Fiat-Hitachi FB90.2, FB100.2, FB110.2 & FB200.2 4WS — 2000 Backhoe Loader Workshop Manual (P/N 604.13.028)

This September 2000 Fiat-Hitachi workshop manual (P/N 604.13.028) covers the FB90.2, FB100.2, FB110.2, and FB200.2 4WS backhoe loaders. The operator’s and maintenance manual and the spare parts catalog are separate publications.

PDF Search, Bookmarks, and Wiring Detail

Finding chapters and circuit labels: The main text is searchable, and embedded bookmarks open the major sections and chapters. Some labels within the drawings don’t appear in text search. Small pin numbers and wire codes are easier to read at higher zoom.

The workshop manual is supplied as a single printable 1,057-page PDF, including the original cover.

Powertrain, Rexroth Hydraulics, and Backhoe Service

This selection of workshop topics includes major repair and diagnostic work. The manual also covers electric fuel lift pump testing and speedometer calibration after tire or instrument changes.

• Engine overhaul: Engine and transmission removal, cylinder-head service, internal inspection, block repair, timing work, and final adjustments for naturally aspirated and turbocharged New Holland four-cylinder diesels.

• Shuttle and Powershift transmissions: Torque-converter checks, transmission removal, hydraulic pressure testing, clutch-pack and shaft overhaul, and shimming.

• Axles, brakes, and steering: Separate 2WD, 4WD, and 4WS coverage, with axle setup, wet-disc brake overhaul and bleeding, and two-wheel, four-wheel, and crab-steer fault tracing.

• Rexroth hydraulics: Load-sensing flow-sharing circuits, loader and backhoe control valve overhaul, relief-valve and pump-flow tests, and swing-system and cylinder service.

• Electrical diagnosis: Wiring diagrams and connector layouts by configuration, fuse and relay boards, harness repair, starter and alternator overhaul, and battery tests.

• Loader and backhoe: Center-pivot and sideshift arrangements, loader and backhoe removal, standard and H.E.D. extendible dipper configurations, and return-to-dig adjustments.

• HVAC and cab: Heater diagnosis, R134a leak testing, recovery, charging and flushing, compressor service, and cab and ROPS repair.

Fiat-Hitachi wrote this manual for skilled service technicians.

Engine, Fuel, and Cooling

The engine chapter distinguishes the two builds by piston, connecting rod, ring, fuel, and timing components. It identifies jobs that can be done in the chassis and those that require separating the engine from the transmission. Overhaul coverage includes valve-seat and guide rework, cylinder sleeving and honing, crankshaft inspection and regrinding data, seal replacement, and oil pump overhaul. The timing section flags the heat-shrunk crankshaft gear as a case where gear damage calls for crankshaft replacement.

Fuel and cooling chapters cover injector testing, Garrett turbocharger overhaul, and cooling-system pressure checks. DP203 coverage includes pump timing, installation, fault finding, and shutoff-solenoid service. The manual directs internal pump setup and repair to a Lucas/CAV specialist.

Transmission, Axles, and Steering

Compact Shuttle diagrams trace oil supply and gear power flow. The Powershift chapter adds electrohydraulic control valve service, microprocessor test modes, speed-sensor checks, modulation and direction-output faults, and limp-home operation.

The axle chapters distinguish foot-operated and electrically operated differential locks and give ring-and-pinion setup, preload, backlash, bearing, and seal procedures. Steering coverage includes hydrostatic steering motor and flow-divider service, 4WS valve logic, and checks for axle sensors and mode solenoids.

Hydraulic Fault Finding and Wiring

The Rexroth schematics show how the tandem gear pump, steering-priority flow divider, pump flow balancer, pressure compensators, and load-sense gallery work together. For a loader or backhoe cylinder that drifts, the fault charts help distinguish internal valve leakage from a piston seal or barrel problem.

The wiring and connector chapter applies to machines outside North America from serial number 031026803. It has separate diagram sets for ROPS Powershuttle, Powershuttle, Powershift, and 4WS Powershift. Circuit indexes pair component and connector IDs with the corresponding drawings. Separate service diagnostics cover stored faults, service-indicator reset, and the immobilizer circuit.

Attachment Controls and Cab Service

The backhoe chapter illustrates three two-lever control patterns and the dealer-installed four-lever arrangement. It also covers linkage overhaul, loader self-leveling, and repairs to the boom, dipperstick, swing post, carriage, loader arms, and buckets. The H.E.D. section warns that overtightening the wear-pad retaining bolts can damage the threaded inserts.

Cab procedures cover removal, glass, trim, controls, and wipers. The air-conditioning chapter includes a refrigerant-flow diagram and procedures for compressor clutch, shaft seal, and valve plate service.

Shop Tools and Reference Data

Illustrations include engine oil flow, four-wheel-drive transmission power flow, two-spool hydraulic flow sharing, and 4WS steering valve schematics. Shop data includes torque tables, fluid capacities and grades, wear limits, electrical test values, and calibration settings.

Special tools include lifting bracket 297392, CAV pump timing tools 297119 / 297512 / 297513, Powershift clutch-pack compressor 297401, test leads 297405 / 297406, relief-valve test tool 297418, and flow-test fittings 297166. A dimensioned drawing covers fabrication of a fuel injection pump gear puller.

Support raised loader or backhoe structures independently, relieve hydraulic pressure, isolate the battery, and use approved refrigerant recovery equipment before repair work.

Valve Lash and Dipper Wear Pad Examples

For both New Holland engine builds, the cold valve lash table lists 0.014–0.018 in (0.36–0.46 mm) on the intake and 0.017–0.021 in (0.43–0.53 mm) on the exhaust.

For the retracted H.E.D. dipper, the inspection section calls for adjustment when the upper wear-pad gap exceeds 1.5 mm and the pad corner chamfer is still visible. A worn-away chamfer is a separate replacement criterion.