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

• Applies to Fiat-Hitachi FB90.2, FB100.2, FB110.2, and FB200.2 4WS backhoe loaders in a 1,057-page PDF; Fiat-Hitachi Print No. 604.13.028, September 2000.
• Documents the New Holland 92-hp naturally aspirated and 108-hp turbocharged four-cylinder engines, including engine/transmission removal, cylinder-head service, internal inspection, timing and fuel-pump work, block repair, and final adjustment.
• Separates 4x4 Compact Shuttle/Powershuttle and Powershift systems, with torque-converter checks, hydraulic diagnosis, transmission removal, clutch-pack and shaft overhaul, control-valve service, shimming, and operational testing.
• Breaks out 2WD, 4WD, and 4WS axle, brake, and steering configurations, including mechanical and electrically operated differential locks, wet-disc brake overhaul and bleeding, axle setup, and 2WS/4WS/crab-steer fault tracing.
• Limits hydraulic coverage to Rexroth systems, with load-sensing flow-sharing schematics, loader/backhoe valve overhaul, relief-valve and pump-flow testing, swing-system service, and removal and overhaul procedures for the major hydraulic cylinders.
• Supplies outside-North-America wiring and connector sets from serial number 031026803 for ROPS Powershuttle, 92–108 hp Powershuttle, 92–108 hp Powershift, and 108 hp 4WS Powershift machines, plus service diagnostics, instrument calibration, immobilizer information, and component test charts.
• Details sideshift and center-pivot loader/backhoe arrangements, standard and H.E.D. extendible dipper configurations, loader and backhoe removal work, return-to-dig and self-leveling adjustments, R134a air-conditioning service, and cab/ROPS repairs.

Engine, Transmission, and Axle Repair

The engine chapters distinguish the naturally aspirated and turbocharged builds at the piston, connecting-rod, ring, fuel, and timing systems. Factory procedures cover valve-seat and guide rework, cylinder-block sleeving and honing, crankshaft inspection and regrinding data, seal replacement, oil-pump overhaul, Lucas CAV injection-pump timing, injector testing, and Garrett turbocharger overhaul. The manual also identifies which repairs can be completed in the chassis and which require engine removal and separation from the transmission.

Compact Shuttle/Powershuttle coverage traces oil supply, solenoid control, gear power flow, pressure-test points, clutch packs, shafts, parking brake, and end-float shimming. Powershift sections add electrohydraulic control-valve operation, microprocessor test modes, speed-sensor checks, modulation and direction-output faults, limp-home operation, and internal shaft and clutch overhaul. Axle chapters separate conventional and 4WS housings and the two differential-lock systems, with ring-and-pinion setup, preload, backlash, bearing, and seal work.

Rexroth Hydraulics and Electrical Diagnosis

The hydraulic chapters explain how the tandem gear pump, steering-priority flow divider, pump flow balancer, pressure compensators, and load-sense gallery work together. Fault charts and factory tests cover loader, backhoe, swing, stabilizer, and extendible-dipper complaints through relief-valve, cylinder leak-down, control-valve, and pump-flow checks. Steering material includes hydrostatic steering-motor repair, flow-divider service, 4WS valve logic, and electrical tests for the steering control unit, axle sensors, and mode solenoids.

Electrical coverage extends from fuse and relay boards to harness repair, starter/alternator overhaul, and battery testing. The diagnostic chapter covers stored malfunction history, service-indicator reset, speedometer calibration after tire or instrument changes, and the immobilizer circuit. The regional and serial limit stated above applies to the wiring-diagram chapter, not to the rest of the workshop manual.

Diagrams, Tools, and Shop Data

Named visual references include Engine Oil Flow, Transmission Power Flows (Four Wheel Drive Version Shown), Load Sensing Flow Sharing – Two Spools Operating, Steering Valve Schematic, Air Conditioning Flow Diagram, and Wiring Diagrams and Connectors – Powershift (4WS) 108 hp. Connector indexes, hydraulic schematics, exploded assemblies, section views, fault charts, and component-test layouts support the repair chapters.

Representative factory tools include engine/transmission lifting bracket 297392, CAV pump-timing tools 297119 / 297512 / 297513, Powershift clutch-pack compressor 297401, speed-sensor test lead 297405, limp-home lead 297406, hydraulic relief-valve test tool 297418, and flow-test fittings 297166. Shop data covers component torque tables, pressure and flow tests, fluid capacities, approved-fluid references, wear limits, clearances, preload and backlash, electrical test values, and calibration settings.

Loader, Backhoe, HVAC, and Cab Procedures

Attachment coverage addresses center-pivot and sideshift machines, three two-lever patterns plus a dealer-installed four-lever arrangement, the optional H.E.D. dipper, and loader self-leveling and return-to-dig systems. Removal and repair sections cover the boom, dipperstick, swing post, carriage, loader arms, buckets, and extendible-dipper wear pads. HVAC and cab material includes heater diagnosis, R134a leak testing, recovery/charging and flushing, compressor overhaul, cab removal, glass replacement, trim, controls, and wipers.

The fuel-system material covers DP203 timing, installation, fault finding, and shutoff-solenoid service, but internal pump setup is directed to a Lucas/CAV specialist. This PDF is the single workshop repair volume; the operation and maintenance instruction manual and spare parts catalog are separate publications.

The engine section warns that the heat-shrunk crankshaft timing gear is not a service-removal item; damage can turn that repair into a crankshaft replacement. The extendible-dipper chapter also flags the wear-pad retaining hardware, where over-tightening can damage the threaded inserts.

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