W90 WHEEL LOADER Service Manual

W90
WHEEL LOADER
Service Manual
Print N° 604.02.341.00 English
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 operator’s safety.
DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other
persons 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
merchandized 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 fundamental
safety rules or precautions. For this reason, MOST
ACCIDENTS CAN BE PREVENTED by recognizing
the real cause and taking the necessary precautions,
before the accident occurs.
Regardless of the care used in design and construction
of any type of equipment, there may be conditions that
cannot be completely safeguarded against without
interfering with reasonable accessibility and efficient
operation.
A careful operator is the best insurance against
accidents. 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 suitably supported by means
other than the hydraulic lift cylinders, cable and/or
mechanical device used for controlling the
equipment.
SUMMARY
SPECIFICATIONS .......................................................................................... pag. 1
CAPACITIES AND FLUID TYPES .................................................................. pag. 3
SAFETY RULES ............................................................................................. pag. 4
UNITS OF MEASURE USED IN THE MANUAL ............................................. pag. 11
TIGHTENING TOR QUES ............................................................................. pag. 12
ENGINE ................................................................ Section 1

DRIVE LINE/TRANSMISSION.............................. Section 2
BREAKING SYSTE .............................................. Section 3
STEERING SYSTEM ............................................ Section 4
BUCKET BOOM AND FRAME ............................. Section 5
ATTACHMENT HYDRAULIC SYSTEM ................ Section 6
ELECTRICAL SYSTEM ........................................ Section 7
CAB ...................................................................... Section 8
W90 0-1
SPECIFICATIONS - WHEEL LOADER W90
IDENTIFICATION - 2620.080.001 Oil pump flow rate (at 2100 rpm) ............... 74 lt/min
Main pressure on the control valve ....... 17 ÷ 20 bar
MARKING: W90 Transmission disengagement sensor ..... 15 ± 1 bar
Transmission induction sensors to gear teeth adjust
ENGINE clearance ............................................ 0.5 ÷ 0.8 mm
Net power at the flywheel ............................. 63 KW
Transmission oil high temperature sensor setting ..
Maximum torque speed ........................... 1400 rpm
................................................................ 122 ± 3 °C
Maximum power speed ........................... 2100 rpm
Make and model ........................... Fiat 8045.25.291
Diesel type, 4 stroke, direct injection, turbocharged
Number of cylinders ............................................. 4
Bore x stroke .................................... 104 x 115 mm AXLES
Total displacement ................................... 3908 cm3 Axles complete with disc brakes in oil bath.
Injector setting .................................... 260 + 12 bar Self-locking differentials.
Valve/rocker operation lash: Planetary final drives.
- intake ............................................................. 0,30 Stiff front axle, support structure type
- exhaust .......................................................... 0,30 - reduction ratio ............................................. 1 : 22
Firing order .................................................. 1-3-4-2 Oscillating rear axle, support structure type
- reduction ratio ............................................. 1 : 22
ENGINE SPEEDS
Minimum idle speed (no load) ......... 785 ÷ 865 rpm
Maximum idle speed (no load) .... 2250 ÷ 2350 rpm
Converter stall speed .................. 2090 ÷ 2190 rpm
Steering stall at idle speed > 600 rpm TYRES
Attachment stall ........................... 2100 ÷ 2200 rpm Type .......................................................... tubeless
Full stal ........................................ 1465 ÷ 1665 rpm Radial type ................... MICHELIN 15.5 R25 XTLA
Minimum starting temperature: .................... - 15° C Inflating pressure
Engine coolant high temperature sender - Work: front = 2.75
setting ...................................................... 101 ± 1°C rear = 1.50 bar
Engine oil low pressure switch - Transfer: front = 2
setting ................................................. 0.5 ± 0.1 bar rear = 2 bar
Wheel tightening torque ........................... 86 daNm
TORQUE CONVERTER BRAKES

Type .............................. single-stage, single-phase Brake pump flow rate ............................. 23.8 lt/min
Main convertor pressure ................................. 5 bar Accumulator recharge start pressure ........... 80 bar
Convertor safety valve pressure .................. 8.5 bar Accumulator recharge end pressure ... 95 ÷105 bar
Accumulator pre-charge pressure (0.75 lt) ... 47 bar
Transmission disengagement pressure switch
setting ..................................................... 15 ± 1 bar
Brake oil low presssure sensor setting ... 60 ± 5 bar
TRANSMISSION Brake lights pressure switch setting ... 1.8 ± 0.5 bar
Maximum ground speeds (forward/reverse) in kph Parking brake applied pressure switch setting .......
(with 15.5R25 tyres): ON 8 bar - OFF 12 bar
Forward speed Kph Reverse speed Kph

st st
1 7.23 1 7.17
2 nd
13.49 2 nd
13.37 STEERING SYSTEM
3 rd
34.20 3 rd
33.90 Cylinders ........................................ 2 double-acting
- bore x stroke .................................. 60 x 395 mm
– – – – Stand-by/main priority valve setting .............. 12 bar
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
0-2 W90
ATTACHMENT HYDRAULIC SYSTEM Three-position control switch as follows:

Sealed type with anti-cavitation and safety valves. Position 0: disengaged
- Flow at rated speed .............................. 119 lt/min Position 1: LTS engaged with speeds exceeding 7
2 or 3 spool control valve kph
Mechanical control by means of levers Position 2: (to be used only for maintenance or repair)
Hydraulic double-acting cylinders: LTS engaged at all times, even with speed lower than
- Boom control ...................................................... 2 5 kph.
- Bore x stroke .................................. 90 x 760 mm - Accumulator safety valve setting .............. 120 bar
- Bucket control cylinder

- Bore x stroke ................................ 110 x 421 mm ELECTRICAL SYSTEM
- Pressure relief valve setting ............. 210 ± 10 bar Operating voltage ............................................. 24 V
- Lift safety valve setting ................. ...230 ± 10 bar Batteries in series .................................................. 2
- Bucket roll-back safety valve setting .................... - maintenance -free type
......................................................... 230 ± 10 bar BOSCH starter motor
- Bucket roll-out safety valve setting ....................... Rated power .................................................... 4 KW
......................................................... 160 ± 10 bar BOSCH alternator with voltage regulator .......... 55 A
OPTIONS WEIGHT
Electronic anti-pitch LTS (Load Travel Stabiliser) Loader weight with 15.5 R25 tyres, 1.3 m3 bucket,
system. fully filled with fluids and operator 7700 kg.
MAIN DIMENSIONS
Dimensions taken with machine with the loader fitted with 15.5 R25 tyres and 1.3 load capacity bucket.
Unit of measure: mm
2389
1725
2145
°
55
45°
4432
1113
3472
3265
3100
2817
2575
49°
70
12
570
347
2265 1275 1275 797
2550
6247
W90 0-3
FLUIDS AND CAPACITY TABLE
Fluids and lubriants

Component to Capacity International
Fluid
be filled (lts) Specification
Engine Oil 9.9 AMBRA - Super Gold 15W40 CCMCD4, API CF-4/SG
Cooling
Radiator fluid 22 AMBRA - Agriflu NH 900 A
system
Transmission Oil 17 AMBRA - Super Gold 10W-30 CCMCD4 - API CF-4/SG
Hydraulic and Hydraulic and 50 AMBRA - Hi Tech 46 ISO VG46, DIN 51524
brake syst. brake oils Part 1 and 2, QFH583/HD
Front axle oil 12

Axles AMBRA TX Fluid SAE 85W-90, QFH586 TR
Rear axle oil 19
Lubrication
of pivot Grease AMBRA - MG2 QFH585GR
points
0-4 W90
SAFETY RULES
GENERALITIES Ensure that nobody is in the machine operating range
Read this Manual carefully before starting, operating, before moving off or operating the attachment. WALK
maintaining, fuelling or servicing the machine. COMPLETELY AROUND the machine before mounting.
Sound the horn.
Read and comply with all safety precautions before any
intervention. Before starting machine, check, adjust and lock the driver's
seat for maximum comfort and control of the machine.
Do not allow unauthorised personnel to operate or service
this machine. Fasten your seat belts(when fitted).
Do not wear rings, wrist watches, jewellery, loose or hang- Obey all flag signals and signs.
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 operator’s 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
may be inadvertently moved and cause unexpected move- OPERATING
ment of the machine or its attachments.
Check wheel and rim retainers before each working shift. If
Never operate the machine or its attachments from any necessary, tighten to the torque specified.
position other than sitting in the driver’s seat.
Do not run the engine of this machine in closed buildings
Keep head, body, limbs, hands and feet inside the opera- without proper ventilation capable to remove harmful ex-
tor’s compartment at all times to reduce exposure to haust gases.
external hazards .
Roll Over Protective Structures (ROPS) are required on
Be careful of possible slippery conditions of the steps and wheel or crawler loaders, dozers, or graders. NEVER
hand rails as well as of the ground around the machine. OPERATE the machine if such protective structure is
Do not leave the machine until it is has come to a complete removed.
stop. Keep the operator’s compartment free of foreign objects,
Check the seat safety belt at least twice per year and especially if not firmly secured. Never use the machine to
replace it if it shows signs of wear, fraying or other transport objects, unless proper securing points are pro-
weakness that could lead to failure. vided.
DO NOT CARRY RIDERS ON THE MACHINE
Study and familiarize with escape routes alternate to nor-
mal exit routes.
According to law provisions, seat belts must be fitted with
STARTING Roll Over Protection Structures or cabs. Keep safety belts
fastened during operation.
NEVER START OR OPERATE A FAILED MACHINE.
Before operating the machine, always ensure that any For your personal safety, do not climb on or off the machine
unsafe 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
by flags, signs and signals.
Ensure all protective guards and panels as well as all
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.
W90 0-5
SAFETY RULES
Do not operate the machine if you are extremely tired or feel is loose or soft since overturn or loss of machine control
ill. Be especially careful towards the end of the working shift. could result.
Do not operate a machine with misadjusted brakes. If noise level is high and continuosly exceeds 90 dBA over
Operate the machine at low speed which can ensure 8 hours at the operator's ear, wear approved ear protection
complete control at all times. in compliance with local regulations.
Travel slowly over very rough terrain, slopes or near drop- Where counterweights are provided, do not operate the
offs, in congested areas or on frozen or slippery surfaces. machine if they have been removed.
When backing, always look to where the machine is to be When transporting a loaded bucket, keept it as rolled-back
moved. Be alert of the position of bystanders. Should and low as possible for maximum visibility, stability and
someone enter the work area, STOP THE MACHINE. safety of there machine. Ground speed should be ad-
equate to the load and ground conditions.
Maintain a safe distance from other machines or obstacles
to ensure required visibility conditions. Give way to loaded The load must always be properly arranged in the bucket;
machines. move with extreme care when transporting oversize loads.
Maintain a clear vision of the surroundings of the travel or Use only the type of bucket recommended for the machine
work area at all times. Keep cab windows clean and and the materials to be handled. Follow the recommenda-
repaired. 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 Do not lift and move loads overhead where persons are
blower fan. standing or working, nor downhill when working crosswise
When pulling or towing through a cable or chain, do not start on slopes. In this case, the bucket should be unloaded on
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 OPERATOR’S COMPART- operation. Stop the machine immediately should any mal-
MENTS OF THE MACHINES INVOLVED ARE PROP- function be signalled.
ERLY PROTECTED AGAINST POSSIBLE BACKLAS IN
Never use the bucket as a man lift or to carry riders.
CASE OF CABLE OR CHAIN FAILURE OR DETACH-
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 driver’s side whenever possible.
moving in with the machine. Use all lights provided. Do not Prior to operating the machine, check which obstacles and/
move into low visibility areas. or difficulties you will encounter, such as narrow streets,
If the engine tends to stall for whatever reason under load overhead doors, cables, piping, as well as ground, bridges,
or at idle, immediately report this problem to the mainte- 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 permit
machine they are driving. When working on slopes or near a safe traverse.
sudden level drops in the terrain, avoid areas where ground Always inspect the working area to identify potential risks
0-6 W90
SAFETY RULES
such as: inclines, overhangs, trees, demolition rubble, Always remember to move the gearshift lever to the neutral
fires, ravines, steep slopes, rough terrain, ditches, crowns, position and engage the control lever lock for safety pur-
ridge trenches, heavy traffic, crowded parking and service poses.
areas, closed ambients. In such conditions, proceed with
Apply the parking brake (if fitted).
extreme care.
NEVER LEAVE THE MACHINE UNATTENDED with the
Whenever possible, avoid going over obstacles such as
engine running.
very rough terrain, rocks, logs, steps, ditches, railroad
tracks. When obstructions must be crossed, do so with Prior to leaving the operator’s seat,and after making sure
extreme care and at an angle, if possible. Slow down and that all people are clear of the machine, always slowly lower
select a lower gear. Ease up to the break-over point, pass the attachment until resting it safely to the ground
the balance point slowly and ease down the other side. Park the machine in a non-operating and no-traffic area.
In steep down-hill operation, do not allow the engine to Park on firm level ground. If this is not possible, position the
over-speed. Select the proper gear before starting down machine at a right angle to the slope, making sure there is
grade. no danger of uncontrolled sliding. Apply the parking brake.
Avoid crosswise hill travel, whenever possible. Drive up If parking in traffic lanes cannot be avoided, provide appro-
and down the slope. Should the machine start slipping priate flags, barriers, flares and signals as required to
sideways when going uphill, steer and turn machine front adequately warn the oncoming drivers.
immediately downhill. Keep head, body, limbs, hands and feet clear of the dozer,
The gradient you may attempt to overcome is limited by arms, bucket or ripper when raised.
factors such as ground conditions, load being handled, Always switch off the battery isolator switch before servic-
machine type and speed, and visibility. ing the machine in whatever manner (i.e., cleaning, repair-
There is no substitute for good judgement and experience ing, maintaining, etc.). Do the same when the machine is
when working on slopes. to remain parked for prolonged periods of time to avoid
accidental or unauthorized starting.
Avoid operating the attachment too close to an overhang
or high wall, either above or below the machine. Beware of Never lower the attachments other than sitting in the
caving edges, falling objects and landslips. Remember operator’s seat. Sound the horn. Make sure that nobody is
that such hazards are likely to be concealed by bushes, within the machine operating range. Lower the attachment
undergrowth and such. slowly. DO NOT USE FLOAT POSITION in case of hydrau-
lic controls.
When pushing-over trees, the machine must be equipped
with proper overhead guards. Never drive a machine up Securely block the machine and lock it every time you leave
the roots, particularly while the tree is being felled. Use it unattended. Return keys to authorized security. Perform
extreme care when pushing over any tree with dead all necessary operations as detailed in the Operation and
branches. Maintenance Instruction Manual. Apply the parking 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
the ground, especially near slopes or drop-offs.
Be alert to avoid changes in traction conditions that could MAINTENANCE
cause loss of control. AVOID driving on ice or frozen ground
when working on steep slopes or near drop-offs.
GENERALITIES
Working in virgin rough terrains is characterized by the
presence of all the perils and risks listed above. In these Before operating or performing any intervention on the
conditions, it is emphasised the danger represented by machine:
large tree limbs (possibly falling on the machine), large - carefully read all the norms contained in this Manual;
roots (which may act as a leverage under the machine
- read and observe all safety plates and instructions lo-
when up-rooted and cause the unit to overturn), etc.
cated on the machine.
Do not allow unauthorized personnel to service the ma-
chine. Do not carry out any maintenance work without prior
authorization. Follow all recommended maintenance and
service procedures.
STOPPING
Keep the operator’s compartment free of loose objects that
When the machine is to be stopped for whatever reason, do
are not properly secured.
so following the instructions given in chapters “Stopping
the machine” and “Shutting off the engine" in the Do not wear rings, wrist watches, jewellery, loose or hang-
Operation and Maintenance Instruction Manual. ing garments, such as ties, torn clothing, scarves, unbut-
W90 0-7
SAFETY RULES
toned or unzipped jackets that can get caught in moving The fuel filler pipe nozzle must be constantly kept in contact
parts. Wear certified safety clothes such as: hard hat, no- with the filler neck. Keep this contact from the beginning to
slip footwear, heavy gloves, ear protection, safety glasses, the end of the fuelling operation to avoid possible genera-
reflector vests, respirators. Ask your employer about spe- tion of sparks due to static electricity.
cific safety equipment requirements.
Tow the machine only from the attaching points provided.
Never service the machine with someone sitting in the Use care in making connections and ensure pins and/or
driver's seat, unless this person is an authorized operator bolt are firmly secured before pulling. Stay clear of draw-
assisting in the maintenance being carried out. bars, cables or chains under load.
Keep the operator’s compartment, step plates, grab rails To move a failed machine, use a trailer or a low platform
and handles clear of foreign objects, oil, grease, mud or truck, if available. In case towing is needed, use all neces-
snow to minimize the danger of slipping or stumbling. sary signals required by local regulations, and follow direc-
Clean mud or grease from your shoes before climbing on tions 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 operator’s seat. trailer. Use strong access ramps, with adequate height and
angle. Keep the loading platform free of mud, oil or slippery
Never stand under the boom. materials.
Should it be necessary to move the attachment through the
Tie the machine securely to the platform of the truck or
hydraulic controls for maintenance purposes, remember
trailer and opportunely wedge machine wheels or tracks as
that this should be done while sitting in the operator’s seat.
required.
Before starting the machine or moving its attachment,
apply the brakes, sound the horn and call that you are Never align holes or slots using your fingers; always use
about to manoeuvre. Raise the attachment slowly. appropriate aligning tools.
Always lock machine arms or any other parts that must be Remove all sharp edges and burrs from re-worked parts.
lifted for maintenance purposes using adequate external
means. Do not allow anyone to pass near or even below a Use only approved and effectively grounded auxiliary
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 correctly
edges of uncontrolled machine parts or deprived of the applied. Use lifting eyes if provided. Pay attention to by-
necessary guards, unless they are suitably and safely standers.
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
Do not run the engine in closed buildings without proper
perform all service or maintenance work with the 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 mate-
force. rials.
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 all
Do not check or fill fuel tanks, batteries and accumulators, times. NEVER USE tools with mushroomed or damaged
nor use the starting liquid if you are smoking or near open 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.
0-8 W90
SAFETY RULES
In case tests during which the engine should be kept appropriate protections (heavy gloves, goggles, etc.) while
runinng, a qualified operator must sit in the driver’s seat handling them.
with the mechanic in sight at all times. Place the transmis-
Handle all parts carefully. Keep hands and fingers away
sion in neutral, apply and lock the brakes. KEEP HANDS
from gaps, gears, and similar. Always use and wear the
OFF MOVING PARTS.
appropriate protections.
In case of field service, move machine to level ground, if
Water can build up in pneumatic systems from condensate
possible, and block it. If work on an incline cannot be
moisture due to changes in atmospheric conditions. If
advised, block the machine and its attachments securely.
necessary, drain such deposits following instructions.
Move damaged to level ground as soon as possible.
Before carrying out any maintenance work or service, lock
Do not trust worn and/or kinked chains and cables. Never
the machine articulated frame modules using the appropri-
use them for lifting or pulling. Always wear heavy gloves to
ate safety device. Remember to remove and store it prop-
handle chains or cables.
erly at the end of work.
Be sure chains and cables are firmly fastened and that If the machine is equipped with hydraulic brakes, make
anchor points are strong enough to withstand the expected sure that the reservoir is always filled up to the correct level.
load. Nobody should stay near the anchor points, cables or
chains. DO NOT PULL OR TOW UNLESS THE OPERA- Always block all wheels, front and rear, before bleeding the
TOR’S COMPARTMENTS OF THE MACHINES IN- braking system or disconnecting control hoses and/or
VOLVED ARE FITTED WITH THE PROPER GUARDS cylinders.
AGAINST BACKLASH IN CASE OF CABLE OR CHAIN
FAILURE OR DETACHMENT.
Keep the area where maintenance is carried out CLEAN
and DRY at all times. Clean immediately all water and oil
spillages.
Do not pile up oily or greasy rags as they represent a major
fire hazard. Always store them in closed metal containers. STARTING
Before starting the machine or its attachment, check, adjust Do not run the engine in closed buildings without proper
and lock the operator’s seat. Also ensure that nobody is ventilation capable to remove lethal exhaust fumes.
within the machine operating range. Sound the horn.
Do not place head, body, limbs, feet, hands or fingers near
Rust inhibitors are volatile and flammable. Use them only rotating fans or belts.
in well ventilated areas. Keep open flames away - DO NOT
SMOKE - Store containers in a cool well ventilatedplace Be especially careful near blower fans.
where they could not be reached by unauthorised people. REMEMBER THAT THE STARTING FLUID IS HIGHLY
Do not carry loose objects in your pockets that might fall FLAMMABLE. Follow recommendations provided in this
unnoticed into open compartments. Manual and printed on the containers. Containers must be
stored in a cool, well ventilated place out of the reach of
Wear safety glasses with side shields, hard hat, safety unauthorised persons.
shoes, heavy gloves when metal particles or similar may be DO NOT PUNCTURE OR BURN CONTAINERS.
ejected and hit you.
Wear appropriate protective equipment such as dark
safety glasses, hard hat, protective clothing, special gloves
and footwear while welding. Nearby persons should also
wear dark safety glasses even if they are not welding. DO
NOT LOOK THE WELDING ARC WITHOUT PROPER ENGINE
EYE PROTECTION.
Loosen the radiator cap very slowly to relieve system
Become acquainted with all your jacking equipment and its pressure before removing it. Always top-up coolant level
capacity. Remember that the jacking point on the machine with the engine off.
should be appropriate for the load applied. Also, be sure the
Avoid that flammable materials could touch exhaust parts.
support area of the jack at the machine and on the ground
If not possible, provide necessary protections.
is appropriate and stable.
Do not refuel with the engine running, especially if hot, as
Any load supported by a jack represents a possible hazard.
this increases fire hazard.
Always transfer the load onto appropriate support means
according to local or national safety requirements before Never attempt to check or adjust fan belt tensions when the
proceeding with service or maintenance work. engine is running.
Metal cables get frayed after prolonged use. Always wear Do not adjust the fuel pump when the machine is motion.
W90 0-9
SAFETY RULES
Do not lubricate the machine with the engine running. any intervention, install all safety devices according to
current regulations. In case the attachment is to be oper-
Do not run the engine with air intakes, door or guards open.
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.
ELECTRICAL SYSTEM
Do not use the machine to transport loose objects, unless
Always disconnect the batteries prior to any intervention on
proper devices to this purpose are provided.
the machine or its electrical system (cleaning, repair,
maintenance). Clutches and brakes of this machine as well as auxiliary
devices and attachments (such as drive cylinder or winch
Should booster batteries be used, remember to connect control valves) should always be properly adjusted in
ends of the booster cables in the proper manner: (+) to (+) accordance with the instructions provided by the Manufac-
and (-) to (-). Do not short-circuit terminals. Thoroughly turer. Never perform adjustments with the engine running,
follow instructions given in this Manual. except when this is specifically required by the relevant
Before any intervention, make sure that the battery isolator procedures.
switch is off.
BATTERY GAS IS HIGHLY FLAMMABLE. Leave the bat-
tery compartment open during recharging to improve ven-
tilation. Never check battery charge by placing metal ob-
jects across the posts. Keep sparks or open flames away
from batteries. Do not smoke near the battery to prevent
explosion hazard.
Before any intervention, make sure that there are no fuel or TYRES AND WHEELS
electrolyte leakages. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined spaces. Make sure that the tyre inflation pressure corresponds to
Ensure proper ventilation is provided to avoid accidental specifications issued by the Manufacturer. Regularly
explosions due to build-up of gas released during charg- check inflation pressure.
ing. Should pressure be changed, do this while staying on the
tyre side and at a safe distance.
Pressure checks should always be carried out with the
machine unloaded and cold tyres.
Never use reconditioned tyre rims, since possible
HYDRAULIC SYSTEM weldings, incorrect heat-treatments or repairs can weaken
the wheels and cause damages or failures.
Pressure fluid escaping from a very small hole can be
almost invisible and still have sufficient force to penetrate Do not cut, nor weld rims with inflated tyres installed.
the skin. Always check any suspected pressure leaks The spare tyre should be inflated only enough to keep the
using a piece of cardboard or wood. DO NOT USE HANDS. rim components assembled. Remember that when not
If injured by escaping fluid, obtain medical attention imme- installed on the disc, a tyre inflated to maximum pressure
diately or serious infection or reaction may develop. can explode.
Stop the engine and relieve all system pressure before Therefore, maximum care must be taken when handling a
removing panels, housings, caps, plugs or covers. fully inflated tyre.
Always use gauges of adequate capacity (end-of-scale Before servicing tyres, block all wheels, front and rear. After
reading) and follow recommended procedures. jacking up the machine, block it in the raised position using
suitable stands conforming to current safety regulations.
Deflate the tyre before removing objects from the tyre
tread.
Never inflate tyres with flammable gas: explosions and
severe bodily injuries may result !!
TOOLS
When starting your work shift, check for loose wheel or rim
Always keep head, body, limbs, feet, or hands away from bolts and brackets and retighten to correct torque as
bucket, blade, or ripper when in the raised position. Prior to necessary.
0 - 10 W90
SAFETY RULES
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, mechani-
cally, 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.
W90 0 - 11
UNITS OF MEASURE CLASSIFICATION OF STANDARD COMPO-

NENTS TO DETERMINE THE TIGHTENING
Units of measure used in this manual are those TORQUES
adopted by the International System which replace
the units previously used by the M.K.S. system.
Force: decanewton (daN) replaces kilogram Note - In case, in the different sections, the tightening
(kg) torque is not listed, refer to the table “TIGHTE-
NING TORQUES”, only after identifying exactly the
Pressure: bar, replaces kg/cm2 component.
Torque: decanewton x meter (daNm) replaces

kgm The latter is identified by a coded eight digit number,
allowing a complete description of the item.
The following tables is to be used to convert units of
measure:
Example:
multiply by to obtain
I / a b c d e / f g
Force kg 0.9807 daN
I - Standard index digit
Pressure kg/cm2 0.9807 bar
It is always represented by the digit 1. This number
Torque kgm 0.9807 daNm indicates that the item can be fabricated in a number
of versions differing for material and coating.
Note - For current service use, the following a - b - c - d - e - Standard base digits
equivalences can be considered to be valid:
kg = daN; kg/cm2 = bar; kgm = daNm. It is a number always composed of five digits
identifying dimensional specifications of the item.
f - Material index digit
This digit indicates the material used for a defined

item. Its meaning is indicated in the table that follows.
g - Coating index digit
It indicates the coating applied to a defined item.
0 - 12 W90
Resistance class and material

Material
index (f)
FIAT UNI DIN SAE BSI BNA
0 R 40 4D - 4S - 4A 1 A 42
1 R50 5S - 6S 3 P 56
2 R80 8G 5 T 80
3 R100 100 10K 8 V 100
4 Brass Brass Messing Brass Brass Laiton
5 Alluminio Alluminio Aluminium Aluminium Aluminium Aluminium
6 Copper Copper Kupfer Copper Copper Cuivre
7 Blank for other metallic materials
WARNING TORQUE TABLES
- Lubricate all hardware until 24 dia., with engine oil. If correct torque is not specifically indicated in the
Use grease for larger diameters. relevant pages, refer to the following tables.
- Tolerance on torque: ± 5%
- Resistance classes R80, R100, R120 must be

understood as follows:
10.9 replaces R100

for screws
12.9 " R120
10 replaces R80
for nuts
12 " R100
CDT= cadmed; FOSF= phosphated; ZNT=

galvanised.
W90 0 - 13
NUTS (ZNT) SCREWS (ZNT / DEIDR)
Strength grade: 10 (R 80) Strength grade: 10.9 (R 100)
Diameter normal low type with polyamide ring Diameter normal self-locking
and pitch normal low type and pitch ZNT ZNT
mm daNm daNm daNm daNm mm daNm daNm
M6 x 1 1.3 1.2 - - M6 x 1 1.3 -
M8 x 1.25 3.2 2.6 3.9 3.2 M8 x 1.25 1.3 3.5
M10 x 1.25 7.2 5.2 8.2 6.2 M10 x 1.25 7.1 7.9
M10 x 1.5 6.5 5 7.7 6 M10 x 1.5 6.5 7
M12 x 1.25 13 8.7 14.5 10.2 M12 x 1.25 12.7 13.9
M12 x 1.75 11 8.1 12.9 9.6 M12 x 1.75 11 12
M14 x 1.5 19.5 13 21.6 15 M14 x 1.5 20 22
M14 x 2 18 12.5 20 14.6 M14 x 2 18 19
M16 x 1.5 30 17 34 20 M16 x 1.5 30 33
M 16 x 2 - - - - M16 x 2 - -
M18 x 1.5 45 25 50 29 M18 x 1.5 45 48
M18 x 2.5 - - - - M18 x 2.5 - -
M20 x 1.5 60 30.5 64.5 35 M20 x 1.5 60 65
M20 x 2.5 - - - - M20 x 2.5 - -
M22 x 1.5 80 41 - - M22 x 1.5 80 90
M22 x 2.5 - - - - M22 x 2.5 - -
M24 x 2 100 47 108 52.5 M24 x 2 100 110
M24 x 3 - - - - M24 x 3 - -
M27 x 2 95 40.1 - - M27 x 2 100 -
M30 x 2 130 49.4 - - M30 x 2 140 -
M33 x 2 170 - - - M33 x 2 190 -
M36 x 3 220 - - - M36 x 3 240 -
SECTION 1
ENGINE
CONTENTS
PARAGRAPH SUBJECT PAGE
1.1 GENERAL DESCRIPTION ........................................................................................ 1
1.2 GENERAL CHARACTERISTICS .............................................................................. 2
1.3 SPECIFICATIONS AND ASSEMBLY CLEARANCES ............................................... 5
1.4 FUEL INJECTION PUMP SPECIFICATIONS ........................................................... 11
1.5 EXTERNAL VIEWS ................................................................................................... 12
1.6 ENGINE SUPPORTS ................................................................................................ 13
1.7 MAIN TIGHTENING TORQUES AND PRESSURE PORTS ...................................... 14
1.8 LUBRICATION SYSTEM ........................................................................................... 15
1.9 COOLING SYSTEM .................................................................................................. 16

1.9.1 General description ................................................................................................... 17
1.9.2 Radiator ..................................................................................................................... 18
1.10 FUEL SYSTEM ......................................................................................................... 19

1.10.1 Fuel tank ................................................................................................................... 20
1.11 AIR INTAKE AND EXHAUST SYSTEM ..................................................................... 21

1.11.1 General description ................................................................................................... 21
1.11.2 Turbocharger ............................................................................................................. 21
1.11.3 Air filter ...................................................................................................................... 23
1.12 ELECTRICAL SYSTEM ............................................................................................ 24

1.12.1 Batteries .................................................................................................................... 24
1.12.2 Start switch ................................................................................................................ 24
1.12.3 Cold engine start ....................................................................................................... 25
1.12.4 Engine shut-down ...................................................................................................... 25
1.12.5 Engine pre-heating sequence ................................................................................... 26
1.12.6 Pre-heating malfunction warning lamp modes .......................................................... 26
1.12.7 Throttle control linkage .............................................................................................. 27
W90 ENGINE 1-1
1.1 GENERAL DESCRIPTION
The loader is fitted with a 4-stroke turbocharged water-cooled diesel engine with overhead valves and direct
injection rotary pump. The engine is assembled in the loader rear. Engine power is transferred to the torque
convertor by the flywheel through a flex plate clutch.
RADIATOR
AIR FILTER
EXHAUST GAS SILENCER
ENGINE
THROTTLE
LINKAGE
FUEL CAP
Fig. 1-1 Engine and ancillary parts
1-2 ENGINE W90
1.2 GENERAL CHARACTERISTICS
Model 8045.25.291
Cycle 4-stroke turbocharged diesel type

with direct injection
No. of cylinders 4 in line
Bore mm 104
Stroke mm 115
Total displacement cm3 3908
Compression ratio 18 : 1
Maximum power KW 63
rpm 2100
Maximum torque daNm 371
rpm 1400
Minimum engine speed

(no load) rpm 785 ÷ 865
Maximum engine speed

(no load) rpm 2250 ÷ 2350

with convertor stall rpm 2090 ÷ 2190

with attachment stall rpm 2100 ÷ 2200

with steering stall rpm > 600
W90 ENGINE 1-3
Maximum engine speed with

attachment+steering stall rpm 1465 ÷ 1665
Pressure at T.D.C.* bar ≥ 26
Minimum permissible
pressure at T.D.C.* bar ≥ 19
Engine cranking
speed rpm ~ 260
VALVE TIMING
Start before T.D.C. A 12°

End after B.D.C. B 31°
Start before B.D.C. D 50°

End after T.D.C. C 16°
Lash clearance
X
{ mm
mm
0.30
0.30
FUEL SYSTEM Through fuel lift pump, fuel injection pump, filters,
injectors, thermostart
Model: BOSCH VE 4/12 F 1050 LV 13655
Pump timing 6°
Delivery start mm 1
Nozzle type DLLA 132S
Injection order
- fuel injection pump A -B-C-D
- engine 1-3-4-2
Injection pressure bar 260 + 12
(*) Pressure taken by cranking the engine using the starter motor only, with oil temperature a 40 to 50°C and
the fuel injection pump stopped.
1-4 ENGINE W90
TURBOCHARGER
Turbocharger BSK 3 M27 AIR 48 - GARRET TO3
LUBRICATION Forced type by means of gear pumps, pressure relief

valve, double-action oil filter
Oil pressure with engine hot:
- at minimum speed bar ≥ 1.2
- at maximum speed bar ≥ 3.5
COOLING By means of a centrifugal pump, adjust thermostat,

fan, radiator, oil cooler.
Water pump drive Poly-V belts
Thermostat
- start to open at 79° ± 2° C
- fully open at
CAPACITIES
Total capacity at 1st filling:

lt. 11.6
Kg 10.6
Capacity at routine changes:
- engine oil pan

lt. 9.9
Kg 9
- engine oil pan + filter

lt. 10.5
Kg 9.6
W90 ENGINE 1-5
1.3 SPECIFICATIONS AND ASSEMBLY

CLEARANCES
CYLINDER ASSEMBLY AND mm
CRANKING ELEMENTS
Cylinder sleeve seats: Ø 1 106.85 ÷ 106.90
Cylinder sleeves:
outside diameter Ø2 107.02 ÷ 107.05
length L 198.00 ÷ 198.50
Cylinder sleeve to block seat 0.2
FIAT
KOBELCO Outside diameter Ø2 0.2
Cylinder sleeves:
inside diameter Ø3 104.000 ÷ 104.024
protrusion X
Pistons:
measuring height X 12
outside diameter Ø1 103.870 ÷ 103.852
piston pin seat Ø2 38.000 ÷ 38.006
Piston to cylinder sleeve 0.130 ÷ 0.172

clearance
FIAT
KOBELCO Piston diameter Ø1 0.6
Piston protrusion X 0.64 ÷ 0.97
Piston pin Ø3 37.984 ÷ 37.990
Piston pin to pin seat clearance 0.010 ÷ 0.022
X 1* 2.73 ÷ 2.70
Piston ring grooves X2 2.55 ÷ 2.57
X3 4.03 ÷ 4.05
* dimension taken at 101 mm dia.
1-6 ENGINE W90
CYLINDER ASSEMBLY
mm
AND CRANKING ELEMENTS
S 1* 2.595 ÷ 2.575
Piston rings S2 2.490 ÷ 2.478
S3 3.990 ÷ 3.975
* dimension taken at 101 mm dia.
1 0.105 ÷ 0.155
Piston ring 2 0.060 ÷ 0.092
to ring groove clearance 3 0.040 ÷ 0.075
FIAT
KOBELCO Piston rings 0.6
Ring end gap inside the

cylinder sleeve
X1 0.40 ÷ 0.65
X2 0.30 ÷ 0.55
X3 0.30 ÷ 0.55
Connecting rod small

end bush seat Ø1 41.846 ÷ 41.884
Connecting rod
bearing seat Ø2 67.407 ÷ 67.422
Connecting rod small end bush

diameter
outside Ø4 41.979 ÷ 42.017
inside Ø3 38.004 ÷ 38.014
Connecting rod saddle
bearings S 1.805 ÷ 1.815
Connecting rod small end bush

0.095 ÷ 0.171
to bush seat clearance
Piston pin to bush clearance 0.014 ÷ 0.031

FIAT
KOBELCO
Connecting rod saddle bearing 0.254 - 0.508
Measuring distance X 125

Max. parallelism error
on connecting
rod axes = 0.07
W90 ENGINE 1-7
CYLINDER ASSEMBLY AND

CRANKING ELEMENTS mm
Main journals Ø1 79.791 ÷ 79.810
Crankpins Ø2 63.725 ÷ 63.744

Main journal saddle
bearings S1 2.169 ÷ 2.178
Connecting rod saddle
bearings S2 1.805 ÷ 1.815
Main bearings Ø3 84.200 ÷ 84.230
Saddle bearings to main

0.034 ÷ 0.101
journals clearance
FIAT
KOBELCO Main journal saddle bearings 0.254 ÷ 0.508
Thrust bearing
journal length X1 32.0 ÷ 32.1
Thrust bearing
journal width X2 25.010 ÷ 25.060
Thrust liners X3 3.378 ÷ 3.429
Crankshaft thrust liner

0.082 ÷ 0.334
clearance
FIAT
KOBELCO Thrust liners 0.127 - 0.254 - 0.508
1 ≤ 0.10
Alignment
2 ± 0.25
Out-of-round 1-2 0.008
Taper 1-2 0.012
1-8 ENGINE W90
CYLINDER HEAD AND VALVE TIMING mm
Valve guide seats in the

cylinder head Ø1 13.950 ÷ 13.983
Ø2 8.023 ÷ 8.043
Valve guides
Ø3 13.993 ÷ 14.016
Valve guides to seats in the

0.010 ÷ 0.066
cylinder head
FIAT
KOBELCO Valve guides 0.2
Valves:
Ø4 7.985 ÷ 8.000
α 60° 30' ± 7'
Ø4 7.985 ÷ 8.000
α 45° 30' ± 7'
Valve stem to guide clearance 0.023 ÷ 0.058
Valve seat bore in the

cylinder head:
Ø1 -
Ø1 39.000 ÷ 39.025
Valve seat outside diameter

Valve seat angle relative to the
head:
-
Ø2
α 60° ± 5'
Ø2 39.136 ÷ 39.161
α 45° ± 5'
Valve stand to cyl. head X 0.7 ÷ 1
Valve seat to cyl. head

0.111 ÷ 0.161
clearance
W90 ENGINE 1-9
Valve spring lengths:
free length H 44.6
length loaded at:

270 ± 14N H1 34
528 ± 26N H2 23.8
Injector protrusion X 0.7 ÷ 1.5
Camshaft bush seats in the

block:
Ø1 54.780 ÷ 54.805
Ø Ø Ø Ø2 54.280 ÷ 54.305
1 2 3 Ø3 53.780 ÷ 53.805
Camshaft bearing journals:

Ø5
Ø4 50.970 ÷ 51.000
Ø5 50.470 ÷ 50.500
Ø4 Ø6 Ø6 49.970 ÷ 50.000
Camshaft bush outside

Ø1 diameters:
Ø2
Ø3 front Ø1 54.875 ÷ 54.930
intermediate Ø2 54.375 ÷ 54.430
rear Ø3 53.875 ÷ 53.930
Bush inside diameter:
Ø1 front Ø1 51.080 ÷ 51.130

Ø2 intermediate Ø2 50.580 ÷ 50.630
Ø3 rear Ø3 50.080 ÷ 50.130
Bush to block seat clearance 0.07 ÷ 0.15
Bush to bearing journal clearance 0.08 ÷ 0.16
Cam working lift:

H 5.97
H 6.25
1 - 10 ENGINE W90
Tappet seat in
the block Ø1 15.000 ÷ 15.018
Tappet outside diameters:
Ø2 14.740 ÷ 14.780
Ø3 14.950 ÷ 14.970
Tappets to seats clearance 0.030 ÷ 0.068
FIAT
KOBELCO
Tappets 0.1 - 0.2 - 0.3
Rocker arm shaft Ø1 17.982 ÷ 18.000
Rocker arms Ø2 18.016 ÷ 18.034
Rocker arm to shaft clearance 0.016 ÷ 0.052
W90 ENGINE 1 - 11
1.4 FUEL INJECTION PUMP SPECIFICATIONS
Fuel injection pump: VE4/12F1050LV

Governor: all-speed
Lift pump: diaphragm type
Pressure lines (ENGINE): dia. 6 x dia. 1.75; lengths 580 mm for cylinder no. 1 = 580 mm; for cylinder no.
2 = 580 mm; for cylinder no. 3 = 580 mm; for cylinder no. 4 = 580 mm; for cylinder no. 5 = 580 mm; for cylinder
no. 6 = 580 mm.
Injector setting (ENGINE): 260 bars.
Minimum engine speed (unloaded): 825 ± 25 rpm.
Statically splined-on 6 +0/–1 degrees B.T.D.C. with fuel injection pump plunger no. 1 at start of delivery and
engine piston no. 1 in compression stroke.
Test bench static and dynamic features conforming to ISO 4008/1 and 4008/2 Standards.
Pipes dia. 6 x dia. 2 x 450 mm (as per ISO 4093.3).
Nozzles as per ISO Standards (metering orifice pads).
Nozzle opening pressure: 250 + 3 bars
Test fluid as per ISO 4113 Standards, temperature: 38 to 42°C
Feed pressure: 0.35 bars.
Glass draining time : .......".
Relief valve setting ........... bars.
Leak-back restrictor hole dia. 0.55 mm.
INTERNAL PUMP TIMING
Piston lift 1 mm (from B.D.C.)

(at port closing)
Injection Order A B C D
1-3-4-2
Rotation anticlockwise (to the left)
BASIC PUMP SETTING

Operation Pump speed Toothed rod mm3/stroke/cyl. Max. drift between Pressure on
performed (rpm) position (mm) cylinders (cm3) LDA (bar)
Setting 700 85 3.5 1
Setting 500 70 3.5 0
Setting 400 minimum 5 4.0 0 minimum
Check 1050 70.5 3.5 1
1 - 12 ENGINE W90
1.5 EXTERNAL VIEWS
DIESEL ENGINE 8045.25.291
6
12
7
1 11 18 21
8
16
13 20
3
19
14
17
5 15 2 10 9 4
Fig. 1-2
1. THERMOSTAT SEAT 12. INTAKE MANIFOLD
2. ENGINE OIL COOLER 13. OIL FILTER
3. ALTERNATOR 14. ENGINE OIL PRESSURE SWITCH
4. OIL LEVEL DIPSTICK 15. WATER DRAIN TAP
5. OIL PAN 16. FUEL FILTERS
6. EXHAUST SILENCER 17. WATER PUMP
7. TURBOCHARGER 18. FUEL INJECTION PUMP
8. EXHAUST MANIFOLD 19. RADIATOR FAN
9. STARTER MOTOR 20. ENGINE SHUT-DOWN SOLENOID VALVE
10. FLYWHEEL HOUSING 21. OIL FILLER NECK
11. INJECTOR HOLDER
W90 ENGINE 1 - 13
1.6 ENGINE SUPPORTS
The engine is secured to the rear frame module in four locations: at the front through the transmission/torque
convertor assembly, which is in turn supported by means of brackets bolted to flexible mounts; at the rear by
means of a plate bolted to the engine and which also rests on flexible mounts.
4 4
1 1
2
9 2
5 3
Fig. 1-3 Engine supports
1. ENGINE REAR RETAINING NUT M12 6. MOUNT

2. LH FRONT SUPPORT BRACKET 7. PLATE
3. RH FRONT SUPPORT BRACKET 8. NUT M20
4. REAR MOUNT BOLT M10 9. ENGINE FRONT RETAINING BOLT M20
5. FRONT BRACKET RETAINING BOLT M16
1 4 daNm 3 20 daNm
2 16.7 daNm 4 4 daNm
1 - 14 ENGINE W90
1.7 MAIN TIGHTENING TORQUES AND PRESSURE PORTS
5.0
5.0 2.3
1.7
5.0
4.0
5.0 2.3 1.7
7.1 5.0
2.3 7.0 *
2.3
5.0
1.4
5.0
Fig. 1-4
daNm Tightening torque Lubrication pressure test port
* Further 180° tightening
W90 ENGINE 1 - 15
1.8 LUBRICATION SYSTEM
Lubrication: .................................................................................................................................. Pressure type

Lubrication pump: .................................................................................................. Gear type, crankshaft-driven
Filtering: ............................................................................................................ Combined total and partial flow
Oil cooler: ....................................................................................................... Integral water-oil heat exchanger
Oil pressure regulation: ..................................................................................................... Spring-loaded piston
Lubrication oil quantity (1st filling): ........................................................................................... 11.6 lt (2.55 gal)
Engine components are lubricated by means of forced circulation oil through a hydraulic pump. The pump
draws the oil from the engine oil pan and pressure feeds it, through the oil filter and cooler, to the main oil gallery
in the engine block to be released to the different engine elements and then return to the oil pan. Abnormal
engine oil pressure is signalled by the pressure switch or the filter clogged switch by means of a warning light
located in the cab instrument panel.
1 2 7
3 4 5 6
12 11 10 9
8
16
15 14 13
Fig. 1-5 Lubrication system schematic
1. OIL FILLING PLUG 9. OUTER OIL RETURN LINE

2. ROCKER ARM SHAFT 10. MAIN LUBRICATION GALLERY
3. CAMSHAFT 11. DELIVERY LINE
4. OIL FILTER 12. CRANKSHAFT
5. LOW PRESSURE SWITCH 13. INTAKE MESH FILTER
6. TURBOCHARGER 14. DRAIN PLUG
7. OUTER LUBRICATION GALLERY 15. RELIEF VALVE
8. OIL LEVEL DIPSTICK 16. OIL PUMP
In the figure: lubrication system schematic for engine type 8065.25, which is similar to the system for the W90 loader
engine.
1 - 16 ENGINE W90
1.9 COOLING SYSTEM
Cooling fluid: ............................................................................................................................................... water

Fan type: ......................................................................................................... 7-blade blower fan, dia. 550 mm
Drive ...................................................................................................................................................... belt type
Water pump: ............................................................................................................. belt-driven centrifugal type
Water thermostat: ............................................................................................................ at cylinder head outlet
Start to open at: .......................................................................................................................................... 79°C
Fully open at : ............................................................................................................................................. 94°C
Engine radiator: ................................................................................................... with wavy fins and core tubes
Convertor radiator: ............................................................................................ water radiator with multiple fins
System capacity: ........................................................................................................................... 22 lt (4.8 gal)
Cab
heating
Header
tank
Thermostat
Air compressor
Cylinder head
Radiator
Fan
Engine
Engine oil
cooler
Water pump
Fig. 1-6 Cooling system schematic
W90 ENGINE 1 - 17
1.9.1 GENERAL DESCRIPTION
The engine cooling system is water type with forced When the cooling water temperature equals the
circulation through a pump. The water pump draws thermostat opening temperature, water flows through
the cooling water from the radiator and sends it to the radiator to be cooled down before entering the
cool the various parts of the engine. water pump.
If the cooling water temperature is lower than the The cooling water temperature is continuously
thermostat opening temperature, the thermostat sensed by a sensor located in the thermostat housing
remains closed and water recirculates inside the and shown by the “engine water temperature gauge”
engine and does not flow into the radiator. in the cab instrument panel.
9
10
8 11
2
4
6
7
Fig. 1-7 Engine cooling system components
1. ENGINE 7. WATER RETURN TO THE ENGINE

2. WATER PIPE TO THE RADIATOR 8. HEADER TANK BRACKET
3. SHROUD 9. TANK PLUG
4. RADIATOR 10. HEADER TANK
5. RUBBER PAD 11. RADIATOR PLUG
6. FAN GUARD
1 - 18 ENGINE W90
1.9.2 RADIATOR
1 2
3 5 4 6
Fig. 1-8 Radiator
1. FROM THE HEADER TANK

2. COOLING WATER INLET
3. COOLING WATER OUTLET
4. TRANSMISSION OIL INLET
5. TRANSMISSION OIL OUTLET
6. WATER DRAIN
W90 ENGINE 1 - 19
1.10 FUEL SYSTEM
Fuel injection pump: ...............................................................................................................................BOSCH

Injector nozzle: .................................................................................................................... with spraying holes
Fuel lift pump: ......................................................................................................... plunger type (hand priming)
Fuel filter: .......................................................................................................................................... paper filter
Governor: ........................................................................................................................................... RSV type
Governor action: ............................................................................................................... Centrifugal, all-speed
Lubrication: .................................................................................................................................. Pressure type
Fuel tank capacity: .................................................................................................................... 130 lt (34.3 gal)
Bar 0.5 ± 0.1
9
8
2
4
1
3
Fig. 1-9 Fuel system schematic
1. MESH FILTER INSIDE THE FUEL TANK

2. PRE-FILTER WITH PRIMER AND WATER DETECTOR (FILTRATION DEGREE 100 µ)
3. DIAPHRAGM FUEL LIFT PUMP WITH INTEGRAL HAND PRIMER
4. HEATED DOUBLE FUEL FILTER
5. ROTARY INJECTION PUMP (VE TYPE)
6. INJECTOR
7. ONE-WAY VALVE
8. START ENABLING SOLENOID VALVE
9. THERMOSTART
1 - 20 ENGINE W90
1.10.1 FUEL TANK
The fuel tank is welded to the inner rear side of the The tank is fitted with a fuel level sensor connected
rear frame module. Fuel supply and return lines are to the level gauge in the cab instrument panel.
duly connected to the engine.
1 8
A
3
5 6
11 B
9 10
Fig. 1-10 Fuel tank and accessories
A: FUEL RETURN FROM THE SOLENOID VALVE

B: TO THE FUEL LIFT PUMP
1. FUEL LEVEL SENSOR 7. MESH FILTER

2. FUEL DELIVERY HOSE 8. PLUG
3. FUEL RETURN HOSE 9. DRAIN PLUG
4. REAR FRAME MODULE 10. COVER
5. FUEL TANK 11. FILTER/WATER SEDIMENTOR
6. FUEL LIFT HOSE
W90 ENGINE 1 - 21
1.11 AIR INTAKE AND EXHAUST

SYSTEM
Air filter ......................................................................................................................... with two paper elements

Silencer ................................................................................................................... DONALDSON dia. 200 mm
Turbocharger ................................................................................................................................ GARRET-T03
Drive ............................................................................................................................. driven by exhaust gases
Lubrication ................................................................................................................... pressure type, oil cooled
The engine air intake system is designed to bring

outer air into the intake manifold through the air filter.
The air filter is fitted with a filter clogged detector to
warn the operator when the filter element requires
cleaning.
The exhaust system is designed to convey
combustion exhaust gases from the exhaust manifold
to the silencer, and then into the atmosphere.
WARNING
Do not touch the silencer and exhaust manifold as

they are hot when the engine is running and for a
certain time after engine shut-down.
1.11.2 TURBOCHARGER
It is possible to increase engine power by feeding

compressed air into the cylinders during the intake
stroke (to supply a greater volume of air) and injecting
more fuel.
Exhaust gas inlet into the turbocharger is connected
to the exhaust manifold. Exhaust gases cause the
turbine wheel to rotate at high speed before entering
the silencer through the exhaust gas outlet.
The compressor wheel, which is assembled at the
opposite end of same shaft as the turbine wheel, also
rotating at high speed compresses the air drawn in
by the air filter and then delivers it to the intake
manifold.
1 - 22 ENGINE W90
NOTE - Finger-tighten the bolts paying attention not NOTE: 1

to over-tigthen the exhaust pipe and connection to
the silencer. Threads: LOCTITE 242
9
1
7
8
10
11
2
13
12
Fig. 1-11 Air intake and exhaust system
1. EXHAUST PIPE 8. EXTENSION

2. COLLARS 9. COVER
3. SILENCER 10. AIR FILTER
4. SUPPORT 11. CLAMP
5. BRACKET 12. EXHAUST MANIFOLD
6. BRACKET 13. DUST DISCHARGE VALVE
7. AIR FILTER SLEEVE
W90 ENGINE 1 - 23
1.11.3 AIR FILTER
3 4
7
5
Fig. 1-12 Air filter
1. AIR FILTER HOUSING 5. COVER RETAINING NUT

2. FILTER COVER 6. DUST DISCHARGE VALVE
3. OUTER FILTER ELEMENT 7. FILTER CLOGGED SENSOR CONNECTION
4. INNER FILTER ELEMENT
1 - 24 ENGINE W90
1.12 ELECTRICAL SYSTEM
Batteries ................................................................................................................................... maintenance-free

Voltage and capacity ..................................................................................................................... 12 V - 100 Ah
Number .............................................................................................................................................................. 2
Weight (each) ............................................................................................................................................. 23 Kg
Starting motor
Type ........................................................................................................................electromagnetic engagement
Voltage and power ...........................................................................................................................24 V - 4 KW
Alternator
Type ..............................................................................................................................................................A.C.
Voltage and power ............................................................................................................................ 24 V - 55 A
Drive ...................................................................................................................................................... belt type
Automatic voltage regulator ...................................................................................................... inner IC regulator
Cold start aid .............................................................................................................................. pre-heating plug
Shut-down system .............................................................................................................. electromagnetic type
1.12.1 BATTERIES
There are two batteries, which are located in the The engine cannot be started is the gearshift control
respective bays, at the right and left sides of the rear lever is not in neutral (see 2.5.4. TRANSMISSION
frame. CONTROL SYSTEM).
Open the battery bay cover to perform necessary This is to prevent that the loader is set suddenly in
checks. motion when the start switch is operated.
OFF
AC
H C
DANGER
ON
Always use special care when handling batteries.
1. Do not cause flames or sparks. Never smoke, nor

approach a flame to a battery as flammable gases STAR
are continuously being released by the batteries.
T
2. Electrolyte contained in the batteries is a sulphuric

acid solution. It may provoke severe and painful (REAR) (FRONT)
burns if it touches the skin. Contact with the eyes
may cause blindness. Should the electrolyte come Fig. 1-13 Start switch
in contact with the eyes, wash the eyes with plenty
of water and seek medical attention.
B G1 G2 ACC M ST POSITION
H
OFF B ST
ACC
G2 G1
1.12.2 START SWITCH ON
START M ACC
The start switch has 4 positions:
OFF - ACC - ON - START
W90 ENGINE 1 - 25
1.12.3 COLD ENGINE START
The cold engine start aid activates when the sensor When the ignition key is turned to the “ON” position,
(3) (Fig. 1-14) detects a temperature lower than 8°C. pre-heating starts and lasts about 30 seconds.
The thermostart (2) becoming incandescent ignites When the ignition key is moved further on to the
the fuel oil diverted in the air intake passage (8) by “START” position, the engine is actually started.
the solenoid valve (4) to heat the air drawn into the
cylinders.
2
4
5
7
Fig. 1-14 Cold engine start system
1. FILTER WITH FUEL PRE-HEATING 5. DIAPHRAGM FUEL LIFT PUMP

2. THERMOSTART 6. ENGINE SHUT-DOWN SOLENOID VALVE
3. TEMPERATURE SENSOR 7. FUEL INJECTION PUMP
4. SOLENOID VALVE 8. AIR INTAKE MANIFOLD
1.12.4 ENGINE SHUT-DOWN SOLENOID VALVE
Diesel engines do not have any electrical device to When the start switch is turned to the OFF position,
cause combustion, as it happens with gasoline the engine shut-down solenoid valve (6) is energised
engines. Therefore, the engine is not stopped by and progressively decreases the amount of fuel
simply rotating the main switch (start switch) to the injected by the injection pump to the injectors down
off position. This is why wheel loaders are fitted with to zero until the engine stops.
an engine shut-down system to stop the engine.
1 - 26 ENGINE W90
1.12.5 ENGINE PRE-HEATING SEQUENCE
WARNING LAMP THERMOSTART SOLENOID VALVE

ENGINE WATER ACTION PERFORMED OR FUNCTION ON ON ON
TEMPERATURE
YES NO YES NO YES NO
≥ 8°C KEY START SWITCH TURNED TO THE RUN POSITION

(VOLTAGE TO TERMINAL "15) X X X
(≥ 46.4 °F) AFTER 2±0.2 SEC. X X X
≤ 8°C KEY START SWITCH TURNED TO THE RUN POSITION X X X

(VOLTAGE TO TERMINAL "15)
(≤ 46.4 °F) AFTER 2 SEC. X X X
PRE-HEATING (LASTS AS PER DIAGRAM) X X X
STATER MOTOR OPERATED BEFORE END OF PRE-HEATING X X X

(WITH LAMP ON).
WRONG YET NOT DISABLED ACTION. THE SYSTEM SELF-RESETS
END OF PRE-HEATING X X X
THE STARTER MOTOR IS NOT OPERATED WITHIN 30 ±1.5 SEC. FROM END X X X
OF PRE-HEATING (DISTRACTION TIME)
ENGINE START (THROUGHOUT STATER MOTOR CRANKING) X X X
AIR HEATING INSIDE THE INTAKE MANIFOLD WITH THE ENGINE RUNNING TX X X
(POST- HEATING)
END OF POST-HEATING X X X
1.12.6 PRE-HEATING MALFUNCTION WARNING LAMP MODES
DIAGNOSTIC THROUGH THE WARNING LAMP DIAGNOSTIC TIME
FAULTY SYSTEM FAULT SIGNAL TYPE CAUSED BY

CIRCUIT AND/OR TYPE UNTIL UNTIL SIGNAL
COMPONENT WARNING FLASHING KEY STARTING POST- REMOVAL OF CONTROL BOX ACTIVATED
LAMP OFF TURNED "15" HEAT. END KEY "15" IS DISCON.
1 Hz 4 Hz 60 SEC
REVERSED POLARITY X
POWER SUPPLY EXCEEDING RATED X

VALUE (32V INSTEAD OF 24V)
NO POWER SUPPLY "30" X X X
CIRCUIT NO POWER SUPPLY "15" X

FAULTS
▲▲
▲▲
OUTSIDE OPEN CIRCUIT X X X
THE THERMOSTARTS
CONTROL SHORT CIRCUIT X X X
BOX
OPEN CIRCUIT X X X
SOLENOID VALVE
▲
▲
SHORT CIRCUIT X X
TEMP. SENSOR OPEN CICUIT X X X
OPEN CIRCUIT X
WARNING LAMP
SHORT CIRCUIT X
CONTACTS NOT X X X
▲ ▲ ▲ ▲
▲ ▲ ▲ ▲
THERMOSTART CLOSED
CIRCUIT RELAY
FAULTS CONTACTS WELDED X X X
INSIDE
THE CONTACTS NOT X X X
CONTROL SOLENOID CLOSED
BOX VALVE RELAY
CONTACTS WELDED X X X
At all times, even when pre/post-heating is not operated

▲
▲
Only when pre/post-heating is operated
W90 ENGINE 1 - 27
1.12.7 THROTTLE CONTROL LINKAGE
Engine speed is controlled by means of the throttle Adjust the linkage as to have the fuel injection pump
pedal. lever at end of travel and touching the stop screw
When you press the throttle pedal to suit engine when the pedal (1) is in contact with the screw (10).
speed to working conditions, the cable is operated
which controls the fuel injection pump control lever. ATTENTION: The stop screw on the pump is factory-
sealed. Do not change the stop screw adjustment.
11
6
1
10 7
2
4
3
9 8 12
Fig. 1-15 Throttle control system
Note - In the figure: fuel injection pump for models W110, W130.
1. THROTTLE PEDAL 7. LEVER ARTICULATED JOINT

2. RUBBER BOOT 8. FUEL INJECTION PUMP
3. SPRING 9. IDLE ADJUST SCREW
4. CONTROL CABLE 10. PEDAL TRAVEL ADJUST SCREW
5. RUBBER BOOT 11. PUMP CONTROL LEVER TRAVEL ADJUST SCREW
6. CABLE RETAINING BRACKET 12. PUMP CONTROL LEVER.
SECTION 2
TRANSMISSION
CONTENTS
2.1 GENERAL DESCRIPTION ..................................................................................... 1
2.2 TORQUE CONVERTOR - TRANSMISSION .......................................................... 2
2.3 TORQUE CONVERTOR ........................................................................................ 5
2.4 TRANSMISSION - CONVERTOR PUMP ............................................................... 6
2.5 TRANSMISSION .................................................................................................... 7

2.5.1 Directional cluth shaft ............................................................................................. 7
2.5.2 Power transfer schematic ....................................................................................... 10
2.5.3 Transmission control valve ..................................................................................... 12
2.5.4 Transmission control system .................................................................................. 28
2.6 TRANSMISSION DISASSEMBLY/ RE-ASSEMBLY ............................................... 33

2.6.1 Disassembly ............................................................................................................ 33
2.6.2 Re-assembly ........................................................................................................... 47
2.6.3 Troubleshooting ....................................................................................................... 61
2.6.4 Standard values for maintenance ........................................................................... 64
2.6.5 Tightening torque values for main bolts .................................................................. 66
2.7 OIL CIRCUIT ........................................................................................................... 67
2.8 DRIVE SHAFTS ...................................................................................................... 69
2.9 AXLES (FRONT AND REAR) ................................................................................. 71

2.9.1 Axle ......................................................................................................................... 71
2.9.2 Differential assembly .............................................................................................. 75
2.9.3 Final drives .............................................................................................................. 77
2.9.4 Axles ....................................................................................................................... 79
2.10 WHEELS ................................................................................................................. 110

2.10.1 Tyres ....................................................................................................................... 110
W90 DRIVE LINE/TRANSMISSION 2-1
The drive line is composed of the control unit (torque Power transmitted to each axle reaches the tyres
convertor and transmission assembly), drive shafts, through the wheels and sets the loader in motion.
front and rear axles and tyres. The diagram shows the drive line of the loader.
Engine power is transmitted to the convertor-
transmission unit, where revolutions are reduced and
torque increased.
Front axle Front wheel
Engine Torque Transmission

converter
Rear Rear
: Drive shaft
axle wheel
Tyre and wheelassembly Torque converter
Rear axle
Drive shaft
Transmission
Front axle
Fig. 2-1 Drive line components
2-2 DRIVE LINE/TRANSMISSION W90
2.2 TORQUE CONVERTOR - TRANSMISSION
TORQUE CONVERTOR
- Name TCM 640-25 (DAIKIN 12.5")
- Type 3 coaxial components (pump impeller, turbine and stator)

single stage
single phase
- Radiator water cooling, tube core type
- Working pressure 3.2 bar (46 psi)
CENTRIFUGAL PUMP
- Name DDG1A23-9
TRANSMISSION
- Name TCM 640-25
- Type solenoid type, full power-shift

with constant mesh gears
- Speeds 3 forward gears and 3 reverse gears
CLUTCH PACKS
- Type multiple discs in oil bath
- Working pressure 17 - 20 bars (242 - 284 psi)
- Oil capacity 17 lt (4.5 gal)
- Weight 415 Kg (915 lbs)
Note - The transmission oil cooler is in the lower tank

of the radiator. For the technical features, see “1.9
COOLING SYSTEM”.
GENERAL DESCRIPTION
The drive line control unit is composed of the torque

convertor and transmission gears in a single unit.
Engine power is transmitted to the transmission
through the flywheel and convertor.
The engine and transmission-convertor unit are
connected by dry flex plates.
1
2
4
5
2
Fig. 2-2 Transmission-convertor unit supports
Note - 1 4.6 daNm (33 ft-lbs) 3 8.5 daNm (62 ft-lbs)
Threads: LOCTITE 262
2 16.7 daNm (121 ft-lbs)
1. (ENGINE)
2. TRANSMISSION-CONVERTOR UNIT
3. SUPPORT BRACKET
4. RUBBER MOUNT
5. PLATE
1. From the OIL COOLER
2. OIL TOPPING-UP HOLE
3. PARKING BRAKE DISENGAGE PRESSURE
4. To the OIL COOLER
5. From the FILTER
11. REVERSE CLUTCH PRESSURE PORT 17 - 20 bars
12. FORWARD CLUTCH PRESSURE PORT 17 - 20 bars
13. 2ND SPEED CLUTCH PRESSURE PORT 17 - 20 bars
14. 1ST SPEED CLUTCH PRESSURE PORT 17 - 20 bars
15. 3RD SPEED CLUTCH PRESSURE PORT 17 - 20 bars
16. PRESSURE SWITCH MOUNTING HOLE
17. TEMPERATURE SENSOR MOUNTING HOLE
18. CONVERTOR OUTPUT PRESSURE PORT
19. CONVERTOR INPUT PRESSURE PORT
21. CHARGE PUMP
22. SUCTION TUBE
23. MESH FILTER
24. CONTROL VALVE
25. OIL DIPSTICK
26. PLUG
27. BREATHER
28. LEVEL PLUG
29. SPRING
30. PISTON (SAFETY VALVE)
31. EMERGENCY STEERING PUMP
32. ATTACHMENT - BRAKE PUMP
Notes:
Clutch oil pressure: 17 - 20 bar
Safety valve opening pressure: 7.2 bar 1 Threads: LOCTITE 572
2 Outer diameter: LOCTITE 572

daNm Tightening torque
3 Control valve solenoid excitement table
Pressure test port

•: ENERGISED
Sol. Fwd Sol. Rev Sol. A Sol. B
3rd Fwd
•
19
2nd Fwd
• • •
st
1 Fwd
• •
N
29 1st Rev
• •
30 32
5.0 2nd Rev
• • •
Section A-A
rd
3 Rev
•
View from "F"
79T 4.1
75T Note - Pressure port plug threads:
LOCTITE 572
27 8.8
5 21
1 4.1 4.6
24
1
F Fwd - Rev
4.1 4.1 22
17
11
A A 18 R
12
3
14 1st-3rd F
5.0 A 19
B B
15 2nd
13
16
D
3
2
B Fwd 10.1
5.0
Fwd
25
31 D
1 28 1.9
3.0
3.3 5.0 2 26 3.3
Note - Sections B-B and D-D: see next page. 23

Fig. 2-3 Convertor/transmission assembly
1. CHARGE PUMP 23. 1ST/3RD SPEED CLUTCH SHAFT
1 1 2. PUMP SLEEVE 24. OIL DISTRIBUTION COVER
3 2
3. PUMP DRIVE GEAR 25. 2ND SPEED CLUTCH SHAFT
4. BEARING SUPPORT 26. OIL DISTRIBUTION COVER
4 2 27. SEALING COVER
5. OIL SEAL COVER
18 6. PUMP IMPELLER PINION GEAR 28. SEAL GASKET
7. SEAL GASKET 29. MOUNT PLATE
5 19 8. TURBINE SHAFT 30. OUTPUT SHAFT
9. PUMP IMPELLER 31. SPACER
20 10. CONVERTOR HOUSING 32. OIL SEAL
6 33. TRANSMISSION HOUSING
11. PLUG
7 21 12. SCREW (TO RELEASE THE PARKING BRAKE) 34. BRAKE HOUSING
13. PLUG 35. PISTON HOUSING
14. MOUNT PLATE 36. COVER
8 22
15. BEARING COVER 37. PIN
16. GEAR 38. SPRING
17. DRAIN PLUG 39. PISTON
18. SHUTTLE GEAR 40. END PLATE
Fwd Rev 19. BALL 41. INNER TOOTHING DISC
23
20. SHAFT 42. OUTER TOOTHING DISC
21. FORWARD/REVERSE CLUTCH SHAFT 43. SENSOR DISC
9 22. OIL DISTRIBUTION COVER 44. ANGULAR SPEED SENSOR (FOR THE
24 SPEEDOMETER)
10 3rd 1st
25
Notes -
26
1 Convertor housing mount plate: LOCTITE 518
3 11
2 Threads: LOCTITE 262
2nd
27
12
28 4 Outer diameter: LOCTITE 572
29
5 Clearance E adjustment: bring sensor to touch the sensor disc (43), then
2 move it away by turning the adjuster out by 1.5 turns
4 13
30 + : Green – : Black
14
E
34 15 31 3 Notes - Seal ring installation procedure
35 32
16 Seal ring outer diameter (metal): LOCTITE 262
43 44 5
33 1
36 17 Seal lip: Grease
37 2
Mount plate chamfers and sliding surfaces: Grease
40
38
41
39 Emergency steering
42
pump power take-off
section Section D-D
Section B-B
Fig. 2-4 Convertor/transmission assembly (2)

2.3 TORQUE CONVERTOR
The torque convertor unit is composed of a convertor, The hydraulic pump control unit activates the charge
a hydraulic pump control unit and a turbine shaft. pump and the main pump through the control gear
The convertor is composed of a pump and a turbine, installed on the hub of the convertor pump.
mounted one in front of the other, with a stator in
between, and it is placed inside the convertor housing
in oil bath.
1
3
1
4
5 2
Fig. 2-5 Convertor assembly
Note - 1 2.0 daNm (14 ft-lbs)
2 6.2 daNm (45 ft-lbs) Threads: LOCTITE 262
3 Mobile surfaces: molybdenum-base grease
1. CONVERTOR PUMP 4. TURBINE 7. WASHER

2. BALL BEARING 5. COUPLING 8. NEEDLE BEARING
3. FRONT COVER 6. STATOR 9. SPACER
2.4 TRANSMISSION - CONVERTOR

PUMP
The pump is mounted on the convertor cover plate.

It supplies the forward-reverse and speed clutches
through the control valve, allows the inner 1
transmission gears to be lubricated, supplies the
convertor and also sends pressure oil necessary to 2
release the machine parking brake.
3
Main pump data:
Type: gear type

Drive: gear type
Flow at rated speed: 74 lt/min
Engine/pump speed ratio 0.9375 : 1
Fig. 2-6 Pump installation on the transmission-convertor

unit
4
5 13
6
7
8
9 14
10
11
15
16
17
12
Fig. 2-7 Transmission-convertor pump components
1. CONVERTOR-TRANSMISSION PUMP 10. CIRCLIP

2. DRIVE SLEEVE 11. BALL
3. TRANSMISSION-CONVERTOR UNIT 12. PUMP BODY
4. PLATE 13. GEARS
5. GASKET 14. GEARS
6. BUSHES 15. SCREW
7. GASKET 16. WASHER
8. MOUNTING PLATE 17. END PLATE
9. OIL SEAL
2.5 TRANSMISSION 2.5.1 DIRECTIONAL CLUTCH SHAFT
The transmission is meant to shift speeds and The directional clutches are meant to engage/
direction of travel. disengage power under load, whatever speed is
The transmission includes three clutch shaft engaged.
assemblies, a shuttle gear, an output shaft, a parking
brake and a control valve.
1 2 3 4 5 6 7 8 1 9 1 10 11 12
FWD. REV.
13 14
1 Detail A 1 Detail B
Fig. 2-8 Directional clutch shaft assembly typical configuration
Note - 1 Sliding surfaces: grease (pay

attention to orientation during
assembly. Refer to the above
magnified insets).
1. SHAFT AND DRUM 6. PISTON 11. SEAL RING

2. GEAR 7. DUMP VALVE 12. PLUG
3. END PLATE 8. SEAL RING (INNER) 13. SPRING LOCK
4. INNER TOOTHING DISC 9. SEAL RING (OUTER) 14. RETURN SPRING
5. OUTER TOOTHING DISC 10. GEAR
(Forward/reverse clutch shaft)
FWD. REV.
(1st / 3rd clutch shaft)
3rd 1st
(2nd clutch shaft)

Disc hub
2nd
Fig. 2-9 Clutch shafts
OPERATION
The clutch is engaged by oil under pressure coming The clutch piston packs up the outer and inner clutch
from the transmission control valve. discs, the clutch shaft becomes one single unit with
Pressure oil flows through the distribution cover and the clutch hub and allows power to be transmitted to
passages in the clutch shaft, reaches the rear end of the transmission output shaft.
the clutch piston and moves it.
2 3 4 5
Pressure oil
From transmission
control valve
1
1. CLUTCH SHAFT
2. CLUTCH PISTON
3. OUTER CLUTCH DISC
4. INNER CLUTCH DISC
5. CLUTCH HUB
Fig. 2-10 Clutch engagement
When oil under pressure does not come from the and hub to turn independently from each other,
transmission control valve, the return spring moves preventing power from being transmitted to the
backward the clutch piston, releases the inner and transmission output shaft.
outer clutch disc pack, and allows the clutch shaft
5
1. CLUTCH SHAFT
2 3 4 6 7
2. CLUTCH PISTON
3. OUTER CLUTCH DISC
4. INNER CLUTCH DISC
5. CLEARANCE
6. RETURN SPRING
7. CLUTCH HUB
To transmission
control valve
Fig. 2-11 Clutch disengagement
2 - 10 DRIVE LINE/TRANSMISSION W90
2.5.2 POWER TRANSFER SCHEMATIC

(3rd Forward / 3rd Reverse)
1. Gearshift lever in the neutral position 2. Gearshift lever in the forward position
When both the forward and reverse clutches are When the gearshift lever is moved in any of the three
disengaged, power from the torque convertor turns forward speeds, power from the torque convertor
the forward/reverse clutch shaft without being reaches the transmission output shaft through the
transmitted to the speed clutches. “forward” clutch and the clutch of the speed selected.
FWD. REV.
3rd 1st
2nd
- - - - - - - - - - 1st speed forward

– – – – – – – 2nd speed forward
–– – –– – –– 3rd speed forward
Fig. 2-12 Power transfer schematic during forward travel
W90 DRIVE LINE/TRANSMISSION 2 - 11
3. Gearshift lever in the reverse position
When the gearshift lever is moved in any of the three reaches the transmission output shaft through the
reverse speeds, power from the torque convertor “reverse” clutch and the clutch of the speed selected.
FWD. REV.
3rd 1st
2nd
- - - - - - - - - - 1st speed reverse

– – – – – – – 2nd speed reverse
–– – –– – –– 3rd speed reverse
Fig. 2-13 Power transfer schematic during reverse travel
2.5.3 TRANSMISSION CONTROL VALVE
The transmission control valve allows to select to selector) move the corresponding spools that direct
which clutches oil at engagement pressure is to be pressure oil flow.
sent to change the loader direction of travel and/or
speed. The control valve is also fitted with a feathering device
that works separately according to the speed
The control valve is composed of a control valve body engaged. If the electric system has a failure, the
and 4 solenoid valves that, being energised/de- control valve can be operated manually.
energised by the gearshift control lever (gearshift
A A
B B
C C
3 4
D 2
Fig. 2-14 Transmission control valve
1. PLATE (FOR MANUAL CONTROL) 16. RESTRICTOR HOLE PLUG [W]

2. COVER 17. RESTRICTOR HOLE PLUG [Z] See Note
3. COVER 18. RESTRICTOR HOLE PLUG [Y]
4. COVER 19. RESTRICTOR HOLE PLUG [X]
5. SOLENOID VALVE 20. CONTROL VALVE BODY (UPPER)
6. CONNECTOR 21. SPRING
7. CONTROL VALVE BODY (LOWER) 22. FLOW VALVE
8. FORWARD/REVERSE SELECTOR SPOOL 23. SPRING
9. ADAPTOR 24. PIN
10. SPRING 25. CAP
11. SPOOL (A) 26. INNER SPRING
12. SELECTOR SPOOL SPRING 27. INTERMEDIATE SPRING
13. SPOOL (B) 28. OUTER SPRING
14. SELECTOR SPOOL SPRING 29. LOAD PISTON (H)
15. HOLE ø 0.8 mm (0.031 in.) (FOR THE SOLENOID 30. PRESSURE REGULATING VALVE
VALVE) 31. PISTON
7 15
sol 8
IND.
9
sol 10
AV. (W)
11
12
A sol (Z) (X)
13
14
B sol (Y)
Section A-A
6 16 17 18 19
View from B-B
20
30
21
31
22 39
32
23
24 33
25 34
26 35
27 36
28 Section D-D
29 38 37
Section C-C
Fig. 2-15 Transmission control valve (2)
Note - Hole diameter in mm (inches)
Inlet hole [W] Hole [X] Hole [Y] Hole [Z]

(1st and 2nd) (2nd) (3rd)
5.5 (0.22) 1.0 (0.039) 1.2 (0.047) 1.6 (0.063)
32. SPRING 37. OUTER SPRING

33. FEATHERING VALVE 38. LOAD PISTON
34. CAP 39. MANUAL SPOOL (FOR EMERGENCY TRAVEL)
35. INNER SPRING
36. INTERMEDIATE SPRING
1 ÷ 4 , FWD. , REV. : Clutches
Forward/reverse FWD.
F REV.
R
selector spool
3 1
2
Rev. sol.
sol. B
Fwd. sol.
To the torque Spool B

convertor
Manual
spool
sol. A
Spool A
Pressure regulating
valve
(Y)
(W) (Z)
(X)
Flow valve
Feathering valve
from the Pump
Accumulator
(load piston)
Fig. 2-16 Transmission control valve (3) - Hydraulic diagram
OPERATION
The feathering valve controls the time needed to The operation of the feathering valve is shown in the
increase oil pressure up to the clutch engagement diagram by means of points A - E. The action of the
value, that is it changes the pressure increase curve solenoid valves and manual spool (emergency travel
according to the speed ratios allowing to shift more spool) is also shown in the following pages.
smoothly.
Speed ratio
A D
2nd
Oil pressure
speed
3rd / 4th
speed E
C
1st
speed
0 Time
Fig. 2-17 Clutch engagement oil pressure variation curves
Forward/Reverse in neutral, 3rd speed in neutral

(Point A of Fig. 2-17)
1. Oil sent to the control valve inlet (1) flows through

the metering hole “a” of the pressure regulating
valve, fills the chamber (2) behind the spool and
moves the spool to the left as shown in the figure.
Oil, its pressure having been regulated to the
clutch engagement pressure value, flows along
the circuit (3) and reaches the circuit of the
feathering valve (5). Excess oil is dumped into
the torque convertor through the circuit (4).
2. Oil in the circuit (5) flows through the orifice left

by the chamfer of the feathering valve piston and
enters the circuit (6) connected with the circuits
of the speed selector spool A (8), flow valve (9),
and forward/ reverse selector spool (12) through
the restrictor hole [W].
3. Oil sent into the circuit (8) reaches, the 3rd speed
clutch piston chamber through (8) → (16) → (17)
→ (18). The other clutches are connected to
dump.
4. Oil in the circuit (8) flows through the axial hole of

spool A and reaches the circuit (19). Then it flows
through the metering hole [Z] and into the
accumulator chamber (20). In this chamber there
are two load pistons, one for low pressure and
the other for high pressure. After the low pressure
piston has come in touch with the cap, the high
pressure piston starts moving.
5. Oil in the circuit (12) is trapped by the forward/

reverse selector spool. The forward and reverse
clutches are both disengaged (neutral).
6. All solenoid valves are “OFF” (de-energised), so

oil reaching them through the corresponding
metering holes is dumped.
W90
Fig. 2-18
FWD CLUTCH 1st
REV 3rd 2nd
TRANSMISSION CONTROL VALVE
“OFF” “OFF”
sol. R sol. B 18
Neutral (3rd speed in neutral)

“OFF”
sol. F/R SELECTOR 12
F SPOOL
“OFF” SPOOL B 17
W sol. A 16
F N R
6
MANUAL SPOOL SPOOL A
8
19
FEATHERING
To TRANSMISSION 5
SPOOL
(LUBRIFICATION)
TORQUE
CONVERTOR
Z X Y
DRIVE LINE/TRANSMISSION
OIL COOLER
3
SAFETY VALVE
FLOW VALVE
4 a
FILTER 20
PRESS REGULATING
PUMP VALVE
1 2
HIGH PRESSURE LOW PRESSURE ACCUMULATOR
2 - 17
1st speed forward

(Point B of Fig. 2-17)
1. The solenoid valves F and A are energised.
2. With the solenoid valve F energised, the oil dump

is closed, so that oil coming from the pressure
regulating valve (1) is diverted towards the circuit
(26) where the forward/reverse selector spool is
placed. Pressure created by the oil flow moves
the forward/reverse selector spool to the right, as
shown in the figure.
3. In the same way, with the solenoid valve A

energised, spool A moves to the right, as shown.
4. When the forward/reverse selector spool moves,

oil from the circuit (12) reaches the circuit (21)
where the forward clutch is placed. As oil fills the
forward clutch piston chamber, a pressure
difference builds up between upstream circuits ((6)
of the feathering valve and (22) of the flow valve
left-hand side) and downstream circuits ((8) of
speed selector spool A, (9) of the flow valve right-
the hand side, and (12) of the forward/reverse
selector spool) relative to the control valve
metering hole [W].
(Upstream circuits have a higher pressure).
5. Pressure difference between the circuits (9) and

(22) moves the flow valve piston to the right , as
shown, dumping accumulator (20) oil.
6. The piston of the feathering valve moves to the

right, as shown, because of the pressure drop in
the circuit (25), admitting only the oil quantity
needed into the circuits (5, 6).
W90
Fig. 2-19
FWD CLUTCH 1st
REV 3rd 2nd
1ST speed forward

21 “OFF”
“OFF”
sol sol B
R
“ON” 26 12
sol F F/R SELECTOR
SPOOL “ON” SPOOL B
W sol A
FN R
6 25
MANUAL SPOOL
SPOOL A
8
5 FEATHERING
To TRANSMISSION SPOOL
(LUBRICATION)
TORQUE
CONVERTOR
9 Z X Y
OIL
COOLER
SAFETY
VALVE
FLOW VALVE
22
FILTER
PRESSURE REGULATING
PUMP 1
VALVE
HIGH LOW
PRESSURE PRESSURE ACCUMULATOR
20
2 - 19
Clutch engagement
(Point C of Fig. 2.17)
1. When the clutches are filled with oil, pressure

difference between upstream and downstream the
metering hole [W] becomes zero. The piston of
the flow valve moves to the left, as shown,
because of the spring force and closes oil dump.
Oil in the circuit (23) flows through the axial hole
in spool A, enters the circuit (24), flows through
the metering hole [X] to enter the accumulator
chamber (20).
2. In the same time, oil flows through the feathering

valve passages (5, 6) and holes in the valve piston
to enter the chamber (7) behind the piston. As a
consequence, the feathering valve piston
gradually moves to the left because of the
combined effect of oil pressure in the chamber
(25) and spring action, gradually increasing the
clutch engagement pressure.
3. When the clutch engagement pressure reaches

the specific value, the load piston in the
accumulator chamber (20) stops against the cap.
W90
Fig. 2-20
FWD CLUTCH 1st
REV 3rd 2nd
“OFF” “OFF”
sol. sol.
R B
“ON”
sol. F F/R
SELECTOR “ON” SPOOL B
SPOOL W A sol.
F NR
Clutch engagement (1ST speed forward)

6 25
MANUAL SPOOL 7 SPOOL A
23 24
5 FEATHERING
To TRANSMISSION
VALVE
(LUBRICATION)
TORQUE
CONVERTOR
Z X Y
OIL
COOLER
SAFETY
VALVE
FLOW VALVE
FILTER
PRESSURE REGULATING
PUMP
VALVE
HIGH LOW
20
2 - 21
After clutch engagement

(Point D of Fig. 2-17)
1. As soon as the forward and 1st speed clutches

are both engaged, pressure in the accumulator
chamber (20) tends to increase, obliging the load
piston to move till it touches the lock cap
(maximum charge).
In the same time, pressure increases also in the
feathering valve chamber (25) till it equals the
pressure on the other side (7) of the feathering
valve piston. The piston, however, moves to the
left following the combined action of pressure and
spring. At this point, pressure reaches maximum
value that corresponds to the setting of the
pressure regulating valve.
W90
Fig. 2-21
FWD CLUTCH 1st
REV 3rd 2nd
“OFF” “OFF”
sol. sol. B
R
“ON”
sol. F/R
F SELECTOR SPOOL B
“ON”
SPOOL W sol. A
FNR
7 25
Condition with clutches engaged (1st speed forward)

FEATHERING
(LUBRICATION)
TORQUE
CONVERTOR
Z X Y
OIL
COOLER
SAFETY
VALVE
FLOW VALVE
FILTER
PRESSURE REGULATING
PUMP
VALVE
HIGH LOW
20
2 - 23
Engagement of forward and 2nd speed clutches

(Point E in Fig. 2-17)
1. As the solenoid valves A and B are energised,

the speed control spools A and B move to the
right, as shown.
2. Oil that enters the circuit (8) of the speed selector

spool A flows into the circuit (23), and feeds, the
circuit (24) through the spool holes. From here
the oil flow is sent partly to the accumulator
chamber (20) through the metering hole [X], and
partly flows from the circuit (24) into the circuit
(27) of selector spool B. From the circuit (27), oil
flows through the circuit (28) and metering hole
[Y] of the circuit (29), and into the accumulator
chamber (20).
In other words, when the gearshift lever engages
the 2nd speed, oil flows through the metering holes
[X, Y] so that the time needed to increase the
clutch engagement pressure is shorter than when
1st speed is selected.
W90
Fig. 2-22
FWD CLUTCH 1st
REV 3rd 2nd
“OFF” “OFF”
sol. B 28
sol. R
“ON”
sol. F F/R SELECTOR
SPOOL “ON” SPOOL B 8 27
W sol. A
FNR
Clutch engagement (2nd speed forward)

23 24
FEATHERING
29
(LUBRICATION)
TORQUE
CONVERTOR
Z X Y
OIL
COOLER
SAFETY
VALVE
FLOW VALVE
FILTER
PRESSURE REGULATING
PUMP
VALVE
HIGH LOW
20
2 - 25
Solenoid valve operation

FWD. sol REV. sol A sol B sol
Four solenoid valves are installed in the lower part
of the control valve.
The solenoid valves are energised by moving the
3rd
•
gearshift lever in the operator’s compartment to
control the forward/reverse selector spool and spools
FWD. 2rd
• • •
A and B.
The table shows how the solenoid valves are
1st
• •
energised according to the corresponding speed
ratios. (
• : energised solenoid). 1st
• •
Note - The model W90 has 3 forward speeds and 3
reverse speeds.
REV. 2nd
• • •
3rd
•
Solenoid valve de-energised
Oil under pressure controlled by the pressure

regulating valve, constantly flows through the DE-ENERGISED
metering hole and into the solenoid valve. When the P
solenoid valve is de-energised, oil flows through it METERING
and then to dump. HOLE
Oil pressure at P is 0 bar (0 psi).
PRESS. REGULATING VALVE
Fig. 2-23
Solenoid valve energised
When the solenoid valve is energised, the oil passage

inside it closes and oil cannot be dumped. Oil ENERGISED
pressure at P becomes equal to the pressure
P
controlled by the pressure regulating valve. Direction
of travel and speed are controlled by means of this
pressure acting on the forward/reverse selector spool
and on the speed ratio selector spools A and B.
PRESS. REGULATING VALVE
Fig. 2-24
Operation of the manual spool

(emergency travel)
If the solenoid valves are not working correctly due regulating valve, flows through the metering holes
to an open electrical connection or any other electrical and reaches the circuits of the manual spool (31,
problem, the control valve can be set in 3rd forward 32). As the circuit (31) is blocked by the spool, oil
or reverse using this spool. flows from the circuit (33) into the circuit (26) of
We suggest to use this spool when the loader must the forward/reverse selector spool, moving it to
be removed from a traffic area to be repaired. the right, as shown, so that oil pressure in the
forward clutch increases.
2. Oil from the circuit (32) flows through the spool

and reverse solenoid valve to dump.
WARNING
3. As the solenoid valves A and B of the speed
Make sure that the engine is not running before using
spools are both de-energised, pressure in the 3rd
the manual spool. If the spool is operated with the
speed clutch increases. (See Fig. 2-17). As a
engine running, the loader may move abruptly
consequence, the loader will shift into 3rd speed
causing accidents.
forward.
a. Shifting into 3rd speed forward b. Shifting into 3rd speed reverse
To shift into 3rd speed forward, pull out the manual To shift into 3rd speed reverse, push in the manual
spool of about 10 mm (0.39 in.) spool of about 10 mm (0.39 inch.).
The operating principle is the same as in the case of
1. Oil, at the pressure controlled by the pressure the 3rd speed forward.
FWD. CLUTCH
REV.
Sol.
“OFF"
REV.
FWD.
Sol. 26
"OFF"
F N R
FWD./REV. SELECTOR
MANUAL SPOOL SPOOL
32 31
33
From the FEATHERING VALVE
From the PRESSURE REGULATING VALVE
Fig. 2-25 Manual spool operation (F)
2.5.4 TRANSMISSION CONTROL SYSTEM
The transmission control system is electrical type. The transmission control system is composed of a
The solenoid valves in the transmission control val- gearshift lever, a button switch to downshift (kick
ve are energised and de-energised through the down), two kick-down relays, a neutral relay (safety
gearshift lever to divert oil into the several passages start).
leading to transmission clutches to select the desired
speed.
–– ––
Kick-down relay 1
13
Kick-down relay 2 Kick-down switch
14
Gearshift selector
lever
Sol. A 1st 2nd 3rd 4th
14
Sol. B
13
F N R
FWD. Sol.
11
REV. Sol.
I H
9
D
Fuse Neutral relay
1 15
Safety start system
Fig. 2-26 Transmission control wiring diagram
Notes - 11 From the parking relay (electrical supply) 9 From the reverse warning light relay
1 From the start switch “C” 15 From the safety relay “S”
3-speed gearshift selector/control lever
The gearshift lever includes a safety system to start

the engine only in neutral and a downshift button
(KICK-DOWN).
CONNECTIONS CABLE TERMINAL COLOUR

1 VP RED
X1 2 E YELLOW
3 F PINK
4 G GREY
1 C BROW
X3 2 D GREEN
3 A BLUE
4 H VIOLET
X1
X3
SOLENOID VALVE EXCITEMENT TABLE ACCORDING TO THE

CONTROL LEVER POSITION
FORWARD SOLENOID VALVES NEUTRAL

A B FWD. REV. RELAY
1st 1 0 1 0
2nd 1 1 1 0 F.
3rd 0 0 1 0
N.
NEUTRAL SOLENOID VALVES
1
R.
REVERSE SOLENOID VALVES
A B FWD. REV.
1st 1 0 0 1
2nd 1 1 0 1
3rd 0 0 0 1
(1) SOLENOID VALVE ENERGISED

(0) SOLENOID VALVE DE-ENERGISED
A CD F (Rev) E (Fwd) G (Neutral)
2 3 R.
N.
F.
1
Gear shifting
1 = 1st speed
2 = 2nd speed
H VP
3 = 3rd speed
Gearshift lever wiring diagram
Fig. 2-27 Gearshift selector lever
Safety engine start system (in neutral) KICK DOWN system

(downshift button)
The safety engine start system does not enable the
engine to be started if the gearshift lever is not in the When the downshift button is pressed, the KICK-
neutral position. This is to prevent the loader from DOWN facility allows to carry out loading operations
moving abruptly when the start switch is turned to in a more effective and faster way, without moving
START. the gearshift lever.
Make sure the gearshift lever is in the neutral position The system consists in a downshift button integral to
before attempting to start the engine. the handle of the boom/bucket control lever and two
The safety start system is integral to the engine downshift relays.
starting circuit.
Switch
Operation (See Fig. 2-26) OFF
Cover
ON
1. When the start switch is turned to START with 2.5 mm
the gearshift lever in the neutral position, the (0.1 in)
neutral relay is closed allowing the electrical
current to flow through the safety relay and supply
the starting motor.
2. When the start switch is turned to START with

the gearshift lever not in the neutral position, the
neutral relay remains open preventing current
from flowing through the safety relay. Therefore,
the engine cannot be started. Body
Fig. 2-28 Downshift button
KICK-DOWN system operation
When the loader starts digging in 2nd forward and

the KICK-DOWN system is operated, the gear is
automatically shifted to the 1st speed by the downshift
relay, thereby transferring more power to the
attachment.
When the control lever is moved to reverse, after
loading or digging, the gear ratio is automatically
brought back to the 2nd speed to have a faster reverse
transfer.
In other words, the kick down system allows to control
both bucket penetration force and loader ground
speed by operating only the bucket control lever
(downshift button), with the gearshift lever in 2 nd
speed while filling the bucket or digging.
KICK-DOWN electrical operation
Gearshift lever in 2nd forward KICK-DOWN activated
1. When the gearshift lever is moved to 2nd forward, 1. When the KICK-DOWN system is switched on,
the solenoid valve F is energised by current “a”, relay 2 is activated by current “e”, that cuts out
while relay 1 is activated by current “b”. current “d” to the solenoid valve B, de-energising
the solenoid valve B. Consequently, transmission
2. The solenoid valve A is energised by current “c”, shifts into 1st forward.
while solenoid valve B is energised by current “d”.
As a consequence, transmission shifts into 2nd
forward.
–– –– ––
––
Relay 1 Relay 1 e
b 13 13
b
Kick-down e Kick-down
Relay 2 button Relay 2 button
14 14
d e
d Gearshift lever d Gearshift lever

A sol. A sol. 1st 2nd 3rd 4th
1st 2nd 3rd 4th
14 14
c e
d
B sol. B sol.
d d
13 F N R 13 F N R
FWD sol. b FWD sol.
a
11 11
REV sol. REV sol.
9 9
15 15
Fig. 2-29 Fig. 2-30
2. At the same time, current “f” appears to keep relay KICK-DOWN reverse operation
2 self-energised, which will remain activated also
after releasing the KICK-DOWN button. 1. When the gearshift lever is moved to reverse,
As a consequence, transmission remains in 1st current “b” is made void and relay 1 is deactivated.
forward even after having switched off the KICK- In this way current “f” to relay 2 is cut out and
DOWN system. relay 2 opens.
2. Current “d” is restored for the excitement of the

solenoid valve B and this changes the speed ratio
–– –– into 2nd.
Relay 1
13 3. Furthermore, the “reverse” solenoid valve is

Kick-down energised by current “g” to shift into 2nd reverse.
Relay 2 f “OFF” button
14
f
Gearshift lever ––
––
A sol. 1st 2nd 3rd 4th Relay 1
b
14 b
13
f Kick-down
Relay 2 button
B sol.
14
f
13 F. N. R. d
Fwd sol.
Gearshift lever
d
A sol.
11 1st 2nd 3rd 4th
Rev sol.
14
9
d
15 B sol
d
13 b F. N. R.
Fwd sol.
11 g
Fig. 2-31 Rev sol.
g
9
15
Fig. 2-32
2.6. TRANSMISSION DISASSEMBLY/ 3. Disassemble the parking brake as follows (in

RE-ASSEMBLY the case of split-type housing).
Note: When the piston housing is separate from
2.6.1. DISASSEMBLY the brake housing
Note: When disassembling the transmission, use a 1) Remove the plug from the cover center and
bench, a hoist (transmission weight: 415 kg) and screw in the brake releasing bolt.
eyebolts (M16 and M10) for your safety and easy
maintenance.
2.6.1.1 Disassembling the torque convertor
a) Removing the Torque Convertor
1. Attach eyebolts (M16) into the tapped holes on
the top surface of the transmission housing and
hoist the torque convertor. Remove the drain
plug to drain off oil.
Oil: 17 lt.
Fig. 2-35
2) Remove the four Allen screws and remove the

cover and piston housing as a set. Before
disassembly, put match marks on the case outer
side. Do not loosen the two hex headed bolts.
Fig. 2-33
2. Remove the suction tube (1) and the charge

pump (2). If they are hard to remove, tap them
with a soft mallet. Remove the pump sleeve
from inside the convertor housing.
Fig. 2-36
Fig. 2-34
3) Then, remove the other two Allen screws. 4. Disassemble the parking brake as follows (in
Remove the brake housing, prying with a the case of one-piece type housing):
screwdriver or a crow. Note: When the piston housing and the brake
housing are made into one-piece:
1) Remove the plug from the cover center and

screw in the brake releasing bolt.
Fig. 2-37 Fig. 2-39
4) Remove the snap ring and slide out the hub 2) Remove the four Allen screws and remove the
disc from the shaft. Remove the end plate, six cover and piston housing as a set.
discs, and seven plates. Do not loosen the two hex headed bolts.
Fig. 2-38 Fig. 2-40
3) Remove the snap ring and slide out the hub 6. Tie a cable to the torque convertor housing
disc from the shaft. flange. Remove the 21 hex head retaining
Remove the end plate , six discs and seven bolts (12 bolts from the convertor and 9 from
plates. the transmission side) and two Allen screws.
Separate the convertor housing from the
transmission, using two puller bolts.
Torque convertor: 130 kg.
Fig. 2-41 Fig. 2-43
5. Using a suitable cable wound around the torque b) Removing and Disassembling Convertor
convertor housing, hoist the transmission a little Wheels
and place it with the convertor housing pointing 1. Remove the eight bolts securing the input plate
upward. and remove the plate.
Fig. 2-42 Fig. 2-44
2. Remove the 24 bolts securing the front cover 4. Remove the snap ring. Lift out the stator wheel
and remove the cover with two puller bolts. and collar.
Fig. 2-45 Fig. 2-47
3. Remove the snap ring from the turbine wheel

and lift out the turbine wheel, holding the rivet 5. Remove the three bolts securing the oil baffle
heads with pliers. on the output side of the torque convertor.
Fig. 2-46 Fig. 2-48
6. Attach a hook to the pump impeller and remove 8. Remove the seven bolts securing the stator
the impeller, oil baffle and gear hub as a set. support on the output side of the torque
convertor
Fig. 2-49 Fig. 2-51
9. Remove the stator support and turbine shaft at

7. Remove the snap ring from the outside of the the same time by tapping the turbine shaft with
pump impeller hub. Slide out the gear and oil a soft mallet.
baffle.
Remove the snap ring from inside the pump 10. Remove the snap ring from the turbine shaft
impeller hub and slide out the bearing. and remove the bearing.
Fig. 2-50 Fig. 2-52
c) Removing the pump drive gear 2. Remove the plug, spring and spool.
1. Remove the bolts securing the pump drive gear
and slide out the gear, bearing and bearing Note: The spool seat is press-fit into the housing.
support. Do not remove it unless it is defective.
2. Remove the snap ring from inside the gear and

slide out the bearing and bearing support.
3. Remove the other pump drive gear, using the

same procedure as above.
Fig. 2-55
2.6.1.2 Disassembling the parking brake

1. Remove the brake releasing bolt from the cover
Fig. 2-53 center.
2. Remove the two bolts securing the cover by
turning them gradually and evenly in turns, and
separate cover from the housing.
Warning:
Do not loosen the bolts abruptly because many
strong springs are installed in the cover;
Otherwise, a serious accident might result.
d) Removing the Safety Valve Loosen the two bolts gradually until spring force
1. Loosen the safety valve plug. is fully relieved.
Fig. 2-54 Fig. 2-56
3. Remove the cover and the 18 springs (1). 3. Remove the lower control valve, using the same
Remove the piston (3) from the piston housing procedure as above, except that the number of
(2). mounting bolts to be removed in this step is
three.
4. Remove the two D-rings from the outer diameter
of the piston. Control valve (lower): 26 kg.
Fig. 2-57 Fig. 2-59

b) Removing the control valve cover and lines
1. Remove the three bolts securing the forward/
reverse clutch shaft control valve cover to the
transmission housing. Remove the control val-
2.6.1.3 Disassembling the transmission ve cover and O-ring.
a) Removing the control valve assembly
1. Attach an eyebolt (M10) to the control valve 2. Remove the three bolts securing the 1st and 3rd
(upper side) and sligthly lift it with a hoist. clutch shaft control valve cover to the
transmission housing. Remove the control val-
Control valve (upper side): 16 kg. ve cover and two O-rings.
In this step, take out the cover nuts from the 3rd
2. Remove the 10 bolts securing the upper control clutch line at the transmission housing side, and
valve and detach it by tapping with a soft mallet. remove.
Fig. 2-58 Fig. 2-60
3. Remove the three bolts securing the 2nd clutch 2. Drive each clutch shaft from the rear side with
shaft control valve cover to the transmission a soft mallet, to remove the bearing from the
housing. Remove the control valve cover. In transmission housing.
this step, remove the cover bolts from the 2nd
clutch line and remove the cover and piping as
well.
Fig. 2-61 Fig. 2-63
3. Remove the forward/reverse clutch shaft from

the convertor side.
Forward/reverse clutch shaft: 24 kg.
c) Removing the clutch shaft 4. After that, remove the 1st and 3rd clutch shaft,
1. Remove the snap ring from the outer diameter and 2nd clutch shaft.
of the rear bearing at each of the three clutch 1st and 3rd clutch shaft: 30 kg.
shafts. 2nd clutch shaft: 24 kg.
Fig. 2-62 Fig. 2-64
d) Removing the output shaft 4. Remove the snap ring from the outer diameter
1. Remove the three bolts securing the retainer of the output shaft bearing, on each side (front
plate from the rear side of the shaft. Remove and rear).
the retainer plate, O-ring and companion flange.
Fig. 2-65 Fig. 2-67
2. Remove the four bolts securing the seal retainer,

and remove the seal retainer.
5. Remove the two bolts securing the oil baffle.
3. Remove the four bolts securing the front bearing Remove the oil baffle from outside of the output
cover, and remove the bearing cover. gear.
Fig. 2-66 Fig. 2-68
6. Withdraw the shaft from the front side by driving 2. Install a puller in the threaded hole (M10) at the
it from rear side with a soft mallet. The output center of the shaft and remove the shaft.
gear and bearing will remain in the transmission
housing.
7. Remove the output gear and bearing from the

transmission case.
Fig. 2-69 Fig. 2-71
e) Removing the rear gear Note: Hold the rear gear, lock ball and bearing with
1. Remove the snap ring from the outer diameter your hand to prevent them from falling while the shaft
of the rear gear shaft. is removed.
Fig. 2-70 Fig. 2-72
f) Removing the rotation sensor 2.6.1.4 Disassembling the clutch shaft

Loosen the lock nut and turn the sensor to a) Disassembling the forward/reverse clutch
remove. shaft
1. Hold the clutch shaft upright in a vice with the
reverse clutch (the side having seal rings)
pointed upward.
2. Remove the three seal rings from the shaft.
3. Remove the snap ring from the reverse bearing.
4. Remove the ball bearing with a bearing puller.
Fig. 2-73 Fig. 2-75
5. Remove the snap ring between the reverse

gear and shaft.
g) Removing the strainer 6. Using a bearing puller remove the reverse gear
Remove the O-ring from the outer diameter of and inner bearing as a set.
the strainer inlet port and pull through the inner Remove the two bearings from the hub gear.
diameter. Remove the two snap rings.
Fig. 2-74 Fig. 2-76
7. Using a screwdriver remove the snap ring from 9. Remove the snap ring securing the return spring
the clutch drum inner groove. retainer. Remove the spring retainer and return
spring.
Fig. 2-77 Fig. 2-79
Warning:
8. Remove the belleville washer, end plate, 7 discs Remove the snap ring with the spring retainer
and 7 plates in this order. pressed downward because the spring force is
considerable. This step can be safely performed by
Note: Some models may not have belleville washers. using atool and a press as shown in the figure.
Fig. 2-78 Fig. 2-80
10. Remove the clutch piston. Remove the rubber 2.6.1.5 Disassembling the control valve
seal rings from the piston outer diameter and a) Disassembling the control valve (upper)
the shaft. 1. Remove the bolts securing the 6-bolt cover and
Note: The bleed valve is press-fit into the clutch remove the cover. If it is stuck, remove by
piston. Do not remove it if it is not defective. tapping with a soft mallet.
Warning:
11. Disassemble the forward clutch at the opposite Do not loosen the bolts abruptly because many
side using the same procedure as above. strong springs are installed in the cover. Otherwise,
a serious accident might result. Loosen the two
b) Disassembling the 1st and 3rd clutch shaft center bolts gradually until spring force is fully
Disassemble the clutch shaft referring to “(a) relieved.
Disassembling the forward/reverse clutch shaft.”
Fig. 2-81 Fig. 2-83
2. Remove the rod (1), inner spring (2), outer

spring (3), center spring (4) and load piston (5)
from the spool seat.
Remove the flow sensing spool (6) and spring
c) Disassembling the 2nd clutch shaft (7) from the center hole.
Remove the snap ring from the front gear and Remove the plug (8) and remove the regulator
remove the gear. spring (9).
8 9 7 6
1 2 3 4 5
Fig. 2-82 Fig. 2-84
3. Remove the seven bolts securing the cover at b) Disassembling the control valve (lower)
the opposite side and remove the cover. If it is 1. Remove the five Allen bolts from the solenoid
stuck, remove by tapping with a soft mallet. valve adaptor to separate the adapter from the
valve body. If the adaptor is stuck, remove it by
Warning: tapping with a soft mallet.
Do not loosen the bolts abruptly because many
strong springs are installed in the cover. Otherwise a
serious accident might occur. Loosen the bolts
gradually and alternately until spring force is fully
relieved.
Fig. 2-85 Fig. 2-87
4. Remove the rod (1), inner spring (2), outer

spring (3), center spring(4) and load piston (5) 2. Remove the four solenoid valves using a wrench
from the spool seat. (34 mm width across flats and 3 mm thickness).
Remove the spring (6) and feathering spool (7)
from the center hole. Remove the regulator 3. Remove the lock plate and lock bolt from the
spool (8) and pistons (10) from the other spool manual spool on the upper side, and remove
holes. the spool.
1 2 4 3 5
7 10 8 6
Fig. 2-86 Fig. 2-88
4. Remove the eight bolts securing the cover and 2.6.2 REASSEMBLY
remove the cover. If it is stuck, remove it by
tapping with a soft mallet. The following should be observed upon
reassembly.
5. Remove the forward/reverse selector spool (1),
adaptor (2) and spring (3) from the spool seat. 1. Wash all disassembled parts using a suitable
Slide out the spool A (4) and spring (5) from the solvent and dry them by blowing compressed
center spool seat. Slide out the spool B (6) and air. Carefully remove any sealant or gasket
spring (5) from the other spool hole. residues from the mating surfaces with a chisel.
2. Handle each washed part with care to prevent

dirt, dent or damage.
5 6 4 3. Check each disassembled part for wear or

damage. Replace any damaged or worn part.
Refer to “2.6.4. STANDARD VALUES FOR
MAINTENANCE.”
4. Replace the seals with new ones.
2.6.2.1 Reassembling the torque convertor

a) Installing the safety valve
Insert the spool, spring, O-ring and plug into
the case in this order, and tighten the plug.
3 2 1 2 3
Fig. 2-89
6. Both adaptor side and valve body mating

surfaces have four meteredg plugs. All of these
plugs can be screwed out with a plug wrench.
Note: The metered plugs are select fit. When you

are going to remove more than one plug at a time,
mark them before removal. Installing a plug in the
wrong bore might cause poor loader performance.
Fig. 2-91
Fig. 2-90
b) Installing the pump drive gear d) Installing the turbine shaft

1. Insert the bearing and bearing support in the 1. Install the bearing into the rear end of the turbi-
gear and secure them with the snap ring. ne shaft and secure it at both ends with snap
2. Insert the reassembled gear into the support rings.
hole inside the convertor housing and lock the 2. Apply convertor oil to the seal ring and install
gear by tightening the retaining bolt. Apply the ring onto the turbine shaft.
LOCTITE 262 to the threaded area of the bolt. 3. Press the turbine shaft at the output side of the
Tightening torque: 4.7 kgm. convertor housing and secure the bearing with
a snap ring.
Note: Install the 79 T gear at the right side and 75 T
gear at the left side when viewed from the torque
convertor input side.
3. Install the other pump drive gear using the same
procedure as above.
Fig. 2-94
Fig. 2-92 e) Reassembling convertor wheels

1. Press the ball bearing into the pump hub and
c) Installing the stator support secure it with a snap ring.
1. Apply convertor oil to the seal ring and install 2. Apply grease to the lip of the oil baffle oil seal
the ring in the stator support. and apply LOCTITE 262 to the outer diameter
2. Insert the stator support into the convertor of the oil seal. Press the oil seal into the oil
housing and tighten the seven mounting bolts baffle. The oil seal should be installed with the
from rear side. main lip (spring side) positioned at the convex
Tightening torque: 10.3 kgm. side of the oil baffle.
Fig. 2-93 Fig. 2-95
3. Install the O-ring in the outer diameter of the oil 6. Lift the pump assembly with the hoist and insert
baffle. the assembly into the stator support. After
making sure that the oil baffle screw holes align
4. Install the oil baffle and the pump hub gear in with the convertor housing holes, press the
the pump impeller and secure them with a snap bearing until it comes in contact with the step of
ring. the stator support.
Fig. 2-96 Fig. 2-98
5. Install a long stud into the screw hole of the oil

baffle so that the hole for the oil baffle securing 7. Remove the stud from the rear side and tighten
screw aligns with convertor housing side. the three oil baffle mounting bolts.
Screw size: M10 x 1.25. Tightening torque: 5.6 kgm.
Fig. 2-97 Fig. 2-99
8. Install the collar and stator wheel and secure 10. Install the front cover assembly (with the needle
them with the snap ring. bearing at its center) on the pump impeller and
tighten the 24 bolts.
Tightening torque: 2 kgm.
Fig. 2-100 Fig. 2-102
11. Install the input plate and washer, and tighten

the eight bolts, with the washer chamfer turned
towards the input plate side.
Apply LOCTITE 262 to the threaded area of
9. Install the snap ring, turbine wheel and snap each bolt.
ring onto the turbine shaft in this order. Tightening torque: 6.2 kgm.
Fig. 2-101 Fig. 2-103
2.6.2.2 Reassembling the clutch shaft 4. Install the spring retainer, return spring and
a) Forward/reverse clutch shaft spring retainer onto the drum shaft in this order.
1. Hold the clutch shaft upright in a vice with the Press the spring retainer to compress the spring,
reverse clutch drum upward. and install the snap ring onto the shaft to secure
the retainer.
2. Install the outer seal ring onto each piston and
the inner seal ring onto the shaft. Note: This step can be safely carried out using the
tool used in disassembling the clutch shaft.
Fig. 2-104 Fig. 2-106
5. Install the seven plates and the seven discs

alternately starting with a plate. Finally, install
the end plate and the belleville washer with the
belleville washer convex side towards the end
plate side.
3. Insert the clutch piston into the reverse clutch
drum. Apply grease to the seal ring and clutch Note: Some models may not have the belleville
piston in the seal ring sliding area. spring.
Fig. 2-105 Fig. 2-107
6. Install the snap ring in the groove inside the 8. Install two snap rings inside the hub gear and
clutch drum. insert it into the clutch drum, engaging the hub
gear with the plate and disc splines.
When inserting the hub gear into the clutch
drum, it is good practice to drive the hub gear
with a soft mallet, slightly moving it to the right
and left
9. Press the shielded bearing onto the shaft and
install the snap ring onto the shaft to secure the
bearing with the shield pointeing outwards.
Fig. 2-108 Fig. 2-110
7. Press the hub gear (inner) ball bearing onto the 10. Install the snap ring, bearing with snap ring, and
drum shaft. snap ring in this order.
Note: Remember that the inner bearing is not fitted The bearing fitted with the snap ring should be
witha shield. installed with the snap ring outward.
Fig. 2-109 Fig. 2-111
11. Install the three seal rings in the ring groove of 2. Install the spring (3), adapter (2) and forward/
the shaft. reverse selector spool (1) into the spool hole at
the eight-bolt cover side.
12. Reassemble the forward clutch at the opposite Install the selector spring (5) and spool (4) into
side, using the same procedure as above. the center spool hole.
b) Reassembling the 1st and 3rd clutch shaft Install the selector spring (5) and spool B (6)
Reassemble the 1st and 3rd clutch referring to into the other spool hole.
“a) Reassembling the forward/reverse clutch
shaft.” 3. Install the gasket to the cover and fit the cover
to the body, securing with the eight bolts. The
c) Reassembling the 2nd clutch shaft eight bolts should be tightened in sequence
Reassemble the 2 nd clutch referring to “a) evenly to compress the spring properly.
Reassembling the forward/reverse clutch shaft.” Tightening torque: 4.2 kgm.
5 6 4
2.6.2.3 Reassembling the control valve
The following should be observed when reassembling

the control valve.
Wash all disassembled parts thoroughly and dry them
by blowing compressed air. Do not wipe them with
cloth or paper as residues might cause troubles in
the hydraulic system.
Check the spool passages and ports for clogging. If
any clogging is found, remove and wash.
Apply LOCTITE 572 to the threaded area of plugs 3 2 1 2 3
which are not fitted with O-rings, before installing
them. Fig. 2-113
Do not use the seal tape because it might cause
clogging.
a) Reassembling the control valve (lower) 4. Install the four solenoid valves into the adapter
1. Apply LOCTITE 572 to the threaded area of the using a wrench (34 mm width across flats,
four metered plugs at the side and the four plugs 3 mm thickness).
at the top, before installing them on the valve
body and tigthten. Use caution not to install the 5. Install the manual spool and lock it with the lock
plugs in the wrong bores. plate and bolt.
Fig. 2-112 Fig. 2-114
6. Install the gasket to the adapter and fit the 3. Install the load piston (5), center spring (4), inner
adapter to the body, securing with five Allen spring (2), outer spring (3) and spool (1) in the
bolts. spool hole at the six-bolt cover side. Install the
Tightening torque: 4.2 kgm. flow sensing spool (6) and spring (7) i the center
spool hole. Install the regulating spring (9) inthe
plug hole on the same side and lock the spring
with the plug (8).
8 9 7 6
1 2 3 4 5
Fig. 2-115 Fig. 2-117
b) Reassembling the control valve (upper)

1. Install the load piston (5), center spring (4), inner
spring (2), outer spring (3) and spool (1) in the
spool hole at the seven-bolt cover side. Install
the spring (6) and feathering spool (7) i the 4. Install the gasket to the cover and fit the cover
center spool hole. to the body, securing with the six bolts.
Install the regulating spool (8) and piston (10)
inthe other spool hole. The six bolts should be tightened in sequence
2. Install the gasket to the cover and fit the cover to compress the strong springs properly. For
to the body, securing with seven bolts. easy removal, the two bolts at the center are
The seven bolts should be tightened in longer than the other bolts. Pay attention to bolt
sequence to compress the spring properly. length during reassembly.
Tightening torque: 4.2 kgm. Tightening torque: 4.2 kgm.
1 2 4 3 5
7 10 8 6
Fig. 2-116 Fig. 2-118
2.6.2.4 Reassembling the parking brake 4. Install the cover to the piston housing, making
sure to match marks made before disassembly,
1. Install the (large and small) D-rings in the outer and tighten the two bolts alternately.
diameter of the brake piston, and insert the Make sure to align the springs and 18 holes.
brake piston into the piston housing.
Apply grease to the D-rings and bore sliding Tightening torque: 5.1 kgm.
areas.
2. Install the O-ring on the piston housing in the

area which mates with the cover.
Fig. 2-119 Fig. 2-121
3. Insert the 18 springs in the piston holes.
Fig. 2-120
2.6.2.5 Reassembling the transmission b) Installing the output shaft

1. Press the bearing into the output shaft front side
Install the eyebolts in the tapped holes at the (the side which does not have the gear). Install
top of the transmission housing, lift the the snap ring on the output shaft at the opposite
transmission ousing with a hoist and put it side.
upright. 2. Place the oil baffle, bearing and output gear in
a) Installing the rear gear the housing, with the output gear rotation sensor
1. Install the snap ring inside the rear gear and plate facing the housing wall.
press the ball bearings at both ends. 3. Insert the shaft from the front side, through the
output gear and bearing.
2. Put both the rear gear and spacer in position 4. Tighten the two bolts securing the oil baffle, on
inside the case. the housing side.
Install the lock ball on the shaft and apply grease
to the ball to prevent it from falling off. Press
the shaft with the ball aligned with the case
groove.
Fig. 2-124
5. Install the snap rings in the transmission housing

grooves at front and the rear sides, to lock the
output shaft.
Fig. 2-122 6. Press the oil seal into the front bearing cap with
the main lip (spring side) towards the housing
inside. Install the bearing cap in the housing
with a gasket and the four bolts. When installing
3. Install the snap ring to lock the shaft. the oil seal, apply grease to the oil seal lip and
LOCTITE 262 to the outer diameter.
Fig. 2-123 Fig. 2-125
7. Press the oil seal into the rear retainer using 9. Apply LOCTITE 572 to the threaded area of the
the same procedure as above. rotation sensor. Screw the rotation sensor into
the transmission housing until it bottoms the
output gear sensing plate. Back off the sensor
one-half turn. After that, lock the sensor with
the nut.
Fig. 2-126 Fig. 2-128
8. Install the spacer onto the shaft rear side, with

the spacer small lubrication hole above the
splines. Apply grease to the chamfers and c) Installing the clutch shaft
sliding area of the companion flange and install 1. Turn the transmission housing upward.
the flange on the shaft. Apply LOCTITE 262 to 2. Insert the 2nd clutch shaft and 1st and 3rd clutch
the threaded area of each of the three bolts and shaft into the transmission housing together.
secure the companion flange, using an O-ring 3. Insert the forward/reverse clutch shaft into the
and plate. transmission housing and turn all shafts by hand
Tightening torque: 9.3 kgm. to engage them each other.
Fig. 2-127 Fig. 2-129
4. Drive each shaft with a soft mallet to press the 3. Install the two O-rings to the 1st and 3rd control
rear bearing into the transmission housing. valve cover mounting surface. Install the cover
to the housing with the gasket and three bolts.
5. Install the snap ring to the rear bearing of each Install the piping at the same time.
clutch shaft. Tightening torque: 5.1 kgm.
4. Install the 2nd control valve cover to the housing
with the gasket andthree bolts. Install the piping
at the same time.
Tightening torque: 5.1 kgm.
Fig. 2-130 Fig. 2-132
d) Installing the control valve cover

1. Apply convertor oil to the clutch shaft seal rings.
e) Installing the control valve
2. Install the O-ring on the forward/reverse control
valve cover mounting surface. 1. Install the control valve (lower) in the
Install the cover to the houising with the gasket transmission housing with the gasket and three
and three bolts. bolts.
Tightening torque: 5.1 kgm. Tightening torque: 5.1 kgm.
Fig. 2-131 Fig. 2-133
2. Align the control valve (upper) with the control 3. Hook the torque convertor with a hoist, install
valve (lower) inserting the gasket and install the the convertor so as to align it with the two dowel
control valve (upper) with the ten bolts. pins and secure it with 21 hex head bolts and
Tightening torque: 5.1 kgm 2 Allen bolts.
12 bolts of the 21 hex head bolts are to be
tightened from the convertor side and the 9 from
the transmission side. The two Allen bolts are
used for the parking brake.
Tightening torque: 5.1 kgm
Fig. 2-134 Fig. 2-136
g) Installing the parking brake

1. Install the two O-rings in the parking brake
housing and install it onto the convertor housing
f) Installing the torque converter with two bolts. (Only for the split-type housing)
1. Place the transmission with the torque convertor Tightening torque: 5.1 kgm
mounting surface upward. 2. Insert the disc hub onto the 2nd clutch shaft top
end and secure with the snap ring.
2. Apply a continuos bead of LOCTITE 509 to the 3. Install the seven plates and the six discs, one
transmission housing mating surface avoiding by one, on the disc hub and then install the
the bolt holes. end plate.
Fig. 2-135 Fig. 2-137
4. Install the previously reassembled parking brake h) Installing the suction strainer
sub-assembly in the housing and secure it with Insert the suction strainer (1) into the
four Allen bolts. transmission housing.
For the one-piece type housing, install the After inserting the suction strainer, secure it with
O-ring in the sub-assembly before installing it the O-ring (2).
in the housing.
Tightening torque: 5.1 kgm.
1 2
Fig. 2-138 Fig. 2-140
ii) Installing the charge pump

1. Install the charge pump sleeve onto the drive
gear. Apply LOCTITE 509 to the charge pump
mounting area and install the charge pump to
the transmission housing securing it with two
bolts.
5. Install the parking brake releasing bolt (1). Tightening torque: 5.1 kgm.
Apply LOCTITE 572 to the threaded area of the
plug (2) and install it. 2. Install the suction tube.
Fig. 2-139 Fig. 2-141
2.6.3. Troubleshooting
2.6.3.1 Torque convertor
Problem Possible Cause Inspection Remedy
Low oil level Check oil level with dipstick Top up to specifie level
Improper oil used Check oil type Change to specified

oil
Oil cooler line malfunction Check coolant for dirt Clean
Measure oil pressure at inlet Disassemble and re-

port of torque convertor place parts
Defective oil seal ring
Check breather for oil splash Disassemble and re-
place parts
Safety valve malfunction Measure oil pressure at inlet port Disassemble and re-
of torque convertor place part
Overheating or
lloss of power Check for foreign matter in tran- Disassemble and re-
smission drain place parts
Broken bearing
Check filter and oil Disassemble and re-
place parts
Check transmission strainer for Clean
clogging
Low charge pump output Measure oil pressure at inlet port Replace pump
of torque converter
Measure transmission clutch oil Replace pump

pressure
Excessive wear Check operating conditions and Use properly
modes
Transmission failure See "2.6.3.2 TRANSMISSION"
Defective oil baffle seal Check for oil leakage in the Replace parts
Oil leakage flywheel
(from the
flywheel) Defective oil baffle O-ring Check for oil leakage in the Replace parts
flywheel
Check for foreign matter in Disassemble and re-
transmission drain place parts
Broken bearing
Check filter and oil Disassemble and re-
place parts
Broken gear or improper Check with noise detector Disassemble and re-
backlash place parts
Excess noise
Broken pump or drive year Check with noise detector Replace pump
Aerated oil Check oil for aeration Retighten piping or re-

place parts
Improper oil used Check oil type Change to specified oil
2.6.3.2 Transmission
Torque convertor overheated See "2.6.3.1 "TORQUE CONVERTOR"
Low oil level Check oil level with oil dipstick Top up to specified
level
Improper oil used Check oil type Change to specified oil
Clutch slipping or seized Measure transmission clutch oil Disassemble and re-
pressure place parts
Overheating or
loss of power
Poor clutch lubrication Measure oil pressure at outlet Clean oil coller
port of torque converter
Check for foreign matter in trans-

mission drain Disassemble and re-
Broken bearing
Check filter and oil place parts
Low engine output and speed Check engine speed Adjust engine speed
Check with noise detector

Broken bearing or misas- Check for foreign matter in trans- Disassemble and re-
sembled mission drain place parts
Check filter and oil
Excess noise Check with noise detector
Broken gear or excessive bac- Check for foreign matter in trans- Disassemble and re-
klash mission drain place parts
Check filter and oil
Clutch seized Measure transmission clutch oil Disassemble and re-

pressure place parts
Low oil level Check oil level with dipstick Top up to specified le-
vel
Machine won't Charge pump malfunction Measure transmission clutch oil Replace charge pump
travel forward or pressure (low in all speeds)
reverse
Regulator valve stuck open Measure transmission clutch oil Disassemble and re-
pressure (low in all speeds) place parts
Broken bolts securing torque Test attachment system opera- Replace parts
Machine won't convertor input plate tion
operate forward/
reverse Parking brake won't release
(stuck or dragged) See "2.6.3.3 PARKING BRAKE"

Manual spool (emergency Check manual spool position at Raise the spool to locate
travel spool) is the reverse the control valve it in the normal condition
Machine won't travel position
travel forward
(can travel Forward clutch slipping (failed Measure forward clutch oil pres- Disassemble and re-
reverse) solenoid valve A) sure place parts
Seized reverse clutch Check if machine travels reverse Disassemble and re-
with clutch in neutral place parts
Manual spool (emergency tra-

Check manual spool position at Lower the spool to locate
vel spool) is in the forward tra-
the control valve it in the normal condition
vel position
Machine won't
travel reverse Reverse clutchslipping (failed Measure reverse clutch oil pres- Disassemble and re-
(can travel solenoid valve I) sure place parts
forward)
Seized forward clutch Check if machine travels forward Disassemble and re-
with clutch in neutral place parts
Machine won't 2 nd clutch slipping (A and B Measure 2nd clutch oil pressure Disassemble and re-
travel in 2nd gear solenoid valves failed) place parts
Machine won't 1st clutch slipping (A solenoid Measure1st clutch oil pressure Disassemble and re-
travel in 1st gear valve failed) place parts
2.6.3.3 Parking brake
Oil leak from parking brake Measure braking oil pressure Disassemble and re-
piston (defective D-ring) (check for oil leakage) place parts
Parking brake
won't release
(stuck or dragged) Disc brake malfunction (Piston Overhaul Wash and replace
has foreign matter caught or parts
stuck, or brake disc seized)
Slackened or broken brake Overhaul Wash and replace

Parking brake disc spring parts
won't activate
Disc brake malfunction (Piston Overhaul Wash and replace
has foreign matter caught or parts
stuck, or brake disc seized)
2.6.4 Standard values for maintenance
(1) Torque convertor

Standard value Wear limit
Item (mm) (mm) Remarks
Pump drive gear backlash 0.13 - 0.23 –
Width (radial direc-

tion) 1.95 - 2.05 1.7
Turbine shaft seal ring
Thickness (radial di-
rection) 1.95 - 2.05 1.9
Turbine shaft seal ring groove width 2.1 - 2.2 2.3
Stator support I.D. in turbine shaft seal ring sliding area

60.33 - 60.35 60.41

Stator support seal ring 1.95 - 2.05 1.7
tion)

1.95 - 2.05 1.9
rection)
Stator support seal ring groove width 2.1 - 2.2 2.3
Pump impeller hub I.D. in stator support seal ring sliding 79.38 - 79.40 79.48
area
(2) Control valve

Free height 94.9 91.1

Regulating spring Setting load kg 25.50 23.0
Setting height 82.4 –
Feathering spring Setting load kg 7.27 6.5
Flow sensor spring Setting load kg 0.90 0.8
Free height 116 111.4
Setting load kg 10.58 9.5 Inner
Setting height 90 –
Free height 116 111.4
Load piston L spring Setting load kg 27.38 24.6 Center
Free height 91 87.4
Setting load kg 32.76 29.5 Outer


Setting load kg 15.69 14.1 Inner
Load piston H spring Setting load kg 23.23 20.9 Center
Setting load kg 28.16 25.3 Outer
Free height 39 37.4
F/R selector spool spring Setting load kg 8.74 7.6
Free height 43 41.3
Spool A spring
Setting load kg 6.84 6.2
Spool B spring
Main (W) 5.5 –
1°/2° (X) 1.0 –
Restrictor diameter 2° (Y) 1.2 –
3°/4° (Z) 1.6 –
Solenoid valve 0.8 –
(3) Transmission
Cover I.D. in the seal ring control valve sliding area (fwd/
40.13 - 40.16 40.20
rev, 1st/3rd, 2nd)

1.95 - 2.05 1.7
tion)
Clutch shaft seal ring
1.95 - 2.05 1.9
rection)
Clutch shaft seal ring groove width 2.10 - 2.15 2.3
Clutch plate thickness 1.54 - 1.66 1.4
Clutch disc thickness 2.32 - 2.47 2.1

Free height 42 40.3
Return spring Setting load kg 73.6 66.2
2.6.5 Tightening torques for main bolts
(1) Torque convertor

Item Tightening torque (kgm) Remarks
Pump drive gear mounting bolt 4.7 Apply LOCTITE 262
Stator support mounting bolt 10.3
Oil baffle mounting bolt 5.6
Front cover mounting bolt 2.0
Input plate mounting bolt 6.2 Apply LOCTITE 262
Charge pump mounting bolt 5.1
(2) Transmission
Item Tightening torque (kgm) Remarks
Control valve cover mounting bolt 5.1
Output shaft bearing cap mounting bolt 5.1
Output flange retainer plate mounting bolt 9.3 Apply LOCTITE 262
Parking brake housing mounting bolt 5.1
Convertor housing mounting bolt 5.1
Control valve mounting bolt 5.1
2.7 OIL CIRCUIT
General description
Oil used to engage the clutches is taken from the through the heat exchanger (oil cooler) to cool down.
transmission housing. After leaving the oil cooler, the oil lubricates and cools
After starting the engine, the feed pump takes the oil every clutch pack before going back into the
from the sump in the transmission housing through transmission housing sump.
the mesh filter and sends it under pressure to the
transmission control valve through the outlet filter.
The control valve divides the oil flow into two parts: Note: The oil cooler is located in the lower tank of
one for the torque convertor and the other for the the engine cooling water radiator. For the oil cooler,
tnsmission clutches. see chapter “1.9 COOLING SYSTEM”.
Oil sent into the convertor, after coming out of it, flows
8
To the PARKING BRAKE
valve
2 7 From the PARKING BRAKE valve
SUCTION
FEED CIRCUIT
LUBRICATION
3 CIRCUIT
Brake circuit
4
Fig. 2-142 Transmission oil circuit
1. TORQUE CONVERTOR 5. OIL COOLER

2. OIL DISTRIBUTION COVER 6. DOUBLE FEED PUMP
3. TRANSMISSION 7. TRANSMISSION CONTROL VALVE
4. MESH FILTER 8. OUTLET FILTER
Carefuly read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
Outlet filter
The outlet filter is placed in the delivery circuit of the When the filter element is clogged, pressure at filter
transmision clutch engagement oil. inlet increases so that the by-pass valve opens and
Oil flows through the filter from outside to inside and lets the oil flow directly to the filter outlet.
filtered oil is sent to the transmission control valve.
By-pass valve working pressure: 1.75 bars (24.9 psi)

Filtering degree: 25 µ
A A
4 2 1
Section A-A
Fig. 2-143 Outlet filter
1. FILTER SUPPORT
2. CONNECTOR
3. FILTER BODY
4. FILTER SAFETY VALVE (BY-PASS)
2.8 DRIVE SHAFTS
The drive shafts are placed between transmission

Cardan type
and front axle and between transmission and rear
axle. They transfer power from the transmission to
Length (between pins):
the axles.
Front 702 mm
The drive shaft connected to the front axle is fitted
Intermediate 433 mm
with a centre support secured to the front frame.
Rear 215 mm
The drive shafts compensate distance and angular
changes between transmission output shafts and
Weight:
input shaft of each axle.
Front 6.9 Kg
Intermediate 9.4 Kg
Rear 7 Kg
1 2
TRANSMISSION
FRONT REAR AXLE

AXLE
1 2 3
Fig. 2-144 Drive shafts
Note - 1 7.5 daNm (55 ft-lbs)

1. FRONT DRIVE SHAFT
Threads: LOCTITE 262
2. INTERMEDIATE DRIVE SHAFT
2 22.8 daNm (165 ft-lbs)
3. REAR DRIVE SHAFT
Front and intermediate drive shafts
1 2 3
1
4 5 6 7 2 8
Fig. 2-145 Front and intermediate drive shafts
1. SPIDER Note - 1 13.5 daNm

2. GREASER
3. SHOULDER RING
4. FORK SHAFT ASSEMBLY 2 7.6 daNm (55 ft-lbs)
5. CENTRE SUPPORT
6. FORK WITH SPLINED SLEEVE
7. STOP PLATE
8. SHAFT/SPLINED SLEEVE ASSEMBLY
Rear drive shaft
1
2
Fig. 2-145a Rear drive shaft
1. SPIDER BEARING
2. COUPLING FORK
2.9 AXLES
(FRONT AND REAR)
Axle mounting
Drive four driving wheel
The front axle is directly bolted to the front frame.
Front axle Fastened to the frame, stiff
type
The rear axle is mounted trunnion-type by means of
supports bolted to the rear frame on either side of
Rear axle Half-swinging, trunnion
the axle. As a consequence, the rear axle can swing
type
around the differential axis over an amplitude
depending on the conditions of the ground where the
Reduction and
loader is working. The trunnion-type mounting of the
differential gears: TCM 640-30
engine axle improves loader driving conditions when
- Model Common type, 2-stage
moving over a rough terrain, because the loader
- Type reduction gears
bumps less compared to a loader with an axle
supported in the traditional way.
Differential casing Integral type
Limited slip system Torque proportion diffe-

rential
Final drives:
- Model TCM 640-30
- Type Planetary reduction gears
Weight:
- Front 396 Kg (873 lbs)
- Rear 382 Kg (842 lbs)
2.9.1 AXLE
The axle is composed of a differential assembly, side

reduction gears (final drives), disc brakes in oil bath
and axle-shafts connected to the wheels.
Power from the convertor/transmission assembly is
transferred to the rear and front axles by means of
the drive shafts. Power is then transmitted to the
differential assembly that shares it on to the right
and left axle-shafts that control the corresponding
final drives to reach the wheels.
The disc brake in oil bath is mounted at the front of
the final drive and is used to brake the loader.
As for the operation of the brakes, see section
“3 - BRAKING SYSTEM”.
3 4
5 5 1
A
B
4 6
2 2
1 2
Fig. 2-146 Axle mounting
Notes - 1 10.3 daNm (74.5 ft-lbs) Threads: LOCTITE 262
2 52 daNm (380 ft-lbs) 7

4 6
Inner surface: grease
4 (Assemble with the chamfered 8
side towards the axle)
5 Assemble with the lip turned outside
6 Assemble with the groove towards 5 5

the thrust plate (7)
9 6
Detail B
1. FRONT AXLE 6. BUSH
2. REAR AXLE 7. THRUST PLATE
3. REAR AXLE SUPPORT 8. THRUST PLATE COVER
4. REAR AXLE SUPPORT 9. SHOULDER RING
5. SEAL GASKET
4 1 2 2 3 4 3 5
7 8 3 9 10 11 3 12 13 5 A
6 1 5
14 3
A Brake hose connection ports, 2 points
Fig. 2-147 Front axle
Notes - 1 9 daNm (65 ft-lbs) Threads: LOCTITE 262
2 23 daNm (170 ft-lbs) Threads: LOCTITE 262
4 Lip: grease
5 Mating surfaces: LOCTITE 509
6 Assemble with the bearing cage groove downwards
1. OIL SEAL 6. FINAL DRIVE 11. BLEED SCREW

2. AXLE-SHAFT 7. AXLE-SHAFT HOUSING 12. BLEED SCREW
3. DIFFERENTIAL CASING 8. OIL DIPSTICK 13. COVER
4. DIFFERENTIAL GEARS 9. RING GEAR 14. DRAIN PLUG
5. PLUG (OIL LEVEL CHECK) 10. PIN
2
3 4
4 1 2
6 7 8 9 3 10 11 5 A 12 3
3 13 6 1 5
14 3
A Brake hose connection ports, 2 points
Fig. 2-148 Rear axle
4 Lip: grease
5 Mating surfaces: LOCTITE 509
6 Assemble with the bearing cage groove downwards
1. OIL SEAL 6. AXLE-SHAFT HOUSING 11. COVER

2. AXLE-SHAFT 7. RING GEAR 12. OIL DIPSTICK
3. DIFFERENTIAL CASING 8. PIN 13. PLUG (OIL LEVEL CHECK)
4. DIFFERENTIAL GEARS 9. BLEED SCREW 14. DRAIN PLUG
5. FINAL DRIVE 10. BLEED SCREW
2.9.2 DIFFERENTIAL ASSEMBLY Differential operation
The differential and reduction gears are mounted in When the loader moves on a straight line, the crown
a single assembly. wheel, differential casing and side gears rotate all
Power from the drive shafts reaches the differential together. Planetary gears in the differential casing
gears through the drive pinion/crown wheel matched do not rotate. The left and right side gears transmit
set. It is then transmitted to the final drives through power to the wheels at the same speed, through the
the right and left gears. The power rpm reduction is axle-shafts. When the loader turns, the left and right
obtained by means of the drive pinion/crown wheel wheels turn at different speeds and the planetary
matched set. gears in the differential casing rotate around their
axis proportionally with the speed difference between
the left and right side gears.
Straight travel During turns

1
2
High Low
speed speed
4 5
6 7
Fig. 2-149 Differential operation
1. PLANETARY GEAR 5. SPIDER

2. SIDE GEAR 6. DRIVE PINION (BEVEL GEARSET)
3. AXLE-SHAFT 7. CROWN WHEEL (BEVEL GEARSET)
4. DIFFERENTIAL CASING
Limited slip differential (with torque proportion)
Wheel loaders oftenwork on rough grounds, sand or cal to the common differentials, only their planetary
marshes. Under such critical operating conditions, gears have an odd number of teeth with a special
the tyres of a loader fitted with a common differential profile. When the tyres are almost slipping on soft
assembly may slip on the ground negatively affecting ground, the planetary gears keep sending power to
loader performance. In addition, tyres would be both side gears without rotating around their own axis
prematurely worn out. To overcome this problem, as long as the ground adherence difference for the
some models are equipped with torque proportion right and left tyres reaches a specific value. This
limited slip differential units. prevents tyres from slipping.
Torque proportion differential units are almost identi-
1 2 3 2 4 5 3 6 7
1
7 8
6
15 16 17 18
9
4
10 11 12 13 14 5
Fig. 2-150 Differential assembly
Notes -
1 5 daNm (36 ft-lbs)
3 9 daNm (65 ft-lbs)
4 55 daNm (180 ft-lbs) ––––
Notes -
5
Outer diameter: liquid sealant Lip: grease
6 Drive pinion to crown wheel backlash: 0.20 ÷ 0.28 mm (0.0079 ÷ 0.0110 in)
7 Adjust through shims (on both sides): 0.55 ÷ 1.55 mm (0.022 ÷ 0.061 in)
1. OIL SEAL GASKET 7. SHOULDER RING 13. COVER

2. BEARING SUPPORT 8. SHOULDER RING 14. GASKET
3. HALF-CASING B 9. DRIVE PINION 15. SHIMS
4. CROWN WHEEL 10. BEARING CAGE 16. SPIDER
5. HALF-CASING A 11. SPACER 17. PLANETARY GEAR
6. SHIMS 12. FLANGE 18. SIDE GEAR
2.9.3 FINAL DRIVES
The final drives consist in planetary reduction gear Power transmitted from the differential to the sun gear
sets and reduce the final speed of the engine power causes the three planetary gears within the ring gear
transmitted through the drive line components. to turn. The planetary gears then rotate the axle-shaft
through the planetary carrier.
8 7 6 5 4 3 2
A
Section A-A Power flow

(Planetary gear operation)
Fig. 2-151 Power flow
1. DRIVE PINION 5. PLANETARY GEAR

2. DIFFERENTIAL ASSEMBLY 6. RING GEAR (fixed)
3. SUN GEAR 7. PLANETARY CARRIER
4. PLANETARY GEAR SHAFT 8. AXLE-SHAFT
1 2 3 4 5 6 7 8 9 1
2 10 11 12 13
14 15 16 17
Fig. 2-297 Final drive
Note - 1 Turn the printed surface towards the piston
2 Use of adjusting shims
1) Tighten screw (12) to a torque of 5 daNm (36 ft-lbs) and settle the taper bearing inward, by rotating the
shaft and resetting the torque to 5 daNm.
2) Loosen screw (12) without turning the shaft.
3) Measure the clearance between the shoulder ring (11) and axle shaft. Measured dimension = Y.
4) Select adjusting shims to form a pack with a total thickness exceeding dimension Y by 0.03 to 0.10 mm.
5) Assemble the shim pack, retaining ring, and screw.
65.7 daNm (475 ft-lbs) Threads: LOCTITE 262
The bearing rolling torque should be 2 to 2.5 daNm (14 to 18 ft-lbs)
1. PLANETARY CARRIER 7. SUPPORT PLATE 13. SOLAR GEAR

2. PLANETARY GEAR SHAFT 8. BRAKE DISC 14. LOCK PIN
3. DETENT BALL 9. THRUST RING 15. SEAL GASKET
4. PLANET GEAR 10. ADJUSTING SHIM 16. PISTON
5. RING GEAR 11. SHOULDER RING 17. SEAL GASKET
6. NEEDLE BEARING 12. SCREW
2.9.4 AXLES Note that the center housing and axle housing are
joined with dowel pins. Separate one from the other
2.9.4.1 Disassembly by prying.
Note: The illustrations for disassembly and

reassembly in this manual show the rear axle of the
model W90.
Note: When disassembling and reassembling the
axle, it is good practice to place it on a suitable
support stand.
a) Removing the axle housing.

1. Remove the drain plug and discharge oil.
Gear oil: 13 to 29 lt.
Fig. 2-155
4. Remove the shaft (sun gear) from the diffe-

rential.
5. Remove the axle housing and shaft at the

opposite side, using the same procedure as
above.
Fig. 2-153
2. Lift the axle housing temporarily with a hoist,

holding the axle housing opposite side to
prevent it from lowering.
Axle housing: 110 to 160 kg.
3. Remove 14 axle housing bolts. Detach the axle
housing assembly from the center housing.
Fig. 2-156
Fig. 2-154
b) Disassembling the axle housing. 4. Remove the outer ring of the axle shaft oil seal
from the axle housing, using a screwdriver.
1. Secure the axle shaft using 2 wheel bolt holes. 5. Push the end of the axle shaft to remove it from
2. Loosen the retainer plate mounting bolt and the axle housing. Use a press if it is hard to
remove it. remove.
A torque of approx. 100 kgm is required to Axle shaft: 33 to 45 kg.
loosen the bolt because it is locked with
LOCTITE.
Fig. 2-157 Fig. 2-159
3. Remove the final drive assembly (planetary

carrier) using a bar.
Remove any shim attached to the axle shaft
end. 6. Remove the bearing cone from inside the axle
Planetary carrier: 17 to 22 kg. housing.
Fig. 2-158 Fig. 2-160
7. Using a puller, remove the bearing cone from 10. If the ring gear is to be replaced, remove it from
the axle shaft. the axle housing using a puller and a plate
8. Cut the axle shaft oil seal sleeve and remove placed into the axle housing to support the
the oil seal. puller shaft.
Fig. 2-161 Fig. 2-163
c) Disassembling the final drive assembly.

9. If the axle shaft bearings are to be replaced,
remove the two bearing races from the axle 1. Remove the snap ring from the planetary gear
housing. shaft.
Fig. 2-162 Fig. 2-164
2. Remove the shaft by driving it out of the opposite 4. Remove the 56 needle rollers and spacers from
side. Use caution not to lose the shaft lock ball. inside the gear.
5. Disassemble the other two planetary gear shafts

using the same procedure as above.
Fig. 2-165 Fig. 2-167
3. Remove the planetary gear and two thrust 6. Remove the reatiner plate from the planetary
washers. carrier. Keep any shim, if used.
Fig. 2-166 Fig. 2-168
d) Removing the brake unit. If the brake piston is hard to remove, drive it out by
blowing compressed air through the brake piping port.
1. Remove the end plate, brake disc, and brake
ring from the center housing in this order. Then, WARNING: Install a stop plate on the center housing,
remove the 8 pins. to prevent the piston from popping out. (See Fig.
2-171).
Fig. 2-169 Fig. 2-171
3. Remove the ring from the outer diameter of the

brake piston.
2. Install 2 jacking bolts into the brake piston

jacking holes (M6) and remove the brake piston, 4. Remove the brake unit at the opposite side,
holding the 2 bolts. using the same procedure.
Fig. 2-170 Fig. 2-172
e) Removing the drive pinion (bearing cage). 4. Remove the companion flange.
Use a puller if it is hard to remove.
1. Loosen the bolts (20 off) securing the cover to
the center housing and remove the cover.
Fig. 2-173 Fig. 2-175
2. Check the ring gear for tooth contact pattern and

backlash. (See page 2-95).
5. Remove the bearing cage mounting bolts.
3. Remove the companion flange lock nut. Take
out the washer and O-ring.
Number of bolts: Front 6
While loosening the lock nut, lock the compa-
nion flange with the ring gear. Rear 8
Fig. 2-174 Fig. 2-176
6. Install two of the mouting bolts previously f) Disassembling the drive pinion.
removed into thebearing cage jacking holes and
tighten. Remove the bearing cage and drive 1. Remove the drive pinion from the bearing cage
pinion a holding the bolts. using a press.
Slide out the spacer from the pinion shaft.
Fig. 2-177 Fig. 2-179
2. Remove the oil seal and bearing cone from the

bearing cage. To remove the oil seal, break it
with a screwdriver.
Remove the O-ring from the outer diameter of
7. Remove any shim from the bearing cage. the bearing cage.
Fig. 2-178 Fig. 2-180
3. If the bearing is to be replaced with a new one, g) Removing the differential casing.
remove the bearing cone from the drive pinion
shaft using a puller. 1. Temporarily lift the centre housing with a hoist.
Centre housing: 35 to 58 kg.
2. Remove the bearing retaining bolts (6 off).
Fig. 2-181 Fig. 2-183
3. Install two of the mouting bolts previously

removed into the bearing retainer jacking holes
and tighten evenly. Slide out the bearing retainer
holding the bolts. Thenremove any shim.
4. After that, remove the 2 bearing cones from Remove the box ring and D-ring from the
inside the bearing cage, using a dirft or a tube. bearing retainer.
Fig. 2-182 Fig. 2-184
4. Remove the bearing retainer and shims at the 6. If the differential bearing is to be replaced with
opposite side using the same procedure as a new one, remove the bearing cup from inside
above. the bearing retainer.
Fig. 2-185 Fig. 2-187
h) Disassembling the differential assembly.
1. Loosen the crown wheel mounting bolts (12 off)

and remove the crown wheel.
5. Remove the crown wheel and differential
assembly from the center housing. If the crown wheel is hard to remove, take it out
by tapping its back with a mallet.
Fig. 2-186 Fig. 2-188
2. Remove the 12 differential casing mounting 3. Remove the 2 side gears, spider, 4 planetary
bolts and disassemble the differential assembly. gears and 6 thrust washers from inside the
differential casing.
Fig. 2-189 Fig. 2-191
4. If the differential bearings are to be replaced,

remove the bearng cone from the differential
Tap the spider with a drift and mallet. casings A and B using a puller.
Fig. 2-190 Fig. 2-192
2.9.4.2 Reassembly 3. Direct the tooth surface of the side gear

downward so that the side gear engages with
Precautions to observed when reassembling the planetary gears.
the shaft axle. Install the side gear thrust washer.
• Wash each disassembled part with a clean

detergent oil and dry it by blowing
compressed air.
• Handle the washed parts with care not to
damage or contaminate them.
• Check the disassembled parts for wear or
damage and replace any worn or damaged
part. Refer to “2.9.4.4 STANDARD
VALUES FOR MAINTENANCE”.
• Replace all the seals with new ones.
a) Reassembling the differential assembly.

1. Place the flanged half case (differential case A)
on a work bench, and install the thrust washer
and side gear.
Fig. 2-195
4. Install the half case (differential case B),

matching the marks made during disassembly.
Tap the case with a soft mallet to make sure
that the half case is installed without looseness.
Fig. 2-193
2. Install 4 planetary gears and 4 thrust washers

on the spider, and install them as a unit on the
side gear, engaging the gear teeth.
Fig. 2-196
Fig. 2-194
5. Install the 12 case bolts and tighten them in 7. Install the crown wheel on the flanged half case
diagonal order. (differential case A) and tighten the mounting
Apply LOCTITE 262 to the threaded area of bolts. Tap the crown wheel with a soft mallet to
each bolt. install it without looseness.
9 kgm No. of bolts: 12 12 - 9 kgm
Fig. 2-197 Fig. 2-199
b) Reassembling the drive pinion (bearing

cage).
6. If the differential bearing was replaced with a new
one, press bearing cones on the differential case 1. If the drive pinion bearing was replaced, press
halves A and B. the 2 bearing cups into the bearing cage.
Fig. 2-198 Fig. 2-200
2. Press the bearing cone into the drive pinion. 4. Place the bearing cage on the drive pinion.
Fig. 2-201 Fig. 2-203
5. Press the bearing cone onto the drive pinion.

3. Insert the spacer onto the drive pinion, directing After that, make sure that the bearing cage turns
the stepped area of the spacer upward. smoothly without looseness.
Fig. 2-202 Fig. 2-204
6. Apply a light coat of liquid seal on the outer 8. Then, insert the O-ring and washer and tighten
diameter of the oil seal and apply grease the lock nut. Before tightening the lock nut, apply
between the lips. LOCTITE 262 on its threaded area. When
Press the oil seal into the bearing cage. tightening the lock nut, lock the companion
flange with a monkey wrench.
55 kgm
Make sure that the bearing cage turns smoothly

without binding.
Fig. 2-205 Fig. 2-207
7. Install the companion flange onto the drive 9. Apply grease to the O-ring. Install the O-ring in
pinion. Slide the flange several times to elimi- the groove at the outer diameter of the bearing
nate strain at the seal lip. cage.
Fig. 2-206 Fig. 2-208
c) Installing the differential assembly. 3. Install the box rings and shims on the 2 bearing
retainers. Use shims of the same size as was
1. If the differential bearing was replaced with a removed during disassembly.
new one, press bearing cups on the 2 bearing
retainers.
Fig. 2-209 Fig. 2-211
2. Lift the reassembled differential assembly with 4. Install the bearing retainers at the right and left
a hoist and put it in the center housing, aligning sides of the center housing to hold the
the crown wheel with the notch in the center differential case. Temporarily install the bearing
housing. retainer mounting bolts (6 off).
Fig. 2-210 Fig. 2-212
5. Make sure that the differential assembly has 2. Temporarily install the bearing cage mounting
no looseness in the right and left directions and bolts temporarily and check gear backlash and
turns smoothly. tooth contact pattern. Refer to steps (e) and (f).
If any defect is found, adjust the bearing retainer
shim thickness. For the front axle, position the bearing cage
groove referring to Fig. 2-215 or Fig. 2-216.
Number of bolts: Front 6

Rear 8
One-groove type Upper part of the vehicle

(Front axle of W90)
Fig. 2-213
Groove position
Fig. 2-215
d) Installing the drive pinion bearing (bearing
cage).
1. Install the bearing cage shims in the center Two-groove type

housing. Then, install the bearing cage and the (Front axle Upper part of the vehicle
of W90)
drive pinion assembly. Use the same size of
shims as was removed during disassembly. The
shims are two-piece type, so divide them in the
upper and lower areas, respectively.
Groove position
Fig. 2-216
Fig. 2-214
3. After positioning, remove the bolts which were e) Adjusting crown wheel backlash
temporarily installed to the bearing cage, apply
LOCTITE 262 to the threaded area of each bolt 1. Place a dial gauge on the tooth profile outer
and retighten to the specified torque. edge of crown wheel.
2. Lock the drive pinion and turn the crown wheel
back and forth to measure the backlash, which
9 kgm should be 0.20 to 0.28 mm.
Fig. 2-217 Fig. 2-219
3. Adjust the backlash by adding or removing a

number of shims from the differential bearing
4. Remove the bolt temporarily installed to the retainers.
bearing retainer, apply LOCTITE 262 to the If the backlash is too large, move some shims
threaded area of each bolt and retighten to the from the crown wheel side to the opposite side.
specified torque. Do not change the total shim thickness.
If the backlash is too small, adjust it following
5 kgm opposite procedure as above.
Adjust the number of shims within the range of

0.55 to 1.55 mm (on both sides)
Fig. 2-218 Fig. 2-220
f) Adjusting the crown wheel tooth surface a. Normal contact pattern(Fig. 2-223).
contact pattern. A correct contact pattern of the tooth surface is
from the toe to the heel and its length is approx.
1. Apply a thin layer of red lead to several crown 80% of the total tooth length (face).
wheel teeth and turn the crown wheel back and Note: The following adjustment steps (b. to e.)
forth with a hand to check the tooth contact show the procedures for checking the convex
pattern. surface of the tooth.
Remember that the concave surface side has
opposite contact conditions.
Crown wheel
Fig. 2-221 Fig. 2-223
b. Adjusting contact condition at the toe (Fig.

2-224).
Move some shims from the side other than the
2. Adjust the tooth contact pattern referring to the crown wheel side to the opposite side to move
steps a. to e. the crown wheel away from the drive pinion.
3. After acquiring the correct tooth contact pattern, Then, reduce shim thickness at the bearing
check the backlash again. cage and bring the crown wheel closer.
Toe (small-end)
Heel (big-end)
Flank
Crown wheel
Face
Drive pinion
Fig. 2-222 Fig. 2-224
c. Adjusting contact condition at the heel (Fig. e. Adjusting contact condition at flank (Fig. 2-227).
2-225). Increase shim thickness at the bearing cage to
Move some shims from the crown wheel side to move the drive pinion away from the crown
the opposite side to bring the crown wheel closer wheel.
to the drive pinion. Then, move some shims from the crown wheel
Then, increase shim thickness at the bearing side to the opposite side to bring the crown
cage and move the drive pinion away from the wheel closer to the drive pinion.
crown wheel.
Crown wheel Crown wheel
Drive pinion Drive pinion
Fig. 2-225 Fig. 2-227
d. Adjusting contact condition at face (Fig. 2-226).

Reduce the shim thickness at the bearing cage
to bring the drive pinion closer to the crown
wheel. g) Installing the brake assembly.
Then, move some shims from the side other than
the crown wheel side to the opposite side to move 1. Install the brake piston ring in the center housing
the crown wheel away from the drive pinion. (bearing retainer).
Crown wheel
Drive pinion
Fig. 2-226 Fig. 2-228
2. Install the ring on the outer diameter of the brake Ensure that the outer diameter convex area of
piston and insert the brake piston into the piston each brake plate and end plate is in alignment
groove in the center housing. with the plug hole for measuring disc thickness.
(See Fig. 2-231).
5. Install pins in the remaining 6 pin grooves at
the inner diameter of the center housing.
6. Reassemble the brake unit at the opposite side,

using the same procedure as a above.
Plug hole
Brake plate or end plate
Fig. 2-229 Fig. 2-231
3. Install two pins in the two lower grooves of the (2) Reassembling the axle housing.
eight grooves at the inner diameter of the center
housing. 1. If the ring gear was replaced with a new one,
4. Install the brake plate, brake disc, and end plate install the ring gear on the axle housing,
in the center housing in this order. securing it with 4 pins.
Fig. 2-230 Fig. 2-232
2. If the axle shaft bearing was replaced, press 5. Remove the inner sleeve from the oil seal
the bearing cup into the wheel side of the axle pressed and press the sleeve onto the axle
housing. shaft.
3. Then, install a proper bearing cone into the cup.
Fig. 2-235
Fig. 2-233
6. Stand the axle housing, directing the wheel side
up, and insert the axle shaft from top.
Drive the axle shaft from top and press the
bearing cup which was inserted into the axle
housing, onto the shaft side.
4. Press the axle shaft oil seal into the axle

housing.
Fig. 2-234 Fig. 2-236
7. Turn the reassembled axle housing and axle 2. Put the retainer plate in the planetary carrier
shaft upside down. If the axle shaft bearing was and tighten the mouting bolt to 5 kgm. Set the
replaced, press the bearing cup into the axle axle shaft bearing cup into the axle shaft, by
housing. turning the axle housing and reset the 5 kgm
torque.
8. The location of the bearing cup should be
adjusted as inpara “i) Adjusting the axle shaft
bearing preload”.
Fig. 2-237 Fig. 2-239
i) Adjusting the axle shaft bearing preload

(shim adjustment).
3. Loosen the bolt and remove the retainer plate.
1. Install the planetary carrier on the axle shaft to Measure the difference in height (Y) between
adjust the axle shaft bearing preload. the axle shaft end surface and the planetary
No gear is attached to the planetary carrier. carrier.
Fig. 2-238 Fig. 2-240
The measurement position of the height difference 5. Install the selected shim on the axle shaft and
(Y) is shown in Fig. 2-241. the retainer plate in this order. Tighten the bolt.
65.7 kgm
Fig. 2-241
Fig. 2-241 Fig. 2-243
Fig. 2-243
4. Select a shim which is 0.03 to 0.10 mm thicker

than the height difference (Y).
Fig. 2-242
8. After the shim thickness is determined, loosen 2. Install the reassembled planetary gear (with the
the bolt securing the retainer plate and remove thrust washers at top and bottom) in the
the planetary carrier which was temporarily planetary carrier.
installed.
Fig. 2-245 Fig. 2-247
l) Reassembling and installing final reduction

gear assembly
1. Install the needle bearings on the planetary

gears. Each planetary gear has 56 needle
rollers and one spacer.
Prevent the bearings from dropping off by 3. Install the lock ball in the planetary gear shaft
applying grease properly. and press the shaft into the planetary carrier.
Fig. 2-246 Fig. 2-248
4. Secure the planetary shaft with a snap ring. 7. Install the selected shims on the axle shaft and
install the reassembled planetary carrier on the
shaft.
Fig. 2-249 Fig. 2-251
8. Apply LOCTITE 262 to the threaded area of the

5. Put the retainer plate in the planetary carrier.
retainer plate mounting bolt and tighten the bolt
to the specified torque to secure the planetary
6. Reassemble the other 2 planetary gears and
carrier.
install them in the planetary carrier, using the
same procedure as above. 65.7 kgm
Fig. 2-250 Fig. 2-252
m) Installing the axle housing. 3. Lift the axle housing assembly and install it on
the differential.
1. Apply LOCTITE 509 to the axle housing surface Apply LOCTITE 262 to the threaded area of the
which will mate with the centre housing. Make 14 mounting bolts and tighten them.
sure that a continuos bead of LOCTITE is
applied on the axle housing surface, inside the 23 kgm
row of the bolt holes.
Bead width: 2 to 3 mm. 4. Install the axle housing assembly at the opposite
side, using the same procedure as above.
Fig. 2-253 Fig. 2-255
5. Fill the differential with gear oil.

Front diff.: 13 lit
2. Insert the shaft (sun gear) into the differential. Rear diff.: 20 lit
Fig. 2-254 Fig. 2-256
6. Apply LOCTITE 509 to the differential cover

mounting area.
Note that LOCTITE should be applied to the
inside of the row of bolt holes.
7. Install the cover on the differential and tighten
the mounting bolts.
Number of bolts: 20 3 kgm
Fig. 2-257
2.8.4.3 Troubleshooting
Problem Possible cause Remedy
Gear worn, damaged or broken Replace
Excessive backlash of each gear Adjust or replace
Bearing worn, damaged or broken Replace bearing

Noisy
differential Loose engagement of side gear and Replace
shaft splines
Loose bolts Retighten
Low gear oil Add oil to specified level
Gear (final reduction gear) worn, damaged or Replace

broken
Excessive backlash of each gear Replace
Bearing worn, damaged or broken Replace bearing

Noisy axle
housing
Loose planetary carrier bolt (retainer plate mounting Retighten (Adjust shimsi)
bolt)
Improper preload of axle shaft bearing Adjust shims
Low gear oil Add oil to specified level
Broken liquid seal of differential cover Apply liquid seal
Broken liquid seal of axle housing Apply liquid seal

Oil leakage from
Worn or damaged O-ring of bearing cage Replace O-ring
differential
Oil seal worn or damaged Replace oil seal
Loose bolt Retighten
Oil seal worn or damaged Replace oil seal

Oil leakage from
axle shaft
Oil seal installed improperly Repair or replace
Problem Possible cause Remedy
Brake piston seal (D-ring) deteriorated or damaged
Brake disc or brake ring worn or damaged
Poor braking Brake piston rusted Overhaul and replace
Foreign matter caught on brake disc
Loose or damaged bleed screw of disc brake Retighten or replace
Brake disc or brake ring run-out or worn unevenly

Erratic braking Overhaul and replace
Worn parallel pin of brake piston
Rusted brake piston

Dragging brake Overhaul and replace
Brake disc and brake ring seized
2.8.4.4 Standard values for maintenance
Standard size
Item Working limit (mm) Remarks
(mm)
Thickness of bearing cage shim 0.1; 0.2; 0.25 –
Length of bearing cage spacer 30.424 to 30.474 –
Inner diameter of differential

23.85 to 23.88
planetary gear
Diameter of differential spider pin 23.72 to 23.75
Thickness of differential planetary gear

1.562 to 1.613 1.45
thrust washer
Thickness of differential side gear thrust

2.31 to 2.36 2.15
washer
Backlash between drive pinion and crown 0.20 to 0.28 – Shim adjustment
wheel
Shim thickness: 0.1;

Shim adjustment of differential bearing Adjust shim thickness within the range of
0.2; 0.25; 0.5; 1.0
retainer 0.55 to 1.55 mm (each sides).
mm
Rolling resistance torque of axle

shaft bearing (on pitch circle of 2.0 to 2.5 kg Shim adjustment
housing mounting bolt)
Brake disc thickness 5.9 to 6.5 5.3
Brake ring thickness 4.9 to 5.1 4.3
2.8.4.5 Tightening torque values for main bolts
Tightening torque
Item Remarks
(Kgm)
Crown wheel mounting bolt 9.0 Apply LOCTITE 262
Differential case mounting bolt 9.0 Apply LOCTITE 262
Differential bearing retainer mounting bolt 5.0 Apply LOCTITE 262
Bearing cage mounting bolt 9.0 Apply LOCTITE 262
Flange nut 55 Apply LOCTITE 262
Planetary carrier lock bolt (Retainer plate mounting bolt) 65.7 Apply LOCTITE 262
Axle housing mounting bolt 23 Apply LOCTITE 262
Differential cover mounting bolt 3.0 Apply LOCTITE 262
2.10 WHEELS
The wheel is composed of rim and disc. The wheel

disc is screwed to the axle-shaft.
The tyre is assembled to the rim to form a single unit
with it. Therefore, it is important to use the correct
rim according to the kind of tyre to be mounted. Using
the wrong rim can shorten tyre life and, even worse,
provoke serious accidents. Also rim size is given in
inches. The first figure indicates rim width and the
following figures indicate rim diameter.
2.10.1 TYRES
As a standard, the loader is fitted with radial L-2 tread

tyres which provide high traction features. We
suggest to always select the most suitable tyres as a
wide range is made available according to use and
working needs.
Tyre size is given in inches.
Example: 15.5 x 25 - XTLA
15.5 = Tyre width

25 = Rim diameter
XTLA = Groove pattern
WORKING TRASFERING
MODELS TYRES FORN. FRONT REAR FRONT REAR WHEEL RIM
W90 15.5R25 XTL Mich. 3.00 2.00 2.00 2.00 12.00-25/1.3
15.5R25 XHA Mich. 2.50 1.50 2.00 2.00 12.00-25/1.3
17.5R25 GP-2B G.Y. 3.50 2.50 2.75 2.75 13.00-25/1.3
Note - Inflating pressures are for a machine in

working conditions.
3 (Tread pattern)
Fig. 2-258 Tyre
1. TYRE
2. RIM
3. VALVE
Fig. 2-259 Rim Note - Wheel nut tightening torque:

86.2 daNm (627 ft-lbs)
1. RIM
2. VALVE CAP
3. DISC
SECTION 3
BRAKING SYSTEM
CONTENTS
3.2 OPERATION .......................................................................................................... 3

3.2.1 Operating conditions .............................................................................................. 3
3.3 DISC BRAKE .......................................................................................................... 5
3.4 BRAKE PEDAL VALVE .......................................................................................... 6

3.4.1 Circuit separation valve operation inside the braking system ................................. 8
3.5 PARKING BRAKE CONTROL VALVE .................................................................... 9
3.6 PARKING BRAKE .................................................................................................. 10

3.6.1 Manual release procedure ...................................................................................... 10
3.6.2 Disc parking brake operation .................................................................................. 11
3.6.3 Brake disengagement ............................................................................................ 11
3.7 OTHER COMPONENTS ........................................................................................ 12

3.7.1 Brake accumulator ................................................................................................. 12
3.7.2 Check valve ............................................................................................................ 12
3.8 BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS ......................................... 13
3.9 DIAGNOSTICS AND TESTING .............................................................................. 14

3.9.1 Brake control pressure testing test ......................................................................... 16
3.9.2 Min. and max. accumulator recharge pressure adjustment .................................... 17
3.9.3 Parking brake engagement test .............................................................................. 18
3.9.4 Accumulator pre-charge test .................................................................................. 19
3.9.5 Accumulator pre-charge reset instructions ............................................................. 20
3.9.6 Bleeding the brake system ..................................................................................... 21
3.9.7 Brake disc wear check ........................................................................................... 22
W90 BRAKING SYSTEM 3-1
The brake system consists in (refer to Fig. 3-1): The parking brake consists in:
- A two-stage gear charge pump (11), bolted to the - A recharge pump, gear type;
convertor cover plate;
- A three-way diverter valve (14) which controls
- A brake pedal valve (5) controlling simultaneously engagement and disengagement of the parking
front and rear brakes (1 and 2, respectively), which brake (17);
are located inside the drive axles;
- A hydraulic ram (16) composed of springs and a
- Two accumulators (8 and 9) which during normal hydraulic cylinder to counter-act them. Spring force
operation stabilises system pressure and, in case is used to lock the parking brake discs (17) when
of emergency, with the engine stopped, allow to pressure oil in the cylinder is dumped by means of
positively apply the brakes for several times; the diverter/control valve. When fed with pressure
oil (by means of the diverter/control valve), the
- Oil in the system is same as the attachment cylinder overcomes spring action and consequently
hydraulic oil; it is taken from the hydraulic reservoir the brake is released;
(S) through a filter fitted with a by-pass valve.
- An accumulator (13) which during normal operation
stabilises system pressure and, with the engine
stopped, allows to release the parking brake several
times.
3-2 BRAKING SYSTEM W90
1 1
7
9
8
4
3 12
P
M
14 13
T 11
15
16
17 2 2
Fig. 3-1 Braking system
S. Reservoir - M. Dump oil - P. From the recharge pump (located on the transmission) - T. Dump oil (transmission hous-
ing) - 1. Front brakes - 2. Rear brakes - 3 & 4. Quick coupling pressure test ports - 5. Brake pedal valve - 6. Brake lights
pressure switch - 7. Transmission disengagement pressure switch - 8 & 9. Braking system accumulators - 11. Oil pump - 12.
Check valve - 13. Parking brake accumulator - 14. Parking brake three-way diverter/control valve -
15. Parking brake pressure switch - 16. Hydraulic ram (integral to the parking brake) - 17. Parking brake.
3.2 OPERATION
GENERALITIES 3.2.1 OPERATING CONDITIONS

(Fig. 3-2) (Fig. 3-2)
Braking system With:

- Engine running
The brake system is fed by the pump (11) which - Brakes released
draws oil from the attachment oil reservoir and sends - Parking brake applied
it to the flow regulator valve (27). This valve is - Accumulators being recharged
controlled by the accumulator recharge valve (18).
Two hydraulic accumulators (7 and 8) and two check The flow from the pump (11) reaches the flow
valves (19 and 20) allow to store an amount of regulating valve (27). The oil flow opens and goes
pressure oil sufficient to positively apply the brakes through the primary check valve (21), then opens
a limited number of times, also with the engine and goes through the check valves (19 and 20)
stopped, and therefore without pump (11) delivery. thereby charging the brake accumulators (7 and 8).
The brake pedal (P) being released, the distributing
valves (22 and 23) stop oil flowing from the pump
and keep dumping oil from the brake pistons (1 and
Parking brake
2). The brakes are disengaged.
The parking brake diverter/control valve (14) is
The parking brake is composed by a disc brake (17)
positioned as to dump oil from the parking brake
which acts on the transmission output shaft. This
chamber. Therefore the parking brake (17) is kept
system, which is separate from the braking system,
applied by the spring force.
receives pressure oil from the recharge pump (25)
Accumulator recharge ends when the maximum
splined to the transmission. The braking force comes
recharge pressure having been attained, the spool
from the spring (26) action. The brake is released
of the valve (18) moves to the right.
when pressure oil is sent to the ram piston by means
of the diverter valve (14). In this way, springs are
compressed and the brake is disengaged.
The pressure switch (15) closes the electrical circuit
signalling “parking brake applied” when pressure
drops below 60 bars with consequent the parking With:
brake engaged.
- Engine running
- Brakes released
- Parking brake applied
- Accumulators charged
Service brakes
In these conditions as shown in the schematic the
The brakes are disc type, in oil bath, and are located spool of the valve (18) opens and allows oil from the
within the axle side reduction gears (1 and 2). When spring side of the valve (27) to dump. Therefore, the
the brake pedal is pressed, the valve (5) supplies valve moves to the right and diverts the pump oil
control oil to the braking circuit at a pressure (and flow to dump (M).
consequently with braking action) proportional to the At the same time, the primary check valve (21) closes
travel of the brake pedal. and traps pressure oil inside the brake hydraulic
When the pedal is released, the valve (5) dumps circuit.
brake circuit oil and nullifies the braking action on When, following braking or leakage in the brake
the discs (1 and 2). valves, pressure after the valve (21) drops below the
During braking, the sensor (4) activates the brake minimum preset value, the spool of the valve (18)
lights electrical circuit. The sensor (3) controls the moves to the left closes the valve (27) and the
transmission disengagement system (24). accumulators start being recharged.
With: The braking pressure acting on the bottom side of

the distributing valve (23) packs the brake discs (1
- Engine running
and 2). In the way, as pressure on the brake discs
- Brakes applied
increases, the distributing valves (22 and 23) are
- Parking brake released
pushed upwards and close the inlet ports.
- Accumulators charged
As a result, the pressure applied to the brake discs
(1 and 2), and consequently the braking action, are
This condition occurs when the machine is braked
proportional to the pressure applied to the pedal (P).
while working.
The presence of two accumulators (7 and 8) and two
The parking brake is released as the diverter valve
distributing valves (22 and 23) allow separate control
(14) sends pressure oil to the brake piston which
circuits for the front and rear brakes. Should one
overcomes the action of the control springs (26).
circuit fail, this will not affect proper operation of the
When the brake pedal (P) is pressed, it compresses
other circuit.
the springs which act on the distributing valves (22
and 23) and cause the inlet ports (1 and 2) to the
brakes to open.
Fig. 3-2 Brake system hydraulic diagram
P. Brake pedal - S. Reservoir - M. To dump - 1. Rear brakes - 2. Front brakes - 3. Transmission disengagement pressure
switch - 4. Brake lights pressure switch - 5. Brake pedal valve - 6. Accumulator control pressure switch - 7 and 8. Brake
system accumulators - 9. Transmission - 10. Inlet oil filter - 11. Oil pump - 12. Check valve - 13. Parking brake accumula-
tor - 14. Parking brake three-way diverter/control valve - 15. Parking brake pressure switch - 16. Hydraulic ram - 17. Parking
brake - 18. Accumulator recharge valve - 19 and 20. Check valves -21. Primary check valve - 22. Front axle brake distributing
valve - 23. Rear axle brake distributing valve - 24. Transmission disengagement system - 25. Recharge pump - 26. Hydraulic
ram springs - 27. Flow regulating valve.
Fig. 3-2 HYDRAULIC BRAKING CIRCUIT SCHEMATIC
13 24
1 1
14
19
5
15 12 7
20
23
22
16 10
8
4 2 2
25
9
6
26 17
21
18
27
11 Braking circuit supply oil
Hydraulic circuit shown with engine running,

accumulators being recharged, brakes Dump oil
disengaged, parking brake applied. (Attachment pump)
S
3.3 DISC BRAKE
The disc brake is composed of a disc in oil bath and The inner disc edge is splined and is coupled to the
is assembled inside the axle center housing. This drive line sun gear. The outer edges of the pressure
loader is fitted with four braking assemblies on the and support plates are secured to the center housing
four wheels, one per wheel. by means of pins. Therefore, when the brake disc is
The disc brake structure is described in the Section pushed tight, the sun gear is stopped and the loader
“DRIVE/LINE TRANSMISSION”. is braked.
OPERATION
1) Applying the brakes 2) Releasing the brakes

The brake oil pressure acts onto the rear surface of When oil pressure is relieved from the brake piston,
the brake piston and tigthens the brake disc between this moves slightly rearwards to release the brake
the brake pressure plate and the support plate. disc and the the braking action stops.
5 6 7
Drive line Brake pressure oil
1 2
3 4
Fig. 3-3 Disc brake operation
1. Axle-shaft - 2. Planetary carrier - 3. Sun gear - 4. Brake disc - 5. Support plate - 6. Pin - 7. Pressure plate - 8. Brake pi-
ston - 9. Sealing ring.
3.4 BRAKE PEDAL VALVE
To dump
To other users or
dump
Rear brakefeed port
Accumulator pressure Front brake feed port

adjustment
Fig. 3-4 Brake pedal valve
Flow regulating valve
Accumulator maximum recharge

pressure adjust screw
Plug
Primary check
valve
Accumulator minimum recharge Accumulator recharge pressure
pressure adjust screw regulating valve
Fig. 3-5 Accumulator recharge pressure and flow regulating valve section view
Angle adjustment with pedal

released 40° to 60°
Min. angle from released

position to start sending
3°
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.
Fig. 3-6 Section view of oil delivery spools to users
From the recharge valve
To accumulator no. 1
4
2
3
To accumulator no. 2
5
Fig. 3-7 Section view of circuit separation valve and accumulator recharge one-way valves
1. ONE-WAY VALVE 3. CIRCUIT SEPARATION VALVE 5. SPRING

2. ONE-WAY VALVE 4. TAPERED PISTON 6. PISTON SEAL SEAT
3.4.1 CIRCUIT SEPARATION VALVE OPERATION

Note - If the leak from the accumulator charge valve
INSIDE THE BRAKING SYSTEM
is considerable due to pressure drop, the piston (4)
pin closes the valve/accumulator communication port
If a preset value is exceeded, this valve connects
before the reference accumulator attains minimum
the reference accumulator and the charge valve
pressure. This feature is to the advantage of normal
pressure sensor. Below said value, it accomplishes
operation, but it alters pressure reading. Therefore,
definite separation of the valve from the accumulator.
it is important that the oil leak purposely created be
small.
Operation description
The charge valve starts operating by sending oil to Possible failures
the accumulators through the one-way valves (see
figure). The pressure created acts also on the tapered 1. Failure in the accumulator no. 2 side, not used as
piston (4) which after reaching a certain pressure, a reference for the charge valve.
overcomes the spring (5) action and moves away In this case, pressure in accumulator no. 1
from the sealing seat (6). decreases to the setting value given by the spring
At charge end, the one-way valves close, and the (5).
charge valve senses only pressure in accumulator
no. 1 through the piston (4) and its seat. The spring Note - If the oil leak is considerable, the accumulator
(5) pin depends upon accumulator pressure and it pressure remains at the value as it is.
is usually kept at -10/-15 bars maximum below the 2. Accumulator no. 1 failure.
accumulator recharge pressure. This adjustment is In this case, accumulator no. 2 remains in the
obtained by means of shims. condition as it is.
To test the separation valve operation and setting, 3. Accumulator charge valve failure.
cause a minor oil leak in the accumulator feed line If the leak is small, accumulator no. 2 remains at
and read the pressure at the reference accumulator the pressure as it is, while reference accumulator
no. 1. Pressure decreases, the spring (5) overcomes no. 1 drops to the cut-out pressure given by the
the pressure on the piston (4) which closes the val- spring.
ve/accumulator communication port. Residual 4. If the leak is considerable, accumulator pressures
pressure into accumulator no. 1 corresponds to the remain as they are as the piston (4) immediately
valve regulation pressure. closes the accumulator/valve port.
3.5 PARKING BRAKE CONTROL

VALVE
The parking brake control valve controls pressure The parking brake valve is fitted with detents to
oil flow to the disc brake. maintain the rod in each position.
The parking brake valve displacement is controlled
by means of the control knob to operate the disc
brake.
A
T
11 12
A T
2 1
A T
7 6 5 4 3
8 9 10
B
Fig. 3-8 Parking brake valve
1. Rod - 2. Valve body - 3. Gland ring - 4. Ring - 5. O-Ring seal - 6. Cover - 7. Spool - 8. Detent spring - 9. Sleeve - 10. Detent
ball - 11. Dust ring - 12. Oil seal.
3 - 10 BRAKING SYSTEM W90
3.6 PARKING BRAKE
Parking brake manual disengagement (in case

of emergency)
WARNING WARNING
If it is not possible to release the parking brake by Disengage the parking brake manually only if it is
means of the control knob following pump failure or absolutely necessary. Namely, this should be done
for any other reason, disengage it manually through only when towing a failed loader to traffic-free areas.
the parking brake release screw. If the loader is on an incline, check that the wheels
are securely blocked with wedges or stones prior to
releasing the parking brake.
3.6.1 MANUAL RELEASE PROCEDURE
1. Remove the manual release bolt and nut (1) from into the threaded hole at the centre of the brake
the parking brake cover on the transmission piston (3), as shown in Fig. 3-10.
housing.
4. Screw the release bolt fully in to retract the brake
2. Remove the plug (2) from the middle of the cover. piston (3) and release the brake disc.
3. Insert the bolt (1) into the plug hole and screw it
Fig. 3-9 Fig. 3-10
W90 BRAKING SYSTEM 3 - 11
The parking brake is multiple disc type, in oil bath, packs the brake discs (rotary) against the fixed
and is assembled to the transmission intermediate plates.
shaft.
The brake is activated by means of an internal spring 2. The brake disc inner edge is coupled to the
and is released by pressure oil controlled by the transmission shaft through the brake disc hub.
parking brake valve. The fixed brake plate outer edge is coupled to
Parking brake structure is detailed in "Section 2 the brake housing. As the brake discs are pushed
“CONVERTOR-TRANSMISSION”. tight against the fixed plates, they stop rotating.
This causes the transmission shaft to stop rotating
by means of the disc hub and the loader is braked.
3.6.2 DISC PARKING BRAKE OPERATION
1. When pressure oil acting on the piston brake is

dumped, this is pushed by the spring force and
3 4 5
Brake pressure oil dump
6 7 8
Fig. 3-11 Parking brake
1. Brake piston - 2. Spring - 3. Support plat e - 4. Brake housing - 5. Fixed brake plate - 6. Disc hub - 7. Brake disc (rota-
ry) - 8. Transmission shaft.
3.6.3 BRAKE DISENGAGEMENT
1. When pressure oil is sent to the rear surface of 2. A clearance is established between each brake
the brake piston, this overcomes the spring action disc and fixed plate, the brake discs are released
and moves. and the brake is disengaged.
3.7 OTHER COMPONENTS
3.7.1 BRAKE ACCUMULATOR
The membrane accumulator is used to store pressure Oil from the charge pump is diverted by the check
oil to release the parking brake. valve to the accumulator which maintains the
pressure at a certain value.
CAPACITY .................................................................................. 0.75 lt.

MAX. WORKING PRESSURE PER ACCUMULATOR ........... 210 bars
3 GAS TO BE USED ............................................................. NITROGEN

GAS PRE-CHARGE PRESSURE ............................................... 9 bars
WEIGHT ................................................................................. 2.8 kg abt
Fig. 3-12 Accumulator
1. Gas filling plug - 2. Accumulator body - 3. Oil inlet connection.
3.7.2 CHECK VALVE
The check valve is used to prevent oil back-feeding

from the accumulator.
. . . . .
B A
. . . . .
B A
Fig. 3-13 Check valve
A. To the accumulator - B. From the outlet filter. Opening pressure: 1.5 kg/cm2 (21 psi)
3.8 BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS
N M
T1
F R1 R2
T2 T2
P TI2
T1
M P
R1
N F
R2
TI1
Fig. 3-14 Brake pedal valve hydraulic connection
F. Accumulator control pressure switch - M. Other users or to dump - N. Dump - P. Inlet - R1-2. Accumulator -T1-2. To the
brakes -TI1-2. Brake control pressure switch.
3.9 DIAGNOSTICS AND TESTING
10 11
8 3 4
S 5
T2
13 P 6
M
T1 1 2
18 15
17
16
14
20
19
Fig. 3-15 Braking system schematic
Brake system schematic
M. Other users or to dump

13. Charge pump (for the braking system)
N. Dump
14. Delivery oil filter
S. From hydraulic oil reservoir
15. Check valve
S1. To hydraulic oil reservoir
16. Parking brake accumulator (capacity = 0.75 lt. -
1. Rear axle brakes pre-charge = 9 bars)
2. Front axle brakes 17. Three-way diverter valve to control parking

brake engagement/disengagement
3. Quick coupling pressure port
18. Parking brake pressure switch (pressure switch
4. Quick coupling pressure port setting: OFF = 12 bars; ON = 8 bars)
5. Transmission disengagement pressure switch 19. Brake shoe control ram

(pressure switch setting = 15 bars)
20. Brake disc
6. Brake lights pressure switch (pressure switch
setting = 1.8 bars)
7. Brake pedal valve (operating pressure = 30 WARNING - DANGER

bars)
Always disconnect and connect all fittings with the
8. Accumulator control pressure switch (60 ± 5 engine stopped and braking system disabled.
bars) Accumulators keep some branches of the circuit
under pressure even if the engine is stopped.
10. Brake accumulator (capacity = 0.75 lt - pre- Pressure oil escaping from loose fittings may cause
charge = 45 bars) personal injury and damages to things.
Wear safety glasses with side shields.
11. Brake accumulator (capacity = 0.75 lt - pre-
charge = 45 bars)
3.9.1 BRAKE CONTROL PRESSURE TESTING

TEST
Connect two pressure gauges (end of scale 100 bars) approximately 30 bars.
to the pressure ports shown in Fig. 3-16.
Release the lock-nut (E, Fig. 3-16) and turn the screw
Apply the parking brake. in or out if pressure values are not within the rated
range.
Start machine engine and wait until it settles to
maximum torque speed. Pressure should be taken with the pedal fully down.
With the engine idling, press the brake pedal and Seal the screw after adjustment.
check that pressure reading on the gauges is
Rear axle
pressure port
Front axle
pressure port
E
Fig. 3-16 Braking pressure adjustment
3.9.2 MINIMUM AND MAXIMUM ACCUMULATOR

RECHARGE PRESSURE ADJUSTMENT
Connect two pressure gauges (end of scale 200 bars) from the rated value, remove the plug (1), release
to the quick coupling pressure ports (7 and 8, Fig. the lock-nut (5) and turn the screw (4) with
3-17) on the accumulators. micrometric variations until obtaining correct value.
Start machine engine and bring oil temperature to Check pressure again before tightening the lock-nut
approximately 40 to 50°C by means of the attachment (5).
control lever. Cycle the brake pedal several times to
make oil temperature even. Maximum recharge value
Minimum recharge value With the engine idling and the parking brake applied,
observe maximum recharge pressure on pressure
With the engine idling and machine at a standstill, gauges M1 and M2.
brake slowly 4 or 5 times. Pressure should be 100 ± 5 bars.
Observe minimum pressure values on pressure If maximum recharge pressure is different from the
gauges M1 and M2 before recharge starts. rated value, remove the plug (1), release the lock-
The pressure gauges should momentarily read nut (3) and turn the screw (2) out to increase the
80 ± 5 bars. If minimum recharge pressure is different accumulator maximum recharge pressure.
M1
M2
7
8
1 2 34
6
Fig. 3-17 Minimum and maximum accumulator recharge pressure adjustment
M1 & M2. Pressure gauges - 1. Plug - 2. Maximum pressure adjust screw - 3. Lock-nut - 4. Minimum pressure adjust
screw - 5. Lock-nut - 6. Accumulators - 7 & 8. Pressure ports.
3.9.3 PARKING BRAKE ENGAGEMENT TEST
Start the engine and let it run for about thirty seconds Operate the control lever two or three times always
to charge the accumulator. checking that the brake linkage moves completely.
Move the parking brake control lever to the “released” The machine must be fully blocked when on an
position. incline.
With the help of an assistant, observe the operation

of the parking brake control linkage.
V
2
S
6
Fig. 3-18 Parking brake schematic
S. Dump to oil reservoir - V. From recharge pump - 1. Parking brake engagement/disengagement lever - 2. Three-way val-
ve - 3. Parking brake accumulator - 4. Check valve - 5. Ram - 6. Parking brake.
3.9.4 ACCUMULATOR PRE-CHARGE TEST
Accumulators fitted to the braking system are mem- - Disconnect tool (D) from the accumulator.
brane type, pre-charged using nitrogen.
- Tighten the screw (2) to a torque of 1.1 daNm.
Normal minimum membrane porosity and continued
use reduce pre-charge pressure in time and limit - Test accumulator sealing using soapy water.
accumulator efficiency.
- Screw on protective cover (1).
It is advised to check the nitrogen pre-charge every
six months and restore it, if necessary. Recharge the accumulator if the pressure is lower
than rated value.
Pre-charge pressure should never drop below
apporximately 90% of the rated value.
Check is to be carried out with the accumulators

drained of hydraulic oil. This condition is obtained as
follows:
- as regards accumulators (7 and 8, Fig. 3-2) by D1
pressing the brake pedal slowly several times
- as regards the parking brake release accumulator
(13, Fig. 3-2) by operating repeatedly the diverter
valve (14) with the engine stopped. D
Check the pre-charge as follows:
- Remove protection cover (1, Fig. 3-19).

M
- Loosen the screw (2) by half turn using an
hexagonal Allen wrench. M D1
- Screw in tool no. 75298472 (D) on the accumulator

connection.
- Ensure tap (D2) is closed.
- Turn the handwheel (D1) to loosen the screw (2).

D
- When the pointer of the pressure gauge (M) starts D2
moving, turn out the handwheel (D1) by one more
turn. 1
Now the pressure gauge shows the accumulator pre-

charge pressure, which should be 45 bars. 2
If pressure is not within the specified range of values,

proceed as follows:
Fig. 3-19 Accumulato pre-charge test
- Close handwheel (D1).
D. Accumulator pre-charge test tool - D1. Plug control
- Open tap (D2) to discharge nitrogen pressure from handwheel (2) - D2. Discharge tap - M. Pressure gauge -
within the tool (D). 1. Protective cover - 2. Threaded plug.
3.9.5 ACCUMULATOR PRE-CHARGE RESET

INSTRUCTIONS
Using tool no. 75298472 (D, Fig. 3-20) screwed to Close the nitrogen bottle tap.
the accumulator connection (see 3.9.4. before) Wait five minutes.
proceed as follows. Check on the pressure gauge (M) that inflating
pressure is 45 bars. Repeat the operation if lower.
Loosen the plug and screw in the hose from a If pressure is higher, proceed as follows:
nitrogen bottle complete with safety valve (V).
- Slowly turn the handwheel (D2) to let the nitrogen
out and close.
WARNING - DANGER
- Check on the pressure gauge (M) that pressure is
Use only nitrogen to recharge accumulators. Never
as required. If not, repeat the operation.
use oxygen or other gases for any reason whatever
as explosion hazard may result.
- Turn the handwheel (D1) to screw in the
accumulator screw (2).
Slowly open the nitrogen bottle tap and check refilling
- Remove tool (D).
pressure as it increases on the pressure gauge (M).
IMPORTANT - Refilling pressure should be 10% at - Check accumulator sealing using soapy water.
least higher than rated pressure considering that
pressure inside the accumulator decreases when the - Screw on protection cover (1).
compressed gas cools down.
D1
D
D1
V
M
D
1 D2 A
Fig. 3-20 Accumulator recharge device
D. Accumulator pre-charge test tool - D1. Plug control handwheel (2) - D2. Discharge tap - A. Nitrogen bottle - M. Pressure
gauge - V. Safety valve - 1. Protection cover - 2. Threaded plug.
3.9.6 BLEEDING THE BRAKE SYSTEM
It will be necessary to bleed the brake system - Park the machine on level ground and start the
whenever one of the following occurs: engine.
- After replacing hydraulic oil in the attachment oil - With the engine idling, one operator should release
reservoir. the bleed screw (two on each axle) while the other
is pressing the brake valve pedal. Tighten the bleed
- When air has entered the system because of poor screw before releasing the brake pedal.
sealing of hoses or charge pump.
- Repeat this operation until bleeding all air from the
- After disconnecting or replacing any of the system system (fluid should come out of the bleed screw
parts. free of bubbles).
Bleed the system as detailed below (this is a two- - Repeat for the other axle.
man operation):
S S
Fig. 3-21 Brake oil bleed screw (S) locations on the axle (1 per brake)
3.9.7 BRAKE DISC WEAR CHECK
1 A
FRONT AXLE
1 B
REAR AXLE
Fig. 3-22 Brake disc wear check hole locations
Drain oil from the assemblies by loosening the plugs The brake disc is to be replaced if disc thickness is
(A) and (B) for the front and rear axles, respectively. lower than 5.3 mm.
Check wear of the two brake discs (per axle) by
inserting a feeler gauge.
SECTION 4
STEERING SYSTEM
CONTENTS
4.2 PRINCIPLES OF OPERATION OF

MAIN PRIORITY VALVE ........................................................................................ 7
4.3 STEERING VALVE (ORBITROL) ........................................................................... 8

4.3.1 Removal .................................................................................................................. 9
4.3.2 Main priority valve .................................................................................................. 14
4.3.3 Secondary priority valve (optional) ......................................................................... 15
4.3.4 Cushion valve .......................................................................................................... 16
4.3.5 Steering cylinders ................................................................................................... 17
4.3.6 Multiple check valve ............................................................................................... 19
W90 STEERING SYSTEM 4-1
The steering system uses the same oil of the equip- block (12) prevent the pressure from exceeding the
ment system. The two systems are combined so that setting of the cushion valve.
the excess oil of the steering pump is sent to the Also, the valves have an anti cavitation function, en-
equipment system. The system is made of an hy- suring that when the orbitrol is in neutral, the cham-
draulic reservoir (S), a pump (1) a main priority valve bers of the cylinders are always filled with oil, thus
(2), a steering unit (orbitrol) (3) complete with valves avoiding cavitations of oil in the circuit, in case of
block, a cushion valve (5) and steering cylinders (4). intervention of the safety valves (anti shock) protect-
ing against strong shocks on the wheels.
The oil in the reservoir (S) is sucked by pump (1),
composed of two sections: one section supplies the Under emergency conditions, the oil flow from the
steering/equipment system, the other supplies the steering pump is lost. When the tyres are rotating,
brake system. emergency pump (7) generates a flow directed to
emergency secondary priority valve (9). Oil flowing
The oil is directed by a priority valve (2) that includes to the steering system is sufficient to ensure the steer-
a control valve spool. ing, when the engine stops for accidental reasons.
When it is required, oil is sent to the steering system On units equipped with emergency steering system,
and the equipment system. When the steering is at besides the standard system, the following items
rest, oil at the end of the priority spool pushes it up- have been added, among other components:
ward, allowing the oil from the pump to flow to the - emergency pump (7);
equipment system. The steering system has a prior- - a secondary priority valve (9);
ity and receives oil first. The priority valve, together - a multiple make-up valve (8) and check valves on
with the orbitrol, make the LOAD SENSING SYS- the main and secondary priority valves.
TEM (LS).
If an accidental drop of the feeding pressure occurs
in the system, pressure switch (10), fitted on the main
priority valve, signals the problem on the dashboard,
switching on the indicator.
The pressure switch signals this pressure drop only
Operation of the LOAD SENSING system when the pressure reaches less than 1 bar. Another
The load sensing system allows the feeding of the pressure switch (11) is positioned on check valve (13)
steering valve (orbitrol) with a quantity of oil (taken signalling a pressure drop in the emergency system,
from the main pump delivery) required by the steer- switching on the same indicator on the dashboard.
ing function, allowing the residual delivery of the pump
to flow into the equipment system (equipment con-
trol valve).
As an example, when the steering wheel is in neu-
tral position, the majority of the oil flow of the main
pump is sent to the hydraulic control valve to oper-
ate the equipment hydraulic system, so that the oil
delivered by the main pump is used in an efficient
manner to obtain the highest conservation of energy.
When the operator actuates the steering wheel, oil

is directed to the steering cylinders through the
orbitrol. The oil directed to the cylinder is diverted to
the cushion valve, working as a shock absorber, to
reduce the shock load, when the rotation of the steer-
ing wheel is over. The spool inside the cushion valve
moves to limit the increase of the pressure in the
cylinders. If the pressure raises beyond the setting
of this valve, the safety and anti cavitation valves (6)
(refer to the hydraulic system diagram) inside valves
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4-2 STEERING SYSTEM W90
11
13
P R
L
T LS
PP
3 S
4 6 12
5
4
2 16
D
F
9
10 8
1
G
Fig. 4-1 Steering system with emergency steering
D. To equipment control valve - F. To brake pedal valve - G. From brake pedal valve - L. To left cylinder (rod side) - LS. Load-
Sensing signal - P. Flow from pump - PP. Pilot pressure - R. To right cylinder (rod side) - T. Discharge to reservoir - 1. Double
feeding pump (for steering, equipment and brakes) - 2. Main priority valve - 3. Steering valve - 4. Steering cylinders -
5. Cushion valve - 6. Safety and anti cavitation valve - 7. Emergency steering pump - 8. Multiple check valve - 9. Secondary
priority valve - 10. Main pump low pressure switch - 11. Emergency steering pump low pressure switch - 12. Valves block -
13. Check valve on reservoir - 16. Check valve.
Fig. 4-2 STEERING SYSTEM DIAGRAM
3 1. Double feeding pump: 17

- Equipment-steering section: (Q = 119 ltr/min)
LS - Brakes section (Q = 23.8 ltr/min) FROM EQUIPMENT
2. Main priority valve (setting = 12 bar) CONTROL VALVE
3. Steering valve OSPL 520 LS
4. Steering cylinders 18
5. Cushion valve
6. Safety and anti cavitation valve (setting = 230 - 250 bar)
12. Valves block OVPL 24
14 14. Main relief valve (setting = 175 bar) 19
15. Spool
17. Plug with pressurising valve
18. Oil filter on return from control valve (10 µ) S
19. By-pass valve on hydraulic oil filter
FROM EQUIPMENT
PP
PILOT VALVE
12
R L T P
CONTROL VALVE
TO EQUIPMENT
2
LS
5
1
EF
P
CF
PP
15
FROM BRAKE VALVE
L R
TO BRAKE VALVE
4
Fig. 4-3 DIAGRAM OF STEERING HYDRAULIC SYSTEM WITH
EMERGENCY STEERING
3
LS 1. Double feeding pump:
- Equipment-steering section (Q = 119 ltr/min) FROM EQUIPMENT 17
CONTROL VALVE
- Brakes section: (Q = 23.8 ltr/min)
2. Main priority valve (setting = 12 bar)
3. Steering valve OSPL 520 LS
4. Steering cylinders
5. Cushion valve 18
14 6. Safety and anti cavitation valve (setting = 230 - 250 bar)
7. Emergency steering pump (capacity 14.4 cucm/rev)
8. Multiple check valve 19
9. Secondary priority valve
10. Main pump low pressure switch 11
11. Emergency steering low pressure switch 13 S
12. Valves block OVPL 24
13. Check valve on reservoir
14. Main relief valve (setting = 175 bar)
15. Spool
16. Check valve on priority and secondary valve
17. Plug with pressurising valve
FROM EQUIPMENT
18. Oil filter on return from control valve (10 µ)
12
19. By-pass valve on hydraulic oil filter
PILOT VALVE
PP
15
9
8
R L T P
LS
16
6 S
EF
P
CF
CONTROL VALVE
5 TO EQUIPMENT
PP
7
10 1
2
LS
PP
16
EF
FROM BRAKE
P
VALVE
CF
L R
4 15 TO BRAKE VALVE
PP
4.2 PRINCIPLES OF OPERATION OF

MAIN PRIORITY VALVE
The oil is sucked by the pump and sent directly to ment only operation mode (boom and bucket) with-
the main priority valve. The oil feeds the valve through out the intervention of the steering is represented.
duct (P, fig. 4-4).
Check valve (1) is closed due to the lack of flow to-
In case of steering of the machine, spool (2) is posi- ward the steering valve, keeping it pressurised. This
tioned as in detail (a). This position is maintained by condition is maintained for a few seconds, due to the
the return spring and by the oil coming from duct dynamic losses inside the steering valve, where an
(LS). alternating closing and opening movement of the
feeding duct (CF) results.
Duct (LS) is connected to the steering valve and the
pressure is directly proportional to the steering speed. The two restrictions (S1 and S2), by creating a pres-
If the steering is gradually zeroed (detail b), the pressure differential after them, allow a gradual move-
sure in the steering valve decreases, as well as in ment of spool (2) during the various phases of
duct (LS). operation.
Being, under these conditions, the delivery pressure

at the steering valve (duct CF), spool (2) moves and
compresses the return spring, freeing, gradually, the
delivery to control valve (EF).
In detail (C) the position of the spool in the equip-
1234567
1234567
Pressurised oil Discharge oil 1234567 Static oil
S2 2 1 1 1
EF CF EF CF EF CF
LS LS LS
PP PP PP
S1
P P P
a b c
Fig. 4-4 Operational phases of the main priority valve
a. Delivery phase of the whole flow to the steering valve - b. Delivery phase at the same time to the steering valve and
equipment control valve - c. Complete cut-off of the steering valve and total flow to the control valve - S1 and S2. Restrictions -
1. Check valve - LS. To steering valve - EF. To equipment control valve - CF. To steering valve and (optional) to secondary
priority valve - P. From hydraulic pump - 2. Spool.
4-8 STEERING SYSTEM W90
4.3 STEERING VALVE (ORBITROL)
The orbitrol consists of the control valve and the ro- Usually it acts as an hydraulic motor performing
tor set. The control valve is a rotary valve which metering functions. In case of emergency, it is used
changes the alignment of oil passages by its rota- as a manual pump acting as a manual steering unit
tion, thus actuating the steering cylinders. The rotor (without hydraulic power).
set is located under the control valve.
3 4 6
L
5 DANFOSS 7
LS
PP
P
8
1
Fig. 4-5 Steering valve
1. Valves block - 2. Steering valve - 3. To main and secondary priority valve (unit with emergency steering unit) - 4. To
reservoir - 5. From pump - 6. To left steering cylinder - 7. To right steering cylinder - 8. To main and secondary priority valve
(unit with emergency steering unit).
L R
P T
OVPL 24
PP
OSPL 520 LS
LS
Fig. 4-6 Hydraulic diagram
4.3.1 STEERING VALVE
Removal
Drain the hydraulic oil from the reservoir, steer com- The steering valve is complete with valves block (2)
pletely to the right and to the left, to reach the area flanged on the steering valve.
under the cab. Tag and disconnect the oil pipes from It is recommended that the sections of the steering
valves block (2). From the inside of the cab, remove valve are marked, to re-assemble them in the same
the steering column cover, so that it is possible to position.
reach the steering valve securing screws, then, re- Remove the securing screws and extract valves block
move the four screws (5). Remove the steering valve (2) from the steering valve (1, fig. 4-7).
complete with valves block.
5 1
4 6
1
2
Fig. 4-7 Steering column complete with steering valve
1. Steering valve - 2. Valves block - 3. Steering column - 4. Steering wheel - 5. Steering valve securing screws - 6. Valves
block securing screws.
Notes - 1 3.5 daNm 3 2 daNm
2 3.5 - 4.5 daNm 4 6.5 daNm ± 0.5
4 - 10 STEERING SYSTEM W90
25 5
6
3 7
2 4
11
10
12
8
13
14
15
16
17
18
19
20
21 24
22
23
Fig. 4-8 Components of steering valve
1. Dust seal - 2. Steering valve body - 3. Check valve ball - 4. Threaded bush - 5. Seal - 6. Parts of thrust bearing -
7. Ring - 8. Rotor set - 9. Sleeve (11) return springs - 10. Sleeve (11) and shaft (12) drive pin - 11. Valve seat sleeve -
12. Rotor (17) drive shaft - 13. O-ring - 14. Intermediate plate - 15. O-ring - 16. Thrust plate - 17. Rotor set - 18. O-ring -
19. Rotor (17) fixed ring - 20. O-ring - 21. Cover - 22. Washers - 23. Screw with pin - 24. Cover (21) securing screws -
25. Pressure relief valve.
W90 STEERING SYSTEM 4 - 11
Disassembly
Remove plugs (8) from the valves block and remove the sliding surfaces are free from scratches.
the safety, anti-shock and anti cavitation multiple
valves (5). Lubricate the components.
Reassemble the components, reversing the disas-

Always from the block, extract check valves (9).
sembly sequence, referring to fig. 4-9.
Clean thoroughly all the components and check that Replace the O-rings.
C1
9 2
3
8
10 7
6
5
5
6
7
8
1
Fig. 4-9 Components of the valves block
1 and 2. O-rings - 3. Dowel - 4. Securing screws - 5. Multiple safety valves - 6. Springs - 7. O-ring - 8. Plugs - 9. Check
valves - 10. Valves body.
Note - 1 3.7 - 4.3 daNm
Disassembly of steering valve
Loosen the securing screws (24, fig. 4-8) and remove

cover (21).
Remove fixed ring (19) complete with inner rotor (17).
Extract spacer (16) and O-ring (15).
Remove intermediate plate (14) and O-ring (13).
Loosen threaded bush (4) and extract ball (3) of the

check valve.
To extract the springs, it is necessary to extract par-

tially the rotor valve of the sleeve, removing flat
springs (9), extract the valve pushing it out the sleeve,
rotating it slowly, to facilitate the operation.
Inspect thoroughly all components.

Check that the sliding surfaces are free from
scratches and deformations.
Replace all damaged components.
Replace all seals and, possibly, the flat springs as
well.
It is important that the reassembly of the steering

valve components is performed in totally clean con-
ditions.
Lubricate freely all components with hydraulic oil.
Check that all ducts are free from cloggings.
Extract sleeve (11) complete with rotor valve (8).

Extract thrust bearing (6) and the return sleeve spring
retaining ring.
Separate the rotor valve from the sleeve, pulling out
drive pin (10).
Reassembly of steering valve
Position the seal on the steering valve body. tighten threaded bush (4).
Reassemble rotor valve (8) into sleeve (11) rotating To facilitate the operations to follow, prior to the in-
it slowly during the operation. stallation of the drive shaft, mark it with a sign paral-
lel to the pin groove.
Align the spring passing boring and insert the springs
Install the drive shaft, checking that the spline enters
inside the sleeve and the rotor valve.
the pin.
NOTE - In case a tool is required to install the springs,
NOTE - Mark (B) on the shaft must be parallel (C)
obtain it from a socket wrench that can be adapted
with the drive pin and the valves block securing sur-
to the seat.
face (D).
The long portion of the wrench must be grooved to a
depth of about 13 mm and a width of 3.2 mm.
Position intermediate plate (14, fig. 4-8) and shim
ring (16) with the relevant O-Rings.
Center the springs mounted correctly to position them
flat with the outside diameter of the sleeve.
Install fixed ring (19) complete with rotor (17).
Insert the spring retaining ring (7).
NOTE - Ensure that the two spaces of the rotor as
indicated in the figure, are parallel (A) with the sign
Install the sleeve/rotor valve drive pin (10).
(B) previously made on the shaft, thus with drive pin
(C) and valve bloc mounting surface (D).
Install thrust bearing (6).
Install the cover, checking that the marks made prior
Insert the sleeve assembly into the steering valve
to the disassembly match.
body, ensuring that the matching parts rotate freely.
Install the assembly, tightening the screws to a torque
NOTE - During the installation of sleeve (11) into the of 3.5 daNm, following the sequence specified in
steering valve body, make sure that the drive pin stays fig. 4-10.
horizontal.
Install the valves block assembly, tightening the se-
Insert ball (3, fig. 4-8) into its seat on the body and curing screws to a torque of 6.5 daNm.
A
6 4
B
C
A D 1 2
C D 3 7
Fig. 4-10 Timing of the steering valve
A - B - C - D. Surfaces that must result parallel among themselves, during the reassembly.
4.3.2 MAIN PRIORITY VALVE
The priority valve is combined with the steering valve

to create a “load sensing” system distributing the flow
of the main pump to the steering and equipment sys-
tems.
P P
LS PP
LS PP
EF CF
EF CF
Fig. 4-11 Diagram of main priority valve
P: PUMP (from main pump)

LS: LOAD SENSING (from Orbitrol)
EF: MAIN CIRCUIT (to equipment control valve)
CF: STEERING CIRCUIT (to steering valve)
PP: PILOT PRESSURE (from Orbitrol)
Setting = 10 bar
Removal Disassembly
The valve is mounted on the frame on the left side of To disassemble the priority valve, perform the fol-
the machine, under the cab. lowing operations:
Drain the hydraulic oil from the reservoir, tagging the 1) loosen plug (1, fig. 4-12) and the relevant O-ring
oil hoses before disconnecting them. Loosen the se- (2) from port (PP);
curing screws and remove the valve.
2) loosen plug (6) and the relevant O-ring (2) from
port (LS) and extract spring (5);
3) extract spool (3) using a nylon rod, pushing from

the opposite side of the valve.
1 1
2
3
5
2
6 1
4
Fig. 4-12 Main priority valve
1. Plug - 2. O-ring - 3. Spool - 4. Valve body - 5. Spring - 6. Plug with orifice.
1 6 daNm
Reassembly and installation 4.3.3 SECONDARY PRIORITY VALVE (OP-

TIONAL)
The reassembly and the installation is performed by
reversing the sequence of operations above. The secondary priority valve is like the main priority
Tighten the components to the prescribed torque, as valve, but has a different “stand-by” pressure of 4
indicated in fig. 4-12. bar, and it is mounted on the frame, on the right side
under the cab.
The removal/disassembly/reassembly and installa-

tion operations are the same as for the main priority
valve.
4.3.4 CUSHION VALVE
At the beginning and at the end of the rotation of the - loosen the valve securing parts and remove it.
steering wheel, a quick surge of the oil pressure in To disassemble the valve, it is enough to loosen
the steering cylinder circuit occurs. The cushion valve plugs (1, fig. 4-13) and to pull-out the components
discharges this pressure temporarily into the return shown in the figure;
circuit to the hydraulic oil reservoir, to ensure a
smooth steering action. - wash and clean all the components with a non flam-
mable, non toxic detergent solution;
Disassembly - check that the plungers are free from scratches

and that they can slide freely in their seats.
The valve is located on the left side of the rear frame.
Reassemble the components, reversing the disas-
Proceed as follows: sembly sequence, making sure that the O-rings are
replaced with new ones.
- discharge the oil from the equipment reservoir;
After the installation of the valve on the machine,
- disconnect the oil pipes; check that no leakages occur.
5
1 1
2
6 1 1
5
Fig. 4-13 Components of cushion valve
1. Plug - 2. O-ring - 3. Plunger - 4. Spring - 5. Retaining ring - 6. Valve body.
1 45 - 55 daNm
4.3.5 STEERING CYLINDERS Removal
The two double acting steering cylinders, with a rod Proceed as follows:
and sleeve, are mounted, respectively, to the front
and rear module of the frame.
- drain the oil from the equipment reservoir;
The steering action of the loader is obtained by push- - disconnect the oil pipes;
ing out or retracting the rod. - from the rod side, loosen the screw securing the
retaining plate and extract the pin;
Specifications:
Inner diameter of sleeve .............................. 60 mm - disconnect the pin greasing pipe of the pivot pin
Diameter of rod............................................. 35 mm from the left cylinder;
Cylinder stroke ..................................... 395 ± 2 mm - from the sleeve side, loosen the retaining plate se
1 1 2 3 4 8 9 10 11 12 2 13 3
5 6 7 14
Inner section
15
16
17
Fig. 4-14 Components of the steering cylinder
1. Cylinder sleeve - 2. O-ring - 3. Back-up ring - 4. O-ring - 5. Mud scraper seal - 6. Bush - 7. Sealing ring - 8. Cylinder rod -
9. Cylinder sleeve - 10. Piston seal - 11. O-ring - 12. Piston - 13. Locking screw - 14. Steel ball - 15. Pivoting bush -16. Snap
ring - 17. Pressure pick-up plug.
Notes - 1 31 daNm (M65 x 2) 3 0.7 daNm (M6 x 1)
2 40 daNm (M24 x 1.5)
curing screw and extract the pin. - tighten screw (13) to torque 3 and stake;
- tighten front sleeve (1) to torque 1.
- remove the cylinder assembly.
Installation
Disassembly and reassembly
Install the cylinder on the machine, reversing the re-
Loosen front sleeve (1) and pull-out rod (8) complete
moval procedure.
with piston (12).
Check that after starting the engine and after sev-
Remove the screw locking the piston and loosen it.
eral movements of the steering, the cylinder rod does
not show oil leakages.
If the ball joint shows an excessive play, replace it as
follows:
Handle all components with great attention. Do not
place hands and fingers between components. Wear
- remove snap rings (16);
glasses, gloves and safety shoes.
- using a punch or a press, extract bush (15) from
its seat, taking care that the outer side of the bush
only is pushed.
Check that the rod is free from imperfections, such

as dents, burrs, or wear.
Check, using a ruler or by positioning it on a flat sur-
face, that the rod is not bent.
Inspect the inside of the cylinder, to verify if scratches
or wear require its replacement.
Replace all damaged parts.
Reassemble the cylinders, reversing the disassem-

bly procedures, considering the following items:
- lubricate adequately the components;

- install new seals, ensuring a proper installation and
correct position;
- tighten the piston to torque 2;
4.3.6 MULTIPLE CHECK VALVE
To secondary
priority valve
PUMP
PUMP
RESERVOIR
RESERVOIR
PUMP
To secondary
priority valve
PUMP
DIAGRAM OF POWER STEERING
Fig. 4-15 Multiple check valve
The valve is located on the right side of the machine under the cab.
SECTION 5
BUCKET BOOMS AND FRAME

CONTENTS
5.1 LOAD HANDLING SYSTEM .................................................................................. 1
5.2 BOOMS, BELLCRANK AND BUCKET ................................................................... 2

5.2.1 General description ................................................................................................ 2
5.2.2 Bucket ..................................................................................................................... 4
5.2.3 Bucket automatic leveller ....................................................................................... 5
5.2.4 Boom kick-out (optional) ......................................................................................... 6
5.3 FRAME PIVOT PINS .............................................................................................. 7

W90 BUCKET BOOMS AND FRAME 5-1
5.1 LOAD HANDLING SYSTEM
The load handling system is operated by hydraulic The linkage employed for the loading system is a
cylinders and is used to dig, load and unload, and Z-shape type which is simpler in design and produces
transport loads. more powerful bucket break-out force than the duplex
or other types.
BUCKET CYLINDER
BUCKET LEVELER
BELLCRANK
BOOM CYLINDER
BOOM
BUCKET
Fig. 5-1
5-2 BUCKET BOOMS AND FRAME W90
5.2 BOOM, BELLCRANK AND BUCKET
- Linkage Z
- Bucket capacity cu m
Heaped 1.3
Struck 1.1
- Bucket automatic leveller
- Boom kick-out
- Weight Kg
Booms 482
Bellcrank 83
Pushrod 21
Bucket 465
The load handling system consists of booms,

bellcrank, pushrod, bucket, bucket cylinder, boom
cylinders, and pins. The bucket leveler helps provide
efficient load handling operation. All connecting pins
of the load handling system have dust seals to
prevent the entrance of water, mud or dust into the
system. The three connecting pins of the bucket are
provided with "O-rings". All the connecting pins are
secured with lock bolts.
2 6
3 7
4
8
11 11 1 13
1
14
14
1 9
1 9
10 10 12 2
12 2
Boom and frame pivot section Bucket pivot section
Fig. 5-2 Booms, bellcrank and bucket
Notes - 1 All pins, bushes and hubs: grease (apply before mounting the pins)
2 Install the mud scrapers with the lip toward the outside
1. BUCKET CYLINDER 6. FRONT FRAME 11. BUSHING

2. BELLCRANK 7. SPACER 12. DUST SEAL
3. PUSHROD 8. BOOM CYLINDER 13. O-RING
4. BOOM 9. PIN 14. LOCK BOLT
5. BUCKET 10. GREASE FITTING
5.2.2 BUCKET
The general purpose bucket with a bolt-on reversible General-purpose bucket with bolt-on teeth
cutting edge (DEB) is standard. The light-material
bucket with welded cutting edge and the general-
purpose bucket with bolt-on teeth are optionally
available.
The bucket should be selected with due care,
considering the condition of job sites, the nature of
loads to be handled, and the operating conditions. A
wrong bucket will cause an inefficient operation and
may cause the malfunction of the load handling
system as well.
General-purpose bucket with bolted reversible

cutting edge, DEB
A
Fig. 5-4
Note - 1 Tightening torque 10.5 daNm
Fig. 5-3
Note - 1 Tightening torque 10.5 daNm
5.2.3 BUCKET LEVELER
With the control lever put in Roll-back after dumping detent coil of the control valve bucket section. The
the bucket, the bucket leveler automatically returns solenoid detent is thus released to let the control lever
the control lever to neutral when the bucket is put in return to neutral, stopping the rolling back operation
horizontal position. of the bucket.
Operation
As the bucket is rolled back, the bucket cylinder piston
rod extends enough to let the leveler plate leave the Note - The bucket spool is a solenoid detent
sensing surface of the proximity switch (thus opening mechanism. When the bucket is rolled back beyond
the electric circuit). the horizontal line, no further electricity will flow to
the solenoid detent coil so that the control lever detent
The proximity switch is connected to the solenoid mechanism won't work.
Wiring
2
1
3
6
Fig. 5-5 Bucket leveler
1. BRACKET 4. BRACKET
2. LEVELER BAR 5. BUCKET CYLINDER
3. PROXIMITY SWITCH 6. CONTROL VALVE
5.2.4 BOOM KICKOUT (optional)
The boom kickout device stops the booms at a preset sensing surface of the proximity switch (thus
height during the lifting phase. With the control lever opening the electric circuit).
in RAISE position, the boom kickout device
automatically returns the control lever into neutral 2. The proximity switch is connected to the solenoid
when the booms are raised to a preset height, thus detent coil of the control valve boom section. The
stopping the lifting operation of the booms. solenoid detent is thus released to let the control
lever return to neutral, stopping the lifting
operation of the booms.
Operation Note - The control valve of loaders equipped with

1. When the booms are raised to a preset height, the boom kickout device differs from that of the
the level plate fitted to the boom leaves the standard loaders.
1
2
3
4
7
Fig. 5-6 Boom kickout device
1. PROXIMITY SWITCH 5. WIRING

2. BRACKET 6. CONTROL VALVE
3. TAPPED PLATE 7. BOOM
4. LEVEL PLATE 8. FRONT FRAME
5.3 FRAME PIVOT PINS
4 3 3 5
3 1
3
Sectional view
Upper pivot point
13 7 1
3 10
15
8
6
9
2 14 12 3
11
Sectional view
Lower pivot point
Fig. 5-7 Frame pivot points
Notes - 1 Tightening torque 56 daNm Threaded area: Loctite 262
2 Tightening torque 3.5 daNm 3 Inner surface

(prior to installation)
SPECIFICATIONS OF PINS
* Diameter of upper pivot pin 49.972 ÷ 49.988
** Diameter of lower pivot pin 59.966 ÷ 59.985
1. BUSH
2. SNAP RING 9. BUSH
3. BUSH 10. COLLAR
4. UPPER PIVOT PIN DIA. 50 * 11. SCREW M24X2X185
5. SECURING SCREW M12X25 12. COLLAR
6. GREASE NIPPLE 13. LOWER PIVOT PIN DIAM. 60 **
7. NUT (apply LOCTITE 262) 14. SCREW M10X65
8. SEAL 15. SHIMS
5.4 BUCKET STOPS
DETTAGLIO
DETAIL A A
TASSELLO DI BATTUTA
STOP BLOCK
STOP
TASSELLO DI
BATTUTA
BLOCK 54
1
A 2
3
50°
48°
460
GROUND LINE
BUCKET ROLL-BACK STOP
– Position the axis of the lower hinging pin at 460 mm from the ground line.
– Extend the bucket dumping cylinder full stroke then retract it 3 mm.
– Weld the two upper stop blocks on the bucket. The thickness of the blocks must be equivalent to the gap
between boom and bucket.
BUCKET DUMP STOP
– Position the booms at maximum height.

– Weld the two stop blocks so that a bucket dumping of 48° is obtained, corresponding to a misalignment of
pins 1-2-3 of about 54 mm.
SECTION 6
ATTACHMENT HYDRAULIC SYSTEM

CONTENTS
6.2 OIL CIRCUIT ........................................................................................................... 2

6.2.1 Attachment hydraulic circuit .................................................................................... 2
6.3 HYDRAULIC SYSTEM PUMP ................................................................................ 3

6.3.1 Attachment/steering pump testing and repair ......................................................... 6
6.4 ATTACHMENTCONTROL VALVE (mechanical) ..................................................... 8

6.4.1 General description ................................................................................................. 8
6.4.2 Control valve operation ........................................................................................... 13
6.4.3 Pressure relief valve ............................................................................................... 18
6.5 CONTROL VALVE CONTROLS ............................................................................. 21
6.6 HYDRAULIC OIL RESERVOIR .............................................................................. 22
6.7 CYLINDERS............................................................................................................ 23
6.7.1 Boom raise cylinders ............................................................................................... 23
6.7.2 Bucket roll cylinder .................................................................................................. 23
6.8 L.T.S. ANTI-PITCH SYSTEM .................................................................................. 26

6.8.1 Description .............................................................................................................. 26
6.8.2 Accumulator discharge ............................................................................................ 26
6.8.3 L.T.S. hydraulic diagram .......................................................................................... 28
6.8.4 L.T.S. system operating tests .................................................................................. 29
6.8.5 L.T.S. accumulator pre-charge check ..................................................................... 30
6.8.6 Accumulator pre-charge reset instructions ............................................................. 31
6.9 AUXILIARY HYDRAULICS OPERATION (Option) ................................................. 32

W90 ATTACHMENT HYDRAULIC SYSTEM 6-1
The hydraulic system receives hydraulic power from The hydraulic system is composed of: main pump,
the main pump and directs the oil flow to the to control valve, control valve hoses and control lever,
different functions according to the attachment hydraulic oil reservoir and hydraulic hoses.
requirements by means of the control valve.
Control valve control lever
Priority valve
Control cables
Pump
Control valve
Control valve
Bucket cylinder
Oil reservoir
Boom lift
left-hand cylinder
Main hydraulic
circuit
Fig. 6-1 Attachment hydraulic system
6-2 ATTACHMENT HYDRAULIC SYSTEM W90
6.2 OIL CIRCUIT
The loader hydraulic circuit is composed of the

attachment hydraulic circuit and steering hydraulic
circuit.
See Section 4 “STEERING SYSTEM” for the steering
hydraulic circuit.
6.2.1 ATTACHMENT HYDRAULIC CIRCUIT
Oil drawn from the hydraulic oil reservoir by the main

pump is sent to the priority valve, from which two
circuits originate: the attachment hydraulic circuit and
the steering hydraulic circuit.
Oil required by the attachment hydraulic circuit is sent
to the control valve. When the control valve is in the
neutral position, oil flows through it and returns to
the hydraulic oil reservoir. When the control valve is
in the control position, oil flows through the holes left
open by the spools to enter the cylinders.
Oil dumped from the cylinders returns to the control
valve which in turn sends it to the reservoir via the
return filter.
Fig. 6-2 ATTACHMENT HYDRAULIC SYSTEM SCHEMATIC (3 SPOOL MECHANICAL CONTROL VALVE)
FILLING
PLUG
RETURN OIL
FILTER
HYDRAULIC
OIL RESERVOIR
STEERING VALVE
EMERGENCY STEERING
PRIORITY VALVE
EMERGENCY
STEERING STEER. VALVE EMERGENCY
240 bar
CYLINDERS STEER. PUMP
ACCUMULATOR
175 bar 4 bar
3-SPOOL MECHANICAL ATTACHMENT

CONTROL VALVE ATTACHMENT
STEER./BRAKE PUMP
BOOM CYLINDERS B3
235
bar
A3
A3 12 bar
24V DC
B2 235
160 bar
bar MAIN PRIORITY
BUCKET CYLINDER A2
VALVE TO THE BRAKE VALVE
24V DC
B1
235
A1 bar
235
210 bar bar
6.3 HYDRAULIC SYSTEM PUMP
The hydraulic cylinder control circuit is fed by a double The pump draws oil from the hydraulic reservoir and
hydraulic pump. if the steering is inoperative sends it to the attachment
One pump section feeds the steering circuit and control valve. Pressure building up in the delivery
attachment circuit through the primary priority valve. circuit is proportional to the required performance
The other section feeds the braking system. The and is however limited by the pressure relief valve.
steering system has priority and receives oil first. If This valve is set to 210 bars and controls maximum
the steering is inoperative, the primary priority valve system pressure by discharging excess pressure.
diverts oil towards the attachment system.
2
3
4
Fig. 6-3 Pump installation on the transmission/convertor assembly
A. from the HYDRAULIC OIL RESERVOIR 2. GASKET

B. to the PRIORITY VALVE 3. PUMP DRIVE SLEEVE
1. ATTACHMENT PUMP 4. TORQUE CONVERTOR
Attachment-steering section
Make: ........................................................................................................................... Kayaba KFP4156

Type: ......................................................................................................................................... gear type
Drive: ...................................................................................................................................... gear-driven
Rated speed flow:...................................................................................................................... 119 lt/min
Maximum pressure: .................................................................................................................... 210 bars
Engine/pump speed ratio: ........................................................................................................ 0.9875 : 1
Brake system section
Make: ...................................................................................................................... Kayaba KP1011CRD

Type: ......................................................................................................................................... gear type
Drive: ...................................................................................................................................... gear-driven
Rated speed flow:..................................................................................................................... 23.8 lt/min
Maximum pressure: ........................................................................................................................ 30 bar
Engine/pump speed ratio: ........................................................................................................ 0.9875 : 1
10
3
6 1 6 19
5 1 18
B A 4
20
13
14
15 B A
17
10 11 12
16 2 11 2
7
8 1
7 8
7
Section A - A Section B - B
Fig. 6-4 Attachment-steering pump sections
Notes - 1 23.2 to 25.8 daNm
2 4.2 to 4.6 daNm
1. INTERMEDIATE PLATE 8. BACK-UP RING 15. O-RING SEAL

2. DRIVE GEAR 9. PLATE 16. BOLT
3. DRIVEN GEAR 10. LOCATING DOWEL 17. WASHER
4. MOUNT PLATE 11. O-RING SEAL 18. BOLT
5. COVER PLATE 12. GASKET 19. WASHER
6. PLATE 13. CIRCLIP 20. BRAKE PUMP
7. GASKET 14. MATING SLEEVE
3
12 1 2 1 14
A B
9 10 8
15
7
11 A B
13
4
6
Section A - A Section B - B
Fig. 6-5 Brake pump sections
Note - 1 3.4 to 3.9 daNm
1. INTERMEDIATE PLATE 6. PLATE 11. O-RING SEAL

2. MOUNT PLATE 7. PLATE 12. LOCATING DOWEL
3. COVER PLATE 8. GASKET 13. GASKET
4. DRIVE GEAR SHAFT 9. GASKET 14. BOLT
5. DRIVEN GEAR SHAFT 10. GASKET 15. CIRCLIP
6.3.1 ATTACHMENT/STEERING PUMP TESTING

AND REPAIR
Suction
Upon disassembly, mark all parts to relocate them chamber
correctly during reassembly. a
Clean each part and check pump components.
1) Gear plate
One of the methods to increase gear pump
volumetric efficiency is to build it as to have the
gear tooth ends turn while always slightly touching
the inner wall of the recess where the gear is
housed. Consequently, once the pump has been
rotating, the trace left by the gear teeth should
be noticed at the inlet (Fig. 6-6).
The trace left is within specifications if less than
1/2 relative to the inner circumference of the gear
recess.
Dimension a of trace depth (Fig. 6-7) is within
Gear tooth
specifications if it is around 0.05 mm. When trace
dimension a exceeds 0.15 mm, shaft or bearing
wear may ensue. Therefore, also these parts
should be carefully checked. Fig. 6-7 Trace depth measure
If a is ≥ 0.15 mm, replace the pump with a new
one.
2) Drive and driven gears

If shaft or gear surfaces show roughness which
can be felt by passing the nail over it or if tooth
surfaces show severely worn areas, the part
should be replaced. If shaft diameter d is less
Suction than 27.48 mm, replace the gear set with a new
chamber
one.
d
Ø
Gear tooth
trace
Fig. 6-6 Gear intermediate plate Fig. 6-8
3) Pressure plate (9, Fig. 6-4)

As shown by Figure 6-9, in normal conditions the Sliding
pressure plate shows some polished irregularities bearing
on the copper alloy side of the surface which
touches the gear.
The part should be replaced with a new one if the
following is encountered upon disassembly:
– Irregularities with many scratches felt by
passing a nail over the surface.
– Thickness is less than 6.656.
Suction side
Irregularities Discharge
side
Suction side Fig. 6-10 Bearing irregularities
Irregularities
Fig. 6-9 Plate irregularities
4) Mount plate (4) and cover plate (5) (Fig. 6-4)

Check the mount and cover plates for possible
severe wear in the bearing area (Fig. 6-10).
If the Teflon coat is worn and the copper red area
of the base metal is exposed over an arc
exceeding 150° along the bearing inner
circumference, the part should be replaced.
8
6.4 ATTACHMENT CONTROL VALVE
ATTACHMENT CONTROL VALVE

(3-SPOOL, MECHANICAL)
Make: ........................................................................................................................ KVS - 120 H - 3 MD
Type: ....................................................................................................................... with 3 spools in series
Spool sequence: ............................................... Pump ––> AUX. ––> BUCKET ––> BOOM ––> Reservor
Primary valve setting: ......................................................................................................... 210 ± 10 bars
Anti-cavitation and safety valve setting (A2): ..................................................................... 160 ± 10 bars
Anti-cavitation and safety valve setting (A1 - B1 - B2 - B3): ................................................ 230 ± 10 bars
Flow rate: ................................................................................................................................... 120 lt/min
Weight: ............................................................................................................................................ 27 Kg
The control valve is multiple type with 3 spool valves, 2) Anti-cavitation and safety valves
one of them optional. It is composed of the oil inlet These valves protect the respective circuits
and outlet sections and sections for the attachment against sudden pressure increases due to
control spools. Oil passages inside the control valve mechanical stresses to the attachment. They are
are in series. installed to each spool valve.
Bucket and boom raise cylinder auxiliary feed
Note - See Fig. 6-11 to disassemble-reassemble the ports are fitted with safety valves which discharge
control valve. excess oil pressure when high loads acting on
the cylinders, cause pressure to increase above
1) Pressure relief valve the preset value. This is to protect the hydraulic
The control valve is complete with a pressure relief cylinders and hoses.
valve which protects the whole attachment
hydraulic system and limits maximum working
pressure to 210 bars.
3) Electrical detents
Two lock devices with a 24 Volt D.C. supply
voltage cut in to keep the boom control in the
boom raise position and the bucket control in the
bucket roll-back position, respectively.
FUNCTION DESCRIPTION
FUNCTION SPOOL SPOOL STROKE DRIVE TYPE ACTUATING FORCES RELEASE FORCES
NO. MOVEMENT ON THE SPOOL ON THE SPOOL
AUXILIARY FUNCTION IN/OUT ± 8 MM NONE 170 - 200 N ––
(P → B)
(P → A)
BUCKET ROLL-BACK 2 IN 8 MM ELECTRIC 108 - 127 N 147 - 245 N
(P → B)
BUCKET ROLL-OUT 2 OUT 8 MM NONE 108 - 127 N ––
(P → A)
BOOM RAISE 3 IN 8 MM ELECTRIC 113 - 146 N 149 - 316 N
(P → B)
BOOM LOWER 3 OUT 8 MM NONE 113 - 146 N ––
(P → A)
FLOAT 3 OUT 16 MM MECHANICAL –– 147 - 294 N
P PF 3/4 JIS O-RING TYPE

T PF 1 JIS O-RING TYPE
PORTS (SIZE AND TYPE) A1 B1 PF 3/4 JIS O-RING TYPE
A2 B2 PF 3/4 JIS O-RING TYPE
A2 B2 PF 1 JIS O-RING TYPE
6-4
10 ATTACHMENT HYDRAULIC SYSTEM W90
3 1 3 2 3 3
4 3
1
OUT
T
OU 2
B3 B2 B1
T
P2
IN
P1
A3 A2 A1
10
5
9 3
6
8 3
Serial circuit
B3 235 Bar
Boom A3 (DET)
(DET)
D.C 24V
160 Bar 235 Bar

Control spool stroke (mm)
Busket B2
A2
(DET)
D.C 24V
AUX B1
A1
BOOM BUCKET AUX

235 Bar 235 Bar
210 Bar
P2 P1 T
Fig. 6-11 3-spool attachment control valve (mechanical control)
Notes - 1 [2 points]: 6.6 daNm (48 ft-lbs) 3 [6 points] 7.8 ÷ 8.8 daNm (57 ÷ 64 ft-lbs)
2 10.3 daNm (74.5 ft-lbs)
1. ANTI-CAVITATION AND SAFETY VALVE (235 bars) 6. BOOM SPOOL SECTION

2. ANTI-CAVITATION AND SAFETY VALVE (235 bars) 7. BUCKET SPOOL SECTION
3. ANTI-CAVITATION AND SAFETY VALVE (235 bars) 8. ANTI-CAVITATION AND SAFETY VALVE (160 bars)
4. PRESSURE RELIEF VALVE (210 bars) 9. ANTI-CAVITATION AND SAFETY VALVE (235 bars)
5. OUTLET SECTION 10. INLET SECTION
W90 ATTACHMENT HYDRAULIC SYSTEM 6 - 11
B A
11
10
4
5
6 7 8 9
1
2 3
Fig. 6-12 Control valve (mechanical) “Bucket” section
1. CONTROL SPOOL 5. CAP 9. SOLENOID ASSEMBLY

2. MUD SCRAPER 6. SPRING 10. CHECK VALVE SPRING
3. SEAL 7. PIN 11. CHECK VALVE
4. CONTROL VALVE BODY 8. PLATE
B A
12 13
4
5 8 9 11
6 7 10
1
2 3
Fig. 6-13 Control valve (mechanical) "Boom" section
1. CONTROL SPOOL 6. SPOOL STOP PIN 10. BOLT

2. MUD SCRAPER 7. SPRING 11. PLATE
3. SEAL 8. CAP 12. CHECK VALVE
4. CONTROL VALVE BODY 9. SOLENOID SPRING
5. SPRING ASSEMBLY 13. CHECK VALVE
6 - 12 ATTACHMENT HYDRAULIC SYSTEM W90
B A
2 3
5 6
7
4 8
10
12
11
Fig. 6-14 Control valve (mechanical) “Aux.” section
1. SPOOL THREADED END 7. SPRING CAP RETAINING SCREW

2. CHECK VALVE SPRING 8. SPRING RETAINER
3. CHECK VALVE 9. SPACER SCREW
4. WASHER 10. CAP
5. CONTROL SPOOL 11. SPRING
6. CONTROL VALVE BODY 12. SPOOL SEAL
6.4.2 CONTROL VALVE OPERATION
When the control lever is moved, spool displacement 1) Control valve neutral position
diverts oil flow inside the control valve and pressure
oil from the priority valve is sent either to the bucket 1. When the bucket and boom spools are in neutral,
cylinder or to boom cylinders, as selected. ports (A) (cylinder rod end) and (B) (cylinder rear
end) are closed by the spools.
Positions “Float” and “Max. height” for the boom and
“Roll back” for the bucket are fitted with special locks 2. Oil sent to the control valve enters the feed
which operate automatically to hold the spool in passage through the inlet element, touches the
position and prevent it from coming back to the neutral auxiliary, bucket, and boom control spools
position when the operator releases the attachment respectively (all spools being in the neutral
control lever. The control lever returns automatically position), exits the control valve through the
in neutral from attachment actuating positions other discharge passage and outlet port (T, Fig. 6-11)
than “Float”, “Max. height”, and “Roll back”. to go back to the hydraulic reservoir.
Note - Figure shows a typical KVS Series control

valve. The control valve outside appearance may
slightly differ from this illustration.
B A
Check
valve
Anti-cavitation Feed Anti-cavitation
and safety valve passage and safety valve
B2 A2
Neutral
Dump Neutral oil passage

passage
Fig. 6-15 Bucket section in neutral (mechanical control)
DELIVERY OIL (from the pump)
DUMP OIL (low pressure)
TRAPPED OIL
2) Bucket control spool operation
(a) Bucket roll back
1. When the control lever is moved to the “Roll back” reach port (B2) and enter the bucket cylinder rear
position, the bucket control spool moves in the end.
direction shown by the arrow.
3. Oil coming out of the bucket cylinder rod end, is
2. The neutral passage is closed by the spool and dumped into the hydraulic oil reservoir through
oil pressure opens the check valve allowing oil to port (A2) and low pressure passage.
Anti-cavitation
and safety valve
Feed
Check valve passage
Anti-cavitation
B2 A2 and safety valve
Neutral oil passage

Dump
passage
Fig. 6-16 Bucket section during roll back (mechanical control)
(b) Bucket roll out
1. When the control lever is moved to the “Roll out” reach port (A2) and enter the bucket cylinder rod
position, the bucket control spool moves in the end.
direction shown by the arrow.
3. Oil coming out of the bucket cylinder rear end is
2. The neutral passage is closed by the spool and dumped into the hydraulic oil reservoir through
pressure oil opens the check valve allowing oil to the port (B2) and low pressure passage.
Anti-cavitation
and safety valve Feed
passage
Check
valve Anti-cavitation
and safety valve
B2 A2
Dump Neutral oil passage

passage
Fig. 6-17 Bucket section during roll out (mechanical control)
3) Boom control spool operation (b) Floating
(a) Boom raise and lower 1. When the control lever is moved further on from
the “Lower” position to the “Float” position, the
Oil passages in the boom section are same as in the boom control spool moves in the direction shown
bucket section. Therefore, operation for boom raising by the arrow in the figure.
is same as for bucket roll back, while operation for
boom lowering is same as for bucket roll out. See 2. Following this displacement, the neutral passage
details of the boom control spool operation in the opens. Oil flow is same as when the spool is in
respective descriptions of the bucket control spool the neutral position.
operation.
3. Ports (A 3) and (B 3) communicating with the
Note - The boom control spool section can receive cylinders, are now communicating to each other
pressure oil only if the bucket control spool is in the through the low pressure passage. Consequently,
neutral position as the control valve is the serial circuit the bucket floats over the ground to follow ground
type. irregular profile under the action of the boom
weight only. Oil, coming out of the boom cylinder
rod ends, can enter the rear end chamber and oil
from the rear end can enter the rod end chamber
through the low pressure passage inside the
control valve.
Feed
Anti-cavitation passage
and safety valve
B3 A3
Dump passage Neutral oil passage
Fig. 6-18 Boom section during floating (mechanical control)
Electromagnetic bucket and boom spool lock
1. The electromagnetic lock is used for the bucket end pin (2) are fully retracted bringing the plate
and boom control spools. The electrical circuit of (3) to touch the solenoid (4). Consequently, the
the lock device consists in a proximity sensor bucket control spool remains in position and the
connected to the battery by means of a solenoid lock remains activated.
assembled in the control valve bucket/boom spool
section. 4. To release the lock, it is necessary to open the
proximity sensor electrical contact to de-energise
2. When the bucket is in the roll out position, the the solenoid or move the control lever manually.
proximity sensor is electrically closed and the
solenoid (4) is energised.
3. When the control lever is moved to the “Roll back”

position, the bucket control spool (1) and spool
Contact
1 2 3
4
Proximity sensor
Battery
Fuse
Fig. 6-19 Bucket spool lock operation
Boom spool lock operation
1. When the control lever is moved fully forward to

the “Float” position, the boom control spool (1)
goes to end of travel. Consequently, the stop pin 1 2 5
(2) assembled to spool end is pushed fully out
and this makes the detent balls (3) enter into the
detent sleeve recess (4).
2. As the balls are pushed by the detent spring (5),

the boom control spool remains in position and
the lock remains activated.
3. To release the lock, move the control lever to the

“Neutral” position manually. 3 4
Fig. 6-20 Boom spool lock operation
6.4.3 PRESSURE RELIEF VALVE b) Operation (A)
1) Primary pressure relief valve When pressure in the neutral passage (HP)
increases above the pressure relief valve setting,
The primary pressure relief valve is located in the the pilot valve (5) opens. Pressure oil, discharged
inlet section, between the neutral passage and by the pilot valve, enters the low pressure passage
the low pressure passage (dump). (LP), passing between the sleeve (4) and valve
seat (6).
Operation
a) Inoperative
4
Delivery pressure oil in the neutral passage (HP)
flows through the primary valve (1) restrictor (2) 6
and fills the inner cavity (3). Following the different
surface upon which oil pressure acts, the primary LP
valve (1) remains closed in its seat in the sleeve
(4).
HP
LP
4
5
LP
Fig. 6-22 Operation (A)

HP
LP
1 2 3
Fig. 6-21 Inoperative
c) Operation (B) Operation
When the pilot valve (5) opens, pressure in the a) Inoperative

internal recess (3) decreases and moves the
primary valve (1). This allows pressure oil in the Pressure oil in the port communicating with the
neutral passage (HP) to dump directly in the low cylinder (HP) flows through the piston valve (1)
pressure passage (LP). hole and acts on the opposite surfaces of the anti-
cavitation valve (2) and safety valve (3). Due to
the difference of the surfaces pressure is acting
on, both valves keep mutually closed.
LP 2
LP
HP
HP
LP
LP
3
1 3 5 1
Fig. 6-24 Inoperative
Fig. 6-23 Operation (B)
b) Operation (A)
When pressure in the port communicating with

the cylinder (HP) increases above the safety val-
ve setting, the pilot valve (4) opens. Pressure oil,
2) Anticavitation and safety valves discharged by the pilot valve, enters the low
pressure passage (LP) passing between the anti-
The anticavitation and safety valves are located cavitation valve (2) and valve seat (5).
in the bucket and boom sections. In the bucket
section, a valve is fitted between the port (A2)
communicating with the cylinder rod end, and the
dump passage; another valve is fitted between 5
the port (B2) communicating with the cylinder rear LP
2
end, and the dump passage.
The boom section has one safety valve only,

located between the port (B3) communicating with HP
the cylinder bottom ends, and the dump passage.
The auxiliary section (mechanical, if fitted) is also
equipped with two valves located between the
ports (A1- B1) and dump respectively. 4
LP
Fig. 6-25 Operation (A)
c) Operation (B) e) Anti-cavitation operation
When the pilot valve (4) opens, pressure on the If pressure in the port (HP) communicating with
piston valve (1) rear end decreases and the piston the cylinder is lower than in the low pressure
valve (1) moves. Consequently, the piston valve passage (LP), a condition of possible cavitation
(1) hole closes and pressure on the safety valve exists. The anti-cavitation valve (2) moves
(3) rear end further decreases. proportionally with the difference of the surface
upon which the negative pressure is acting.
Consequently, to prevent cavitation, oil is allowed
from the low pressure passage (LP) to the port
LP (HP) communicating with the cylinder.
HP LP 2
1 3 4 HP
LP
Fig. 6-26 Operation (B)

LP
Fig. 6-28 Anti-cavitation operation
d) Operation (C)
Pressures acting on opposite ends of the safety

valve (3) become unbalanced. Because of this
pressure difference, the safety valve opens to
allow pressure oil to dump directly into the low
pressure passage (LP) through the port (HP)
communicating with the cylinder.
LP
HP
LP 3
Fig. 6-27 Operation (C)
6.5 CONTROL VALVE CONTROLS
The control valve is operated by means of a single To this aim, the cab panel is ready to accommodate
mechanical lever as a standard. When the lever is the second control lever.
moved, the control valve spools also move. When
the lever is moved lengthwise (forward and
backward) the boom control spool is operated; when
WARNING
the lever is moved crosswise it activates the bucket
control spool.
The control valve control system is complete with a
The lever handle incorporates a downshift button
safety device to lock the system. Activate the device
(kick down). See details of the kick down facility in
to lock the lever in the neutral position when the
chapter 2.5.4 “TRANSMISSION CONTROL
attachment is not in use.
SYSTEM".
Should it be necessary to use a special type of

attachment requiring a third hydraulic function a
second lever may be installed upon request.
6
2
1
3
8
5
Fig. 6-29 Attachment control valve control assembly (mechanical type)
Notes - 1 Threads: LOCTITE 262 2 Apply grease during assembly
1. HANDLE (BUTTON) 6. CONTROL LEVER

2. PROTECTION BOOT 7. BALL JOINT
3. CONTROL VALVE 8. CABLE (BUCKET)
4. BRACKET 9. CABLE (BOOM)
5. RUBBER INSERT
6.6 HYDRAULIC OIL RESERVOIR
Type ........................................................................................................................................... under pressure

Reservoir capacity ......................................................................................................................... 50 lt (13 gal)
By-pass valve setting oil filter ....................................................................................................... 2.5 ± 0.2 bars
Return filter .......................................................................................... inorganic fibre type, filtration power 10µ
The reservoir contains hydraulic oil for the main plete with a by-pass valve which, in case of clogging
hydraulic circuit, steering circuit, and brakes circuit. of the filter element, discharges oil directly into the
Inside the reservoir there is a filter for return oil com- reservoir.
1
2
3
4
5
7
8
9
10
16
17 15
14
13
12
11
Fig. 6-30 Hydraulic oil reservoir
1. OIL FILTER COVER 7. O-RING SEAL 13. MOUNT PLATE

2. O-RING SEAL 8. FILTER HOUSING 14. INLET OIL FILTER
3. FILTER HEAD 9. O-RING SEAL 15. FILTER
4. O-RING SEAL 10. OIL LEVEL SIGHT GLASS 16. OIL FILLER PLUG
5. SPRING 11. OIL RESERVOIR 17. PLUG
6. FILTER 12. O-RING SEAL
6.7 CYLINDERS
Boom cylinders
Type ........................................................................................................................................... double-acting
Quantity ......................................................................................................................................................... 2
Cylinder inside diameter .............................................................................................................. 90 mm (3.5")
Rod diameter ............................................................................................................................... 55 mm (2.2")
Cylinder rod stroke .................................................................................................................. 760 mm (29.9")
Weight (each) .......................................................................................................................... 53 Kg (117 lbs)
Bucket cylinder
Type ........................................................................................................................................... double-acting
Quantity ......................................................................................................................................................... 1
Cylinder inside diameter ............................................................................................................ 110 mm (4.3")
Rod diameter ............................................................................................................................... 60 mm (2.4")
Cylinder rod stroke ................................................................................................................... 421mm (16.6")
Weight (each) .......................................................................................................................... 56 Kg (123 lbs)
6.7.1 BOOM RAISE CYLINDERS
The two boom raise cylinders are double-acting type.

The cylinders are extended or retracted to raise or
lower the boom, respectively. The boom cylinder is
composed of: cylinder, cylinder bottom, rod, piston
and seal set.
6.7.2 BUCKET ROLL CYLINDER
The bucket control cylinder is double-acting type.

When the cylinder is extended or retracted, the bucket
is rolled back or out by means of control linkage. The
bucket cylinder is composed of: cylinder, cylinder
bottom, rod, piston and seal set.
6 - 24
6 ATTACHMENT HYDRAULIC SYSTEM W90
1 1 2 3 4 8 9 10 11 12 2
5 6 7 14 3 13
Inner section
15 16
17
Fig. 6-31 Boom cylinder
2 132 daNm (976 ft-lbs)
3 1.65 daNm (11.9 ft-lbs) (Stalk in two places after tightening)
4 6.0 daNm (43 ft-lbs)
1. CYLINDER BOTTOM 7. SEAL 13. STOP SCREW

2. O-RING SEAL 8. ROD 14. STEEL BALL
3. BACK-UP RING 9. CYLINDER 15. PIVOT PIN BUSH
4. O-RING SEAL 10. SLIDING RING 16. MUD SCRAPER
5. MUD SCRAPER 11. O-RING SEAL 17. HOSE
6. BUSH 12. PISTON
W90 ATTACHMENT HYDRAULIC SYSTEM 6 6- 25
-7
1 1 2 3 4 8 9 10 11 12 14 3
5 6 7 13 2 15
Inner section
16 17
5 4
18
Fig. 6-32 Bucket cylinder
2 245 daNm (1810 ft-lbs)
3 3.1 daNm (23.2 ft-lbs) (Stalk in two places after tightening)
4 12 daNm (86.8 ft-lbs)
5 Pressure port (PT1/8)
1. CYLINDER BOTTOM 7. SEAL 13. NUT

2. O-RING SEAL 8. ROD 14. STOP SCREW
3. BACK-UP RING 9. CYLINDER 15. STEEL BALL
4. O-RING SEAL 10. SLIDING RING 16. PIVOT PIN BUSH
5. MUD SCRAPER 11. O-RING SEAL 17. MUD SCRAPER
6. BUSH 12. PISTON 18. HOSE
6.8 L.T.S. ANTI-PITCH SYSTEM Position 0 (L.T.S. disengaged)

(Option)
Position 1 (L.T.S. engaged)
6.8.1 DESCRIPTION Automatic gearshift
The system is automatically engaged when ground
The L.T.S. (Load Travel Stabilised) system, which is speed exceeds 5 kph. This allows to work without
supplied upon request, is designed to guarantee disturbing machine waving. The switch indicator light
optimum driving comfort and reduce dynamic loads illuminates to signal automatic system engagement.
on the machine components (frame-axles/boom) We advice to select this position for normal machine
when machine is moving with a full bucket. operation.
Due to ground roughness, a machine without the
L.T.S. system undergoes unwanted pitching which Manual gearshift
increases as ground speed increases. The L.T.S. system is excluded when the gearshift
With the L.T.S. system engaged, ground irregularities lever is in first speed.
are dampened by means of a gas accumulator.
This makes it possible to fully exploit machine Position 2 (L.T.S. always engaged)
possibilities, above all on rough terrains, without The switch indicator light remains on at all times.
stressing mechanical components and with maximum This position is used only to allow accumulator
driver’s comfort. discharge in view of maintenance or repair work (to
this aim the attachment control valve should be set
in the floating position).
This system is mainly composed of: This position can also be used to obtain the
- an L.T.S. switch with integral indicator light, located dampening effect when ground speed is lower than
on the dashboard, to engage/disengage the 5 kph.
system;
- a piston accumulator (oil capacity = 3.9 litres; gas WARNING - For the L.T.S. system to be effective,
capacity = 4 litres), with nitrogen pre-charge and the boom movement should not be locked.
connected to the boom raise/lower cylinders Never use the L.T.S. system when the boom should
- a solenoid valve operated valve block. be locked for driving on public roads.
L.T.S. system engagement
The system is engaged through the dashboard switch WARNING - DANGER

(with indicator light).
Always empty the accumulator prior to carrying out
any maintenance work on the attachment system and
L.T.S. system, to prevent pressure oil to escape.
The L.T.S. switch has three positions:
6.8.2 ACCUMULATOR DISCHARGE
Discharge the accumulator as follows:

- Start the engine at idle speed.
- Set the L.T.S. switch to position 2 (the switch
indicator light should come on).
0 1 2
- Rest the bucket to the ground.
- Lock the attachment control lever in the “Float”
position.
- Wait a few seconds for the accumulator to
Fig. 6-33 Three-position L.T.S. switch discharge.
Gearshift lever
L.T.S. control switch
Attachment
control valve
To the control
valve (boom To the control box
section)
L.T.S. valve
Hydraulic accumulator
Transmission assembly
Fig. 6-34 L.T.S. system components
6.8.3 L.T.S. HYDRAULIC DIAGRAM
6
4 5
3
CONTROL LOGIC WIRING DIAGRAM
ON
L.T.S.
ON/OFF
ON
SOL1 5 sec Supply from 5 sec
L.T.S. line
ON SOL1 SOL 2
SOL 2
Timer Relay 24V/10A
Fig. 6-35 L.T.S. hydraulic diagram
1. ACCUMULATOR 6. SEQUENCE VALVE

2. SOLENOID VALVE “1” 7. SEQUENCE VALVE
3. SOLENOID VALVE “2” 8. ATTACHMENT CONTROL VALVE
4. CYLINDER BOTTOM END VALVE 9. RAISE CYLINDERS
5. CYLINDER ROD END VALVE
W90 ATTACHMENT HYDRAULIC SYSTEM 66- 29
-9
6.8.4 L.T.S. SYSTEM OPERATING TESTS
Electrical system check

Lower the bucket to the ground.
Start the engine.
Engage the L.T.S. system by moving the switch to
Activate the L.T.S. switch to position 2: the indicator position 2 (the light should come on).
light inside the switch should illuminate.
The bucket should raise of approximately 200 mm.
Bring engine speed to medium-high and raise the boom
to maximum height.
Hydraulic test of the raise cylinder bottom ends to
Lower the boom quickly and stop it abruptly at mid- accumulator circuit.
height.
Start the engine and let it idle.
You should observe the boom oscillate before stopping
and no waving should be felt inside the cab. With the bucket on level ground, raise it approximately
30 cm from the ground.
Bring back engine speed to idle and move the L.T.S.
switch to position 1. Lift the machine from the ground by rolling the bucket
out.
The switch light should remain off.
Move the attachment control lever to the “Float”
Engage second gear and start moving off. position to lower the machine to the ground.
When machine ground speed is around 7 kph (2nd Engage the system by moving the L.T.S. switch to
speed) the switch light should illuminate. position 2 (the switch light should come on) to empty
the accumulator.
Slow down the machine and stop it: the switch light
should go off. Move the attachment lever to neutral.
Roll back the bucket: the boom should lower until.

resting on to the ground.
Valve opening check
Test aim is to check valve opening (4 and 5, Fig.

6-35).
Start the engine and let it idle.
Move the L.T.S. switch to position 2: the switch light

should illuminate.
With the bucket on level ground, move the attachment

control lever to the “Float” position to empty the
accumulator (1).
Move the attachment control lever to the neutral

position.
Disengage the system by moving the L.T.S. switch to

position 0.
Raise the attachment to maximum height and keep it

in position (valve latch) for approximately five seconds.
6.8.5 L.T.S. ACCUMULATOR PRE-CHARGE

CHECK
The accumulator fitted to the L.T.S. anti-pitch system

is piston type with nitrogen pre-charge.
Rated pre-charge pressure is 18 bars at 15°C with a
capacity of 4 litres.
D1
Important - Accumulator pre-charge lower than rated
value may cause L.T.S. anti-pitch system malfunction.
D
It may prove useful to check the accumulator every
year and reset the nitrogen pre-charge, if necessary.
Checking should be carried out with the accumulator
drained of hydraulic oil.
M
D1
WARNING M
Always empty the accumulator prior to carrying out

any maintenance work on the attachment system and
L.T.S. system, to prevent pressure oil to escape.
D
D2
Refer to point 6.8.2 for the accumulator discharge 1

procedure.
Accumulator
Check pre-charge as follows:
- Remove the accumulator protection cover (1, Fig.
6-36).
- Loosen the screw (2) by 1/2 turn using an Allen
wrench.
- Screw in tool no. 75298472 (D) to the accumulator
connection.
- Ensure tap (D2) is closed.
- Turn the handwheel (D1) to loosen the screw (2).
- When the pressure gauge (M) pointer starts
moving, turn the handwheel (D1) by one more turn.
Now the pressure gauge indicates the accumulator 2
pre-charge pressure which should be 18 bars.
Recharge the accumulator if reading is lower than

rated value. Fig. 6-36
After tightening the screw (2) using the handwheel
(1), open the tap (D2) to discharge nitrogen built up D. Tool - D1. Handwheel - D2. Tap - M. Pressure gauge -
in the block (D). 1. Protection cover - 2. Threaded plug.
6.8.6 ACCUMULATOR PRE-CHARGE RESET

INSTRUCTIONS
Screw the tool shown in the figure to the accumulator - Close the nitrogen bottle tap.
connection and proceed as follows. Wait five minutes.
- Loosen the plug and screw in the hose from a - Check on the pressure gauge (M) that filling
nitrogen bottle complete with pressure reducing pressure is 18 bars. Repeat the operation if lower.
valve (V).
If pressure is higher, proceed as follows:
WARNING - DANGER
- Slowly turn the handwheel (D2) to let the nitrogen
Use only nitrogen to recharge accumulators. Never out and close.
use oxygen or other gases for any reason whatever
as explosion hazard may result.
- Check on pressure gauge (M) that pressure is as
required. If not, repeat the operation.
- Turn handwheel (D1) to screw in the accumulator

screw (2).
- With the tap (D2) closed, slowly open the nitrogen
bottle tap and check refilling pressure on the
- Remove recharge equipment.
pressure gauge (M) as it increases.
Important - Filling pressure should be 10% at least
higher than rated value considering that pressure - Check accumulator sealing using soapy water.
inside the accumulator decreases when the
compressed gas cools down. - Screw on protection cover to the accumulator.
M D1
A
V
D
D2
Fig. 6-37
A. Nitrogen bottle - D. Tool - D1. Handwheel - D2. Tap - M. Pressure gauge.
6.9 AUXILIARY HYDRAULICS OPERATION (Option)
Auxiliary hydraulics
control lever
Auxiliary attachment
connection hose
Control cable
Control valve 3° spool
Auxiliary attachment
connection hose
Fig. 6-38 Auxiliary hydraulics components (mechanical control)
SECTION 7
ELECTRICAL SYSTEM
CONTENTS
SAFETY RULES .............................................................................................................................. 7-1
7.1 GENERAL LAY-OUT OF ELECTRICAL SYSTEM ................................................. 7-2
7.2 LOGIC BOARD AND CAB CONNECTIONS ......................................................... 7-3

7.2.1 Connections - relays - timers - buzzer ................................................................... 7-3
7.2.2 Fuses ..................................................................................................................... 7-4
7.3 CONNECTORS ..................................................................................................... 7-5
7.4 CAB INSTRUMENT PANEL .................................................................................. 7-7

7.4.1 Indicators on instrument panel .............................................................................. 7-9
7.5 SWITCH PANEL .................................................................................................... 7-9
7.6 TRANSMISSION CONTROL SELECTOR ............................................................ 7-10
7.7 STARTER SWITCH ............................................................................................... 7-11
MACHINE GROUPS ELECTRIC DIAGRAMS ................................................................................. 7-23

W90 ELECTRICAL SYSTEM 7-1
SAFETY RULES
WARNING: When working on the electrical sys-

tem, always wear protective glasses and remove
all rings, wrist watches and any other metal jew-
ellery.
WARNING: Prior to proceeding with any inspec- DISCONNECT

tion or repair intervention on electrical equipment,
DISCONNECT GROUND CABLE “A” from the
negative terminal “B” on the battery. DISCON-
NECT CABLE “C” from positive terminal “D”.
BATTERY 12V x 2
GROUND
WARNING: NEVER REST METAL OBJECTS

on the battery to prevent short circuits.
WARNING: ELECTROLYTE GAS FROM BATTERIES IS FLAMMABLE.

Do not approach batteries with sparks or open flames. During battery recharging, the emission of gases
is stronger.
WARNING: BATTERY GAS IS DANGEROUS if it contacts skin or materials.
7-2 ELECTRICAL SYSTEM W90
7.1 GENERAL LAY-OUT OF

ELECTRICAL SYSTEM
Electric wires are divided into three main groups: 3. Rear frame wire group, identified by a number
stamped, connecting all the components involv-
1. Cab wire group identified by a different colour coding the rear frame.
ing to which all the electrical components located
in the cab are connected. The three groups of main wires are interconnected
by four connectors (A-B-C-D) located in under the
2. Front frame wire group, identified by a number cab floor. All wires reach logic board (S) located in-
stamped, connecting all the components involv- side the rear panel, behind the operator's seat.
ing the front frame.
A B C D
1
3
A-B-C-D. Connectors - S. Logic board - 1. Cab wires - 2. Front frame wires - 3. Rear frame wires
7.2 LOGIC BOARD AND CAB

CONNECTIONS
The logic box is located inside the rear panel, behind Also, the fuses, solenoid switches (relays “R”), timers
the operator's seat. To reach it, loosen the two (Z) and two switches “SW!” and “SW2” converting the
retaining knobs. transmission from manual to mechanical and vice
All components of the machine are connected to the versa, are located
board, through connections “CN”.
7.2.1 CONNECTIONS - RELAYS - TIMERS - BUZZER
CONNECTIONS CN
CN LINE CONNECTED COLOUR TERMINALS
A cab violet 17
B switches black 21 B
A
C engine white 17
D switches brown 17
R2 R3 R4 R5
E transmission box white 17
F dashboard and lights red 17 C D
G dashboard yellow 17 SW1
1 INPUT Km/h
2 INPUT Km/h
H engine black 19 3 MODE SELECT
4 MODE SELECT
J switches green 11 Z1 Z2
K engine violet 21 E F
L optional instruments light blue 13
M engine white 21
N transmission white 11
O gearshift white 7 G H Z3
P engine yellow 13
FUSES
Q voltage reduction white 5
R thermo starter white 13
R7
S service relay, buzzer black 5 SW2 J K R6 R8
SYSTEM
N-N bridges manual gearshift white 11 1

2
ATC
3
4
RELAY R
R=relay FUNCTION L M R9 R10 R11 R12
2 horn
3 light switching
N O P
4 starter and anti repetition
5 neutral starter safety
6 clock
7 back-up lights and alarm
N-N Q R
8 air cond. condenser fan
9 transmission cut-off
10 L.T.S.
11 kick-down (W90 manual transmission)
12 kick-down (W90 manual transmission)
TIMERS AND OTHERS

Z1 steering low pressure switch
Z2 check timer
Z3 emergency flasher
C1 capacitor 4
C2 capacitor
SW1 micro switch
SW2 micro switch
5
JP1 bridge
S
JP2 bridge
R1 resistor 6
7
3
P
2
1
P. Engine warm-up control unit

S. Logic board - 1. Wiper timer - 2. Steering column wire - 3. Front dashboard wire - 4. Cab roof wire - 5. Heater wire - 6. Side
dashboard wire - 7. Cab wire
7.2.2 FUSES
A SPARE FUSE
F1 B SPARE FUSE
C SPARE FUSE
A R.H. TAIL LIGHT FUSE

F2 B L.H. TAIL LIGHT FUSE
C AUXILIARY FUSE
A FRONT WORK LIGHTS FUSE

F3 B LIGHT SWITCH FUSE
C TAIL LIGHT SWITCH POW. FUSE
A NEUTRAL START. RELAY FUSE

ELECTRIC CUT-OFF - NEUTRAL RELAY
F4 B STARTER CONTACTS (R5) START RELAY
AND ANTI-REPETITION (R4)
C EMERGENCY LIGHT FUSE
A REAR WORK LIGHTS FUSE

F5 B AUXILIARY FUSE
C FRONT WIPER FUSE
LOW BEAM LIGHTS (UNSTABLE POSITION)
A VOLTAGE REDUCTION FUSE

B HIGH BEAM FUSE
F6
C SENSORS FUSE - S.V. FLOAT -KICK-OUT -
BUCKET
A BACK-UP LIGHTS FUSE

BACK-UP ALARM FUSE
F7 B AUXILIARY FUSE
C AIR COND. CONDENS. FUSE
A REAR WIPER FUSE

TURNING LIGHTS
F8 B LOW BEAM FUSE
C CAB FAN FUSE
A ROTARY BEACON FUSE -

4 TH FUNCTION SWITCH
F9 B SERVICE RELAY FUSE
TIMERS Z1, Z2, BUZZER
C ROOF LIGHT FUSE
HORN - CLOCK
A STOP LIGHTS FUSE

F10 B CIGARETTE LIGHTER FUSE
C RADIO / 12 V SOCKET FUSE
A LTS FUSE - TRAN. SOLENOIDS

ATC UNIT - MONITOR
F11 B AUXILIARY FUSE
C (NOT USED)
7.3 CONNECTORS
Connectors (A-B-C-D) are located in the lower side Connectors A-B-C (fig. connectors) have 24 con-
of the cab and connect the main wires to logic board nection points, whereas connector D (fig. connector
(S). D) has 18. The description and the function of each
The colour coded wires (cab) arrive from the top side; wire on the connector has a number/colour corre-
the number coded wires (machine) from the bottom spondence, as it can be found in the description of
side. each connector.
CONNECTOR A
Ref. on Description - function Colour Wire 1 2 3 4 5 6

connector
1) SIGNAL BOOM KICK-OUT – 980 980 981 995 980 994 981
2) SIGNAL BUCKET POSITION – 981
3) POWER TO KICK-OUT 7 103 109 339 330 231 223 12
PROXIMITY S–N 995
4) BOOM KICK-OUT SIGNAL S–G 980
5) POW. TO BUCK. POS. PROX. V–B 994 13 221 219 138 000 18
6) BUCKET POSITION SIGNAL V–N 981
7) R.H. TURNING LIGHT A 103
8) L.H. TURNING LIGHT L 109 956 954 844
9) L.H. HEAD LIGHT G 339
10) R.H. HEAD LIGHT G–N 330
11) L.H. LOW BEAM H 231 19 20 21 22 23 24
12) R.H. LOW BEAM H–N 223
13) R.H. HIGH BEAM V 221
14) L.H. HIGH BEAM V–R 219
16) * – –
17) POWER TO HORN C–N 138
18) GND N 000
19) LTS S.V. Z–N 956
20) GND LTS S.V. B–N 954
21) * – –
22) * – –
23) EMER. STEERING PRESSURE 844
24) * – –
* NOT CONNECTED
A B C D
Wire symbols
C = Orange N = Black
A = Light blue S = Pink
B = White R = Red
L = Blue V = Green S
G = Yellow Z = Violet
H = Grey
A-B-C-D. Connectors
CONNECTOR B
Ref. on Description - function Colour Wire 1 2 3 4 5 6

connector
225 226 172 177 332 331
1) R.H. REAR WORK LIGHT G 225
2) L.H. REAR WORK LIGHT C 226
3) R.H. STOP LIGHT G-V 172 7 125 120 337 163 302 301 12
4) L.H. STOP LIGHT B-G 177
5) L.H. HEAD LIGHT G 332
6) R.H. HEAD LIGHT G-N 331 13 885 835 886 974 044 895 18
7) R.H. TURNING LIGHT A 125
8) L.H. TURNING LIGHT L 120 903
9) LICENCE PLATE LIGHT L-G 337
10) BACK-UP ALARM C-N 163
11) R.H. BACK-UP LIGHT A-G 302 19 20 21 22 23 24
12) L.H. BACK-UP LIGHT R-V 301
13) FRONT WASHER 885
14) EMERGENCY STEERING PRESSURE
OUTLET A-B 835
15) REAR WASHER – 886
16) TRANSM CUT-OFF PRESSURE V-B 974
17) GND CLOCK G-R 044
18) PRE-HEATING RELAY POWER Z-N 895
20) – – –
24) ELECTRIC CUT-OFF R-N 903
CONNECTOR C
Ref. on Description - function Colour Wire
1 2 3 4 5 6
connector
637 522 802 987 827 503
1) D+ G 637
2) W ALTERNATOR G-N 522
3) STARTER RELAY CONTROL G-V 802 7 613 559 663 528 000 552 12
4) S.V. B POWER – 987
5) COLD START. TEMP. SENSOR C-N 827 13 557 555 550 1 2 960 18
6) ENGINE OIL LOW PRESSURE B 503
7) BRAKES ACCUMUL. LOW
PRESSURE A 613 3 4 979 965 986
8) TRANSM. OIL PRESSURE B-V 559
9) AIR CLEANER SWITCH C-B 663
10) COOLANT HIGH TEMPER. V-N 528 19 20 21 22 23 24
11) GND N 000
12) COOLANT TEMP. GAUGE R-V 552
13) FUEL LEVEL Z 557
14) RESERVE IND. LIGHT-OPT. Z-B 555
15) TRANSM. OIL TEMPER. A-G 550
16) S.V. A A-R 1
17) S.V. B A-B 2
18) S.V. A POWER A-N 960
19) S.V. F L-G 3
20) S.V. R Z-N 4
21) S.V. F POWER S 979
22) 1 ST COLD START FUEL S.V. – 965
23) 2 ND COLD START FUEL S.V. –
24) S.V. R POWER – 986
CONNECTOR D 7
Ref. on Description - function Colour Wire
6 8
connector 989
18 9
1) 60 AMP R 772 1
2) OP SENSOR – – 535
3) OP SENSOR – – 5 772
2
4) OP SENSOR – –
5) HORN 17 536 116 534 10
(PEDAL BUTTON) – 116
7) 2 ND COLD STARTER (25 AMP) R 963
8) ELEC. CUT-OFF INIT. 25 AMP) B 964 978 4 3 537
9) GROUND 1 ST SPEED SENSOR N 535 11
10) SPEED SENSOR 1 L 534
16
981 117
11) SPEED SENSOR 2 G-R 537
12) STOP LIGHTS POWER SWITCH R 117 538 175
13) STOP LIGHT SWITCH OUTPUT R-N 175 15 12
14) THROTTLE PEDAL SENSOR SIGNAL
INPUT B-N 538 14 13
15) PARK. BRAKE PRESS. SWITCH SIGNAL B 960
16) PARK. BRAKE PRESS. SWITCH SIGNAL – 969
17) GROUND 2 ND SPEED SENSOR – 536
7.4 CAB INSTRUMENT PANEL
The monitoring system controls the operating condi- The instrument panel is composed of instruments,
tions of the loader through sensors and switches lo- including the tachometer, monitoring indicator lights
cated on the machine and signals information to the signalling whether each system is operating correctly
instrument panel of the compartment indicating the or not (alarm indicators) and signal indicators.
current operating conditions of the loader to the op-
erator.
4-6-
13 22 12 25 2 3 8-15 5 7 16 21 26 1 23 11 18-19
C H C H
OIL TRAM
COOLANT TEMP
1 2 3 4
E\G OIL PRESS. BRAKE PRESS
COOLANT TEMP T\M OIL TEMP
20 30
CHARGE E F EMG STE
10
AIR CLEANER
40 1\10 h PARKING
FUEL 50 HOURMETER GENERAL

WARNING
FUEL
km\h
10 17 27-28
CN1 CN3
CN2
1 Accum. oil low pressure indicator light 18 Buzzer

2 Eng. coolant high temp. indicator light 19 General indicator
3 Coolant temperature indicator 20 Instrument panel lights
4 Instrument panel light CONNECTION 21 Transm. oil temperature indicator
5 Left arrow light CN2 22 Air cleaner clogging indicator
6 Instrument panel light 23 Emergency steering indicator
7 High beam light 24 Batteries
CONNECTION 8 Instrument panel light 25 Engine oil low pressure indicator
CN1 9 Ground 26 Transmission oil high temp. indicator
10 Fuel level CONNECTION 27 Hourmeter (ground)
11 Parking brake indicator light CN3 28 Hourmeter (battery)
12 Battery failure indicator light
13 Fuel reserve indicator light
14 Not connected
15 Instrument panel light
16 Right arrow light
17 Tachometer
Positions on connections
CNI-4
LI
CNI-6
L2
CNI-8
L3
CNI-15
L4
DC24V CN2-24
CN2-22
L5
CN2-25
L6
CN2-26
L7
CNI-13 3W
L8
CN2-23
L9
CNI-2
L10
CNI-11
L11
CNI-1
L12
Connection CN1
Connection CN1
Connection CN2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 CN2-18 3W
BUZZER L13
CN2-19
CNI-7
L14
Connection CN2 CNI-16
L15
18 19 20 21 CNI-5
L16
22 23 24 25 26 G
CNI-12
L17
CNI-10
RI
Connection CN3 CNI-3

R2
28
CN2-21
R3
27 CN3-28
Connection CN3 CN3-27
CNI-17
R4
ZDI
CN2-20
L18
L19
L20
L21
L22
CNI-9
Instrument panel wiring diagram
FM : FUEL LEVEL INDICATOR

WTM : ENGINE COOLANT TEMPERATURE GAUGE
OTM : TRANSMISSION-TORQUE CONVERTER OIL TEMPERATURE GAUGE
EHM : HOURMETER
SM : TACHOMETER
L1-L13 : INDICATOR LIGHTS
L14-L18 : INSTRUMENTATION LIGHTS
7.4.1 INDICATORS ON INSTRUMENT PANEL
Instrument Engine coolant Transmission oil Fuel level

temperature gauge temperature gauge indicator
67°C 135°C 150°C

102°C 120°C E F
50°C 50°C
E F
C
▲
▲
▲
H C ▲
H
▲ ▲
Scale ▲ ▲ ▲
1st point of measurement 67°C00 102°C00 50°C00 120°C00 E00 F00
↓
↑
↑
↑
Resistance nom. value 49.8Ω 16.8Ω 91.7Ω 10.4Ω 80Ω 10Ω
7.5 SWITCH PANEL

2 3 17 4 5
1 12
A
13
11 6
7
10 14
8
16 F/R
15
9
18
1. Front washer button - 2. Rear wiper switch - 3. Rotary beacons switch - 4. Automatic transmission switch - 5. Pre-heating
indicator - 6. Emergency lights switch - 7. Rear work light switch - 8. Front work lights switch - 9. Head lights and low beams
switch - 10. L.T.S. engagement switch - 11. Transmission cut-off switch - 12. Fan switch - 13. Warm-cold switch - 14. Air re-
circulation switch - 15. Air conditioner switch - 16. Cigarette lighter - 17. Boom kick-out function switch - 18. Direction
reverser auxiliary switch control button.
7 - 10 ELECTRICAL SYSTEM W90
7.6 TRANSMISSION CONTROL SELECTOR
CONNECTIONS WIRE TERMINAL COLOUR

1 VP RED
2 E YELLOW
X1
3 F PINK
4 G GREY
1 C BROWN
2 D GREEN
X3 3 A BLUE
4 H VIOLET
ND
X1
4
3
2
1
X3
1
2
3
4
SPEED SELECTION SELECTION

1 = 1st speed F = FORWARD
2 = 2nd speed R = REVERSE
3 = 3rd speed N = NEUTRAL
A CD F (R) E (F) G (N)
2 3 R
N
1 F
H VP
Transmission electric selector wiring diagram
W90 ELECTRICAL SYSTEM 7 - 11
7.7 STARTER SWITCH
LOCATION - Cab right console
OFF
AC
H C R B M
ON
STAR
T
L BG
B G1 G2 ACC M ST POSITION
H B ST
OFF
ACC
G2 G1
ON M ACC
START
WIRES TECHNICAL DATA

RED: position "B" DC: 24 Volt
BROWN: position "G1" B-G1, G2: 8 Amp
WHITE/YELLOW: position "ACC" B-ACC: 10 Amp
BLUE: position "M" B-M: 5 Amp
WHITE: position "ST" B-ST: 3 Amp
7) ENGINE OIL
PRESSURE
4) COLD STARTING SWITCH
1) TRANSMISSION OIL 2) TRANSMISSION OIL
TEMPERATURE SENSOR TEMPERATURE SWITCH 5) FUEL SOLENOID
VALVE
▲
3) FUEL LEVEL SENSOR
6) COOLANT
▲
▲
▲
TEMPERATURE
▲ SENSOR
▲
▲
8) AIR CLEANER CLOGGING
▲
SENSOR
▲
▲
9) “LINK” FUSE
10) ENGINE
STARTER
▲
11) ENGINE CUT-OFF
SOLENOID
21) COLD STARTING
THERMOSTAT 14) BACK-UP ALARM
▲
12) COOLANT
TEMPERATURE
▲
SWITCH
20) BATTERY MASTER SWITCH
13) ALTERNATOR
19) STARTER RELAY GROUP

▲
15) TRANSMISSION
CUT-OFF
PRESSURE ▲
SWITCH
▲
▲
▲
16) BRAKES ACCUMULATOR LOW

PRESSURE SENSOR ▲
17) STOP LIGHTS

PRESSURE
SWITCH
▲
18) PARKING BRAKE PRESSURE
SWITCH
1) TRANSMISSION OIL
TEMPERATURE SENSOR
1 - TRANSMISSION OIL TEMPERATURE SENSOR

WIRES
550 To transmission oil temperature indicator on 550
dashboard
TECHNICAL DATA
Thread: M16x1.5
Location: On FOR-REV clutch oil
distribution cover
2 - TRANSMISSION OIL MAX TEMPERATURE SWITCH
559 000
WIRES
559 To indicator light on dashboard and
switches
000 To ground
TECHNICAL DATA
Thread: M16x1.5
Setting: 122 ± 3°C (252 ± 5 °F)
Tightening torque: 2 daNm
3 - FUEL LEVEL SENSOR
WIRES
557 To fuel level instrument (dashboard)
555 To fuel level indicator light (dashboard)
LOCATION - fuel reservoir

FLOATER
557 555
35
FULL
(73)
145.5
3/4
57
∞
(213)
223
S
G
260
1/2 0
29
R
POSITION RESIST Ω
FULL 10
1/4
3/4 (19)
W ARNING POINT
1/2 32
1/4 (49.5)
EMPTY 63 EMPTY 80
4 - COLD STARTER 5 - FUEL SOLENOID VALVE
989
965
000
6 - COOLANT TEMPERATURE SENSOR
WIRES
552 To coolant temperature indicator on dash-
board
TECHNICAL DATA
Thread: M16x1.5
7 - ENGINE OIL LOW PRESSURE SENSOR
503
WIRE
503 To instrument and switch panel
TECHNICAL DATA
Thread: R 1/8 tapered
Setting: 0.5 ± 0.1 bar
8 - AIR CLEANER CLOGGING SENSOR
WIRES
663 To indicator on instrument panel
000 To ground
TECHNICAL DATA
Setting (closed contact): 57 ÷ 67 mbar
Tightening: tighten manually, without using tools
663
000
9 - 50 Amp “LINK” FUSES
WIRES
772 To diverter box
773 To alternator
777 To “+” of batteries
777 772
777 773
10 - STARTER MOTOR
WIRES +
+ To battery 000
888 To starter solenoid switch
000 To ground 888
LOCATION - Left rear side of engine under the fuel

filters
11 - ENGINE CUT-OFF SOLENOID
903
WIRES
903 To starter switch (7)
LOCATION - On injection pump
12 - COOLANT MAX TEMPERATURE SWITCH
528 000
WIRES
528 To indicator light on instrument panel
000 To ground
TECHNICAL DATA
Thread: M16x1.5
Setting: 110 ± 1 °C (230 ± 1.8 °F)
13 - ALTERNATOR
000 552
W
B-
D+
637
B+
773
WIRES 773 To LINK fuse

637 To connector "C" (cab connections)
522 To connector "C" (cab connections)
000 To ground
LOCATION - Right side of engine
TECHNICAL DATA - NOMINAL VOLTAGE OF ELECTRICAL SYSTEM : 24 VOLT

- CURRENT NOMINAL OUTPUT: 55 AMP
- RECOMMENDED BATTERY CAPACITY: FROM 66 Amph Through 176 Amph
- THE NEGATIVE TERMINAL B IS GROUNDED
- “FIRST EXCITATION” CHARGE INITIAL SPEED, WITH
PRE-EXCITATION FROM 3 W INDICATOR LIGHT BULB: ≤ 1600 rpm
- RECOMMENDED SPEED WITH ENGINE AT LOW IDLE: 1600 rpm
- MINIMUM CONSTANT SPEED ALLOWED : 1000 rpm
14 - BACK-UP ALARM
000
WIRES
163 To back-up alarm solenoid switch
000 To ground
163
PRESSURE SWITCHES ON BRAKE PEDAL VALVE
15 – TRANSMISSION CUT-OFF PRESSURE 16 – BRAKES ACCUMULATOR OIL LOW PRES-

SWITCH SURE SENSOR
WIRES WIRES
974 To transmission cut-off arrangement switch 613 To instrument and switch panel
000 To ground 000 To ground
TECHNICAL DATA TECHNICAL DATA

Tread: M10x1 Thread: R 1/8 tapered
Setting: 15 ± 1 bar Setting: 60 ± 5 bar
Tightening torque: 2 daNm
17 – STOP LIGHTS CONTROL PRESSURE

SWITCH
WIRES
117 To fuse F9A on logic board
175 To stop lights
TECHNICAL DATA
Thread: M10x1
Setting: 1.8 ± 0.5 bar
18 - PARKING BRAKE ENGAGED PRESSURE SWITCH
WIRES 000 662

662 To indicator light on dashboard
000 To ground
TECHNICAL DATA
Thread: R 1/8 tapered
Setting: 12 ± 1 bar
19 - STARTER RELAY GROUP
LOCATION - left side of engine compartment,

behind the cab
Relay
(q.ty 3)
Fuses 20
▲ Amp (q.ty 3)
▲
▲
Starting safety
solenoid switch Diverter box
100 Amp
LOCATION OF RELAY AND FUSE SEATS
Fuse seat
772 898
▲ H A 86
87a
772 897 895 30 87

F A B
898 85
946
A
B
772 846 894
▲
D A A
Number coding of relay
895 895 Relay seat terminals
B B (seen from wire inlet side)
846 897
847
923
A
B B
894 894
A A
Note: The position of numbers on connectors is

referred to the view from the wire inlet side.
19.1 – STARTER RELAY 87
WIRES: Please refer to “arrangement of fuse relay 86 85

87a
seats”
30
TECHNICAL DATA
Nominal voltage: 24 Volt
Operating voltage: 19.2 - 30 Volt
Excitation voltage: ≤ 14 Volt
Release voltage: ≥ 4.8 Volt WIRING DIAGRAM 85 87 87a
▲
Max. cut-off current: 20 Amp (N.A.) 86 30
Max. cut-off current: 10 Amp (N.C.) Diode 1N4004
19.2 – STARTER SAFETY SOLENOID SWITCH

WIRES
700 Position G to starter switch
802 Position g to starter safety solenoid switch
888 Position B to starter motor 802
000 To ground
g
888
TECHNICAL DATA
Nominal voltage: ≤ 24 Volt G B
Coil nominal current: ≤ 2 Amp
Nominal load: 100 Amp
700
e
000
20 - BATTERY CUT-OFF MASTER SWITCH

LOCATION - Rear side of machine
BATTERY TO GROUND
+ –
21 - COLD STARTER THERMOSTAT

827
22 - BUCKET POSITIONING PROXIMITY SWITCH
WIRES
981 To boom solenoid switch
994 To fuse F5C on logic board
000 To frame ground
TECHNICAL DATA
Thread: M18x1 000
Tightening torque: 2.5 daNm
994
LOCATION - Installed on front frame, at the upper
end of left boom
Proximity switch 981
23 – BOOM KICK-OUT PROXIMITY SWITCH
WIRES
980 To boom solenoid valve
995 To fuse F5C on logic board
000 To frame ground
TECHNICAL DATA
Thread: M18x1 000
Tightening torque: 2.5 daNm
995
LOCATION - Installed on front frame, at the upper
end of left boom
980
24 – HORN
WIRES
138 To horn solenoid switch 80
000 To ground
138 000
W90 7 - 23
MACHINE GROUPS ELECTRIC DIAGRAMS
7 - 24 W90
FUEL FILTER PRE-HEATER
W90 7 - 25
Description of main components
Item Description Location
“M” ‘‘M’’ key switch contact Cab R.S. of the operator seat
F5B Fuse in the main bord Back of the operatore seat
M Connector Back of the operatore seat
Connect. B between cab and mach. Underneath the cab
142a Fuse 20A Engine compartment
142b Fuse 20A Engine compartment
142c Fuse 20A Engine compartment
205a Relay Engine compartment
205b Relay Engine compartment
205c Relay Engine compartment
206 Temperature sw. On the top of one fuel filter
207a Heater Fuel filter
207b Heater Fuel filter
222 Fuse LINK Radiator shroud
224 Connection box Main board
225 Pre-filter heater Fuel pre-filter
Numbered cables outside the cab.

Coloured cables inside the cab.
A LIGHT BLUE H GREY R RED
B WHITE L BLUE S PINK
C ORANGE M BROWN V GREEN
G YELLOW N BLACK Z PURPLE
7 - 26 W90
ENGINE COLD START
W90 7 - 27
“ST” “ST” switch contact Right side of the operator seat
“M” “M” key-switch contact Right side of the operator seat
B-O-D-R-C-H Connectors Main board
C-D Connectors Underneath the cab
Conn. on trans. selec. terminal 4 Steering column
F4A, F4B Fuses Main board
D7, D44 Diodes Main board
203 Glow-plug Intake manifold
204 Temperature sensor Cylinder head
30 (+) Connection from the batteries Main board
EV5 Solenoid valve Near the intake manifold
K6 Cold starting control unit Untherneath the main board
L18 Indicator lamp Switches panel
R5 Neutral start relay Main board
R4 Starting safety relay Main board
S41 Direction selector Steering column
MVI Transient suppressor Main board

7 - 28 W90
LTS CONTROL WITH MANUAL TRANSMISSION
W90 7 - 29
“ACC” “ACC” key switch contact 1st pos. Right side of the operator seat
B-O-D-N-K-A Connectors Main board
Connector A Underneath the cab
Conn. on trans. selec. term. 3-2 Steering column
169 EV1 Front module
230 EV2 Front module
231 Timer Front module
232 Relay Front module
233 Relay Front module
D15-D34-D35-D37 Diodes Main board

D39-D40-D41
F11A Fuse Main board
R10 Relay of LTS Main board
R11 DSS Relay Main board
S38 LTS Switch Switch panel
S39 DSS Push button Hydr. control lever
S41 Speed selector Steering column
SW2-2/3/-4 DIP-Switch 2 Main board

7 - 30 W90
INSTRUMENT PANEL 1ST PART
BR. CHARGE
PER BUZZER SUPPLEMENTARE

FOR ADDITIONAL BUZZER
W90 7 - 31
“ACC” “ACC” key switch contact (1st pos.) Cab R. S. of the operator seat
C-E-F-G-H-M-S Connectors Main board
A-B-C-D Connectors Underneath the cab
Instrument panel connectors Behind the instrument panel
Instr. panel and m. board connect. Steering column
1-2 3-4
Gear indicator lamp Instrument panel
F9B- F11A Fuses Main board
D8-D9-D11-D14 Diodes Main board

60A Coolant temperature switch Engine
88 Hand brake pressure switch Transmission
91 Emerg. steer. low pressure switch Side of the hydraulic oil tank
92 Main steer. low pressure switch Near the main priority valve
110 Fuel level sensor Fuel tank
114 Eng. oil low pressure switch Engine
117 Brake accumulator low press. sw. Brake pedal valve
118 Air filter clogging switch Air filter housing
120 Transmiss. oil high temp switch Out port of torque converter
BZ1 Warning buzzer Main board
G Alternator Side of engine
h Hourmeter Instrument panel
K8 A.T.C. Near the main board
Z1 Steering alarm timer Main board
Z2 Check timer Main board


7 - 32 W90
INSTRUMENT PANEL 2ND PART
W90 7 - 33
C-E-F-G-H-K Connectors Main board
A-B-C-D Connectors Underneath the cab
Instrument panel connectors Behind the instrument panel
Instr. panel and m. board connect. Steering column
60B Coolant temperature sensor Engine

110 Fuel lever sensor Fuel tank
121 Transmiss. oil temp. sensor Out port of torque converter
181 Speed sensor Transmission
208 Main speed sensor Transmission
F6B Fuse Main board
K8 A.T.C. Near main board
R3 Lights relay Main board
SW1/2 DIP-Switch 1/2 Main board
JP1 Jump Main board
JP2 Jump Main board


7 - 34 W90
MANUAL TRANSMISSION CONTROL
W90 7 - 35
“ACC” “ACC” key-switch contact 1st pos. Right side of the operator seat
B-C-D-M-N-O-P Connectors Main board
C Connector Underneath the cab
On trans. selector connectors Steering column
D1,D2,D28,D30
D31,D32,D37,D40 Diodes Main board
D41,D42,D43
75 Trans-cut-off pressure switch Brake pedal valve
88 Parking brake switch Parking brake (transmission)
A Spool A solenoid Transmission control valve
B Spool B solenoid Transmission control valve
F Forward solenoid Transmission control valve
F11A Fuse Main board
MV3 Transient suppressor Main board
R Reverse solenoid Transmission control valve
R9 Transmission solenoids relay Main board
R12 DS Relay Main board
S37 Trans cut-off switch Switch panel
S39 DSS Switch Hydr. control lever
S41 Transmission control lever Steering column
SW1-3/4 DIP-switch 1 Main board
SW2-1-2/3/4 DIP-switch 2 Main board


7 - 36 W90
STARTING AND SAFETY
GROUND CLOCK
AND CAB LIGHT
W90 7 - 37
“M” “M” Key switch contact Cab R. S. of the operator seat
“ST” “ST” Key switch contact Cab R. S. of the operator seat
B-H-O-R Connectors Main board
C Connector Underneath the cab
Connector on trans. selector Steering column
F4A, F4B Fuses Main board

D7, D12, D20 Diodes Main board
+30 Connection from batteries Main board
I Batteries Back of the machine one each side
2 Master switch Engine compartment
4 Cranking relay 100A Engine compartment
50A Link LINK Fuse Inside of radiator shoroud
G Alternator Engine right side
K6 Cold starting control unit Underneath the main board
M Starting motor Engine compartment
R4 One-off starting relay Main board
R5 Neutral cranking relay Main board
S41 Gear selector Steering column
229 Engine stop valve Engine compartment


7 - 38 W90
EMERGENCY STEERING AND BOOM PROXIMITY
BUCKET AND SPOOL DETENT
W90 7 - 39
“M” “ACC” Key-switch contact (2nd pos.) Right side of the operator seat
F-G-J-H-K-M-S-D Connectors Main board
A-B-C Connectors Underneath the cab
VC2 From tractor relay contact Underneath board

D+ D+ Alternator connection Engine compartment
F6C-F9B-F11A Fuses Main board
D8, D9 Diodes Main board
D13, D16, D19
91 Pressure sw. emergency steering Side of hydraulic oil tank
92 Press. sw. main steering circuit Near to priority valve
132 Inductive proximity sw. for boom foot hinge Near to priority valve
136 Inductive proximity sw. for bucket cylinder Near to priority valve
137 Indicator light Sw. panel (r. side operator seat)
138 Limitation/OFF switch Sw. panel (r. side operator seat)
EV.9 Boom floating detent solenoid Hydr. manipulator
EV.10 Bucket detent solenoid Hydr. manipulator
EV.11 Boom max. lift detent solenoid Hydr. manipulator
BZ1 Buzzer Main board
Z1 Steering alarm timer Main board
Z2 Check timer Main board


7 - 40 W90
AIR CONDITIONING
W90 7 - 41
“M” “ACC” Key-switch contact Right side of the operator seat
H-N-J Connectors Main board
B Connector Underneath the cab
VC2 From tractor relay contact Underneath the main board

D18 Diode Main board
F5B, F8C, F7C Fuses Main board
145 Condit. pressure trinary switch Right side of machine near cond.
146 Electron condensers Right side of machine near cond.
227 Compressor electromagnet cluctch Engine compartment
K3 Control unit heat. cock and recir. Behind the switch panel
M7 Recircle motoreduction gear Near switch panel
M8 Motoreduct. gear for heater cock Near switch panel
M9 Heating electrical fan Inside the cab right side
R8 Relay for condenser fan Main board
S21 Switch for recircle control Near switch panel
S22 Temp. control potentiometer Inside the cab right side
S23 Control for heating cock Near switch panel
S24 Cab fan switch Near switch panel
S25 Conditioner switch Near switch panel
S26 Conditioner thermostat Inside the cab near the evapor.


7 - 42 W90
LIGHTS
W90 7 - 43
A-M-K-F-B Connectors Main board
A-B Connectors Underneath the cab
F2A, F2B, F3A

F3B, F3C, F5B Fuses Main board
F5C, F6C, F8C
19 Right tail light Rear counterweight
21 Left side light Front module
22 Right side light Front module
23 (optional) Left side light T.U.V. Bucket tooth guard
24 (optional) Right side light T.U.V. Bucket tooth guard
26 Left tail light Rear counterweight
28 Number-plate light Rear of the machine
31 Left flood light Front module
33 Right flood light Front module
34 Left head light Front module
36 Right head light Front module
65 Rear right working light Rear of the machine
66 Rear left working light Rear of the machine
L12 Working light Front of the machine
L13 Working light Front of the machine
R2 Relay for lights switch Main board
S32 Lights switch Switch panel
S33 Rear working lights switch Switch panel
S34 Front working lights switch Switch panel
S42 Lights sw. and direct. indicators Steering column


7 - 44 W90
LIGHTS
W90 7 - 45
“M” “ACC” Key switch contact Cab R. S. of the operator seat
D-K-M-F-C-D Connectors Main board
A-B-C Connectors Underneath the cab
F4C,F8A Fuses Main board

F9C, F10A
V2C From tractor relay contact Main board
25 (optional) Left front turn light T.U.V. Bucket tooth guard
27 (optional) Right front turn light T.U.V. Bucket tooth guard
39 Left front turn light Front module
41 Left rear turn light Rear of machine
45 Right front turn light Front module
47 Right rear turn light Rear of machine
69 Stop pressure switch Underneath the cab
71 Right stop light Rear of machine
72 Left stop light Rear of machine
82 Back-up alarm Radiator compartment
95 Horn Front module
107 Horn pedal switch Cab floor
191 Right Back-up light Rear of machine
192 Left Back-up light Rear of machine
R1 Horn relay Main board
S28 Warning switch Switch panel
S41 Horn switch Steering column left side
S42 Lights sw. and turning indicator Steering column right side
Z3 Flasher unit Main board
Z7 Back-up alarm relay Main board

7 - 46 W90
CAB COMPONENTS
W90 7 - 47
A-B-D-F-J-K-M-Q Connectors Main board
B Connector Underneath cab
F2B, F3C, F5C

F6A, F8A, F9A Fuses Main board
F9C, F10B, F10C
F11B
D45, D46 Transient suppressors Main board
53 Front windshield motor pump Engine compartment
57 Rear windshield motor pump Engine compartment
K4 Timer for front windshield wiper Steering column
K7 Voltage regulator Underneath the main board
L14 Cab ceiling light Cab roof
L15 Rotating beacon Top of cab
L16 Rotating beacon Top of cab
M10 Front windshield wiper motor Front of cab
M6 Rear windshield wiper motor Rear of cab
N1 Radio Inside cab
N2 Clock Cab roof
12V Jack 12V Left side seat
24V Connector for electric seat Underneath the main board
S27 24V Lighter Right side cab
S30 Rear windshield washer button Switch panel
S31 Rear windshield wiper switch Switch panel
S35 Rotating beacon switch Switch panel
S43 Wind. wiper switch and front pump Steering column


7 - 48 W90
SINGLE LEVER PILOT CONTROL
BUCKET AND BOOM SPOOLS DETENT
W90 7 - 49
J-K-D Connectors Main board
A Connectors Underneath the cab
VC2 From tractor relay contact Underneath board

F6C Fuse Main board
D13, D16, D19 Diodes Main board
132 Inductive proximity sw. for boom Near to priority valve
136 Inductive proximity sw. for bucket Near to priority valve
137 Indicator light Sw. panel (r. side operator seat)
138 Limitation/OFF switch Sw. panel (r. side operator seat)
EV.9 Boom floating detent solenoid Hydr. manipulator
EV.10 Bucket detent solenoid Hydr. manipulator
EV.11 Boom max. lift detent solenoid Hydr. manipulator
234 Relay Manipulator support
235 Relay Manipulator support
236 Diode box Manipulator support


SECTION 8
CAB
CONTENTS
8.1 GENERAL DESCRIPTION .................................................................................... 1
8.2 WINDSCREEN WIPERS AND WASHERS............................................................ 2
8.3 HEATER ............................................................................................................... 3

8.3.1 Generalities ........................................................................................................... 3
8.3.2 Main components and specifications .................................................................... 3
8.4 GLASSES ............................................................................................................. 4

8.4.1 Characteristics ...................................................................................................... 4
8.4.2 Disassembly and assembly .................................................................................. 5
8.5 REPAIR ................................................................................................................ 8

8.5.1 Cab (removal/installation) ...................................................................................... 8
8.6 AIR CONDITIONING UNIT ................................................................................... 11

8.6.1 Operating instructions ........................................................................................... 11
8.6.2 Technical data ...................................................................................................... 12
8.6.3 Service precautions .............................................................................................. 13
8.6.4 Tool connections .................................................................................................. 15
8.6.5 Discharging ........................................................................................................... 16
8.6.6 Refrigerant charging ............................................................................................. 16
8.6.7 Leak inspection ..................................................................................................... 17
8.7 TROUBLESHOOTING ......................................................................................... 19

W90 CAB 8-1
Fig. 8-1
The cab is a tested protection structure against roll-

over hazard (ROPS).
The cab is complete with the driver’s seat, steering
column, controls and instruments to drive and ope-
rate the machine.
Other standard features are the heating system,
demister, front and rear windscreen washer-wipers,
ceiling 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
lock.
The main components such as the hydraulic Fig. 8-2
reservoir, hydraulic pump and control valve, steering
control valves and cylinders, and drive shafts can be The cab serial number is etched on a plate located
removed or repaired without disassembling the cab. on the inner side of the cab left-hand post.
8-2 CAB W90
8.2 WINDSCREEN WIPERS AND

WASHERS
The front windscreen wiper motor (1) is located at Note 1 - Before setting the wiper blades in motion,
the front of the steering column. The front windscreen operate the windscreen washer to minimise the risk
wiper has two intermittent working speeds: 35 strokes of scratching the glass.
per min (slow) and 55 strokes per min (fast).
A dog-leg mechanism transforms the motor shaft
Note 2 - Use the cleaning fluid DP1 diluted with water
rotary motion into 45° strokes of the wiping arm.
dependent upon working temperature. A 50%
detergent/water solution does not freeze down to
-10°C. Below this temperature, use cleaning fluid
The rear windscreen wiper motor (2) is located under
only.
the cab trim behind the driver’s seat, on the right-
hand side. The rear windscreen motor has but one
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.
3
5
4
Fig. 8-3
The windscreen washer fluid bottle (3) is located

inside the engine compartment, on the left-hand side.
The bottle is fitted with two pumps (4) and (5) for the
Fig. 8-4
front and rear windscreens, respectively.
In case of motor or arm assembly replacement, it

will be necessary to reassemble the arm assembly
Specifications to the drive part correctly to centre the wiping action
Bottle capacity ................................................ 2.5 lt. over the glass width.
Rated voltage ................................................... 24V To this aim, select the most suitable position for the
Absorbed current .............................................. ≤2A arm on the knurled drive part shown by the arrow in
Max. flow .................................................. ≥3 lt./min the figure.
W90 CAB 8-3
8.3 HEATER
8.3.1 GENERALITIES
The cab heater is placed in a special compartment, 6

on the cab right-hand side.
The associated switches are located on the control 3
console and are used to: 2
1
- adjust air temperature; 9
- control air flow intensity;
- admit air from the outside or recirculate the air
inside the cab.
In case of air intake from the outside, air is drawn in

through the filter A. If air is being recirculated, internal
cab air is driven through the filtering panel B.
Both filter A and filtering panel B should be replaced 4
periodically.
8
5
Fig. 8-6
8.3.2 MAIN COMPONENTS AND

SPECIFICATIONS
B
The heater main components are:
1. Electrical fan
Fig. 8-5
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
8-4 CAB W90
8.4 GLASSES
8.4.1 CHARACTERISTICS
All cab glasses are differential hardening type. 4

Glasses should be ordered from FIAT KOBELCO.
They should be kept clean at all times to guarantee 6
good visibility. When cleaning the glasses, pre-wash 2
them with a water and detergent solution or other
proprietary product using a squeegee to reduce
abrasion and make cleaning easier.
NOTICE - Never use hot water over cold glasses.
All glasses fitted to the cab have been subjected to 5

differential hardening and have a 5 ± 0.2 mm
thickness. They are firmly bonded to their seats by
means of a polyurethane sealant.
7
5 ± 0.2 mm
3
Fig. 8-7
Fig. 8-8
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
W90 CAB 8-5
8.4.2 DISASSEMBLY AND ASSEMBLY
Disassembly Preparing the replacement glass
1. Push a pointed object through the adhesive from 1. Place the glass momentarily in position and mark
inside the cab and insert the wire with adhesive tape to position it correctly during
final bonding.
2. Using the wire, cut the adhesive all around the
glass. Lift out the glass using two suction cups.
3. Using a knife, cut off the adhesive left on the body

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
molecular weight (monomolecular) volatile
isocyanates. Therefore, 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.
Fig. 8-10
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.
Fig. 8-9
WARNING
Always wear gloves and use special suction cups

with handles when replacing the glasses.
Do not strike the glasses to remove.
Fig. 8-11
8-6 CAB W90
3. Shake well the glass activator bottle before use 5. Punch the membrane in the threaded connection.
(at least 1 minute after ball separation from the
sediment). Apply an even continuous bead of
activator along the black stencil using the
applicator supplied.
Important - Once applied, allow the activator to dry

for at least 10 minutes keeping the surface clean.
Fig. 8-14
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.
Fig. 8-12
4. Remove the sealant cartridge bottom cover and

salts therein.
Fig. 8-15
Fig. 8-13
W90 CAB 8-7
Glass assembly
WARNING
1. Position the glass in its seat slightly pressing it.
Any variation to instructions specified, such as use
of materials after expire date or improper work
procedures, may negatively affect the results of the
operation. The manufacturer does not assume any
responsibility for damages which may derive to
persons and/or things.
Fig. 8-16
Note - The glass must be fitted to the machine within

maximum 15 minutes after applying the BETASEAL
sealant-adhesive.
Note - Work only in well ventilated premises. The

polyurethane adhesive does not contain low
molecular weight (monomolecular) volatile
isocyanates. Therefore, 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
temperature of 23°C. During this period the machine
should not be submitted to any stress whatever.
8-8 CAB W90
8.5 REPAIR
8.5.1 CAB (REMOVAL/INSTALLATION)
Removal
Park the machine on level ground and block wheels

securely to prevent motion.
Disconnect the battery isolator switch.
Fig. 8-18
WARNING
Always disconnect the battery isolator switch before
cleaning, repairing, overhauling or parking the
machine.
Fig. 8-19
Fig. 8-17
Provide a suitable hoist above the cab and hook it
to the lifting eyebolts. These should have been
screwed in at the cab top beforehand (cab weight:
Remove rear fenders and steps. 700 kg approx.). Take out any slack in the lifting
chains.
Remove protection panels at the cab bottom, on both
sides.
Disconnect the cab to frame ground braid.

WARNING
Always use hoists or similar devices of suitable
capacity to lift or move heavy components. Ensure
that the sling is perfectly made. Use lifting eyebolts
if specified.
W90 CAB 8-9
Loosen the cab to frame retaining bolts. Leave the

rubber mounts on their supports.
Detach the throttle control linkage from the engine

compartment and the parking brake linkage at the
three-way valve on the cab left-hand side.
Close the heater supply taps.

Detach both heater hoses located at the cab rear
right-hand side.
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.
WARNING
Do not work under or near an attachment of the
machine or any of its parts which are not suitably
supported and locked.
Note - Mark all lines and electrical cables before

removal to assist correct reassembly.
Ensure all machine connections have been

disconnected. Raise the cab and move it to one side.
8 - 10 CAB W90
Installation
Installation is carried out in reverse order of removal.
1 1
3
1 1
4
6
7
Fig. 8-20 Securing the cab to the machine
Note - 1 21 daNm
1. Cab retaining nut M16 5. Frame - ROPS front retaining bolt M24
2. Frame - ROPS rear retaining bolt M30 6. Cab front support
3. Rubber mount to frame bolt 7. Cab rear support.
4. Rubber mount
W90 CAB 8 - 11
8.6 AIR CONDITIONING UNIT
8.6.1 OPERATING INSTRUCTIONS

The principle of operation can be summarised as follows: the refrigerant, Freon R134a, in its gaseous state, is
sucked by the compressor at a pressure of 1-5 bar and taken to a final compression at a pressure of 10-20 bar.
The gas, heated by the compression to 89-100 °C, flows, still in a gaseous state, into the condenser where, under
the effect of the cooling provided by the air flowing through it by the action created by the fan, reaches the
condensation point, passing into a liquid state at high pressure.
Subsequently, the refrigerant, at liquid state, reaches a dehydration filter, which has the function of capturing
impurities, absorb moisture trapped into the system and operate as a reserve reservoir for the refrigerant itself.
Then, the Freon reaches the expansion thermostatic valve, which has the purpose of regulating the refrigerant
flow into the evaporator at a pressure of 1~5 bar, causing its passage from liquid to gaseous state. At the same
time, the air flowing through the evaporator, under the action of the fan, having a temperature which is higher than
the refrigerator contained by the evaporator itself, causing its boiling and full evaporation, releasing heat.
The air, being cooled, deposits on the fins of the evaporator parts of its moisture content, under the form of little
drops, which drop into the tanks and are discharged outside the cab.
Air cooled and dehumidified, is sent into the cab. The refrigerant, at the outlet of evaporator, is sucked again by
the compressor, beginning a new cycle.
Expansion valve Fan unit Evaporator Compressor
High
pressure
Condenser
Intake
Low
pressure
Pressure switch Filter
Fig. 8-21
8 - 12 CAB W90
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
Evaporator
Power 8,17 KW
Rate of flow 500 l/h
Air flow 575 m3/h
Input air temperature 43°C
Relative humidity 30%
Vaporisation temperature 5°C
Condensation temperature 60°C
Condenser
Mass dimension 330 x 600 mm
Input air temperature 43°C
Relative humidity 30%
Vaporisation temperature 5°C
Condensation temperature 60°C
Expansion valve
Type TGK TEV 216 PO-2
Gas Freon R134A
Superheat 4°C
Condenser fan (double)
Voltage 24V
Electrical input 9,8A x 2 (press. = 0)
Air flow 2500 m3/h x 2 (press. = 0)
Compressor
Type SANDEN SD7H15 md 7948 for 134A
Displacement 154.9 cc
Pulley ø 135,6 mm
Lubricant oil q.ty 200 cc
Filter
Type SKG CC164
Dimension 141 x ø76 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
ON 2,6 bar
High pressure OFF 28 bar
ON 25 bar
(Fan) OFF 12 bar
ON 17 bar
Thermostat
Type RANKO K50-L9421
Setting Cold OUT 0 °C
IN 5 °C
W90 CAB 8 - 13
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 resulting
from the destruction of the ozone layer. - Coat the piping connections and the O-rings with
They remain in the atmosphere in excess of 100 years PAG oil.
with possible increase of cataracts and skin cancer.
As a result of the evaluation of the global - Fit the nuts and unions tightly against the base
environmental problems, new R134a refrigerants has of the companion pieces then hand tighten the
been adopted. nut as much as possible. Then, tighten to the
This refrigerant has an ozone depletion potential (ODP) specific torque.
of 0 and a low global warming potential (GWP)
Note
Always use oil specified for R134a systems to coat
the O-rings.
WARNING
Direct contact with refrigerant can cause frostbite or
blindness.
Always wear safety glasses and protective gloves.
Do not work with refrigerant colse to the face.
CAUTION
PAG oil , in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere
Handle the air conditioner componenets carefully. Do

not knock or drop them. Fig. 8-22
8 - 14 CAB W90
Do not mistakes refrigerants CAUTION

Before charging an air conditioning system be sure Cap the oil container after use and the air conditioner
that refrigerant is correct. Confirm before charging that system parts, when servicing.
the type of air conditioner system is in fact an R134a Never mix compressor oil with other types of oil
system.
R 12 R134a
CFC12 HFC134a
Fig. 8-23
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
not be released into the air.
Fig. 8-25
WARNING
The oil must be replaced or replenished in the following
When removing refrigerant from the air conditioner cases:
system, always use a refrigerant recovery unit made
- when refrigerant or oil leaks from the system
especially for R134a
- when refrigerant is suddenly discharged from
the system
- when system components are replaced.
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
temperatures. At these temperatures, the refrigerant
R134a may appear 'cloudy' when checked using the
sightglass, and the charge may be mistakenly judged
as insufficient.
Fig. 8-24
Compressor oil
Use compressor oil made specifically for use with

R134a.
R134a system compressor oil has an extremely high
moisture absorption capacity.
Fig. 8-26
W90 CAB 8 - 15
8.6.4 TOOL CONNECTIONS
WARNING 1. Fully close both manifold gauge valves.

Do not connect hoses to the air conditioner system
2. Connect the three hoses securely to the manifold
when the manifold gauge valves are open.
gauge.
3. Connect the utility hose to the vacuum pump or

refrigerant source
CAUTION 4. Connect the couplers to the high and low

If there is any refrigerant in the air conditioner system, pressure hoses. Turn the knob on the fitting to
connect the hoses only after the service hoses and depress the core if so equipped.
the manifold gauge have been evacuated. Before disconnecting hoses, close both
manifold gauge valves.
Fig. 8-27
8 - 16 CAB W90
8.6.5 DISCHARGING
CAUTION
If the needle moves towards 0, the system is not
WARNING alright. Check the system for leaks and repair.
Do not release the refrigerant into the air.
Discharge refrigerant only into the refrigerant recovery
unit.
CAUTION
Never use a refrigerant recovery unit for CFC12 on
an HFC134a system.
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

Fig. 8-28
recovery unit handling and operations.
Evacuation
1. Operate the vacuum pump.
8.6.6 REFRIGERANT CHARGING 2. Open both manifold gauge valves
3. Evacuate the system for at least 20 minutes.
There are various methods of charging refrigerant into 4. Close both manifold gauge valves.
the air conditioner system. these include using
refrigerant recovery units and direct charging using a
Initial charge
scale.
1. Put the refrigerant container on the scale.
Note: Change refrigerant in the system of wheel

loader W170-W190-W230-W270 every 2 years.
Initial evacuation
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 valves.
5. Operate the vacuum pump.
6. Evacuate the system for at least 5 minutes to
stabilize the vacuum inside the system. Fig. 8-29
7. Close both valves and stop the vacuum pump.
2. Disconnect the utility hose from the vacuum
pump and connect it to the refrigerant container.
Checking air tightness 3. Purge air from the utility hose.
1. Leave the system as it is for 5 to 10 minutes. 4. Record the refrigerant weight.
Ensure the low pressure gauge needle does not 5. Open the refrigerant container valve.
move towards the atmospheric pressure side 6. Slowly open the manifold gauge's low pressure
(gauge pressure 0). side valve to charge refrigerant from the low
pressure side valve to charge refrigerant from
the low pressure side.
W90 CAB 8 - 17
7. Charge with refrigerant until the low pressure

gauge reaches 0.2 MPa (2 bar, 28psig).
The optimal refrigerant's weight is
approximally 1100 gr.
8. Close the manifold gauge's low pressure valve.
CAUTION
Do not overcharge the system.
Initial Leak check

Using the leak detector, check the system connection
for leaks. Fig. 8-31
Note
As the system pressure is not yet high, only large
leaks can be detected at this time.
Inspection procedure
Evacuation
Refrigerant
charging
Operate compressor for

Repair
at last 5 min
Fig. 8-30
Check for refrigerant

leaks from high
pressure side parts
8.6.7 LEAK INSPECTION

Operation test
To facilitate refrigerant leak detection, operate the air
conditioner at the full cooling setting with the fan
running at maximum speed for at least 5 minutes.
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
decreases gradually, as shown in the graph, while
the low pressure side pressure increases gradually.
8 - 18 CAB W90
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
Fig. 8-32
W90 CAB 8 - 19
8.7 TROUBLESHOOTING
8 - 20 CAB W90
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 Replace.
malfunction tester. If there is no conductance, the motor is malfunction-
ing.
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.
malfunction 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.
The high-pressure side pressure will be high and even if Discharge small
2. Excessive refrigerant the condenser is cooled using water, air bubbles will not amounts of refrigerant
appear in the sightglass. until air bubbles appear
periodically in the
sightglass.
W90 CAB 8 - 21
(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, Check operation,
components thermoswitch, relay, etc. referring to the wiring
diagram, and replace
defective parts.
8 - 22 CAB W90
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 low-pressure side pressure normally becomes too high when
sure too high. the high-pressure side pressure is too high. As this is explained be-
low, the following inspection is only used when the low-pressure
side pressure 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-pressure
tact. 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 Remove and clean the fil-
suction filter. not. ter.
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 tem- The expansion valve's outlet side is chilled, and low pressure Clean or replace the piping.
perature sensor gas leak gauge indicates a vacuum.
(damaged capillary tube,
etc.)
5.Clogged or blocked pip- When the piping is clogged or blocked, the low-pressure gauge Clean or replace piping.
ing. reading will decrease, or a negative reading may be shown.
6. Defective thermoswitch. The evaporator is frozen. Adjust or replace.
High-pressure side
pressure too high.
1. Poor condenser cooling. Dirty or clogged condenser. Cooling fan does not operate cor- Clean, and repair the fan.
rectly. Blown fuse, broken wiring or poor contact. Fan motor mal- Repair the wiring or replace
function. 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.
W90 CAB 8 - 23
Gauge pressure diagnosis • Problems in the system can be diagnosed using a

manifold gauge by reading the system's low and high
pressures.
Normal pressures
Low pressure side High pressure side
Low-pressure side: 0.13 ~ 0.2 MPa {1.3 ~ 2.0 kgf/
0.13 - 0.2 MPa 1.47 - 1.67 MPa cm2, 18 ~ 28 psig}
{1.3 - 2.0 kg/cm2, {15 - 17 kg/cm2,
18 - 28 psig} 213 - 242 psig} High-pressure side: 1.47 ~ 1.67 MPa {15 ~ 17 kgf/
6 7 8 1.5 2.0
cm2, 213 ~ 242 psig}
5 9
1.0 15 20 2.5
4 5 10
10 10 25
11
3 5
2 12
0.5
0
30
35
3.0
Conditions
0 15 13
1 0
0
15
14
3.5
Atmospheric temperature: 30 ~ 35°C
(86 ~ 95°F)
Engine speed: 1,500 r/min
Blower speed: HI (high-speed)
Temperature switch: Full cooling
Insufficient refrigerant
Indications:
Fig. 8-33
• Low pressures on both the low pressure and high-
pressure sides.
• Discharge temperature will not decrease.
Cause: Refrigerant leakage.
Remedy: Inspect using a gas leak detector, repair
the leak, and replenish the refrigerant.
98 MPa 0.78 - 0.98 MPa

{1.0 kg/cm2, {8 - 10 kg/cm2,
18 psig} 114 - 142 psig}
6 7 8 1.5 2.0
5 9
1.0 15 20 2.5
4 5 10
10 10 25
11
3 0.5 5 3.0
30
2 12
0 35
0 15 13
1 0
3.5
0 14
15
Fig. 8-34
8 - 24 CAB W90
Excessive refrigerant (poor condenser

radiation)
0.25 - 0.29 MPa 2.26 MPa
{2.5 - 3.0 kg/cm2, {23 kg/cm2,
36 - 43 psig} 327 psig} Indication: both the low and high pressures are too
7
5
6 8
9
1.0
1.5
15
2.0
20 2.5
high.
4 5 10
10 10 25
11
3
2 12
0.5 5
0
30
35
3.0
Causes:
0 15 13 0
1
0
15
14
3.5
• Pressure increase due to excessive refrigerant.
• Insufficient condenser cooling.
Remedy:
• Clean the condenser.
• Inspect and adjust the fan belt and condenser motor.
• Check the refrigerant level.
Air in cooling system

Fig. 8-35
(insufficient suction)
Indications:
• Both the low and high pressures are too high.
0.25 - 0.34 MPa 1.96 - 2.45 MPa • The low-pressure side piping is not cold.
{2.5 - 3.5 kg/cm2, {20 - 25 kg/cm2,
36 - 50 psig} 284 - 356 psig}
Cause: Air has entered the cooling system. When
5
6 7 8
9
1.0
1.5 2.0
2.5
suction is not applied, the gauge readings are as
4 10 15 20
5
3
10
11
0.5 5
10 25
30 3.0
shown in the left hand illustration.
2 12
0 35
0
1
0
15
15
14
13 0
3.5 Remedy:
• Evacuate the system, replenish the refrigerant and
check the gauge readings.
• After prolonged operation with air in the system, the
receiver drier must be replaced.
Fig. 8-36
W90 CAB 8 - 25

Defective expansion valve
0.25 MPa 2.16 - 2.26 MPa
{2.5 kg/cm2, {22 - 23 kg/cm2, Indication: Both the low and high pressures are too
36 psig} 313 - 327 psig}
high.
6 7 8 1.5 2.0
5 9
4 5
10
10
11
1.0
10
15 20
25
2.5
Causes: Improper refrigerant charge.
3 5
2 12
0.5
0
30
35
3.0
Defective expansion valve.
0 15 13
1 0
0
15
14
3.5
Improper temperature sensor installation.
Remedy:
• Check temperature sensor installation, and
insulation.
• If normal, replace the expansion valve.
Insufficient compressor compression

Fig. 8-37 Indications:
• High pressure on the low-pressure side, pressure
Low pressure side High pressure side too low on the high pressure side.
0.39 - 0.59 MPa 0.69 - 1.08 MPa • The high and low pressures are already equal when
{4 - 6 kg/cm2, {7 - 11 kg/cm2,
18 psig} 99 - 156 psig} operation is stopped.
5
6 7 8
9
1.0
1.5 2.0
2.5
Causes: Insufficient compression due to a defective
4 10 15 20
5
3
10
11
0.5 5
10 25
30 3.0
compressor gasket or damaged suction
12
2
1
0 15 13 0
0 35
3.5
valve.
0 14
15
Remedy: Disassemble and repair the compressor.
Fig. 8-38
8 - 26 CAB W90

Moisture intrusion
Vide - 0.13 MPa 0.59 - 1.77 MPa
{Vide - 1.3 kg/cm2, {6 - 18 kg/cm2, Indication: The low-pressure side pressure alternates
Vide - 18 psig} 85 - 256 psig} between a vacuum and normal pressure.
5
6 7 8
9
1.5 2.0 Causes: Moisture has frozen in the air conditioner
1.0 15 20 2.5
3
4 5
10
10
11
5
10 25 system, clogging the expansion valve,
0.5 30 3.0
2
1
0 15 13
12
0
0 35 which then blocks the air conditioner
3.5
0
15
14
system. When the ice melts, normal
operation resumes.
Remedy:
• Replace the receiver drier.
• Evacuate the system.
• Recharge with refrigerant to the proper level.
Refrigerant does not circulate

Fig. 8-39
Indications:
Low pressure side High pressure side • The low pressure side pressure becomes a vacuum
and the high pressure side pressure reads 0.49 ~
- 101.3 MPa 0.49 - 0.59 MPa
{- 760 mm Hg, {5 - 6 kg/cm2, 0.59 MPa {5 ~ 6 kgf/cm2, 71 ~ 85 psig}.
- 29.92 in Hg} 71 - 85 psig}
7
• Frost or condensation appear on the front and rear
6 8 1.5 2.0
4
5
5
9
10
1.0 15 20 2.5 pipe connections of the receiver drier or expansion
10 10 25
3
2
11
12
0.5 5 30 3.0 valve.
0 35
0 15 13
1 0
3.5
0
15
14
Causes:
• The air conditioner system is blocked by ice or dirt.
• The air conditioner system is shut off by a defective
expansion valve temperature sensor.
Remedy: Stop operation and check for ice or
contamination.
• If moisture is the problem, evacuate the system.
• Replace the expansion valve temperature sensor if
Fig. 8-40
defective.
• Replace the receiver drier.
• Recharge with refrigerant to the proper level.
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Reproduction of text or illustration,

in whole or in part, is strictly prohibited.
Print No. 604.02.341.00 - English - VII - 2002

Printed by Satiz - Turin (Italy)
Coordinamento Editoriale Satiz - Torino

W90 WHEEL LOADER Service Manual

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W90

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Most accidents and injuries occurring in industry, on the

On machines having hydraulically, mechanically

SPECIFICATIONS .......................................................................................... pag. 1

CAPACITIES AND FLUID TYPES .................................................................. pag. 3

SAFETY RULES ............................................................................................. pag. 4

UNITS OF MEASURE USED IN THE MANUAL ............................................. pag. 11

TIGHTENING TOR QUES ............................................................................. pag. 12

ENGINE ................................................................ Section 1

SPECIFICATIONS - WHEEL LOADER W90

TORQUE CONVERTER BRAKES

Forward speed Kph Reverse speed Kph

ATTACHMENT HYDRAULIC SYSTEM Three-position control switch as follows:

- Bucket control cylinder

2265 1275 1275 797

FLUIDS AND CAPACITY TABLE

Fluids and lubriants

Transmission Oil 17 AMBRA - Super Gold 10W-30 CCMCD4 - API CF-4/SG

Front axle oil 12

UNITS OF MEASURE CLASSIFICATION OF STANDARD COMPO-

Torque: decanewton x meter (daNm) replaces

f - Material index digit

This digit indicates the material used for a defined

g - Coating index digit

It indicates the coating applied to a defined item.

Resistance class and material

3 R100 100 10K 8 V 100

4 Brass Brass Messing Brass Brass Laiton

5 Alluminio Alluminio Aluminium Aluminium Aluminium Aluminium

6 Copper Copper Kupfer Copper Copper Cuivre

7 Blank for other metallic materials

WARNING TORQUE TABLES

- Resistance classes R80, R100, R120 must be

10.9 replaces R100

CDT= cadmed; FOSF= phosphated; ZNT=

NUTS (ZNT) SCREWS (ZNT / DEIDR)

Strength grade: 10 (R 80) Strength grade: 10.9 (R 100)

M8 x 1.25 3.2 2.6 3.9 3.2 M8 x 1.25 1.3 3.5

M10 x 1.5 6.5 5 7.7 6 M10 x 1.5 6.5 7

M12 x 1.25 13 8.7 14.5 10.2 M12 x 1.25 12.7 13.9

M12 x 1.75 11 8.1 12.9 9.6 M12 x 1.75 11 12

M14 x 1.5 19.5 13 21.6 15 M14 x 1.5 20 22

M14 x 2 18 12.5 20 14.6 M14 x 2 18 19

M16 x 1.5 30 17 34 20 M16 x 1.5 30 33

M18 x 1.5 45 25 50 29 M18 x 1.5 45 48

M18 x 2.5 - - - - M18 x 2.5 - -

M20 x 1.5 60 30.5 64.5 35 M20 x 1.5 60 65

M20 x 2.5 - - - - M20 x 2.5 - -

M22 x 1.5 80 41 - - M22 x 1.5 80 90

M22 x 2.5 - - - - M22 x 2.5 - -

M24 x 2 100 47 108 52.5 M24 x 2 100 110

M27 x 2 95 40.1 - - M27 x 2 100 -

M30 x 2 130 49.4 - - M30 x 2 140 -

M33 x 2 170 - - - M33 x 2 190 -

M36 x 3 220 - - - M36 x 3 240 -

PARAGRAPH SUBJECT PAGE

1.1 GENERAL DESCRIPTION ........................................................................................ 1

1.2 GENERAL CHARACTERISTICS .............................................................................. 2

1.3 SPECIFICATIONS AND ASSEMBLY CLEARANCES ............................................... 5