Fiat Hitachi Fb90 100 110 200-2-4ws Workshop Manual

Fiat Hitachi Fb90 100 110 200 2 4ws Workshop Manual
MODELS
Full download: http://manualplace.com/download/fiat-hitachi-fb90-100-110-200-2-4ws-workshop-manual/
FB90.2 FB100.2 FB110.2

FB200.2 4WS
WORKSHOP MANUAL
19900
Print 604.13.028 edition 09/2000
This is the cut pages sample. Download all 1057 page(s) at: ManualPlace.com
TO THE READER
• This manual has been written for a skilled content, please contact:
technician, in order to give him the
information necessary to repair this FIAT-HITACHI EXCAVATORS S.p.A.
machine. Strada Settimo, 323
San Mauro Torinese (TO)
- Read this manual carefully for correct 10099 ITALIA
information about repair procedures. PRODUCT SUPPORT
DOCUMENTATION CENTER
- For any question or comment, or in case Fax. ++39 011 6877357
you notice a mistake in this manual
ADDITIONAL REFERENCE MANUALS
• In addition to this Workshop Manual, refer also

to the following:
- Operation and maintenance instruction

manual
- Spare parts catalog
DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL
• The complete repair manual consists of one remove and install procedures, disassembly
volume: and assembly procedures.
FB90.2 FB100.2 FB110.2FB200.2 4WS - • The complete Workshop Manual FB90.2

Workshop Manual "Terna" FB100.2 FB110.2FB200.2 4WS - Workshop
Manual "Terna" consists of the following volu-
• “Terne" Workshop Manual contains the me identified by print number as shown
technical information necessary for machine/ herebelow:
engine service and repair, service equipment,
information on maintenance standards,
VOLUME MACHINE TYPE PRINT No.

- Workshop Manual FB90.2 FB100.2 FB110.2 604.13.028
"TERNA" FB200.2 4WS
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or

on the highway, are caused by the failure of some individuals to follow
simple and fundamental safety rules or precautions. For this reason
MOST ACCIDENTS CAN BE PREVENTED by recognising the real
cause and doing something about it before the accident occurs.
Regardless of the care used in the design and construction of any type
of equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient
operation.
Carefully read indications, cautions and safety warning quoted in the
“SAFETY RULES” section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many
thousand serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.
ATTENTION
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.
COPYRIGHT BY FIAT-HITACHI EXCAVATORS S.p.A.

Product Support - Documentation Centre
Strada di Settimo, 323 - S. Mauro T.SE (TO) ITALY
All rights reserved. Reproduction of text and illustrations in whole or in part,

is strictly prohibited.
CONTENTS
SECTION 00 – HEALTH, SAFETY, MAINTENANCE

CHAPTER 1 – General
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 2 – General Specifications
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 3 – Tooling
Tooling and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

2 CONTENTS
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SECTION 10 – ENGINE – NEW HOLLAND 92 to 108 hp

CHAPTER 1 – Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CHAPTER 2 – Fuel System
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CHAPTER 3 – Turbocharger
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHAPTER 4 – Lubrication System
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHAPTER 5 – Cooling System
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

CONTENTS 3
SECTION 17 – TORQUE CONVERTER

CHAPTER 1 – With Powershuttle Transmission
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHAPTER 2 – With Powershift Transmission
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 21 – TRANSMISSIONS
CHAPTER 1 – 4x4 Compact Shuttle
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHAPTER 2 – Powershift Introduction
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CHAPTER 3 – Powershift Operating Lever
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHAPTER 4 – Powershift Overhaul (includes 4 Wheel Steer)
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

4 CONTENTS
SECTION 25 – FRONT AXLES

CHAPTER 1 – Front Axle (2 and 4 Wheel Drive Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHAPTER 2 – Front Axle (4 Wheel Steer Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 27 – REAR AXLES

CHAPTER 1 – Rear Axle with Foot Operated Diff Lock (2 and 4 Wheel Drive Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHAPTER 2 – Rear Axle with Electrically Operated Diff Lock (2 and 4 Wheel Drive
Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAPTER 3 – Rear Axle (4 Wheel Steer Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 33 – BRAKE SYSTEMS

CHAPTER 1 – Brakes (2 and 4 Wheel Drive Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAPTER 2 – Brakes (4 Wheel Steer Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

CONTENTS 5
SECTION 35 – HYDRAULIC SYSTEMS

CHAPTER 1– Hydraulic Circuits and Components (REXROTH ONLY)
Hydraulic Circuits ................................................................. 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CHAPTER 2 – Fault Finding, Pressure and Flow Testing

Preliminary Checks ......................................................................2

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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CHAPTER 3 – Hydraulic Cylinders

General Specifications
......................................................................... 1
Description and
. . .Operation
............................................................................ 3
Removal and Installation
........................................................................... 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

6 CONTENTS
SECTION 39 – VEHICLE CHASSIS

CHAPTER 1 – CHASSIS COMPONENTS
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 41 – STEERING SYSTEMS

CHAPTER 1 – Steering (2 and 4 Wheel Drive Only)
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAPTER 2 – Steering (4 Wheel Steer Only)
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 50 – CAB HEATING AND AIR CONDITIONING

CHAPTER 1 – Cab Heating
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHAPTER 2 – Air Conditioning
Description & operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

CONTENTS 7
SECTION 55 – ELECTRICAL SYSTEM

CHAPTER 1 – System General
Controls & Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuse Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CHAPTER 2 – Wiring Diagrams
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wiring Diagrams (outside of N/America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHAPTER 3 – Starter Motor

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAPTER 4 – Alternator
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHAPTER 5 – Battery
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance & Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHAPTER 6 – Service Diagnostics, Calibration and Immobiliser
Service Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Instrument Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHAPTER 7 – Component Testing
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

8 CONTENTS
SECTION 82 – LOADER REMOVAL

CHAPTER 1 – OVERHAUL (2 and 4 Wheel Drive Only)
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHAPTER 2 – OVERHAUL (4 Wheel Steer Only)

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 84 – BACKHOE REMOVAL

CHAPTER 1 – OVERHAUL
Backhoe Control Linkage Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Component Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Extendible Dipperstick Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
.............................................................................
SECTION 90 – CAB PARTS

CHAPTER 1 –

Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cab Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

SECTION 00 – MAINTENANCE – CHAPTER 1 1
SECTION 00 – MAINTENANCE
Chapter 1 – General Instructions
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by authorised
workshops. All instructions detailed should be carefully observed and special equipment indicated should be
used if necessary.
Everyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible of deriving damages.
SHIMMING
At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up
recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value
indicated for each shim.
ROTATING SHAFT SEALS

To correctly install rotating shaft seals, observe the following instructions:
– Let the seal soak into the same oil as it will seal for at least half an hour before mounting;
– Thoroughly clean the shaft and ensure that the shaft working surface is not damaged;
– Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and
orient grooves in order that they deviate the fluid towards the inner side of the seal;
– Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill with grease the gap between
the sealing lip and the dust lip of double lip seals;
– Insert the seal into its seat and press it down using a flat punch. Do no tap the seal with a hammer or a drift;
– Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled,
ensure that it contacts the thrust element if required.;
– To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.
‘O’ RINGS
Lubricate the ‘O’ rings before inserting them into their seats. This will prevent the ‘O’ rings from rolling over and
twine during mounting which will jeopardise sealing.
SEALERS
Apply FLEXIBLE GASKET SEALANT 82995770 or a suitable equivalent, over the mating surfaces marked with
an X.
Before applying the sealer, prepare the surface as follows:
– remove possible scales using a metal brush;
– thoroughly degrease the surfaces using DEGREASER 82995779, or a suitable equivalent.
BEARINGS
It is advisable to heat the bearings to 80 to 90°C before mounting them on their shafts and cool them down before
inserting them into their seats with external tapping.
SPRING PINS
When mounting split socket spring pins, ensure that the pin notch is oriented in the direction of the effort to stress
the pin.
Spiral spring pins should not be oriented during installation.
FB 90.2–200.2 604.13.028
2 SECTION 00 – MAINTENANCE – CHAPTER 1
NOTES FOR SPARE PARTS
USE EXCLUSIVELY GENUINE SPARE PARTS

Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
– Machine model (commercial name) and frame number;
– engine type and number;
– part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”,
which is the base for order processing.
NOTES FOR EQUIPMENT

Equipment which proposes and shows in this manual are as follows:
– studied and designed expressly for use on company machines;
– necessary to make a reliable repair;
– accurately built and strictly tested to offer efficient and long–lasting working means.
– we also remind the Repair Personnel that having these equipment means:
– work in optimal technical conditions;
– obtain best results;
– save time and effort;
– work more safely.
NOTICES
Wear limits indicated for some details should be intended as advised, but not binding values. The words “front”,
“rear”, “right hand”, and “left hand” referred to the different parts should be intended as seen from the operator’s
seat oriented to the normal sense of movement of the Machine.
HOW TO MOVE THE MACHINE WITH THE BATTERY REMOVED

Cables from the external power supply should be connected exclusively to the respective terminals of the Ma-
chine positive and negative cables using pliers in good condition which allow proper and steady contact.
Disconnect all services (lights, wind–shield wipers, etc.) before starting the Machine.
If it is necessary to check the Machine electrical system, check it only with the power supply connected. At check
end, disconnect all services and switch the power supply off before disconnecting the cables.
604.13.028 FB 90.2–200.2
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL

This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this manual you will find this symbol together with the following key–words:
WARNING (ATTENZIONE) – it gives warning about improper repair operations and
deriving potential consequences affecting the service technician’s personal safety.
DANGER (PERICOLO) – it gives specific warning about potential dangers for person-
al safety of the operator or other persons directly or indirectly involved.
TO PREVENT ACCIDENTS • Stop the engine and ensure that all pressure is
Most accidents and personal injuries taking place in relieved from hydraulic circuits before removing
workshops are due from non–observance of some caps, covers, valves, etc.
simple and essential prudential rule and safety pre- • All repair and maintenance operations should be
cautions. For this reason, IN MOST CASES THEY carried out with the greatest care and attention.
CAN BE AVOIDED. It suffices to foresee possible • Service stairs and platforms used in a workshop
causes and act consequently with necessary caution or in the field should be built in compliance with
and care. the safety rules in force.
The possibility that an accident might occur with any • Disconnect the batteries and label all controls to
type of machines should not be disregarded, no mat- warn that the Machine is being serviced. Block
ter how well the machine in question was designed the machine and all equipment which should be
and built. raised.
A wise and careful service technician is the best pre- • Never check or fill fuel tanks and accumulator
cautions against accidents. batteries, nor use starting liquid if you are smok-
Careful observance of this only basic precaution ing or near open flames as such fluids are flam-
would be enough to avoid many severe accidents. mable.
DANGER: Never carry out any cleaning, lubrication • Brakes are inoperative when they are manually
or maintenance operations when the engine is run- released for maintenance purposes. In such
ning. cases, the machine should be kept constantly
under control using blocks or similar devices.
SAFETY RULES • The fuel filling gun should remain always in con-
• Carefully follow specified repair and mainte- tact with the filler neck. Maintain this contact until
nance procedures. the fuel stops flowing into the tank to avoid pos-
sible sparks due to static electricity buildup.
• Do not wear rings, wristwatches, jewels, unbut-
toned or flapping clothing such as ties, torn • Use exclusively specified towing points for tow-
clothes, scarves, open jackets or shirts with open ing the Machine. Connect parts carefully. Ensure
zips which could get hold into moving parts. We that foreseen pins and/or locks are steadily fixed
advise to use approved safety clothing such as before applying traction. Do not stop near towing
anti–slipping footwear, gloves, safety goggles, bars, cables or chains working under load.
helmets, etc. • To transfer a failed Machine, use a trailer or a low
• Never carry out any repair on the machine if loading platform trolley if available.
someone is sitting on the operator’s seat, except • To load and unload the machine from the trans-
if they are certified operators to assist in the op- portation mean, select a flat area providing a firm
eration to be carried out. support to the trailer or truck wheels. Firmly tie
• Never operate the machine or use attachments the machine to the truck or trailer platform and
from a place other than sitting at the operator’s block wheels as required by the forwarder.
seat. • For electrical heaters, battery–chargers and sim-
• Never carry out any operation on the machine ilar equipment use exclusive auxiliary power
when the engine is running, except when specifi- supplies with a efficient ground to avoid electrical
cally indicated. shock hazard.
FB 90.2–200.2 604.13.028
• Always use lifting equipment and similar of ap- ensure that there are no persons within the Ma-
propriate capacity to lift or move heavy compo- chine or attachment operating range.
nents. • Do not keep into your pockets any object which
• Pay special attention to bystanders. might fall unobserved into the Machine’s inner
• Never pour gasoline or diesel oil into open, wide compartments.
and low containers. • Whenever there is the possibility of being
• Never use gasoline, diesel oil or other flammable reached by ejected metal parts or similar, use
liquids as cleaning agents. Use non–flammable protection eye mask or goggles with side guards,
non–toxic proprietary solvents. helmets, special footwear and heavy gloves.
• Wear protection goggles with side guards when • Wear suitable protection such as tinted eye
cleaning parts using compressed air. protection, helmets, special clothing, gloves and
footwear whenever it is necessary to carry out
• Do not exceed a pressure of 2.1 bar, in accor-
welding procedures. All persons standing in the
dance with local regulations.
vicinity of the welding process should wear tinted
• Do not run the engine in a closed building without eye protection. NEVER LOOK AT THE WELD-
proper ventilation. ING ARC IF YOUR EYES ARE NOT SUITABLY
• Do not smoke, use open flames, cause sparks in PROTECTED.
the nearby area when filling fuel or handling high- • Metal cables with the use get frayed. Always
ly flammable liquids. wear adequate protections (heavy gloves, eye
• Do not use flames as light sources when working protection, etc.)
on a machine or checking for leaks. • Handle all parts with the greatest caution. Keep
• Move with caution when working under a Ma- your hands and fingers far from gaps, moving
chine, and also on or near a Machine. Wear prop- gears and similar. Always use approved protec-
er safety accessories: helmets, goggles and spe- tive equipment, such as eye protection, heavy
cial footwear. gloves and protective footwear.
• During checks which should be carried out with
the engine running, ask an assistant to seat at the START UP
operator’s seat and keep the service technician • Never run the engine in confined spaces which
under visual control at any moment. are not equipped with adequate ventilation for
• In case of operations outside the workshop, drive exhaust gas extraction.
the Machine to a flat area and block it. If working • Never bring your head, body, arms, legs, feet,
on an incline cannot be avoided, first block the hands, fingers near fans or rotating belts.
Machine carefully. Move it to a flat area as soon
as possible with a certain extent of safety.
ENGINE
• Ruined or plied cables and chains are unreliable.
Do not use them for lifting or trailing. Always han- • Always loosen the radiator cap very slowly be-
dle them wearing gloves of proper thickness. fore removing it to allow pressure in the system
to dissipate. Coolant should be topped up only
• Chains should always be safely fastened. En- when the engine is stopped or idle if hot.
sure that fastening device is strong enough to
hold the load foreseen. No persons should stop • Do not fill up fuel tank when the engine is running,
near the fastening point, trailing chains or cables. mainly if it is hot, to avoid ignition of fires in case
of fuel spilling.
• The working area should be always kept CLEAN
and DRY. Immediately clean any spillage of wa- • Never check or adjust the fan belt tension when
ter or oil. the engine is running.
Never adjust the fuel injection pump when the
• Do not pile up grease or oil soaked rags, as they Machine is moving.
constitute a great fire hazard. Always place them
into a metal container. • Never lubricate the Machine when the engine is
Before starting the Machine or its attachments, running.
check, adjust and block the operator’s seat. Also
604.13.028 FB 90.2–200.2
ELECTRICAL SYSTEMS • To remove the wheels, block both front and rear
• If it is necessary to use auxiliary batteries, cables Machine wheels. Raise the Machine and install
must be connected at both sides as follows: (+) safe and stable supports under the Machine in
to (+) and (–) to (–). Avoid short–circuiting the ter- accordance with regulations in force.
minals. GAS RELEASED FROM BATTERIES IS • Deflate the tyre before removing any object
HIGHLY FLAMMABLE. During charging, leave caught into the tyre tread.
the battery compartment uncovered to improve • Never inflate tyres using flammable gases as
ventilation. Avoid checking the battery charge by they may originate explosions and cause injuries
means of “jumpers” made by placing metallic ob- to bystanders.
jects across the terminals. Avoid sparks or
flames near the battery area. Do no smoke to
prevent explosion hazards.
• Prior to any service, check for fuel or coolant REMOVAL AND INSTALLATION
leaks. Remove these leaks before going on with • Lift and handle all heavy components using lifting
the work. equipment of adequate capacity. Ensure that
• Do not charge batteries in confined spaces. En- parts are supported by appropriate slings and
sure that ventilation is appropriate to prevent hooks. Use lifting eyes provided to this purpose.
accidental explosion hazard due to build–up of Take care of the persons near the loads to be
gasses relieved during charging. lifted.
• Always disconnect the batteries before perform- • Handle all parts with great care. Do not place
ing any type of service on the electrical system. your hands or fingers between two parts. Wear
approved protective clothing such as safety
HYDRAULIC SYSTEMS goggles, gloves and footwear.
• Some fluid slowly coming out from a very small • Do not twine chains or metal cables. Always wear
port can be almost invisible and be strong protection gloves to handle cables or chains.
enough to penetrate the skin. For this reason,
NEVER USE YOUR HANDS TO CHECK FOR
LEAKS, but use a piece of cardboard or a piece
of wood to this purpose. If any fluid is injected
into the skin, seek medical aid immediately. Lack
of immediate medical attention, serious infec-
tions or dermatosis may result.
• Always take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES

• Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi-
cally check possible damages to the rims and
tyres.
• Keep off and stay at the tyre side when correcting
the inflation pressure.
• Check the pressure only when the Machine is un-
loaded and tyres are cold to avoid wrong read-
ings due to over–pressure. Do not reuse parts of
recovered wheels as improper welding, brazing
or heating may weaken the wheel and make it
fail.
• Never cut, nor weld a rim with the inflated tyre as-
sembled.
FB 90.2–200.2 604.13.028
PRODUCT IDENTIFICATION
The Backhoe Loader and its major components are
identified by serial numbers and letters for recogni- 1
tion in After Sales Service. The following information
provides the locations of these identification plates,
stamped numbers and examples of what can be
found on the machine.
VEHICLE SERIAL NUMBER (1), Figure 1.

The Serial Number is stamped on the top of the right
hand main frame, in front of the right hand loader
post, in position (1). . . . . . . . . . . 2
Example: *000005017*
VEHICLE IDENTIFICATION PLATE’S (2), Figure

1.
The machine identification plate’s are located on the
right–hand loader post, as shown at position (2). Re-
cord the data of your machine below.
MODEL/TECHNICAL TYPE
Example: *699.510.700*
UNIT SERIAL NO.

Example: *000005017*
YEAR
Example: *1995*
1
ENGINE IDENTIFICATION, Figure 2.
The engine identification information is located on
the right hand engine sump rail. Record the informa-
tion below for quick reference.
MODEL NO.
Example: *EA5*
SERIAL NO.
Example: *57018*
DATE CODE. 1
Example:*5J25*=5(1995),J(September),25(Day)
2
604.13.028 FB 90.2–200.2
FRONT WHEEL DRIVE IDENTIFICATION

The serial number and axle type is printed on the
plate (1), located on the front of the axle housing. Re-
cord the information below for quick reference.
AXLE TYPE
Example: *26–18*
SERIAL NO.
Example: *000102*
ROTATION
Example: LH = Left Hand RH = Right Hand
RATIO
Example: 12.33 to 1 – 12.8 to 1 1
TAP424011
3
TRANSMISSION, P/SHUTTLE
The serial number and type is printed on the plate (1),
on the lower right side of the transmission. Record
the information below for quick reference.
MODEL NO.
Example: *COM–T4–2025*
SERIAL NO.
Example: *15647 E95 01*
4
TRANSMISSION, P/SHIFT Figure 5
The serial number and type is printed on the plate (1),
on the lower right side of the transmission. Record
the information below for quick reference.
MODEL NO.
Example: *GT PRODUCTION *
SERIAL NO.
Example: *TBEA 419323 09/96*
5
REAR AXLE IDENTIFICATION, Figure 6
The serial number (1) is stamped on the left side of
the rear axle housing. Record the serial number
below for quick reference.
MODEL NO.
Example: *85801201*
DATE CODE
Example: 5D05=5(1995), D(APRIL), 05(DAY) 1
FB 90.2–200.2 604.13.028
CAB IDENTIFICATION PLATES, Figure 7
The cab serial number and details are printed on the

certification plate‘s (1) on the rear left hand window.
Record the serial number below for quick reference.
Serial No.
Date Code
IMPORTANT ECOLOGICAL CONSIDERATIONS

The following are recommendations which may be of oils, brake fluids, etc. Do not mix drained brake
assistance: fluids or fuels with lubricants. Store them safely
• Become acquainted with and ensure that you un- until they can be disposed of in a proper way to
derstand the relative legislation applicable to comply with local legislation and available re-
your country. sources.
• Where no legislation exists, obtain information 5. Modern coolant mixtures, i.e. antifreeze and
from suppliers of oils, fuels, antifreeze, cleaning other additives, should be replaced every two
agents, etc., with regard to their effect on man years. They should not be allowed to get into the
and nature and how to safely store, use and dis- soil but should be collected and disposed of safe-
pose of these substances. ly.
6. Do not open the Air–Conditioning system your-
HELPFUL HINTS self. It may contain gasses which should not be re-
leased into the atmosphere. Your air conditioning
1. Avoid filling tanks using jerry cans or inappropri-
specialist has a special equipment for discharging
ate pressurised fuel delivery systems which may
and charging the system.
cause considerable spillage.
7. Repair any leaks or defects in the engine cooling
2. In general, avoid skin contact with all fuels, oils,
or hydraulic system immediately.
acids, solvents, etc. Most of them contain sub-
stances which can be harmful to your health. 8. Do not increase the pressure in a pressurised cir-
cuit as this may lead to a catastrophic failure of
3. Modern oils contain additives. Do not burn con-
the system components.
taminated fuels and/or waste oils in ordinary
heating systems. 9. Protect hoses during welding as penetrating
weld splatter may burn a hole or weaken them,
4. Avoid spillage when draining off used engine
causing the loss of oils, coolant, etc.
coolant mixtures, engine, gearbox and hydraulic
604.13.028 FB 90.2–200.2
Fiat Hitachi Fb90 100 110 200 2 4ws Workshop Manual
Full download: http://manualplace.com/download/fiat-hitachi-fb90-100-110-200-2-4ws-workshop-manual/
SERVICE TECHNIQUES
GENERAL A hose with a chafed outer cover will allow water

Clean the exterior of all components before carrying entry. Concealed corrosion of the wire reinforcement
out any form of repair. Dirt and abrasive dust can re- will subsequently occur along the hose length with
duce the efficient working life of a component and resultant hose failure.
lead to costly replacement. Ballooning of the hose indicates an internal leakage
Time spent on the preparation and cleanliness of due to structural failure. This condition rapidly de-
working surfaces will pay dividends in making the job teriorates and total hose failure soon occurs.
easier and safer and will result in overhauled compo- Kinked, crushed, stretched or deformed hoses gen-
nents being more reliable and efficient in operation. erally suffer internal structural damage which can re-
Use cleaning fluids which are known to be safe. Cer- sult in oil restriction, a reduction in the speed of oper-
tain types of fluid can cause damage to ‘O’ rings and ation and ultimate hose failure.
cause skin irritation. Solvents should be checked that Free-moving, unsupported hoses must never be al-
they are suitable for the cleaning of components and lowed to touch each other or related working sur-
also that they do not risk the personal safety of the faces. This causes chafing which reduces hose life.
user.
Replace ‘O’ rings, seals or gaskets whenever they
are disturbed. Never mix new and old seals or ‘O’
rings, regardless of condition. Always lubricate new ‘O’ RING FLAT FACE SEAL FITTINGS
seals and ‘O’ rings with hydraulic oil before installa-
When repairing ‘O’ ring face seal connectors, the fol-
tion.
lowing procedures should be observed.
When replacing component parts, use the correct
tool for the job. WARNING
NEVER DISCONNECT OR TIGHTEN A HOSE OR
HOSES AND TUBES TUBE THAT IS UNDER PRESSURE. IF IN DOUBT,
ACTUATE THE OPERATING LEVERS SEVERAL
Always replace hoses and tubes if the cone end or TIMES WITH THE ENGINE SWITCHED OFF
the end connections on the hose are damaged. PRIOR TO DISCONNECTING A HOSE OR TUBE.
When installing a new hose, loosely connect each
end and make sure the hose takes up the designed 1. Release the fittings and separate the hose or
position before tightening the connection. Clamps tube assembly, then remove and discard the ‘O’
should be tightened sufficiently to hold the hose with- ring seal from the fitting.
out crushing and to prevent chafing.
2. Dip a new ‘O’ ring seal into clean hydraulic oil
After hose replacement to a moving component, prior to installation. Install a new ‘O’ ring into the
check that the hose does not foul by moving the com- fitting and, if necessary, retain in position using
ponent through the complete range of travel. petroleum jelly.
Be sure any hose which has been installed is not 3. Assemble the new hose or tube assembly and
kinked or twisted. tighten the fitting finger tight, while holding the
Hose connections which are damaged, dented, tube or hose assembly to prevent it from turning.
crushed or leaking, restrict oil flow and the productiv- 4. Use two suitable wrenches and tighten the fitting
ity of the components being served. Connectors to the specified torque according to the size of the
which show signs of movement from the original fitting. Refer to the following torque chart.
swagged position have failed and will ultimately sep-
NOTE: To ensure a leak-free joint is obtained, it is im-
arate completely.
portant that the fittings are not over or under torqued.
FB 90.2–200.2 604.13.028
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Fiat Hitachi Fb90 100 110 200 2 4ws Workshop Manual

FB90.2 FB100.2 FB110.2

Print 604.13.028 edition 09/2000

ADDITIONAL REFERENCE MANUALS

• In addition to this Workshop Manual, refer also

- Operation and maintenance instruction

DESCRIPTION OF THE COMPLETE

FB90.2 FB100.2 FB110.2FB200.2 4WS - • The complete Workshop Manual FB90.2

VOLUME MACHINE TYPE PRINT No.

Most accidents, whether they occur in industry, on the farm, at home or

On machines having hydraulically, mechanically and/or cable

COPYRIGHT BY FIAT-HITACHI EXCAVATORS S.p.A.

All rights reserved. Reproduction of text and illustrations in whole or in part,

SECTION 00 – HEALTH, SAFETY, MAINTENANCE

General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tooling and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

SECTION 10 – ENGINE – NEW HOLLAND 92 to 108 hp

604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

SECTION 17 – TORQUE CONVERTER

LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

SECTION 25 – FRONT AXLES

SECTION 27 – REAR AXLES

SECTION 33 – BRAKE SYSTEMS

604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

SECTION 35 – HYDRAULIC SYSTEMS

CHAPTER 2 – Fault Finding, Pressure and Flow Testing

Preliminary Checks ......................................................................2

CHAPTER 3 – Hydraulic Cylinders

LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

SECTION 39 – VEHICLE CHASSIS

SECTION 41 – STEERING SYSTEMS

SECTION 50 – CAB HEATING AND AIR CONDITIONING

604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

SECTION 55 – ELECTRICAL SYSTEM

CHAPTER 3 – Starter Motor

LB 75–115 / FB 90.2–200.2 604.56.061.00 / 604.13.028.00 – 09/2000

SECTION 82 – LOADER REMOVAL

CHAPTER 2 – OVERHAUL (4 Wheel Steer Only)

SECTION 84 – BACKHOE REMOVAL

SECTION 90 – CAB PARTS

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

604.56.061.00 / 604.13.028.00 – 09/2000 LB 75–115 / FB 90.2–200.2

Chapter 1 – General Instructions

ROTATING SHAFT SEALS

NOTES FOR SPARE PARTS

USE EXCLUSIVELY GENUINE SPARE PARTS

NOTES FOR EQUIPMENT

HOW TO MOVE THE MACHINE WITH THE BATTERY REMOVED

PAY ATTENTION TO THIS SYMBOL

WHEELS AND TYRES

VEHICLE SERIAL NUMBER (1), Figure 1.

VEHICLE IDENTIFICATION PLATE’S (2), Figure

UNIT SERIAL NO.

FRONT WHEEL DRIVE IDENTIFICATION

CAB IDENTIFICATION PLATES, Figure 7

The cab serial number and details are printed on the

IMPORTANT ECOLOGICAL CONSIDERATIONS

GENERAL A hose with a chafed outer cover will allow water

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