GLAZING
All cab glasses are differential hardening type.

Glasses should be ordered from the manufactured.
4
They should be kept clean at all times to guarantee
good visibility. When cleaning the glasses, pre-wash
6
them with a water and detergent solution or other pro-
prietary product using a squeegee to reduce abrasion
2
and make cleaning easier.
Notice Never use hot water over cold glasses.
All glasses fitted to the cab have been subjected to

differential hardening and have a 5 0.2 mm thick-
ness. They are firmly bonded to their seats by means
of a polyurethane sealant. 5
1
5 0.2 mm
7 3
0.19 0.007 in
W110R0305 W110R0306
1. Front windscreen - 2. Rear windscreen - 3. Door glass

- 4. RH side glass (emergency exit) - 5. LH rear glass -
6. RH rear glass - 7. Bonding kit.
8 - 10 CAB W110/W110TC
8.5.1 DISASSEMBLY AND ASSEMBLY Preparing the replacement glass

Disassembly 1. Place the glass momentarily in position and mark
with adhesive tape to position it correctly during
1. Push a pointed object through the adhesive from
final bonding.
inside the cab and insert the wire.
2. Using the wire, cut the adhesive all around the glass.
Lift out the glass using two suction cups.
3. To leave a smooth bevel of approximately 1 or 2
mm, which should be kept clean as it will be the
bonding base for the polyurethane adhesive.
Should the paint be partially damaged, apply some
glass primer as a protection against corrosion.
Note Work only in well ventilated premises. The

polyurethane adhesive does not contain low molecu-
lar weight (monomolecular) volatile isocyanates.
Therefore, there is no danger of irritation for the res-
piratory tract. However, all precautions required when
using chemicals should be observed. Avoid contact
with the eyes and skin.
W110R0308
2. Thoroughly clean the glass edge using the special

cloth moistened in the degreaser supplied.
Important After degreasing, wipe the degreased part

using a clean dry cloth.
W110R0307
WARNING
Always wear gloves and use special suction cups
with handles when replacing the glasses.
Do not strike the glasses to remove.
W110R0309
W110/W110TC CAB 8 - 11
3. Shake well the glass activator bottle before use (at 5. Punch the membrane in the threaded connection.
least 1 minute after ball separation from the sedi-
ment). Apply an even continuous bead of activator
along the black stencil using the applicator sup-
plied.
Important Once applied, allow the activator to dry

for at least 10 minutes keeping the surface clean.
W110R0312
6. Cut off the nozzle and apply a smooth continuous

bead of BETASEAL sealant-adhesive along the
edge of the body or windscreen keeping the gun
vertical.
W110R0310
4. Remove the sealant cartridge bottom cover and

salts therein.
W110R0313
W110R0311
8 - 12 CAB W110/W110TC
Glass assembly Note Work only in well ventilated premises. The

polyurethane adhesive does not contain low molecu-
1. Position the glass in its seat slightly pressing it.
lar weight (monomolecular) volatile isocyanates. There-
fore, there is no danger of irritation for the respiratory
tract. However, all precautions required when using
chemicals should be observed. Avoid contact with
the eyes and skin.
Note The BETASEAL sealant-adhesive hardens

with air moisture. Hardening depends upon ambient
humidity and relative penetration degree. Therefore,
machine downtime ranges from 2 to 3 hours at a tem-
perature of 23 C (73 F). During this period the ma-
chine should not be submitted to any stress what-
ever.
WARNING
Any variation to instructions specified, such as
use of materials after expire date or improper work
W110R0314
procedures, may negatively affect the results of
the operation. The manufacturer does not assume
Note The glass must be fitted to the machine within any responsibility for damages which may derive
maximum 15 minutes after applying the BETASEAL to persons and/or things.
sealant-adhesive.
W110/W110TC CAB 8 - 13
8.6 AIR CONDITIONING UNIT
8.6.1 OPERATING INSTRUCTIONS erant itself. Then, the Freon reaches the expansion
thermostatic valve, which has the purpose of regulat-
The principle of operation can be summarised as fol-
ing the refrigerant flow into the evaporator at a pres-
lows: the refrigerant, Freon R134a, in its gaseous state,
sure of 1-5 (14.5 to 72 psi) bar, causing its passage
is sucked by the compressor at a pressure of 1-5 bar
from liquid to gaseous state. At the same time, the air
(14.5 to 72 psi) and taken to a final compression at a
flowing through the evaporator, under the action of
pressure of 10-20 bar (145 to 290 psi). The gas, heated
the fan, having a temperature which is higher than the
by the compression to 89-100 C (192 to 212 F), flows,
refrigerator contained by the evaporator itself, caus-
still in a gaseous state, into the condenser where,
ing its boiling and full evaporation, releasing heat.
under the effect of the cooling provided by the air flow-
The air, being cooled, deposits on the fins of the
ing through it by the action created by the fan, reaches
evaporator parts of its moisture content, under the
the condensation point, passing into a liquid state at
form of little drops, which drop into the tanks and are
high pressure.
discharged outside the cab.
Subsequently, the refrigerant, at liquid state, reaches
Air cooled and dehumidified, is sent into the cab. The
a dehydration filter, which has the function of captur-
refrigerant, at the outlet of evaporator, is sucked again
ing impurities, absorb moisture trapped into the sys-
by the compressor, beginning a new cycle.
tem and operate as a reserve reservoir for the refrig-
Compressor
Fan unit Evaporator
Condenser
Expansion valve
High
pressure
Intake
Low
pressure
Pressure switch Filter
W110R0315
8 - 14 CAB W110/W110TC
8.6.2 TECHNICAL DATA

Fan
Voltage ........................................................................................................................................................ 24 V
Electrical input ............................................................................................................................................ 17 A
Air flow ................................................................................................................................................ 1190 m3/h
Speed .............................................................................................................................................................. 3
Heater
Power ................................................................................................................................................... 11,7 KW
Rate of flow .............................................................................................................................................. 500 l/h
Air flow ................................................................................................................................................. 575 m3/h
Input air temperature ..................................................................................................................... -15 C (5 F)
Evaporator
Power ................................................................................................................................................... 8,17 KW
Rate of flow .............................................................................................................................................. 500 l/h
Air flow ................................................................................................................................................. 575 m3/h
Input air temperature ................................................................................................................... 43 C (109 F)
Relative humidity ........................................................................................................................................ 30%
Vaporisation temperature ................................................................................................................ 5 C (41 F)
Condensation temperature .......................................................................................................... 60 C (140 F)
Expansion valve
Type .................................................................................................................................... TGK TEV 216 PO-2
Gas ............................................................................................................................................... Freon R134A
Superheat ....................................................................................................................................... 4 C (39 F)
Compressor
Type ......................................................................................................... SANDEN SD7H15 md 7948 for 134A
Displacement ........................................................................................................................................ 154.9 cc
Pulley .............................................................................................................................................. 135.6 mm
Lubricant oil q.ty ...................................................................................................................................... 200 cc
Filter
Type ................................................................................................................................................ SKG CC164
Dimension .................................................................................................................................. 141 x 76 mm
Capacity .................................................................................................................................................. 415 cc
Dehydrating ............................................................................................................................................. 140 gr
Pipe fitting ..................................................................................................................................... 5/8'' - 18 UNF
Pressure switch
Type ..................................................................................................................................... 3L-F LMH-971-641
Interruption: Low pressure ........ OFF 2.45 bar (36 psi)
ON 2.6 bar (38 psi)
High pressure ....... OFF 28 bar (406 psi)
ON 25 bar (363 psi)
(Fan) ..................... OFF 12 bar (174 psi)
ON 17 bar (247 psi)
Thermostat
Type ..................................................................................................................................... RANKO K50-L9421
Setting Cold ...................... OUT 0 C (32 F)
IN 5 C (41 F)
W110/W110TC CAB 8 - 15
Conditioning Performance
IN ACCORDING WITH ISO 10263
8.6.3 SERVICE PRECAUTIONS Piping precautions

It is known that CFC refrigerants (including R 12) are - Position the O-ring against the bulge in the pipe
among those substancens that destroy the ozone layer when connecting hoses and pipes.
producing an increase of ultra violet radiation result- - Coat the piping connections and the O-rings with
ing from the destruction of the ozone layer. PAG oil.
They stay in the atmosphere for over 100 years, with
a potential increment of cataract and skin cancer. As - Fit the nuts and unions tightly against the base of
a result of the global evaluation of the environmental the companion pieces then hand tighten the nut as
impact, a new refrigerant R134a has been used. This much as possible. Then, tighten to the specific
refrigerant has a potential destruction of the ozone torque.
(ODP) equal to 0 and a low global warming potential
(GWP). Note Always use oil specified for R134a system to
coat the O-rings.
WARNING
Piping connection procedure
Direct contact with refrigerant can cause frostbite
or blindness. Union Nut
Always wear safety glasses and protective gloves.
Do not work with refrigerant colse to the face.
CORRECT INCORRECT
CAUTION
PAG oil, in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere. Damage
Handle the air conditioner componenets carefully. Do

not knock or drop them.
Gnawing at pipe end
W110R0316
8 - 16 CAB W110/W110TC
Do not mistakes refrigerants

Before charging an air conditioning system be sure WARNING
that refrigerant is correct. Confirm before charging that Cap the oil container after use and the air condi-
the type of air conditioner system is in fact an R134a tioner system parts, when servicing.
system. Never mix compressor oil with other types of oil.
Do not exchange the A/C refrigerants
R 12 R 134 a
OIL
CFC12 HFC134a
W110R0317
Do not release refrigerant into the air

Although R134a is not subject to CFC regulations, it
can have an effect on global warming, and so should Cap all container and components
not be released into the air. W110R0319
The oil must be replaced or replenished in the follow-

WARNING ing cases:
When removing refrigerant from the air conditioner - when refrigerant or oil leaks from the system;
system, always use a refrigerant recovery unit - when refrigerant is suddenly discharged from the
made especially for R134a. system;
- when system components are replaced.
Do not release the refrigerants
into the atmosphere Note The oil plug O-ring must be replaced with a
new one.
Refrigerant charge inspection

As shown in the left hand figure, R134a compressor
oil will not blend with refrigerant (R134a) at certain
R 134 a temperatures. At these temperatures, the refrigerant
may appear 'cloudy' when checked using the
sightglass, and the charge may be mistakenly judged
as insufficient.
Temperature
Recovery unit
Oil-refrigen
W110R0318 Condensation separation
temperature
Blending range
Compressor oil range
Use compressor oil made specifically for use with

Vaporization
R134a. temperature
R134a system compressor oil has an extremely high range
moisture absorption capacity.
Oil-refrigerant blending rate W110R0320
W110/W110TC CAB 8 - 17
8.6.4 TOOL CONNECTIONS 1. Fully close both manifold gauge valves.

2. Connect the three hoses securely to the manifold
WARNING gauge.
Do not connect hoses to the air conditioner sys- 3. Connect the utility hose to the vacuum pump or
tem when the manifold gauge valves are open. refrigerant source.
4. Connect the couplers to the high and low pressure
hoses. Turn the knob on the fitting to depress the
CAUTION
core if so equipped.
If there is any refrigerant in the air conditioner Before disconnecting hoses, close both manifold
system, connect the hoses only after the service gauge valves.
hoses and the manifold gauge have been evacu-
ated.
Manifold gauge
Low pressure High pressure
Charging hose
Charging hose
Coupler
Vacuum pump
Refrigerant container
W110R0321
8 - 18 CAB W110/W110TC
8.6.5 DISCHARGING
CAUTION
WARNING If the pointer moves toward 0 (zero) the system is
not sealed. Inspect the system to identify the leak-
Do not release the refrigerant into the air.
ages and repair them.
Discharge refrigerant only into the refrigerant re-
covery unit.
CAUTION
- 101.3 kPa
Never use a refrigerant recovery unit for CFC12 on
{ - 760 mmHg,
an HFC134a system. - 29.92 inHg
The recovered refrigerant must be recycled trough a

refrigerant recovery unit to ensure that it is clean and
free of moisture.
Refer to the user's instruction manual for refrigerant Check for leaks and
repair if gauge needle
recovery unit handling and operations.
moves towards 0 W110R0322
Evacuation
8.6.6 REFRIGERANT CHARGING
1. Operate the vacuum pump.
There are various methods of charging refrigerant into
the air conditioner system. These include using refrig- 2. Open both manifold gauge valves
erant recovery units and direct charging using a scale. 3. Evacuate the system for at least 20 minutes.
4. Close both manifold gauge valves.
Note Change refrigerant in the system of wheel
loader every 2 years. Initial charge
Initial evacuation 1. Put the refrigerant container on the scale.
1. Close both manifold gauge valves.

2. Connect the high and low pressure hoses to the
system.
3. Connect the utility hose to the vacuum pump.
4. Open the manifold gauge's high and low pressure R 134 a
valves.
5. Operate the vacuum pump.
6. Evacuate the system for at least 5 minutes to sta-
bilize the vacuum inside the system.
7. Close both valves and stop the vacuum pump.
Scale W110R0323
Checking air tightness
2. Disconnect the utility hose from the vacuum pump
1. Leave the system as it is for 5 to 10 minutes.
and connect it to the refrigerant container.
Ensure the low pressure gauge needle does not move
towards the atmospheric pressure side (gauge pres- 3. Purge air from the utility hose.
sure 0). 4. Record the refrigerant weight.
5. Open the refrigerant container valve.
6. Slowly open the manifold gauge's low pressure side
valve to charge refrigerant from the low pressure
side valve to charge refrigerant from the low pres-
sure side.
W110/W110TC CAB 8 - 19
7. Charge with refrigerant until the low pressure gauge

reaches 0.2 MPa (2 bar, 28 psi). Pressure in high
The optimal refrigerant's weight is approximally pressure line
1100 gr.
8. Close the manifold gauge's low pressure valve.
Pressure
CAUTION
Do not overcharge the system.
Pressure in low
Initial Leak check pressure line
Using the leak detector, check the system connec- Time

tion for leaks. Compressor stops
W110R0325
Note As the system pressure is not yet high, only

large leaks can be detected at this time.
Inspection procedure
Evacuation
Refrigerant
charging
Leak detector
Operate compressor
for at last 5 min Repair
W110R0324
8.6.7 LEAK INSPECTION

To facilitate refrigerant leak detection, operate the air Check for refrigerant
conditioner at the full cooling setting with the fan run- leaks from high
ning at maximum speed for at least 5 minutes. pressure side parts
Stop the engine and, using a leak detector, check for
refrigerant leaks on the high pressure side.
This must be done immediately because when the
refrigerant stops circulating, the high pressure de-
creases gradually, as shown in the graph, while the Operation test
low pressure side pressure increases gradually.
8 - 20 CAB W110/W110TC
Inspection sequence
High pressure side
Compressor Condenser Cooling unit Receiver drier inlet

discharge port inlet and outlet inlet and outlet
Low pressure side
Compressor Cooling unit

suction port outlet
CAUTION
Clean all inspection points.
Check all connections carefully.
To prevent incorrect diagnoses, ensure there is
no refrigerant or cigarette smoke in the vicinity of
the vehicle.
Inspection points
W110R0315
W110/W110TC CAB 8 - 21
8.7 TROUBLESHOOTING
Air conditioner switch ON
Lights Does not light
Air conditioner fuse inspection
Normal Fuse blown

Air outlet flow rate check
Replace
No air flow Air flow
Blower motor inspection
Does not operate Operates, but low flow rate Compressor operation
inspection
A (a) A (b)
Magnetic clutch rotates Magnetic clutch does not rotate
A (d)
Sightglass inspection
CAUTION
Refer to REFRIGERANT CHARGE

INSPECTION on page 4
Air bubbles (no cooling) Air bubbles (no cooling)
A (c)
Refrigerant pressure
inspection
Connect the manifold gauge to the service

valves and check the gauge reading
Refer to page 12
8 - 22 CAB W110/W110TC
Troubleshooting chart
(a) Fan motor does not operate
Possible cause Inspection Remedy
1. Blown fuse. Inspect the air conditioner fuse. Replace.
2. Broken wiring Check the fan motor earth and connectors. Repair the wiring or
or bad connection. connect correctly.
3. Fan motor Check the two lead wires from the motor with a circuit tester. Replace.
malfunction. If there is no conductance, the motor is malfunctioning.
4. Broken resistor wiring. Check resistor conductance using a circuit tester. If there is Replace.
no conductance, the wiring is broken.
5. Fan motor switch Operate the fan switches in sequence and check whether Replace.
failure. the fan operates.
(b) Fan motor operates normally, but air flow is insufficient
1. Evaporator iniet Check the iniet. Remove the

obstruction. obstruction and clean.
2. Air leak. Check the cooling unit case fittings. Repair of adjust.
3. Defective thermo Check whether the evaporator is frozen. Check the switch Replace.
switch. using a circuit tester.
(c) Insufficient cooling although air flow and compressor operation are normal
1. Insufficient There will be little temperature difference between the low- Repair any leaks and
refrigerant. and high-pressure sides. Air bubbles or a "cloudy" flow will recharge the refrigerant
be visible in the sightglass. to the correct level.
2. Excessive refrigerant. The high-pressure side pressure will be high and even if the Drain small quantity of
condenser is cooled using water, air bubbles will not ap- refrigerant until air bub-
pear in the sightglass. bles appear periodically
through the window.
W110/W110TC CAB 8 - 23
(d) The compressor does not operate at all, or operates improperly
1. Loose V-belt. The belt oscillates considerably. Adjust the tension.
2. Internal compressor The V-belt slips. Repair or replace.

malfunction.
3. Magnetic clutch related.
Low battery voltage. Clutch slips. Recharge the battery.
Faulty coil. Same as above. Replace the magnetic

clutch.
Oil on the clutch The magnetic clutch face is dirty, causing it to slip. Replace, or clean the
surface. clutch surface.
Excessive clearance Adjust the clearance, or

between the clutch replace.
plate and clutch disk.
The clutch plate clings
when pushed.
Open coil. Clutch does not engage and there is no reading when a Replace.
circuit tester is connected between the coil terminals.
Broken wiring or poor Clutch will not engage at all. Inspect the earth and connec- Repair.
earth. tions.
Wiring harness Test the conductance of the pressure switch, thermoswitch, Check operation, refer-
components. relay, etc. ring to the wiring dia-
gram, and replace de-
fective parts.
8 - 24 CAB W110/W110TC
Normal compressor suction and discharge pressures at an atmospheric temperature of 30 ~ 35 C (86 ~ 95 F)

and engine speed of approx. 1500 rpm are:
High pressure side pressure : 1.47 ~ 1.67 MPa (15 ~ 17 kg/cm2, 213 ~ 242 psi)
Low pressure side pressure: 0.13 ~ 0.2 MPa (1.3 ~ 2.0 kg/cm2, 18 ~ 28 psi)
Low -pressure side pres- The pressure in the low-pressure side becomes, normally, too high
sure too high. when the pressure on the high-pressure side is excessive. As
explained here below, the check that follows is performed only
when the pressure on the low-pressure side is too high.
1. Defective The magnetic clutch switch turns off before the outlet air tempera- Adjust or replace.
thermoswitch. ture is sufficiently low.
2. Defective compressor The high- and low-pressure side gauge pressures equalize when Repair or replace the com-
gasket or valve. the magnetic clutch is turned off. pressor.
3. Poor expansion valve Frost has adhered to the compressor connector so that the tem- Install the temperature sen-
temperature sensor con- perature is lower than that of the evaporator outlet side piping. sor against the low-pres-
tact. sure pipe.
4. The expansion valve Same as above, or there is little pressure fluctuation when the Replace.
opens too far. temperature sensor is places against the pipe and then removed.
5. Clogged compressor The compressor connector is cool but the low-pressure hose is not. Remove and clean the filter.
suction filter.
Low-pressure side
pressure too low.
1. Insufficient refrigerant. Refer to "Insufficient refrigerant" on previous page. Same as at left.
2. Clogged receiver drier. Considerable temperature difference between the inlet and outlet Replace the receiver drier.
sides, or the tank is frosted.
3. Clogged expansion The expansion valve's inlet side is frosted. Clean the filter or replace
valve. the expansion valve.
4. Expansion valve The expansion valve's outlet side is chilled, and low pressure gauge Clean or replace the piping.
temperature sensor indicates a vacuum.
gas leak (damaged
capillary tube, etc.)
5. Clogged or blocked When the piping is clogged or blocked, the low-pressure gauge Clean or replace piping.
piping. reading will decrease, or a negative reading may be shown.
6. Defective The evaporator is frozen. Adjust or replace.

thermoswitch.
High-pressure side
pressure too high.
1. Poor condenser Dirty or clogged condenser. Cooling fan does not operate correctly. Clean, and repair the fan.
cooling. Blown fuse, broken wiring or poor contact. Fan motor malfunction. Repair the wiring or replace
the fuses.
2. Excessive refrigerant. Refer to "Excessive refrigerant" on previous page.
3. Air in the system. Evacuate and recharge

with refrigerant.
High-pressure side
pressure too low.
1. Insufficient refrigerant. Refer to "Insufficient refrigerant" on previous page. Same as at left.
W110/W110TC CAB 8 - 25
Gauge pressure diagnosis Problems in the system can be diagnosed using a

manifold gauge by reading the system's low and
high pressures.
Low pressure side High pressure side
Normal pressures
0.13 - 0.2 MPa 1.47 - 1.67 MPa
{1.3 - 2.0 kg/cm2, {15 - 17 kg/cm2, Low-pressure side: 0.13 ~ 0.2 MPa
18 - 28 psig} 213 - 242 psig} {1.3 ~ 2.0 kgf/cm2, 18 ~ 28 psig}
High-pressure side: 1.47 ~ 1.67 MPa
6 7 8 1.5
4
5 9
10
1.0 15
2.0
20 2.5
{15 ~ 17 kgf/cm2, 213 ~ 242 psig}
5
10 10 25
11
3 0.5 5 3.0
30
2 12
0 35
1
0 15
14
13 0
3.5
Conditions
0
15
Atmospheric temperature ........................ 30 ~ 35 C

............................................................. (86 ~ 95 F)
Engine speed ......................................... 1 500 r/min
Blower speed ................................... HI (high-speed)
Temperature switch ............................... Full cooling
W110R0326
Insufficient refrigerant
Low pressure side High pressure side Indications: Low pressures on both the low pres-
98 MPa 0.78 - 0.98 MPa sure and high-pressure sides.
{1.0 kg/cm2, {8 - 10 kg/cm2, Discharge temperature will not de-
18 psig} 114 - 142 psig} crease.
Cause: Refrigerant leakage.
5
6 7 8
9
1.5 2.0 Remedy: Inspect using a gas leak detector, repair
1.0 15 20 2.5
3
4 5
10
10
11
0.5 5
10 25
3.0
the leak, and replenish the refrigerant.
30
2 12
0 35
0 15 13
1 0
3.5
0 14
15
W110R0327
8 - 26 CAB W110/W110TC
Excessive refrigerant
(poor condenser radiation)
Indication: Both the low and high pressures are too
0.25 - 0.29 MPa 2.26 MPa
high.
{2.5 - 3.0 kg/cm2, {23 kg/cm2, Causes: Pressure increment due to excessive
36 - 43 psig} 327 psig} refrigerant.
Insufficient condenser cooling.
7
5
6 8
9
1.0
1.5
15 20
2.0
2.5
Remedy: Clean the condenser.
4 5 10
3
10
11
0.5 5
10 25
30 3.0
Inspect and adjust the fan belt and con-
2 12
1
0 15 13 0
0 35
3.5
denser motor.
0 14
15
Check the refrigerant level.
W110R0328
Air in cooling system

(insufficient suction)
Low pressure side High pressure side Indications: Both the low and high pressures are too
0.25 - 0.34 MPa 1.96 - 2.45 MPa high.
{2.5 - 3.5 kg/cm2, {20 - 25 kg/cm2, The low-pressure side piping is not cold.
36 - 50 psig} 284 - 356 psig} Cause: Air entered the cooling system. When the
suction is not applied, the reading of the
5
6 7 8
9
1.0
1.5 2.0 instruments are indicated in the illustra-
10 15 20 2.5
4
3
5
10
11
0.5 5
10 25
30 3.0
tion on the left.
12
2
1
0 15 13 0
0 35
Remedy: Evacuate the system, replenish the re-
3.5
14
0
15
frigerant and check the gauge readings.
After prolonged operation with air in the
system, the receiver drier must be re-
placed.
W110R0328
W110/W110TC CAB 8 - 27
Defective expansion valve

Indication: Both the low and high pressures are too
high.
0.25 MPa 2.16 - 2.26 MPa
Causes: Improper refrigerant charge.
{2.5 kg/cm2, {22 - 23 kg/cm2, Defective expansion valve.
36 psig} 313 - 327 psig} Improper temperature sensor installation.
Remedy: Check temperature sensor installation,
7
5
6 8
9
1.0
1.5
15 20
2.0
2.5
and insulation.
4 5 10
3
10
11
0.5 5
10 25
30 3.0
If normal, replace the expansion valve.
2 12
0 35
0 15 13
1 0
3.5
0 14
15
W110R0328
Insufficient compressor compression

Indications: High pressure on the low-pressure side,
Low pressure side High pressure side pressure too low on the high pressure
0.39 - 0.59 MPa 0.69 - 1.08 MPa side.
{4 - 6 kg/cm2, {7 - 11 kg/cm2, The high and low pressures are already
18 psig} 99 - 156 psig} equal when operation is stopped.
Causes: Insufficient compression due to a defec-
5
6 7 8
9
1.0
1.5 2.0
tive compressor gasket or damaged suc-
10 15 20 2.5
4
3
5
10
11
0.5 5
10 25
30 3.0
tion valve.
12
2
1
0 15 13 0
0 35
Remedy: Disassemble and repair the compressor.
3.5
0 14
15
W110R0329
8 - 28 CAB W110/W110TC
Infiltration of moisture
Indication: The low-pressure side pressure alter-
nates between a vacuum and normal
Vide - 0.13 MPa 0.59 - 1.77 MPa
pressure.
{Vide - 1.3 kg/cm2, {6 - 18 kg/cm2, Causes: Moisture has frozen in the air conditioner
Vide - 18 psig} 85 - 256 psig} system, clogging the expansion valve,
which then blocks the air conditioner sys-
6 7 8 1.5
4
5 9
10
1.0 15
2.0
20 2.5
tem. When the ice melts, normal opera-
5
10
3
10
11
12
0.5 5
25
30 3.0 tion resumes.
2 0 35
1
0 15
14
13 0
3.5
Remedy: Replace the receiver drier.
0
15
Evacuate the system.
Recharge with refrigerant to the proper
level
W110R0330
Refrigerant does not circulate

Indications: The low pressure side pressure becomes
Low pressure side High pressure side a vacuum and the high pressure side
- 101.3 MPa 0.49 - 0.59 MPa pressure reads 0.49 ~ 0.59 MPa
{- 760 mm Hg, {5 - 6 kg/cm2, {5 ~ 6 kgf/cm2, 71 ~ 85 psi}.
- 29.92 in Hg} 71 - 85 psig} Ice or condensation are forming on the
piping connections of the drier receiver
5
6 7 8
9
1.0
1.5 2.0 or the expansion valve.
10 15 20 2.5
4
3
5
10
11
0.5 5
10 25
30 3.0
Causes: The air conditioner system is blocked
12
2
1
0 15 13 0
0 35
by ice or dirt.
3.5
14
0
15
The air conditioner system is shut off
by a defective expansion valve tempera-
ture sensor.
Remedy: Stop operation and check for ice or con-
tamination.
If the problem is moisture, evacuate the
system.
Replace the expansion valve tempera-
ture sensor if defective.
W110R0331 Replace the receiver drier.
Recharge with refrigerant to the proper
level.
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A.

Product Support
Strada di Settimo, 323 - 10099 S. MAURO T.SE (TO) - ITALY
Reproduction of text or illustration,

in whole or in part, is strictly prohibited.
Print No. 604.13.487.00 - English - II - 2005

Printed by Satiz - Turin (Italy)
Coordinamento Editoriale Satiz - Torino

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Copyright New Holland

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Most accidents and injuries occurring in industry, on

GENERALITIES .................................................... Section 0

SAFETY RULES ........................................................................................................................................... 0-1

SPECIFICATIONS ........................................................................................................................................ 0-8

DIMENSIONS AND WEIGHT ....................................................................................................................... 0-19

TABLE OF FLUID CAPACITIES ...................................................................................................................0-20

UNITS OF MEASURE ................................................................................................................................. 0-21

STANDARD TORQUE SPECIFICATION .......................................................................................................0-23

LOCTITE PRODUCT CHART ....................................................................................................................... 0-27

W110/W110TC GENERALITIES 0-1

0-2 GENERALITIES W110/W110TC

W110/W110TC GENERALITIES 0-3

0-4 GENERALITIES W110/W110TC

W110/W110TC GENERALITIES 0-5

0-6 GENERALITIES W110/W110TC

W110/W110TC GENERALITIES 0-7

0-8 GENERALITIES W110/W110TC

Fuel #2 Diesel (#1 & 2 Mixture Permitted For Cold

Bore and Stroke 4.29" (104 mm) x 5.20" (132 mm)

Displacement 275 cu. in. (4.5 Liters)

Electrical System 24 Volts

Batteries (2) 12 Volts

Compression Ratio 17.5 to 1

Air Cleaner Dry Type Elements With Warning Restriction Indicator

Oil Filter Full Flow Replaceable Cartridge

Lubrication Positive Pressure

Cooling System Mid-mount Air/Water

- Net (per SAE J1349) 110 hp (82 kW) Maximum

Valve clearance (Engine cold)

- Exhaust valves 0.572 mm (0.023 inch)

W110/W110TC GENERALITIES 0-9

Radio 1st 2nd 3rd 4th

Forward 4.012 2.024 1.088 0.619

Stall Ratio 2.549:1

SPEEDS: mph (km/h)

(17.5 x 25 L2/L3 Tires)

AXLES Front Rear

Brake Area of Service Brakes 184 in2 (0.119 m2)/Hub

Brake Area of Parking Brake 9.0 in2 (58 cm2)

Brake Pressure Front: 899 psi (6200 kPa)

Cut Out 2800 psi (19305 kPa)

Low Pressure Warning 1500 psi (10342 kPa)

Transmission Declutch 350 psi (2413 kPa)

Charge Pressure (N2) 800 psi (5516 kPa)

17.5 R 25 XHA TL 50 psi Front 40 psi Rear

17.5 R 25 GP-2B 50 psi Front 40 psi Rear

HYDRAULICS AND STEERING

Reservoir: Filtered vent with relief on hydraulic reservoir main-

Valves: Closed-center, load sensing circuit, positive low pres-

Inlet section gives steering priority with maximum pres-

Loader control valve section contains float circuitry.

Senses steering demand to control oil flow to loader

System: A variable displacement piston pump is used to sup-

Pump displacement 4.33 in3/rev (71 cc/rev).

Pump uses full displacement at pressures up to 1800

The steering Orbitrol provider 3.9 turns lock-to-lock.

(TC) 3.75 dia x 36.32 stroke x 2.25 rod

Lift: 4.00 dia x 30.82 stroke x 2.25 rod

Steer: 2.50 dia x 18.21 stroke x 1.375 rod

Diameter of Hydraulic Inlet and Outlet Ports:

One Inlet 2.0" Split Flange (50.8 mm)